Yanmar 4BY2 Operation Manuals Download

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EPA WARRANTY

USA ONLY

YANMAR CO., LTD. LIMITED

EMISSION CONTROL

SYSTEM WARRANTY - USA

ONLY

The following EPA Warranty only applies to

engines built on or after January 01, 2006

and labeled with the proper nameplate.

THIS EMISSION WARRANTY APPLIES TO

THE ENGINES CERTIFIED TO UNITED

STATES EPA 40 CFR 94 AND SOLD BY

YANMAR THAT ARE INSTALLED IN

VESSELS FLAGGED OR REGISTERED IN

THE UNITED STATES.

Your Warranty Rights and

Obligations:

Yanmar warrants to the first user and each

subsequent purchaser the emission control

system on your engine for periods of time

listed below provided the engine has been

installed according to Yanmar installation

requirements and there has been no abuse,

neglect, or improper maintenance of your

Yanmar marine engine.

Yanmar warrants that the engine is

designed, built and tested using genuine

parts and equipped so as to conform to all

applicable emission requirements of the

U.S. Environmental Protection Agency and

is free from defects in material and

workmanship which would cause this

engine to fail to conform to the applicable

emission regulations over its limited

emission control system warranty period.

Where a warrantable emissions condition

exists, Yanmar will repair your engine at no

charge to you for diagnosis, parts, and labor.

Warranty service or repair will be provided

at authorized Yanmar marine dealers or

distributors.

It is recommended that any replacement

parts used for maintenance, repair or

replacement of emission control systems

are Yanmar parts. The owner may elect to

have maintenance, replacement or repair of

the emission control components and

systems performed by any repair

establishment or individual and may elect to

use parts other than Yanmar parts for such

maintenance, replacement or repair.

However, the cost of such service or parts

and subsequent failures from such service

or parts will not be covered under this

emission control system warranty:

BY Series Operation Manual

Summary of Contents for 4BY2

Page 1: ...MARINE ENGINES BY series OPERATION MANUAL 4BY2 6BY2 P N 0ABY0 G00200 ...

Page 2: ...product service or maintenance improvement We reserve the right to make any change at any time without notice Yanmar and are registered trademarks of Yanmar Co Ltd in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information...

Page 3: ... viewed from flywheel 4BY2 11 Right Side as viewed from flywheel 4BY2 11 Top View 4BY2 12 Left Side 6BY2 12 Right Side 6BY2 13 Top View 6BY2 13 Location of Nameplates 14 Function of Major Components 16 Fuses and Relays 18 Engine Cover 19 Before You Operate 21 Diesel Fuel 22 Diesel Fuel Specifications 22 Filling the Fuel Tank 24 Bleeding the Fuel System 24 Engine Oil 25 Engine Oil Specifications 25...

Page 4: ...ar Marine Dealer or Distributor For Help 39 Required EPA Maintenance 39 EPA Requirements 40 Conditions to Ensure Compliance with EPA Emission Standards 40 Inspection and Maintenance 40 Tightening Fasteners 40 Periodic Maintenance Schedule 42 Inspection and Maintenance of EPA Emission Related Parts 46 Daily Checks 46 Visual Checks 46 Checking Diesel Fuel Engine Oil and Engine Coolant Levels 47 Chec...

Page 5: ...ostic Trouble Codes 64 Diagnostic Trouble Code Table 65 Long Term Storage 69 Prepare Engine for Long Term Storage 69 Draining the Seawater Cooling System 70 Specifications 71 Engine Specifications 71 EPA Warranty USA Only 75 Yanmar Co Ltd Limited Emission Control System Warranty USA Only 75 Your Warranty Rights and Obligations 75 Warranty Period 76 Warranty Coverage 76 Exclusions 76 Owner s Respon...

Page 6: ...This Page Intentionally Left Blank TABLE OF CONTENTS vi BY Series Operation Manual 2008 Yanmar Marine International ...

Page 7: ...ures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized Yanmar marine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part of the engine and remain with it Constant efforts are made to improve the quality and performance of Yanm...

