Yanmar BY series Spezifikationen Seite 1

BY series4BY6BYOPERATION MANUAL

BY Series Operation Manual 3BY Series Operation ManualSAFETYYanmar considers safety of great importance and recommends that anyone that comes into clo

PERIODIC MAINTENANCEBY Series Operation Manual 933. Check the seawater pump belt (Figure 8, (1)) and alternator belt (Figure 8, (2)) for wear, cracks

PERIODIC MAINTENANCE94 BY Series Operation ManualClean or Replace Air Filter ElementFigure 10Note: Washing kit WA250-355 is recommended for cleaning.

PERIODIC MAINTENANCEBY Series Operation Manual 95Perform the following maintenance every 500 hours of operation.• Check the Fuel Pump and Fuel Lines•

PERIODIC MAINTENANCE96 BY Series Operation Manual7. Install heat exchanger. Ensure the drain cock (Figure 12, (1)) on the heat exchanger is closed.8.

BY Series Operation Manual 97BY Series Operation ManualTROUBLESHOOTINGIf a problem occurs, stop the engine immediately. Refer to the Problem / Symptom

TROUBLESHOOTING98 BY Series Operation ManualTROUBLESHOOTING CHARTStarting TroubleExhaust ColorProblem / Symptom Cause ActionEngine Will Not CrankDisch

TROUBLESHOOTINGBY Series Operation Manual 99Vibration - Drive DisengagedVibration - Drive EngagedBlue SmokeWorn piston rings / cylindersSee your autho

TROUBLESHOOTING100 BY Series Operation ManualEngine KnocksLow Power OutputProblem / Symptom Cause ActionExcess Fuel InjectedDefective fuel injectorSee

TROUBLESHOOTINGBY Series Operation Manual 101Engine OverheatEngine Runs ColdCoolant LossProblem / Symptom Cause ActionInstrument Shows High Temperatur

TROUBLESHOOTING102 BY Series Operation ManualTROUBLESHOOTING INFORMATIONIf your engine does not operate properly, refer to the troubleshooting chart o

SAFETY4 BY Series Operation ManualSAFETY PRECAUTIONSBefore You OperateA CAUTIONCaution (the word “CAUTION” is in black letters with a yellow rectangle

TROUBLESHOOTINGBY Series Operation Manual 103Diagnostic Trouble Code TableCode Part or System ModeRun Or ConditionEngine Can StartCheck Engine AlarmNo

TROUBLESHOOTING104 BY Series Operation ManualP0122Throttle SignalBoth throttle signals are missing / short circuit to Ground1600 yes alarmThrottle Sig

TROUBLESHOOTINGBY Series Operation Manual 105P0237Boost PressureUnder 0.5 bar (7.3 psi) (absolute**)reduce yes alarmBoost Pressure SensorNo connection

TROUBLESHOOTING106 BY Series Operation ManualP0672Glow System - Glow Spark No. 2Not connected, short circuit yes yes alarmP0673Glow System - Glow Spar

BY Series Operation Manual 107BY Series Operation ManualLONG-TERM STORAGEIf the engine is not to be used for an extended period of time, special measu

LONG-TERM STORAGE108 BY Series Operation Manual8. Waterproof the engine room to prevent rain or seawater from entering.9. Charge the battery once a mo

LONG-TERM STORAGEBY Series Operation Manual 1093. Remove the seawater pump cover. See your authorized Yanmar dealer or distributor.4. Remove zinc anod

LONG-TERM STORAGE110 BY Series Operation ManualThis Page Intentionally Left Blank

BY Series Operation Manual 111BY Series Operation ManualSPECIFICATIONSENGINE SPECIFICATIONSEngine Model 4BY150 / 150Z 4BY180 / 180Z 6BY220 / 220Z 6BY

SPECIFICATIONS112 BY Series Operation ManualNo. of Valves per Cylinder 4Valve Adjustment Hydraulic self-adjustingTurbocharger MHI w/pneumatic wastegat

