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Yanmar 6BY Manuals
Manuals and User Guides for Yanmar 6BY. We have
1
Yanmar 6BY manual available for free PDF download: Service Manual
Yanmar 6BY Service Manual (275 pages)
Brand:
Yanmar
| Category:
Engine
| Size: 22.04 MB
Table of Contents
General Service Information
22
Table of Contents
22
Engine Outline Drawings
24
4BY - Inboard Version (Borg Warner Flange)
24
4BY - Stern Drive Version
25
6BY - Inboard Version (Borg Warner Flange)
26
6BY - Stern Drive Version
27
Engine Piping Diagrams
28
Location of Labels
30
Engine Nameplates (Typical)
30
Diesel Fuel
31
Diesel Fuel Specifications
31
Bleeding the Fuel System
32
Engine Oil
32
Engine Oil Specifications
32
Recommended Engine Oil
33
Recommended Marine Gear or Stern Drive Oil
35
Recommended Power Steering Fluid
35
Engine Coolant
36
Engine Coolant Specifications
36
Recommended Engine Coolant
37
Principal Engine Specifications
38
Tightening Torques for Standard Bolts and Nuts
40
Tightening Fasteners
40
Hexagon Bolts and Nuts
40
Hose Clamps
40
Abbreviations and Symbols
41
Abbreviations
41
Symbols
41
Periodic Maintenance
44
Before You Begin Servicing
45
EPA Requirements
49
Conditions to Ensure Compliance with EPA Emission Standards
49
Inspection and Maintenance
50
Introduction
49
The Importance of Periodic Maintenance
49
Performing Periodic Maintenance
49
Yanmar Replacement Parts
49
Required EPA Maintenance
49
Periodic Maintenance Schedule
51
Periodic Maintenance Procedures
54
After Initial 50 Hours of Operation
54
Every 50 Hours of Operation
54
Every 250 Hours of Operation
54
Every 500 Hours of Operation
54
Engine
56
Before You Begin Servicing
58
Introduction
62
Specifications
62
General Information
62
Test and Adjustment Specifications
62
Repair Specifications
63
Special Torque Chart
66
Special Service Tools
69
Measuring Instruments
70
Tests and Adjustments
72
Testing Compression
72
Repair
73
Cylinder Head
74
Cylinder Head Components
74
General Guidelines
75
Remove and Install Cylinder Head Cover
75
Remove and Install Glow Plugs
77
Removal of Cylinder Head
78
Disassembly of Cylinder Head
81
Cleaning Cylinder Head Components
83
Pressure Testing Cylinder Head
83
Inspection of Cylinder Head Components
83
Replacing Valve Stem Seals
84
Assembly of Cylinder Head
85
Determining Cylinder Head Gasket Thickness
86
Installation of Cylinder Head
87
Pistons and Cylinders
91
Removal and Disassembly of Piston and Connecting Rod
91
Inspection of Pistons and Piston Rings
92
Assembling Piston and Connecting Rod
93
Installation of Piston and Connecting Rod
94
Flywheel and Flywheel Housing
97
Remove and Install Flywheel Housing
97
Remove and Install Drive Coupling
97
Removal of Flywheel
99
Replacement of Rear Crankshaft Seal
99
Installation of Flywheel
100
Camshaft and Timing Gear Train
101
Components
101
Checking and Adjusting Camshaft Timing
103
Removing and Installing Vibration Damper - 4BY
105
Removing and Installing Vibration Damper - 6BY
106
Removing Timing Case Cover
107
Removing and Installing Timing Chain
107
Installing Timing Case Cover
108
Removing and Installing Timing Chain Tensioner
109
Removal of Camshafts
109
Installation of Camshafts
112
Cylinder Block and Crankshaft
115
Components
115
Removal of Crankshaft
117
Measuring Oil Clearance
118
Inspection of Crankshaft
119
Inspection of Cylinder Block
121
Crankshaft Installation
121
Replacing Front Crankshaft Seal
123
Intake Manifold
125
Removal
125
Installation
126
Exhaust Manifold
127
Remove
127
Install
127
Attaching Engine to Repair Stand
128
Fuel System
130
Before You Begin Servicing
132
Introduction
135
Specifications
135
Test and Adjustment Specifications
135
Special Service Tools
137
Fuel System Components
138
4BY Engines
138
Fuel Flow Diagram
139
Tests and Adjustments
140
Measuring Fuel Feed Pump Pressure
140
Testing Return Fuel Pressure
141
Repair
142
Removal of Fuel Injector
142
Cleaning Fuel Injector Cavities
143
Installation of Fuel Injector