Page 8: ...ents to record the information you need when you contact Yanmar for service parts or literature Engine Model Engine Serial No Date Purchased Dealer Dealer Phone INTRODUCTION 2 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 9: ...e same time This safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol DANGER Indicates an hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious inj...

Page 10: ...y message that follows has DANGER level hazards NEVER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized...

Page 11: ...source of ignition Store any equipment in a designated area away from moving parts NEVER use the engine compartment for storage Sever Hazard Rotating parts can cause severe injury or death NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing and ALWAYS tie long hair back when working near moving rotating parts such as the flywheel or PTO shaft Keep hands feet and tools away from all ...

Page 12: ...e is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning CAUTION The safety messages that follow have CAUTION level hazards Poor Lighting Hazard Ensure that the work area is adequately illuminated ALWAYS install wire cages on portable safety lamps Tool Hazard ALWAYS use too...

Page 13: ...ave an installation with two or three engines and only one engine is operating the water pickup thru hull of the non running engine s should be closed This will prevent water from being forced past the seawater pump and eventually finding its way into the engine The result of water entering the engine could cause seizure or other serious problems If you have an installation with two or three engin...

Page 14: ... 5 ton 60 0 5 ton Before filling with cooling water close the drain cock The drain cock is open during shipment ATTENTION Replacement items Lube oil Lube oil filter element Fuel filter element Pre fuel filter element Anitcorrosion zinc Air filter please refer to operation manual for details 120650 07070 After 250 hrs or 1 year 3 2 1 6 7 4 9 5 8 1 Figure 1 1 120650 07030 2 120650 07040 3 120650 070...

Page 15: ...st be installed correctly with the seawater or cooling water piping exhaust gas piping and electrical wiring Any auxiliary equipment attached to the engine should be easy to use and accessible for service To handle the drive equipment propulsion systems including the propeller and other on board equipment be sure to observe the instructions and cautions given in the operation manuals supplied by t...

Page 16: ...r new engine under a substantial load at all times For best break in results operate the engine at various speeds During the first 50 hours of operation try to reduce unnecessary idling in Neutral During the break in period carefully observe the engine oil pressure and engine temperature During the break in period check the engine oil and coolant levels frequently PRODUCT OVERVIEW 10 BY Series Ope...

Page 17: ...557 1 2 3 Figure 1 1 Engine Oil Dipstick 2 E Box Panel 3 High Pressure Fuel Pump Right Side as viewed from flywheel 4BY2 0006559 4 1 5 9 8 7 6 2 3 Figure 2 1 Zinc Anode 2 Zinc Anode 3 Exhaust Water Mixing Elbow 4 Coolant Drain Cock 5 Heat Exchanger 6 Seawater Pump 7 Seawater Drain Cock 8 Hydraulic Oil Cooler 9 Coolant Drain Plug PRODUCT OVERVIEW BY Series Operation Manual 11 2008 Yanmar Marine Int...

Page 18: ... separating pre filter for mounting by the installer The engine is equipped with an on engine fine filter Figure 3 1 Figure 4 Figure 5 and Figure 6 illustrate a typical version of a 6BY2 engine Your engine may have different equipment from that illustrated Left Side 6BY2 0006558 1 2 3 Figure 4 1 Engine Oil Dipstick 2 E Box Panel 3 High Pressure Fuel Pump PRODUCT OVERVIEW 12 BY Series Operation Man...

Page 19: ...p View 6BY2 6 3 2 4 5 7 1 0006562 Figure 6 1 Fuel Fine Filter 2 Intake Air Manifold 3 Engine Oil Filter 4 Power Steering Filler Port if equipped 5 Engine Oil Filler Port 6 Coolant Filler Port 7 Air Filter Note Yanmar supplies a water separating pre filter for mounting by the installer The engine is equipped with an on engine fine filter Figure 6 1 PRODUCT OVERVIEW BY Series Operation Manual 13 200...

