Yanmar Marine Engines 4BY, 6BY Repair Service Manual (0BBY0-G00101)

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Price: US$ 45.00

Complete service repair manual with Electrical Wiring Diagrams for Yanmar Marine Engine BY-Series (4BY, 6BY), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Yanmar Marine Engine BY-Series (4BY, 6BY) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 232 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

0BBY0-G00101 - Yanmar Marine Engine BY-Series (4BY, 6BY) Service Manual.pdf

MAIN SECTIONS
Table of Contents...3
Introduction...5
  Revision History...6
    Revision Control Table...6
Safety...7
  Safety Precautions...8
General Service Information...13
  Safety Precautions...15
  Engine Outline Drawings...16
    4BY with KMH40A...16
    6BY with KMH40A...17
  Engine Piping Diagrams...18
  Location of Nameplates...20
    Engine Nameplates (Typical)...20
  Diesel Fuel...21
    Diesel Fuel Specifications...21
      Additional Technical Fuel Requirements...21
      Diesel Fuel Lines...21
    Bleeding the Fuel System...22
  Engine Oil...22
    Engine Oil Specifications...22
      Service Categories...22
      Definitions...22
      Engine Oil Viscosity...23
    Acceptable Engine Oil...24
    Recommended Marine Gear or Stern Drive Oil...26
    Recommended Power Steering Fluid...26
  Engine Coolant...27
    Engine Coolant Specifications...27
      Engine Coolant Mixture...27
    Acceptable Engine Coolant...28
  Principal Engine Specifications...29
  Tightening Torques for Standard Bolts and Nuts...31
    Tightening Fasteners...31
    Hexagon Bolts and Nuts...31
    Hose Clamps...31
  Prepare Engine for Long-Term Storage...32
  Abbreviations and Symbols...33
    Abbreviations...33
    Symbols...33
  Unit Conversions...34
    Unit Prefixes...34
    Units of Length...34
    Units of Volume...34
    Units of Mass...34
    Units of Force...34
    Units of Torque...34
    Units of Pressure...34
    Units of Power...34
    Units of Temperature...34
Periodic Maintenance...35
  Introduction...37
    The Importance of Periodic Maintenance...37
    Performing Periodic Maintenance...37
    Yanmar Replacement Parts...37
    Required EPA Maintenance...37
  EPA Requirements...37
    Conditions to Ensure Compliance with EPA Emission Standards...37
    Inspection and Maintenance...38
  Periodic Maintenance Schedule...39
  Periodic Maintenance Procedures...43
    After Initial 50 Hours of Operation...43
    Every 50 Hours of Operation...43
    Every 250 Hours of Operation...44
    Every 500 Hours of Operation...44
    Every 1000 Hours of Operation...45
    Every 2000 Hours of Operation...45
Engine...47
  Before You Begin Servicing...49
  Introduction...50
  Specifications...50
    General Information...50
    Test and Adjustment Specifications...50
    Repair Specifications...51
  Special Torque Chart...54
  Special Service Tools...57
  Measuring Instruments...58
  Sealants and Compounds...59
  Tests and Adjustments...60
    Test Compression...60
  Repair...61
  Cylinder Head...62
    Cylinder Head Components...62
    General Guidelines...63
    Remove and Install Cylinder Head Cover...63
      Cylinder Head Cover Components...63
      Removal...63
      Installation...64
    Remove and Install Glow Plugs...64
    Remove Cylinder Head...65
    Disassemble Cylinder Head...68
    Clean Cylinder Head Components...70
    Pressure Test the Cylinder Head...70
    Inspect Cylinder Head Components...70
      Inspection of Valve Guides...71
    Replace Valve Stem Seals...71
    Assemble Cylinder Head...72
    Determine Cylinder Head Gasket Thickness...72
    Install Cylinder Head...73
  Pistons and Cylinders...77
    Remove and Disassemble Piston and Connecting Rod...77
    Inspect Pistons and Piston Rings...78
    Assemble Piston and Connecting Rod...79
    Install Piston and Connecting Rod...80
  Flywheel and Flywheel Housing...83
    Remove and Install Flywheel Housing...83
    Remove and Install Drive Coupling...84
      Engines with Marine Gear...84