145
Removing and Installing High-Pressure Fuel Lines
146
Replacing the Fuel Feed Pump
148
Replacing High-Pressure Fuel Pump
149
Replacing Fuel Filters
153
Removing and Installing Fuel Rail
156
Replacing Injector Return Fuel Line
157
Bleeding the Fuel System
158
Cooling System
160
Before You Begin Servicing
162
Introduction
164
Specifications
164
Test and Adjustment Specifications
164
Special Torque Chart
164
Special Service Tools
165
Cooling Flow Diagram
166
Tests and Adjustments
167
Pressure Testing Cooling System and Filler Cap
167
Testing Thermostat
168
Repair
169
Prepare Engine for Long-Term Storage
169
Drain Seawater Cooling System
169
Check and Replace Zinc Anodes
170
Draining and Filling Closed Cooling System
171
Disconnect and Connect Quick-Connect Fittings
172
Remove and Install Hydraulic Oil Cooler
172
Inspect and Clean Hydraulic Oil Cooler
173
Remove and Install Charge Air Cooler
173
Disassemble and Assemble Charge Air Cooler
174
Remove and Install Heat Exchanger
175
Disassemble and Assemble Heat Exchanger
175
Remove and Install Coolant Pump
176
Remove and Install Thermostat
178
Seawater Pump
179
Lubrication
182
Before You Begin Servicing
184
Introduction
187
Specifications
187
Test and Adjustment Specifications
187
Special Torque Chart
187
Measuring Instruments
188
Special Service Tools
188
Tests and Adjustments
189
Engine Oil Flow
189
Checking Engine Oil Pressure
190
Repair
192
Engine Lubrication System Components
192
Replace Engine Oil and Engine Oil Filter Element
193
Remove and Install Oil Cooler
195
Remove and Install Oil Filter Housing
196
Remove and Install Oil Sump
197
Oil Pump
198
Turbocharger
200
Before You Begin Servicing
202
Introduction
204
Specifications
204
Test and Adjustment Specifications
204
Special Torque Chart
204
Special Service Tools
205
Tests and Adjustments
206
Measuring Charge Pressure
206
Adjusting Charge Pressure - 4BY
207
Repair
208
Turbocharger Removal
208
Turbocharger Installation
209
Alternator
220
Before You Begin Servicing
222
Introduction
224
Specifications
224
General Specifications
224
Special Torque Chart
224
Repair
225
Replace Alternator Belt
225
Remove and Install Alternator
226
Remove and Install Alternator Belt Tensioner
226
Electrical and Ecu
228
Before You Begin Servicing
230
Introduction
232
Specifications
232
Special Torque Chart
232
Function Description - Engine Management System
233
Component Locations
233
Electrical Panel Connector (X1) Connections
238
Component Tests
241
Relays
241
Oil Pressure Sensor
243
Fuel Injector
243
Engine Coolant Temperature Sensor
244
Fuel Rail Pressure Control Valve
244
Water-In-Fuel Sensor
245
Crankshaft Speed Sensor
245
Glow Plug / Control Unit
246
Fuel Temperature Sensor
247
Fuel Volume Regulator
248
Charge Air Temperature Sensor
248
Charge Air Pressure Sensor
249
Fuel Rail Pressure Sensor
249
Camshaft Speed Sensor
250
Throttle Position Sensor
250
Repair
252
Replace Coolant Temperature Sensor
252
Replacing Engine Control Unit (ECU)
252
Replacing Charge Air Pressure Sensor
253
Replacing Charge Air Temperature Sensor
253
Replacing Camshaft Sensor
254
Replacing Crankshaft Sensor
254
Replacing High-Pressure Fuel Control Valve
255
Replacing High-Pressure Fuel Sensor
256
Replacing Fuel Temperature Sensor
258
Replacing Fuel Volume Regulator
259
Remove and Install Oil Pressure Sensor
260
Troubleshooting
262
Engine Faults and Torque Limitations
264
Torque Limitation for Failed Sensors
264
Torque Limitation for Smoke Limitation
264
Torque Limitation for Overheat Protection
266
Introduction
264
Troubleshooting Chart
267
Starting Trouble
267
Exhaust Color
267
Vibration - Drive Disengaged
268
Vibration - Drive Engaged
268
Engine Knocks
269
Low Power Output
269
Engine Overheat
269
Engine Runs Cold
270
Coolant Loss
270
Helm Panel Display
270
Trouble Codes
271
Working Procedure
271
Diagnostic Trouble Codes
271
After Troubleshooting or Repair
275
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