Yanmar 6BY2 Manuals

Manuals and User Guides for Yanmar 6BY2. We have 2 Yanmar 6BY2 manuals available for free PDF download: Service Manual, Operation Manuals

Yanmar 6BY2 Service Manual

Yanmar 6BY2 Service Manual (248 pages)

MARINE ENGINES

Brand: Yanmar | Category: Engine | Size: 57.44 MB

Table of Contents

Table of Contents
3
Safety

13
- Safety Precautions
  14
General Service Information

19
- Safety Precautions
  21
- Engine Outline Drawings
  22
  - 4BY2 (Inboard)
    22
  - 4BY2 (Stern Drive)
    23
  - 6BY2 (Inboard)
    24
  - 6BY2 (Stern Drive)
    25
- Engine Piping Diagrams
  26
  - 4By2
    26
  - 6By2
    27
- Location of Nameplates
  29
  - Engine Nameplates (Typical)
    29
- Diesel Fuel
  30
  - Diesel Fuel Specifications
    30
  - Bleeding the Fuel System
    32
- Engine Oil
  32
- Engine Coolant
  37
  - Engine Coolant Specifications
    37
  - Acceptable Engine Coolant
    38
- Principal Engine Specifications
  39
- Tightening Torques for Standard Bolts and Nuts
  41
  - Tightening Fasteners
    41
  - Hexagon Bolts and Nuts
    41
  - Hose Clamps
    41
- Prepare Engine for Long-Term Storage
  42
- Abbreviations and Symbols
  43
  - Abbreviations
    43
  - Symbols
    43
- Unit Conversions
  44
  - Unit Prefixes
    44
  - Units of Length
    44
  - Units of Volume
    44
  - Units of Mass
    44
  - Units of Force
    44
  - Units of Torque
    44
  - Units of Pressure
    44
  - Units of Power
    44
  - Units of Temperature
    44
Periodic Maintenance

45
Engine

63
- Safety Precautions
  65
- Introduction
  65
- Specifications
  66
- Special Torque Chart
  70
- Special Service Tools
  73
- Measuring Instruments
  74
- Sealants and Compounds
  75
- Tests and Adjustments
  76
  - Test Compression
    76
- Repair
  77
- Cylinder Head
  78
  - Cylinder Head Components
    78
  - General Guidelines
    79
  - Remove and Install Cylinder Head Cover
    79
  - Remove and Install Glow Plugs
    81
  - Remove Cylinder Head
    81
  - Disassemble Cylinder Head
    84
  - Clean Cylinder Head Components
    86
  - Pressure Test the Cylinder Head
    86
  - Inspect Cylinder Head Components
    86
  - Replace Valve Stem Seals
    87
  - Assemble Cylinder Head
    88
  - Determine Cylinder Head Gasket Thickness
    88
  - Install Cylinder Head
    89
- Pistons and Cylinders
  93
- Flywheel and Flywheel Housing
  99
  - Remove and Install Flywheel Housing
    99
  - Remove and Install Drive Coupling
    100
  - Remove Flywheel
    101
  - Replace Rear Crankshaft Seal
    102
  - Install Flywheel
    103
- Camshaft and Timing Gear Train
  104
  - Components
    104
  - Check and Adjust Camshaft Timing
    106
  - Remove and Install Vibration Damper - 4BY2
    108
  - Remove and Install Vibration Damper - 6BY2
    109
  - Remove Timing Case Cover
    110
  - Remove and Install Timing Chain
    111
  - Install Timing Case Cover
    111
  - Remove and Install Timing Chain Tensioner
    112
  - Remove Camshafts
    113
  - Install Camshafts
    116
- Cylinder Block and Crankshaft
  118
  - Components
    118
  - Remove Crankshaft
    120
  - Measure Oil Clearance
    121
  - Inspect Crankshaft
    123
  - Inspect Cylinder Block
    124
  - Install Crankshaft
    124
  - Replace Front Crankshaft Seal
    126
- Intake Manifold
  128
  - Remove
    128
  - Install
    129
- Exhaust Manifold
  131
  - Remove
    131
  - Install
    131
Fuel System