      Engines with Stern Drive...84
    Remove Flywheel...85
    Replace Rear Crankshaft Seal...85
    Install Flywheel...86
  Camshaft and Timing Gear Train...88
    Components...88
    Check and Adjust Camshaft Timing...90
      Check Camshaft Timing...90
      Adjust Camshaft Timing...91
    Remove and Install Vibration Damper - 4BY...92
    Remove and Install Vibration Damper - 6BY...93
    Remove Timing Case Cover...94
    Remove and Install Timing Chain...94
    Install Timing Case Cover...95
    Remove and Install Timing Chain Tensioner...96
    Remove Camshafts...96
    Install Camshafts...99
  Cylinder Block and Crankshaft...102
    Components...102
    Remove Crankshaft...104
    Measure Oil Clearance...105
    Inspect Crankshaft...107
      Crankshaft Specifications...107
    Inspect Cylinder Block...108
    Install Crankshaft...108
    Replace Front Crankshaft Seal...110
  Intake Manifold...112
    Remove...112
    Install...113
  Exhaust Manifold...114
    Remove...114
    Install...115
  Attach Engine to Repair Stand...115
Fuel System...117
  Safety Precautions...119
  Introduction...119
  Specifications...120
    Test and Adjustment Specifications...120
    Special Torque Chart...120
  Special Service Tools...121
  Fuel System Components...122
    4BY Engines...122
    6BY Engines...122
  Fuel Flow Diagram...123
  Tests and Adjustments...124
    Measure Fuel Feed Pump Pressure...124
      Procedure...124
      Results...124
    Test Return Fuel Pressure...125
      Results...125
  Repair...126
    Remove Fuel Injector...126
    Clean Fuel Injector Cavities...127
    Install Fuel Injector...128
    Remove and Install High-Pressure Fuel Lines...129
    Replace the Fuel Feed Pump...130
    Replace High-Pressure Fuel Pump...130
      Removal...130
      Installation...132
    Replace Fuel Filters...134
      Replace Fuel Fine Filter...134
      Replace the Fuel Filter / Water Separator...135
    Remove and Install Fuel Rail...136
    Replace Injector Return Fuel Line...136
    Bleed the Fuel System...137
Cooling System...139
  Before You Begin Servicing...141
  Introduction...142
  Specifications...142
    Test and Adjustment Specifications...142
    Repair Specifications...142
    Special Torque Chart...142
  Special Service Tools...143
  Measuring Instruments...143
  Cooling Flow Diagram...144
  Tests and Adjustments...145
    Pressure Test Cooling System and Filler Cap...145
      Cooling System...145
      Filler Cap...145
    Test Thermostat...146
  Repair...146
    Drain and Refill Seawater Cooling System...146
    Check and Replace Zinc Anodes...147
    Drain and Fill Closed Cooling System...148
    Disconnect and Connect Quick-Connect Fittings...149
      Disconnect...149
      Connect...149
    Remove and Install Hydraulic Oil Cooler...149
    Inspect and Clean Hydraulic Oil Cooler...150
    Remove and Install Charge Air Cooler...150
    Disassemble and Assemble Charge Air Cooler...151
    Remove and Install Heat Exchanger...152
    Disassemble and Assemble Heat Exchanger...152
    Remove and Install Coolant Pump...153
    Remove and Install Thermostat...155
      Removal...155
      Installation...155
    Seawater Pump...156
      Inspect / Replace Impeller...156
      Remove and Install Seawater Pump...157
      Replace Seawater Pump Belt...157
Lubrication...159
  Introduction...161
  Specifications...161
    Test and Adjustment Specifications...161
    Special Torque Chart...161
  Special Service Tools...162
  Measuring instruments...162
  Tests and Adjustments...163
    Engine Oil Flow...163
    Check Engine Oil Pressure...164
      Results:...164
  Repair...165
    Engine Lubrication System Components...165
    Change Engine Oil and Replace Engine Oil Filter Element...166
    Remove and Install Oil Cooler...166
    Remove and Install Oil Filter Housing...168
    Remove and Install Oil Sump...169
    Oil Pump...169
      Remove Oil Pump...169
      Install Oil Pump...170
Turbocharger...171
  Introduction...173
  Specifications...173
