Yanmar BY series Manuals

Manuals and User Guides for Yanmar BY series. We have 3 Yanmar BY series manuals available for free PDF download: Service Manual, Installation Manual

Yanmar BY series Service Manual (248 pages)

MARINE ENGINES

Brand: Yanmar | Category: Engine | Size: 57 MB

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

Yanmar BY series Service Manual (275 pages)

Brand: Yanmar | Category: Engine | Size: 22 MB

General Service Information

22
- Table of Contents
  22
- Engine Outline Drawings
  24
- 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 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
Engine

56
- Before You Begin Servicing
  58
- Introduction
  62
- Specifications
  62
- Special Torque Chart
  66
- Special Service Tools
  69
- Measuring Instruments
  70
- Tests and Adjustments
  72
  - Testing Compression
    72
- Repair
  73
- Cylinder Head
  74
- Pistons and Cylinders
  91
- Flywheel and Flywheel Housing
  97
- 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
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
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
- 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

Yanmar BY series Installation Manual (33 pages)

Electronic Control System

Brand: Yanmar | Category: Engine | Size: 1 MB

Table of Contents
4
Components
5
Installation
7
Checkout and Operation
13
- Start The Engine
  13
- Move The Boat
  13
- Shut Down
  13
- Tachometer Display
  13
Operation
14
- Tachometer Menu Structure
  14
- Warning Light
  17
- Engine Status Information
  17
3" Gauge (Tachometer) With Key Cut
18
Templates
18
3" Gauge (Tachometer) Without Key Cut
20
2" Gauge With Key Cut
22
2" Gauge Without Key Cut
22
- Ch18000 Top Mount
  24
- Ch18000 Side Mount
  26
- Key Switch Panel - CP19400
  28
Appendix A: Analog Gauges
30
Appendix B: Gauge Measurements
31

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Yanmar BY series Manuals

Yanmar BY series Service Manual (248 pages)

Table of Contents

Safety

General Service Information

Periodic Maintenance

Engine

Fuel System

Cooling System

Lubrication

Turbocharger

Starter Motor

Alternator

Electrical and ECU

Troubleshooting

Yanmar BY series Service Manual (275 pages)

Table of Contents

General Service Information

Periodic Maintenance

Engine

Fuel System

Cooling System

Lubrication

Turbocharger

Alternator

Electrical and Ecu

Troubleshooting

Yanmar BY series Installation Manual (33 pages)

Table of Contents

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