135
- Safety Precautions
  135
- Introduction
  135
- Specifications
  136
  - Test and Adjustment Specifications
    136
  - Special Torque Chart
    136
- Special Service Tools
  137
- Fuel System Components
  138
  - 4BY2 Engines
    138
  - 6BY2 Engines
    138
- Fuel Flow Diagram
  139
- Tests and Adjustments
  141
  - Measure Fuel Feed Pump Pressure
    141
  - Test Return Fuel Pressure
    142
- Repair
  143
  - Remove Fuel Injector
    143
  - Clean Fuel Injector Cavities
    144
  - Install Fuel Injector
    145
  - Remove and Install High-Pressure Fuel Lines
    146
  - Replace the Fuel Feed Pump
    147
  - Replace High-Pressure Fuel Pump
    147
  - Replace Fuel Filters
    151
  - Remove and Install Fuel Rail
    152
  - Replace Injector Return Fuel Line
    153
  - Bleed the Fuel System
    154
Cooling System

155
- Safety Precautions
  157
- Introduction
  158
- Specifications
  158
  - Test and Adjustment Specifications
    158
  - Repair Specifications
    158
  - Special Torque Chart
    158
- Special Service Tools
  159
- Measuring Instruments
  159
- Cooling Flow Diagram
  160
- Tests and Adjustments
  161
  - Pressure Test Cooling System and Filler Cap
    161
  - Test Thermostat
    162
- Repair
  162
Lubrication

175
- Safety Precautions
  177
- Introduction
  177
- Specifications
  178
  - Test and Adjustment Specifications
    178
  - Special Torque Chart
    178
- Special Service Tools
  179
- Measuring Instruments
  179
- Tests and Adjustments
  180
  - Engine Oil Flow
    180
  - Check Engine Oil Pressure
    181
- Repair
  182
  - Engine Lubrication System Components
    182
  - Change Engine Oil and Replace Engine Oil Filter Element
    183
  - Remove and Install Oil Cooler
    183
  - Remove and Install Oil Filter Housing
    185
  - Remove and Install Oil Sump
    185
  - Oil Pump
    186
Turbocharger

187
- Safety Precautions
  189
- Introduction
  189
- Specifications
  189
  - Test and Adjustment Specifications
    189
  - Special Torque Chart
    189
- Special Service Tools
  190
- Sealants and Compounds
  190
- Tests and Adjustments
  191
  - Measure Charge Pressure
    191
- Repair
  192
  - Remove Turbocharger
    192
  - Install Turbocharger
    192
Starter Motor

195
- Safety Precautions
  197
- Introduction
  197
- Starter Motor Specifications
  197
  - General Specifications
    197
  - Special Torque Chart
    197
- Starter Motor Troubleshooting
  198
- Remove and Install Starter Motor
  199
Alternator

203
- Safety Precautions
  203
- Introduction
  204
- Specifications
  204
  - General Specifications
    204
  - Special Torque Chart
    204
- Repair
  205
Electrical and ECU

207
- Safety Precautions
  209
- Introduction
  209
- Specifications
  209
  - Special Torque Chart
    209
- Function Description - Engine Management System
  210
- Component Tests
  218
  - Relays
    218
  - Oil Pressure Sensor
    220
  - Fuel Injector
    220
  - Engine Coolant Temperature Sensor
    221
  - High-Pressure Fuel Regulator
    221
  - Water-In-Fuel Sensor
    222
  - Crankshaft Speed Sensor
    222
  - Glow Plug / Control Unit
    223
  - Fuel Temperature Sensor
    224
  - Fuel Volume Regulator
    224
  - Charge Air Temperature Sensor
    225
  - Charge Air Pressure Sensor
    225
  - High-Pressure Fuel Rail Pressure Sensor
    226
  - Camshaft Speed Sensor
    226
  - Throttle Position Sensor
    227
- Repair
  228
  - Replace Engine Control Unit (ECU)
    228
  - Replace Coolant Temperature Sensor
    228
  - Replace Charge Air Pressure Sensor
    229
  - Replace Charge Air Temperature Sensor
    229
  - Replace Crankshaft Sensor
    230
  - Replace Camshaft Sensor
    230
  - Replace High-Pressure Fuel Regulator
    231
  - Replace High-Pressure Fuel Rail Pressure Sensor
    232
  - Replace Fuel Temperature Sensor
    232
  - Replace Fuel Volume Regulator
    233
  - Replace Oil Pressure Sensor
    233
Troubleshooting