SAFETYBY Series Operation Manual 5During Operation and MaintenanceA DANGEREXPLOSION HAZARD!• Keep the area around the battery well-ventilated. While t

SPECIFICATIONSBY Series Operation Manual 113Operational Angles: Front-to-Rear and Left-to-RightContinuous 10° maximumPeak 20° maximumHeight 721 mm (28

SPECIFICATIONS114 BY Series Operation ManualTightening FastenersUse the correct amount of torque when you tighten fasteners on the machine. Applying e

BY Series Operation Manual 115BY Series Operation ManualEPA WARRANTYUSA ONLYYANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLYThe fo

EPA WARRANTY USA ONLY116 BY Series Operation ManualIt is recommended that any replacement parts used for maintenance, repair or replacement of emissio

EPA WARRANTY USA ONLYBY Series Operation Manual 117Owner’s Responsibility:As the Yanmar marine engine owner, you are responsible for the performance o

EPA WARRANTY USA ONLY118 BY Series Operation ManualThis Page Intentionally Left Blank

119

120Declaration of Conformity for Recreational Craft Propulsion Engine with the Exhaust and Noise emission requirements of Directive 94/25/EC as amende

SAFETY6 BY Series Operation ManualA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.• When you remov

SAFETYBY Series Operation Manual 7A DANGERFIRE AND EXPLOSION HAZARD!• Only use the key switch to start the engine.• NEVER jump start the engine. Spark

SAFETY8 BY Series Operation ManualA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.• Before you ope

SAFETYBY Series Operation Manual 9A DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.• Be sure to pla

SAFETY10 BY Series Operation ManualA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.• When you prim

SAFETYBY Series Operation Manual 11A DANGERCRUSH HAZARD!• ALWAYS use the engine lifting eyes when lifting the marine engine. The lifting eyes are engi

SAFETY12 BY Series Operation ManualA WARNINGEXHAUST HAZARD!• NEVER operate the engine in an enclosed area such as a garage, tunnel, underground room,

BY Series Operation ManualBY seriesOPERATION MANUAL4BY 6BYP/N: 0ABY0-G00100MARINEENGINES

SAFETYBY Series Operation Manual 13A WARNINGEXPOSURE HAZARD!• Wear personal protective equipment such as gloves, work shoes, eye and hearing protectio

SAFETY14 BY Series Operation ManualA WARNINGHIGH PRESSURE HAZARD!• Avoid skin contact with high pressure diesel fuel spray caused by a fuel system lea

BY Series Operation Manual 15A WARNINGWELDING SHOCK HAZARD!• Turn off the battery switch (if equipped) or disconnect the negative battery cable and th

SAFETY16 BY Series Operation ManualA WARNINGBURN HAZARD!• If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to

SAFETYBY Series Operation Manual 17A CAUTIONCOOLANT HAZARD!• Wear eye protection and rubber gloves when you handle Long Life engine coolant. If contac

SAFETY18 BY Series Operation ManualCAUTIONBe sure to close the seacock.Neglecting to close the seacock could allow water to leak into the boat and may

SAFETYBY Series Operation Manual 19CAUTIONObserve the following environmental operating conditions to maintain engine performance and avoid premature

SAFETY20 BY Series Operation ManualCAUTIONNew Engine Break In:• On the initial engine start-up, check for proper engine oil pressure, diesel fuel leak

SAFETYBY Series Operation Manual 21CAUTIONMake sure the engine is installed on a level surface. If a Yanmar Marine Engine is installed at an angle tha

SAFETY22 BY Series Operation ManualCAUTIONEstablish a periodic maintenance plan according to the engine application and make sure you perform the requ

ii BY Series Operation ManualDisclaimers:All information, illustrations and specifications in this manual are based on the latest information availabl

BY Series Operation Manual 23BY Series Operation ManualPRODUCT OVERVIEWYANMAR BY-SERIES FEATURES AND APPLICATIONSThe BY-series engines are in-line 4-

PRODUCT OVERVIEW24 BY Series Operation ManualThis engine is designed for pleasure boat applications. The engine is designed to be operated at: Maximum