Page 20: ...engines Figure 8 4BY2 0006563 Gear Model ENG No Model min 1 min 1 min 1 Speed of prop shaft Fuel stop power kW Continuous power kW Figure 7 6BY2 0006631 Gear Model ENG No Model min 1 min 1 min 1 Speed of prop shaft Fuel stop power kW Continuous power kW Figure 8 The engine block information is etched into the cylinder block behind the engine oil cooler near the end of the starting motor Figure 9 P...

Page 21: ...ENGINE TRANSOM DRIVE MERCRUISER MODEL TRANSOM ASSEMBLY AND STERN DRIVE SERIAL NUMBER DECAL STRIPS TO THE RESPECTIVE BLANK ON THIS DECAL DIVISION OF MERCURY MARINE STILLWATER OK U S A Figure 9 PRODUCT OVERVIEW BY Series Operation Manual 15 2008 Yanmar Marine International ...

Page 22: ...t driven and has a replaceable rubber impeller Avoid impeller damage do not operate it without seawater Coolant Fill Cap When the coolant temperature rises the pressure inside the heat exchanger increases causing the pressure valve in the filler cap to open forcing hot water and steam through a rubber hose to the coolant recovery tank When the engine becomes cool and the pressure inside the coolan...

Page 23: ... if a system or sensor indicates a problem In most cases a Check Engine light will be displayed The engine may or may not run normally depending on the fault Not all inputs are monitored by the ECU Low oil pressure and water in fuel are two examples Either of these conditions will result in a warning indicator and possible audible alarm Low oil pressure will also be indicated by the oil gauge at t...

Page 24: ...fuse out Insert 3 A fuse to configure for CAN 9 K1 Starter Relay 10 K3 Fuel Supply Pump Relay 11 K2 Main Power Relay 12 ECU 13 Connector X1 Communication to Helm Display 14 Connector X21 1 Engine Wiring Harness 15 Connector X22 1 Fuel Injector Wiring Harness To access the fuse and relay panel remove the four bolts from the E Box cover and remove cover NOTICE The electrical panel cables must be con...

Page 25: ...ENGINE COVER 0006552 Figure 11 To remove the cover from the engine remove all bolts then lift cover from engine PRODUCT OVERVIEW BY Series Operation Manual 19 2008 Yanmar Marine International ...

Page 26: ...This Page Intentionally Left Blank PRODUCT OVERVIEW 20 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 27: ...on of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them It also describes the daily engine checkout BY Series Operation Manual 21 2008 Yanmar Marine International ...

Page 28: ...e purchased only from recognized and authorized diesel fuel suppliers Precautions and concerns regarding the use of bio fuels Bio diesel fuels have a higher content of methyl esters which may deteriorate certain metal rubber and plastic components of the fuel system The customer and or boat builder are responsible to verify the usage of bio diesel compatible components on the vessel fuel supply an...

Page 29: ...cause engine damage Fuel additives are not recommended Some fuel additives may cause poor engine performance See your authorized Yanmar marine dealer or distributor for more information Lubricity HFRR 400 micrometer ISO 12156 HFRR High Frequency Reciprocating Rig Diesel Fuel Lines 0003638A 1 3 5 7 4 6 2 Figure 1 1 To Fuel Feed Pump 2 Less Than 500 mm 19 68 in 3 Fuel Return Line 4 Fuel Tank 5 Fuel ...

Page 30: ... time After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the fuel filter water separator or replacing a fuel system component The fuel feed pump is ECU controlled and will operate for only 10 seconds when the key switch is turned ON while the engine is not running or being started For this reason the key sw...

Page 31: ... operation and then at every 250 hours thereafter 3 Select the oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart 4 Yanmar does not recommend the use of engine oil additives Engine Oil Viscosity Select the appropriate engine oil viscosity based on the ambient temperature shown in the SAE Service Grade Viscosity Chart Figure 2...

Page 32: ...Limited Castrol Formula SLX Long Tex Castrol Limited Castrol Formula SLX Turbodiesel Castrol Limited Castrol Syntec Castrol Limited Castrol Syntec 0W 30 European Formula Castrol Limited Castrol Super Racing 0W 40 Castrol Limited Castrol TXT Softec LL01 Castrol Limited Cepsa Star Mega Synthetic Cepsa Lubricantes S A Divinol Syntholight Zeller Gmelin Elf Excellium Full Tech Total Elf Excellium LDX T...