    Test and Adjustment Specifications...173
    Special Torque Chart...173
  Special Service Tools...174
  Sealants and compounds...174
  Tests and Adjustments...175
    Measure Charge Pressure...175
      Results:...175
      Specifications...175
    Adjust Charge Pressure - 4BY...176
  Repair...177
    Remove Turbocharger...177
    Install Turbocharger...177
Starter Motor...179
  Before You Begin Servicing...181
  Introduction...182
  Starter Motor Specifications...182
    General Specifications...182
    Special Torque Chart...182
  Starter Motor Troubleshooting...183
  Remove and Install Starter Motor...184
Alternator...185
  Before You Begin Servicing...187
  Introduction...188
  Specifications...188
    General Specifications...188
    Special Torque Chart...188
  Repair...189
    Replace Alternator Belt...189
    Remove and Install Alternator...189
    Remove and Install Alternator Belt Tensioner...190
Electrical and ECU...191
  Introduction...193
  Specifications...193
    Special Torque Chart...193
  Function Description - Engine Management System...194
    Component Locations...194
      4BY...194
      6BY...196
      Electrical Panel Components...198
    Electrical Panel Connector (X1) Connections...198
      Connector X1 Pin Assignments...199
  Component Tests...202
    Relays...202
      Start Relay (K1)...202
      Main Relay (K2)...203
      Fuel Pump Relay (K3)...203
    Oil Pressure Sensor...204
      Results of Failed Sensor...204
      Test Values...204
    Fuel Injector...204
      Results of Failed Injector...204
      Test Values...204
    Engine Coolant Temperature Sensor...205
      Results of Failed Sensor...205
      Test Values...205
    Fuel Rail Pressure Control Valve...205
      Results of Failed Valve...205
      Test Values...205
    Water-in-Fuel Sensor...206
      Results of Failed Sensor...206
      Test Values...206
    Crankshaft Speed Sensor...206
      Results of Failed Sensor...206
    Glow Plug / Control Unit...207
      The System...207
      Function...207
      Results of Component Failure...207
      Test Values...207
    Fuel Temperature Sensor...208
      Results of Failed Sensor...208
      Test Values...208
    Fuel Volume Regulator...208
      Results of Failed Regulator...208
      Test Values...209
    Charge Air Temperature Sensor...209
      Results of Failed Sensor...209
      Test Values...209
    Charge Air Pressure Sensor...209
      Results of Failed Sensor...209
      Test Values...209
    Fuel Rail Pressure Sensor...210
      Results of Failed Sensor...210
      Test Values...210
    Camshaft Speed Sensor...210
      Results of Failed Sensor...210
    Throttle Position Sensor...211
      Results of Failed Sensor...211
      Test Values...211
  Repair...212
    Replace Engine Control Unit (ECU)...212
    Replace Coolant Temperature Sensor...212
    Replace Charge Air Pressure Sensor...213
    Replace Charge Air Temperature Sensor...213
    Replace Crankshaft Sensor...214
    Replace Camshaft Sensor...214
    Replace High-Pressure Fuel Control Valve...215
    Replace High-Pressure Fuel Sensor...216
    Replace Fuel Temperature Sensor...216
    Replace Fuel Volume Regulator...217
    Replace Oil Pressure Sensor...217
Troubleshooting...219
  Introduction...221
  Engine Faults and Torque Limitations...221
    Torque Limitation for Failed Sensors Mode...221
    Torque Limitation for Smoke Limitation Mode...221
    Torque Limitation for Overheat Protection Mode...223
  Troubleshooting Chart...224
    Starting Trouble...224
    Exhaust Color...224
    Vibration - Drive Disengaged...225
    Vibration - Drive Engaged...225
    Engine Knocks...226
    Low Power Output...226
    Engine Overheat...226
    Engine Runs Cold...227
    Coolant Loss...227
    Helm Panel Display...227
  Trouble Codes...228
    Working Procedure...228
    Diagnostic Trouble Codes...228
  After Troubleshooting or Repair...235

Yanmar Marine Engines 4BY, 6BY Repair Service Manual (0BBY0-G00101)

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