PRODUCT OVERVIEWBY Series Operation Manual 25COMPONENT IDENTIFICATIONLeft Side - 4BYFigure 1, Figure 2, and Figure 3 illustrate a typical version of a

PRODUCT OVERVIEW26 BY Series Operation ManualTop View - 4BYFigure 31 – Fuel Fine Filter2 – Intake Air Manifold3 – Engine Oil Filter4 – Power Steering

PRODUCT OVERVIEWBY Series Operation Manual 27Right Side - 6BYFigure 51 – Zinc Anode2 – Zinc Anode3 – Exhaust / Water Mixing Elbow4 – Coolant Drain Coc

PRODUCT OVERVIEW28 BY Series Operation ManualLOCATION OF LABEL AND NAMEPLATESThe engine data and drive information nameplates on Yanmar BY series engi

PRODUCT OVERVIEWBY Series Operation Manual 29FUNCTION OF MAJOR COMPONENTSName of Component Function Fuel Filter / Water SeparatorRemoves dirt and wate

PRODUCT OVERVIEW30 BY Series Operation ManualCoolant Recovery Tank The coolant fill cap valve releases vapor and hot water overflow to the coolant rec

PRODUCT OVERVIEWBY Series Operation Manual 31FUSES AND RELAYSFigure 91 – Fuse F1 (3 A) - Switched B+ to CAN2 – Fuse F2 (10 A) - B+ to Key Switch3 – Fu

PRODUCT OVERVIEW32 BY Series Operation ManualENGINE COVERFigure 101. Turn screws (Figure 10, (1)) one-quarter turn to loosen.2. Lift cover off of engi

BY Series Operation Manual iiiBY Series Operation ManualTABLE OF CONTENTSPageRecord of Ownership ... 2S

BY Series Operation Manual 33BY Series Operation ManualBEFORE YOU OPERATEThis section of the Operation Manual describes the diesel fuel, engine oil, a

BEFORE YOU OPERATE34 BY Series Operation ManualA DANGERSCALD HAZARD!• NEVER remove the coolant filler cap if the engine is hot. Steam and hot engine c

BEFORE YOU OPERATEBY Series Operation Manual 35A DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.• B

BEFORE YOU OPERATE36 BY Series Operation ManualA WARNINGHIGH PRESSURE HAZARD!• Avoid skin contact with high pressure diesel fuel spray caused by a fue

BEFORE YOU OPERATEBY Series Operation Manual 37A CAUTIONCOOLANT HAZARD!• Wear eye protection and rubber gloves when you handle Long Life engine coolan

BEFORE YOU OPERATE38 BY Series Operation ManualCAUTION• ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governmenta

BEFORE YOU OPERATEBY Series Operation Manual 39DIESEL FUELDiesel Fuel SpecificationsDiesel fuel should comply with the following specifications. The t

BEFORE YOU OPERATE40 BY Series Operation ManualFilling the Fuel TankA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under c

BEFORE YOU OPERATEBY Series Operation Manual 41IMPORTANTOperate bilge ventilation (blowers) for a minimum of 5 minutes to purge fumes from engine comp

BEFORE YOU OPERATE42 BY Series Operation Manual1. Turn the key switch on and leave on for 10 seconds.2. Turn key switch OFF for 5 seconds, then turn k

TABLE OF CONTENTSiv BY Series Operation ManualEngine Coolant ... 49Recommended Engine Coolant ..

BEFORE YOU OPERATEBY Series Operation Manual 43Engine Oil SpecificationsUse a full synthetic - long life engine oil that meets or exceeds the followin

BEFORE YOU OPERATE44 BY Series Operation ManualRecommended Engine OilLongLife 01 OilsTrade name Producer/SupplierAddinol Super power MV 0537 Addinol L

BEFORE YOU OPERATEBY Series Operation Manual 45Elf Excellium XLL TotalEsso Ultron FE ExxonMobilGalp Formula XLD Petrogal SAGulf Formula TLX TotalHavol

BEFORE YOU OPERATE46 BY Series Operation ManualShell Helix Ultra AB Shell International Petroleum CompanyShell Helix Ultra AL Shell International Petr