Page 33: ...F Shell Helix Ultra AB Shell International Petroleum Company Shell Helix Ultra AL Shell International Petroleum Company Statoli LazerWay B Statoil Lubricants Tecar Motorenöl Supersyn Techno Einkauf GmbH Titan Supersyn SL Fuchs Petrolub AG Titan Supersyn SL Longlife Fuchs Petrolub AG Tor Synthetic LL De Oliebron Total Activa Expertise 9000 Total Total Quartz Expertise 9000 Total Valvoline SynPower ...

Page 34: ...strol Limited Elf Excellium LSX Total Galp Energy Ultra LS Petrogal SA Liqui Moly TopTec 4100 Liqui Moly Midland Synova Oel Brack AG Midland Synova Oel Brack AG Mobil 1 ESP Formula ExxonMobil Motorenöl Low Emission Meguin GmbH Motul 1 Specific LL 04 Motul S A OMV eco plus OMV AG Repsol Elite Evolution Repsol YPF Shell Helix Ultra AP Shell International Petroleum Company Titan GT1 Fuchs Petrolub AG...

Page 35: ...n the dipstick 0003826 1 2 Figure 4 5 Fully reinsert dipstick Adding Engine Oil 0006565 2 1 Figure 5 Note 4BY2 series shown 6BY2 is similar 1 Remove the oil filler port cap Figure 5 2 and pour engine oil into filler port See Engine Oil Specifications on page 25 2 Fill with oil to the upper limit on the dipstick Figure 4 1 NOTICE NEVER overfill the engine with engine oil 3 Fully insert the dipstick...

Page 36: ...nufacturer s literature for power steering fluid specifications Checking Power Steering Fluid Level 1 Remove power steering filler cap 2 Power steering fluid level must be between the upper Figure 6 1 and lower Figure 6 2 level marks 1 2 0004042 Figure 6 3 Add fluid if necessary BEFORE YOU OPERATE 30 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 37: ... GlycoShell Shell International Glyco star Bremin Mineralöl GmbH Co Glysantin G48 24 Engine Coolant UNICO Ltd Glysantin Protect Plus G48 BASF GUSOFROST LV 505 Chemische Industrielle Gesellschaft Mobil Frostchutz 600 Mobil Schmierstoff GmbH Havoline AFC BD04 Chevron Texaco Arteco Mobil Frostschutz 600 ExxonMobil OMV Kühlerfrostschutz OMV AG Total Thermofreeze Plus Total Note Yanmar recommends using...

Page 38: ...dversely affect the properties of the engine coolant 2 Start the engine and allow to idle for approximately 5 minutes 3 Stop the engine and check the coolant level Add additional coolant if necessary 4 Install the pressure cap and tighten firmly WARNING Securely tighten the filler cap after checking the coolant level Steam can escape during engine operation if the cap is loose 5 Remove the coolant...

Page 39: ...ipment movement Shift the marine gear into the NEUTRAL position any time the engine is at idle To prevent accidental equipment movement NEVER start the engine in gear Sever Hazard Keep children and pets away while the engine is operating Exhaust Hazard Avoid serious injury or death NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal c...

Page 40: ...ange NEVER engage the starter motor while the engine is running Damage to the starter motor pinion and or ring gear will result STARTING THE ENGINE NOTICE If the vessel is equipped with a water lift water lock muffler excessive cranking could cause sea water to enter the cylinders and damage the engine If the engine does not start after cranking for 10 seconds close the thru hull water intake valv...

Page 41: ...s normal and allows the ECU computer to store data Wait at least 10 seconds after the engine stops before turning the battery master switch to OFF Emergency Shut Down NOTICE NEVER use the emergency stop switch for a normal engine shut down Use this switch only when stopping the engine suddenly in an emergency 1 Ensure lanyard is connected to the emergency stop switch 2 Attach the lanyard to a secu...