235
- Safety Precautions
  237
- Introduction
  237
- Engine Faults and Torque Limitations
  237
- Troubleshooting Chart
  240
  - Starting Trouble
    240
  - Exhaust Color
    240
  - Vibration - Drive Disengaged
    241
  - Vibration - Drive Engaged
    241
  - Engine Knocks
    242
  - Low Power Output
    242
  - Engine Overheat
    242
  - Engine Runs Cold
    243
  - Coolant Loss
    243
  - Helm Panel Display
    243
- Trouble Codes
  244
  - Working Procedure
    244
  - Diagnostic Trouble Codes
    244
- After Troubleshooting or Repair
  248

Advertisement

Yanmar 6BY2 Operation Manuals

Yanmar 6BY2 Operation Manuals (88 pages)

BY series

Brand: Yanmar | Category: Engine | Size: 14.73 MB

Table of Contents

Table of Contents
3
Introduction

7
- Record of Ownership
  8
Safety

9
- Safety Precautions
  10
  - General Information
    10
  - Before You Operate
    10
  - During Operation and Maintenance
    10
- Safety Decals
  14
Product Overview

15
- Yanmar BY-Series Features and Applications
  15
  - New Engine Break in
    16
- Component Identification
  17
  - Left Side (as Viewed from Flywheel) - 4BY2
    17
  - Right Side (as Viewed from Flywheel) - 4BY2
    17
  - Top View - 4BY2
    18
  - Left Side - 6BY2
    18
  - Right Side - 6BY2
    19
  - Top View - 6BY2
    19
- Location of Nameplates
  20
- Function of Major Components
  22
- Fuses and Relays
  24
- Engine Cover
  25
Before You Operate

27
- Diesel Fuel
  28
  - Diesel Fuel Specifications
    28
  - Filling the Fuel Tank
    30
  - Bleeding the Fuel System
    30
- Engine Oil
  31
  - Engine Oil Specifications
    31
  - Acceptable Engine Oil
    32
  - Checking Engine Oil
    35
  - Adding Engine Oil
    35
- Marine Gear or Stern Drive Oil
  36
- Power Steering Fluid Specifications
  36
  - Checking Power Steering Fluid Level
    36
- Engine Coolant
  37
  - Acceptable Engine Coolant
    37
Engine Operation

39
- Starting the Engine
  40
  - Starting at Low Temperatures
    41
- Shutting down the Engine
  41
  - Emergency Shut down
    41
- Checking the Engine after Operation
  42
Periodic Maintenance

43
Troubleshooting

65
- Troubleshooting Information
  65
- Troubleshooting Chart
  66
  - Starting Trouble
    66
  - Exhaust Color
    67
  - Vibration - Drive Disengaged
    67
  - Vibration - Drive Engaged
    68
  - Engine Knocks
    68
  - Low Power Output
    68
  - Engine Overheat
    69
  - Engine Runs Cold
    69
  - Coolant Loss
    69
- Diagnostic Trouble Codes
  70
  - Diagnostic Trouble Code Table
    71
Long-Term Storage

75
- Prepare Engine for Long-Term Storage
  75
  - Draining the Seawater Cooling System
    76
Specifications

77
- Engine Specifications
  77
EPA Warranty USA Only

81
- Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
  81
  - Your Warranty Rights and Obligations
    81
  - Warranty Period
    82
  - Warranty Coverage
    82
  - Exclusions
    82
  - Owner's Responsibility
    82
  - Customer Assistance
    83
  - 2008 Yanmar Marine International
    84
  - Maintenance Log
    84

Advertisement

Related Products

Yanmar Categories

Engine Tractor Portable Generator Outboard Motor Excavators

More Yanmar Manuals