BEFORE YOU OPERATEBY Series Operation Manual 47LongLife 04 OilsTrade name Producer/SupplierAddinol Super power MV 0537 Addinol Lube Oil GmbHAgip Formu

BEFORE YOU OPERATE48 BY Series Operation ManualChecking Engine OilFigure 3Note: 4BY series shown. 6BY is similar.1. Remove dipstick (Figure 3, (1)) an

BEFORE YOU OPERATEBY Series Operation Manual 49MARINE GEAR OR STERN DRIVE OILRefer to the instruction book for each marine gear or stern drive.ENGINE

BEFORE YOU OPERATE50 BY Series Operation ManualA CAUTIONCOOLANT HAZARD!• Wear eye protection and rubber gloves when you handle Long Life engine coolan

BEFORE YOU OPERATEBY Series Operation Manual 51Recommended Engine CoolantTrade Name ManufacturerAddinol Antifreeze Super Addinol Lube Oil GmbHAral Ant

BEFORE YOU OPERATE52 BY Series Operation ManualPOWER STEERING FLUID SPECIFICATIONSRefer to the stern drive manufacturer’s literature for power steerin

TABLE OF CONTENTSBY Series Operation Manual vPeriodic Maintenance Procedures ... 83After Initial 50 Hours of Operation ...

BEFORE YOU OPERATEBY Series Operation Manual 53Visual Checks1. Check the exterior of the engine for leaks, wear, or damage.2. Check for engine oil lea

BEFORE YOU OPERATE54 BY Series Operation ManualChecking Diesel Fuel, Engine Oil, and Engine Coolant LevelsFollow the procedures in Filling the Fuel Ta

BY Series Operation Manual 55BY Series Operation ManualENGINE OPERATIONThis section of this Operation Manual describes the procedures for starting the

ENGINE OPERATION56 BY Series Operation ManualA DANGEREXPLOSION HAZARD!• Keep the area around the battery well-ventilated. While the engine is running

ENGINE OPERATIONBY Series Operation Manual 57A WARNINGSEVER HAZARD!• Keep hands and other body parts away from moving / rotating parts such as the fly

ENGINE OPERATION58 BY Series Operation ManualA WARNINGEXPOSURE HAZARD!• Wear personal protective equipment such as gloves, work shoes, eye and hearing

ENGINE OPERATIONBY Series Operation Manual 59CAUTIONObserve the following environmental operating conditions to maintain engine performance and avoid

ENGINE OPERATION60 BY Series Operation ManualSTARTING THE ENGINE1. Open the seacock (if equipped).2. Open the fuel cock.3. Turn the battery master swi

ENGINE OPERATIONBY Series Operation Manual 61SHUTTING DOWN THE ENGINEUnder normal operating conditions, shut down the engine by turning the key switch

ENGINE OPERATION62 BY Series Operation ManualThis Page Intentionally Left Blank

TABLE OF CONTENTSvi BY Series Operation ManualTroubleshooting Chart ... 98Starting Trouble...

BY Series Operation Manual 63BY Series Operation ManualPERIODIC MAINTENANCEThis section of the Operation Manual describes the procedures for proper ca

PERIODIC MAINTENANCE64 BY Series Operation ManualDuring Operation and MaintenanceA DANGEREXPLOSION HAZARD!• Keep the area around the battery well-vent

PERIODIC MAINTENANCEBY Series Operation Manual 65A DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.•

PERIODIC MAINTENANCE66 BY Series Operation ManualA DANGERFIRE AND EXPLOSION HAZARD!• Only use the key switch to start the engine.• NEVER jump start th

PERIODIC MAINTENANCEBY Series Operation Manual 67A DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.•

PERIODIC MAINTENANCE68 BY Series Operation ManualA WARNINGSEVER HAZARD!• Keep hands and other body parts away from moving / rotating parts such as the

PERIODIC MAINTENANCEBY Series Operation Manual 69A WARNINGALCOHOL AND DRUG HAZARD!• NEVER operate the engine while you are under the influence of alco