Page 42: ...round the fill opening are clean to avoid contamination of the fuel Close seawater cock s If there is a risk of freezing check that the cooling system contains enough coolant See Engine Coolant on page 31 If there is a risk of freezing drain the seawater system See Draining the Seawater Cooling System on page 70 ENGINE OPERATION 36 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 43: ...nect the negative battery cable and the leads to the alternator when welding on the equipment Remove the multi pin connector to the engine control unit Connect the weld clamp to the component to be welded and as close as possible to the welding point NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket Whenweldingiscompleted reconne...

Page 44: ...harnesses for cracks abrasions and damaged or corroded connectors NOTICE Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use Yan...

Page 45: ...f Engine Hours and Daily Checks Keep a log of the number of hours the engine is run each day and a log of the daily checks performed Also note the date type of repair e g replaced alternator and parts used for any service needed between the periodic maintenance intervals Periodic maintenance intervals are every 50 250 500 1000 and 2000 engine hours Failure to perform periodic maintenance will shor...

Page 46: ...er Note Inspections are divided into two sections in accordance with who is responsible for performing the inspection the user or the maker Inspection and Maintenance See Inspection and Maintenance of EPA Emission Related Parts on page 46 Inspection and maintenance procedures not shown in the Inspection and Maintenance of EPA Emission Related Parts on page 46 are covered in Periodic Maintenance Sc...

Page 47: ...29 ft lb M8 x 1 25 N m 221 in lb 35 N m 26 ft lb 42 N m 31 ft lb M10 46 N m 34 ft lb 64 N m 47 ft lb 77 N m 57 ft lb M10 x 1 25 49 N m 36 ft lb 68 N m 50 ft lb 82 N m 60 ft lb M12 80 N m 59 ft lb 110 N m 81 ft lb 135 N m 100 ft lb M12 x 1 5 88 N m 65 ft lb 125 N m 92 ft lb 150 N m 111 ft lb Hose Clamps Note Reuse and retightening is prohibited for all hose clamps Always install new hose clamps Siz...

Page 48: ... be treated only as a general guideline CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See your authorize...

Page 49: ...ting Check the fuel level and refill if necessary Before starting Drain water and sediment from fuel tank Drain the fuel filter water sep arator If necessary Replace the fuel fine filter Replace fuel filter water separator ele ment Check the fuel pump and fuel lines Lubricating System Check the en gine oil level and refill if necessary Before starting Change the en gine oil and re place the oil fi...

Page 50: ...comes first Cooling System Seawater Circuit Visual inspection of cooling system Before starting Check the seawater outlet Before starting Check seawater pump belt for wear replace if necessary Check seawater filter if equipped and inlet Replace the anodes Check or replace the sea water pump impeller Air Intake and Exhaust System Visual inspec tion Before starting Replace turbo charger heat shield ...

Page 51: ...ernator belt for wear replace if necessary Miscellane ous Items Check the alarm and indicators if equipped Check or change power steering fluid Check for water or oil leakage Before starting Check shift cable adjust ment Initial 50 Adjust the propeller shaft alignment if equipped with marine gear Initial 50 Check hydraulic oil cooler Check and replace rubberized ho ses fuel and wa ter Check flexib...

Page 52: ...e prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engine Make sure you check the following items Visual Checks Check the exterior of the engine for leaks wear or damage Check for engine oil leaks Check for fuel leaks Check for engine coolant leaks Check for damaged or missing parts Check for loose missing or damaged faste...

Page 53: ...fill on board to be ready for emergencies Checking Power Steering Fluid See Checking Power Steering Fluid Level on page 30 Draining the Fuel Water Separator Check the fuel filter water separator for presence of water and contaminants If you find any water or contaminants drain the fuel filter water separator If you have to drain the fuel filter water separator frequently drain the fuel tank and ch...

Page 54: ...rm WARNING If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection 1 Turn engine OFF 2 Remove engine cover 3 NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick and the surrounding area before you remove the cap Loosen the engine oil filter cap Figure 1 2 1 2 turns with a socket w...

