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