PERIODIC MAINTENANCE70 BY Series Operation ManualA WARNINGSUDDEN MOVEMENT HAZARD!• Be sure the boat is in open water away from other boats, docks, and

PERIODIC MAINTENANCEBY Series Operation Manual 71A WARNINGENTANGLEMENT HAZARD!• Stop the engine before you begin to service it. • NEVER leave the key

PERIODIC MAINTENANCE72 BY Series Operation ManualA WARNINGBURN HAZARD!• Keep your hands, and other body parts, away from hot engine surfaces such as t

BY Series Operation Manual 1BY Series Operation ManualINTRODUCTIONWelcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems a

PERIODIC MAINTENANCEBY Series Operation Manual 73CAUTION• Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engi

PERIODIC MAINTENANCE74 BY Series Operation ManualCAUTION• Only use the engine coolant specified. Other engine coolants may affect warranty coverage, c

PERIODIC MAINTENANCEBY Series Operation Manual 75CAUTIONMake sure the engine is installed on a level surface. If a Yanmar Marine Engine is installed a

PERIODIC MAINTENANCE76 BY Series Operation ManualCAUTIONNEVER allow engine oil or diesel fuel oil to contact the flexible rubber mount. Oil makes rubb

PERIODIC MAINTENANCEBY Series Operation Manual 77PRECAUTIONSThe Importance of Periodic MaintenanceEngine deterioration and wear occur in proportion to

PERIODIC MAINTENANCE78 BY Series Operation ManualKeep a Log of Engine Hours and Daily ChecksKeep a log of the number of hours the engine is run each d

PERIODIC MAINTENANCEBY Series Operation Manual 79Pay particular attention to these important points:• Replacing the engine oil• Replacing the lube oil

PERIODIC MAINTENANCE80 BY Series Operation Manualc: Check : Replace z: Contact your authorized Yanmar marine dealer or distributorSystem Item Periodi

PERIODIC MAINTENANCEBY Series Operation Manual 81Cooling System - Seawater CircuitVisual inspection of cooling systemcBefore startingCheck the seawate

PERIODIC MAINTENANCE82 BY Series Operation ManualNote: These procedures are considered normal maintenance and are performed at the owner’s expense.Ins

INTRODUCTION2 BY Series Operation ManualRECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar for service,

PERIODIC MAINTENANCEBY Series Operation Manual 83PERIODIC MAINTENANCE PROCEDURESPerform the following maintenance after the initial 50 hours of operat

PERIODIC MAINTENANCE84 BY Series Operation Manual1. Turn engine OFF.2. Remove engine cover.Figure 13. Loosen the engine oil filter cap (Figure 1, (2))

PERIODIC MAINTENANCEBY Series Operation Manual 8513.Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil leve

PERIODIC MAINTENANCE86 BY Series Operation ManualCheck the Battery Electrolyte Level (Serviceable Batteries Only)Check the Battery Electrolyte Level (

PERIODIC MAINTENANCEBY Series Operation Manual 874. If the level is lower than the minimum fill level (Figure 3, (1)), fill with distilled water (Figu

PERIODIC MAINTENANCE88 BY Series Operation ManualDrain the Fuel TankFigure 4Note: Typical fuel tank shown. Actual equipment may differ.1. Turn engine

PERIODIC MAINTENANCEBY Series Operation Manual 89Replace the Fuel Fine Filter1. Disconnect the battery negative (-) cable.2. Close the fuel tank cock.

PERIODIC MAINTENANCE90 BY Series Operation ManualFigure 53. Loosen inlet (Figure 5, (1)) and outlet (Figure 5, (2)) hose clamps and remove hoses from

PERIODIC MAINTENANCEBY Series Operation Manual 911. Disconnect the battery negative (-) cable.2. Close the fuel tank cock.Figure 63. Loosen the drain

PERIODIC MAINTENANCE92 BY Series Operation ManualFigure 77. Clean the filter bowl. Inspect the water sensor probe (Figure 7, (1)) for damage. Inspect