Page 55: ... procedures perform the following procedures every 50 hours or monthly whichever comes first Checking Seawater Filter If Equipped and Inlet Checking the Air Intake System Checking Battery Electrolyte Level Serviceable Batteries Only Checking the Seawater Filter If Equipped and Inlet Refer to boat builder s literature for information on the seawater filter Checking the Air Intake System Check the a...

Page 56: ...of operation or yearly whichever comes first Draining the Fuel Tank Replacing the Fuel Fine Filter Replacing the Fuel Filter Water Separator Element Changing the Engine Oil and Replacing the Engine Oil Filter Element Checking or Replacing the Seawater Pump Belt Replacing the Anodes Checking or Replacing the Seawater Pump Impeller Replacing the Turbocharger Heat Shield Checking the Exhaust Water Mi...

Page 57: ... Replacing the Fuel Fine Filter 1 Disconnect the battery negative cable 2 Close the fuel tank cock 1 0006638 Figure 5 3 Unscrew and remove filter cartridge Figure 5 1 4 Replace rubber seal 5 Replacefilter NOTICE Whenreplacing fuel filters always pre fill them with fresh clean fuel to improve the system s ability to be bled 6 Hand tighten cartridge to filter 7 Connect battery negative cable 8 Bleed...

Page 58: ...ter bowl Inspect the water sensor probe Figure 6 1 for damage if equipped Inspect the bowl seal Figure 6 2 NOTICE When replacing fuel filters alwayspre fillthemwithfresh cleanfuel to improve the system s ability to be bled 3 1 2 4 0003650 5 Figure 6 8 Lubricate the seal at the top of the new filter element Figure 6 3 and install 9 Lubricate the filter bowl seal Figure 6 2 and install the filter bo...

Page 59: ...e Zinc Anodes 0006569 1 2 Figure 8 There are zinc anodes in the seawater cooling system and they should be inspected and replaced periodically Zinc anodes are located in the heat exchanger Figure 8 1 and the charge air cooler Figure 8 2 An additional zinc anode may also be located in the exhaust water mixing elbow 1 Disconnect battery negative cable 2 Remove each anode and inspect for corrosion An...

Page 60: ...nmar dealer or distributor Checking Shift Cable Adjustment See Checking Shift Cable Adjustment on page 49 Adjusting the Propeller Shaft Alignment See Adjusting Propeller Shaft Alignment If Equipped with Marine Gear on page 49 Checking Hydraulic Oil Cooler See your authorized Yanmar dealer or distributor Checking or Replacing Rubber Hoses Check rubber water and fuel hoses for wear or damage See you...

Page 61: ... exchanger to access the cylinder block drain plug behind it Note The charge air cooler has been removed for clarity of Figure 10 5 WARNING NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool before attempting to remove the filler cap Remove drain plug Figure 10 1 from the engine block Allow coolant to dr...

Page 62: ... the heat exchanger and recovery tank with approved coolant mix See Adding Engine Coolant on page 32 Every 1000 Hours of Operation Perform the following maintenance every 1000 hours of operation or every 4 years whichever comes first Checking Flexible Engine Mounts Checking Flexible Engine Mounts Check flexible engine mounts for damage cracksorwear SeeyourauthorizedYanmar marine dealer or distribu...

Page 63: ...cing Seawater Pump Impeller Replacing Alternator Belt Replacing Seawater Pump Impeller See your authorized Yanmar marine dealer or distributor for replacement Replacing Alternator Belt See your authorized Yanmar marine dealer or distributor for replacement PERIODIC MAINTENANCE BY Series Operation Manual 57 2008 Yanmar Marine International ...

Page 64: ...This Page Intentionally Left Blank PERIODIC MAINTENANCE 58 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 65: ...th the following information Model name and serial number of your engine Boat name hull material size Use and type of boating Total number of operation hours refer to hourmeter age of boat Operating conditions when the problem occurred Engine rpm Color of exhaust smoke Type of diesel fuel Type of engine oil Any abnormal noises or vibration Operating environment such as high altitude or extreme amb...

Page 66: ...ker Engine Cranks but Will Not Start No fuel to engine Check fuel level in tank See your authorized Yanmar dealer or distributor No fuel to cylinders Check fuel filter water separator Clean or replace clogged fuel fine filter Bleed air from fuel system Replace blown fuse F3 See your authorized Yanmar dealer or distributor Low ambient temperature See your authorized Yanmar dealer or distributor Oil...

Page 67: ... Damaged piston cooling nozzles Black Smoke Under Load Clogged intake air filter Replace or clean as necessary Incorrect valve timing See your authorized Yanmar deal er or distributor Defective leaking fuel injector Low charge air pressure Clean or replace clogged air filter See your authorized Yanmar deal er or distributor Excessive exhaust back pressure See your authorized Yanmar deal er or dist...

Page 68: ... Worn crankshaft bearings See your authorized Yanmar dealer or distributor Broken piston rings Low Power Output Problem Symptom Cause Action Miscellaneous Clogged air filter Replace air filter Leaking cylinder head gasket SeeyourauthorizedYanmardeal er or distributor Damaged turbocharger Incorrect propeller Excessive exhaust back pres sure Fuel Plugged fuel filter s Replace as necessary Faulty fue...

Page 69: ...or instrument See your authorized Yanmar dealer or distributor Defective thermostat Cabin heater or boiler too large Coolant Loss Problem Symptom Cause Action Repeated Low Coolant Level Defective cylinder head gasket external leakage See your authorized Yanmar dealer or distributor External leakage at connection Coolant Forced Out of Cool ant Recovery Tank Turbocharging pressure enters cooling sys...

Page 70: ...ickly find the cause of the fault and correct it Some conditions will produce an alarm but do not generate a trouble code An example is engine overheat over 108 C caused by an obstructed seawater inlet The overheat alarm will sound and the engine torque will be reduced to protect the engine but no code will be set Under some conditions the warning alarm will sound until the fault code is checked a...

Page 71: ...m P0087 Rail Pressure Gover nor Deviation Fuel rail pressure out of range reduce or shut off depends on fault alarm P0088 Rail Pressure Gover nor Deviation Fuel rail pressure out of range reduce or shut off depends on fault alarm P0089 Rail Pressure Gover nor Deviation Fuel rail pressure out of range yes yes alarm P0090 Fuel Pressure Control Valve Not connected no no alarm Rail Pressure Gover nor ...

Page 72: ...rcuit short circuit to Ground reduce yes alarm P0204 Injector No 4 Open circuit short circuit to Ground reduce yes alarm P0205 Injector No 5 Open circuit short circuit to Ground reduce yes alarm P0206 Injector No 6 Open circuit short circuit to Ground reduce yes alarm P0222 Throttle Signal Both throttle signals are miss ing short circuit to Ground 1600 yes alarm Throttle Signal Throttle signal 2 i...

Page 73: ...tor Not connected short circuit yes yes alarm P0562 System Voltage Low yes no alarm P0563 System Voltage High yes yes alarm P0602 Control Module Pro gramming Error Hwemon Overvoltage undervoltage no no alarm Shut Off Path Control module programming error no no alarm P0607 Injector Chip Fault Injector control module per formance no no alarm P0642 Sensor Supply Moni toring 1 Short circuit reduce yes...

Page 74: ...Short circuit on high side to Ground B reduce yes P2227 Atmospheric Pres sure Plausibility check with BPS boost pressure sensor fail yes yes alarm P2228 Atmospheric Pres sure Short circuit low yes yes alarm P2229 Atmospheric Pres sure Short circuit high yes yes alarm P2614 Camshaft Speed Sensor No connection short circuit reduce yes alarm P2617 Crankshaft Speed Sensor No connection short circuit n...

Page 75: ...AGE NOTICE Do not drain closed cooling system for long term storage Antifreeze must be used to avoid freezing and damaging of components Antifreeze will prevent rusting during long term storage 1 Change engine oil and filter 2 Drain seawater cooling system See Draining the Seawater Cooling System on page 70 3 Wipe off any dust or oil from the outside of the engine 4 Drain fuel tank or fill the tan...

Page 76: ...o cool before attempting to opening the drain cocks 1 Open the lower seawater drain cock Figure 1 3 located in the piping between the seawater pump and hydraulic oil cooler Allow to drain 2 Open the drain cock Figure 1 4 on the bottom of the charge air cooler 3 Remove the seawater pump cover See your authorized Yanmar dealer or distributor 4 Remove zinc anodes from the heat exchanger Figure 1 2 an...

Page 77: ... hp 132 kW 180 hp 162 kW 220 hp 191 kW 260 hp Mean Pressure 1 66 MPa 240 8 psi 1 95 MPa 287 2 psi 1 62 MPa 234 96 psi 1 92 MPa 278 47 psi Torque 320 N m 236 ft lb 360 N m 265 ft lb 500 N m 369 ft lb 550 N m 407 ft lb Low Idle Speed Warm En gine 88 C 190 F 750 rpm ECU controlled 670 rpm ECU controlled ColdStartSpeed 20 C 68 F 1200 rpm gradually decreasing to warm engine idle 88 C 190 F ECU controll...

Page 78: ...ooler Engine coolant system Engine Oil Pressure at 4000 rpm 3 5 6 0 bar 51 87 psi Engine Oil Pressure at 1000 rpm 0 6 1 0 bar 8 7 14 5 psi Engine Oil Capaci ty 8 0 L 8 5 qt 11 0 L 11 5 qt Crankcase Ventilation Closed with filter Drive Options Stern Drive ZT350 or MerCruiser Bravo 1 2 3 Marine Gear KMH40 or KMH50 KMH50 Operational Angles Continuous Front to Rear 5 to 20 Side to Side 20 Peak Front t...

Page 79: ... fuel 40 C 104 F at fuel pump inlet 1 hp metric horsepower 0 7355 kW Fuel condition Density at 15 C 59 F 0 840 g cm3 Fuel temperature at the inlet of the fuel injection pump 1080 rpm at startup for alternator excitation The TotalEngineLubricatingOilCapacity includesoilintheoilpan channels coolers andfilter The Effective Engine Lubricating Capacity indicates the difference in maximum scale of the d...

Page 80: ...This Page Intentionally Left Blank SPECIFICATIONS 74 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 81: ...uirements of the U S Environmental Protection Agency and is free from defects in material and workmanship which would cause this engine to fail to conform to the applicable emission regulations over its limited emission control system warranty period Where a warrantable emissions condition exists Yanmar will repair your engine at no charge to you for diagnosis parts and labor Warranty service or r...

Page 82: ...ot extend to the following malfunction caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance improper storage or use of non recommended fuels and lubricating oils accident caused damage and replacement of expendable and or consumable items made in connection with scheduled maintenance Owner s Responsibility As the Yanmar marin...

Page 83: ...on on the nearest authorized Yanmar dealer or distributor you should contactYanmarMarineUSACorporationfor assistance Yanmar Marine USA Corporation 101 International Parkway Adairsville GA 30103 USA Telephone 770 877 9894 Fax 770 877 7567 EPA WARRANTY USA ONLY BY Series Operation Manual 77 2008 Yanmar Marine International ...

Page 84: ...Maintenance Log Date Operating Hours Maintenance Performed Dealer Name Stamp or Signa ture EPA WARRANTY USA ONLY 78 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 85: ...Date Operating Hours Maintenance Performed Dealer Name Stamp or Signa ture EPA WARRANTY USA ONLY BY Series Operation Manual 79 2008 Yanmar Marine International ...

Page 86: ...EPA WARRANTY USA ONLY 80 BY Series Operation Manual 2008 Yanmar Marine International ...

Page 87: ...EPA WARRANTY USA ONLY BY Series Operation Manual 81 2008 Yanmar Marine International ...

Page 88: ...This Page Intentionally Left Blank EPA WARRANTY USA ONLY 82 BY Series Operation Manual 2008 Yanmar Marine International ...

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