OPERATION MANUAL - Yanmar.fi

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BY series OPERATION MANUAL 4BY 6BY P/N: 0ABY0–G00101 MARINE ENGINES

Disclaimers: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and / or specifications to explain and / or exemplify a product, service or maintenance improvement. We reserve are the right to make any change at any time without notice. Yanmar and registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries. All Rights Reserved: No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of Yanmar Marine International. 2006 Yanmar Marine International 1006 ii BY Series Operation Manual

TABLE OF CONTENTS Page Introduction . 1 Record of Ownership . 2 Safety . 3 Safety Precautions . General Information . Before You Operate . During Operation and Maintenance . 4 4 4 4 Safety Decals . 8 Product Overview . 9 Yanmar BY-Series Features and Applications . 9 New Engine Break In . 10 Component Identification . 11 Left Side - 4BY . 11 Right Side - 4BY . 11 Top View - 4BY . 12 Left Side - 6BY . 12 Right Side - 6BY . 13 Top View - 6BY . 13 Location of Nameplates . 14 Function of Major Components . 15 Fuses and Relays . 17 Engine Cover . 18 Before You Operate . 19 Diesel Fuel . 19 Diesel Fuel Specifications . 19 Filling the Fuel Tank . 21 Bleeding the Fuel System . 21 Engine Oil . 22 BY Series Operation Manual iii

TABLE OF CONTENTS Engine Oil Specifications . 22 Acceptable Engine Oil . 23 Checking Engine Oil . 26 Adding Engine Oil . 26 Marine Gear or Stern Drive Oil . 27 Power Steering Fluid Specifications . 27 Checking Power Steering Fluid Level . 27 Engine Coolant . 28 Acceptable Engine Coolant . 28 Daily Checks . 29 Visual Checks . 29 Checking Diesel Fuel, Engine Oil and Engine Coolant Levels . 29 Checking the Battery Electrolyte Level . 29 Checking the Alarm Indicators . 29 Preparing Fuel, Oil and Coolant in Reserve . 29 Checking Power Steering Fluid . 29 Draining the Fuel / Water Separator . 30 Engine Operation . 31 Starting the Engine . 33 Starting at Low Temperatures . 33 Shutting Down the Engine . 34 Emergency Shut Down . 34 Checking the Engine After Operation . 34 Periodic Maintenance . 35 Safety Precautions . 35 Precautions . 37 The Importance of Periodic Maintenance . 37 Performing Periodic Maintenance . 37 The Importance of Daily Checks . 37 Keep a Log of Engine Hours and Daily Checks . 37 Yanmar Replacement Parts . 37 Tools Required . 37 Ask Your Authorized Yanmar Marine Dealer or Distributor For Help . 37 Required EPA Maintenance . 37 EPA Requirements . 38 Conditions to Ensure Compliance with EPA Emission Standards . 38 Inspection and Maintenance . 38 Periodic Maintenance Schedule . 39 iv BY Series Operation Manual

TABLE OF CONTENTS Inspection and Maintenance for EPA EmissionRelated Parts . 43 Periodic Maintenance Procedures . 44 After Initial 50 Hours of Operation . 44 Every 50 Hours of Operation . 45 Every 250 Hours of Operation . 46 Every 500 Hours of Operation . 51 Every 1000 Hours of Operation . 52 Every 2000 Hours of Operation . 53 Troubleshooting . 55 Troubleshooting Chart . 55 Starting Trouble . 55 Exhaust Color . 56 Vibration - Drive Disengaged . 56 Vibration - Drive Engaged . 57 Engine Knocks . 57 Low Power Output . 57 Engine Overheat . 58 Engine Runs Cold . 58 Coolant Loss . 58 Troubleshooting Information . 58 Diagnostic Trouble Codes . 59 Long-Term Storage . 65 Prepare Engine for Long-Term Storage . 65 Draining the Seawater Cooling System . 66 Specifications . 67 Engine Specifications . 67 Tightening Fasteners . 70 EPA Warranty USA Only . 71 Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only . 71 Your Warranty Rights and Obligations: . 71 Warranty Period: . 71 Warranty Coverage: . 72 Exclusions: . 72 Owner’s Responsibility: . 72 Customer Assistance: . 72 BY Series Operation Manual v

TABLE OF CONTENTS This Page Intentionally Left Blank vi BY Series Operation Manual

INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of Yanmar Marine is second to none. We design our engines to respect nature. This means quieter engines, with minimal vibrations, cleaner than ever. All of our engines designed after 1996 meet most of the present and future emission regulations, such as BSO II, SAV, EPA II, IMO and RCD. To help you enjoy your Yanmar BY engine for many years to come, please follow these recommendations: Read and understand this Operation Manual before you operate the machine to ensure that you follow safe operating practices and maintenance procedures. Keep this Operation Manual in a convenient place for easy access. If this Operation Manual is lost or damaged, order a new one from your authorized Yanmar marine dealer or distributor. BY Series Operation Manual Make sure this manual is transferred to subsequent owners. This manual should be considered a permanent part of the engine and remain with it. Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about these differences, please contact your authorized Yanmar marine dealer or distributor. The specifications and components (instrument panel, fuel tank, etc.) described in this manual may differ from ones installed on your vessel. Please refer to the manual provided by the manufacturer of these components. 1

INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Engine Model: Engine Serial No.: Date Purchased: Dealer: Dealer Phone: 2 BY Series Operation Manual

SAFETY Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products exercise care, common sense and comply with the safety information in this manual and on the machine’s safety decals. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a decal attached to it, make sure you order the new part and decal at the same time. ! This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol. BY Series Operation Manual ! DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. ! CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a situation which can cause damage to the machine, personal property and / or the environment or cause the equipment to operate improperly. 3

SAFETY SAFETY PRECAUTIONS General Information There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance. During Operation and Maintenance ! DANGER The safety message that follows has DANGER level hazards. Crush Hazard NEVER stand under hoisted engine. If the hoist mechanism fails, the engine will fall on you. Before You Operate ! DANGER The safety messages that follow have WARNING level hazards. NEVER permit anyone to install or operate the engine without proper training. Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures. Safety signs and decals are additional reminders for safe operating and maintenance techniques. See your authorized Yanmar marine dealer or distributor for additional training. 4 BY Series Operation Manual

SAFETY ! WARNING The safety messages that follow have WARNING level hazards. Explosion Hazard Avoid serious personal injury or equipment damage. While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flames and any other form of ignition out of the area. Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions. NEVER use a shop rag to catch the fuel. Wipe up all spills immediately. NEVER refuel with the engine running. Store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition. NEVER place diesel fuel or other flammable material such as oil, hay or dried grass close to the engine during engine operation or shortly after shut down. Fire Hazard Avoid injury or equipment damage from fire. Undersized wiring systems can cause an electrical fire. BY Series Operation Manual Sever Hazard Rotating parts can cause severe injury or death. NEVER wear jewelry, unbuttoned cuffs, ties or loose fitting clothing and ALWAYS tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. Exposure Hazard To avoid injury, ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand. Entanglement Hazard NEVER leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. Avoid personal injury. NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals. Stop the engine before you begin to service it. If you must service the engine while it is operating, remove all jewelry, tie back long hair, and keep your hands, other body parts and clothing away from moving / rotating parts. 5

SAFETY ! WARNING Alcohol and Drug Hazard NEVER operate the engine while under the influence of alcohol or drugs or feeling ill. Piercing Hazard Avoid skin contact with highpressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment. NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor repair the damage. Burn Hazard surfaces. Avoid serious injury. Some of the engine surfaces become very hot during operation and shortly after shut-down. Keep hands and other body parts away from hot engine ! CAUTION The safety messages that follow have CAUTION level hazards. Poor Lighting Hazard Avoid personal injury or equipment damage. Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps. Tool Hazard Avoid personal injury or equipment damage. ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts. Flying Object Hazard Avoid personal injury. ALWAYS wear eye protection when servicing the engine or when using compressed air or highpressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Coolant Hazard Wear eye protection and rubber gloves when you handle Long Life engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water. Sudden Movement Hazard Avoid personal injury. ALWAYS stop the engine before beginning service. Exhaust Hazard Avoid serious injury or death. NEVER block windows, vents or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning. 6 BY Series Operation Manual

SAFETY NOTICE The safety messages that follow have NOTICE level hazards. It is important to perform daily checks as listed in the Operation Manual. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine. See your authorized Yanmar marine dealer or distributor if you need to operate the engine at high altitudes. At high altitudes the engine will lose power, run rough and produce exhaust gases that exceed the design specifications. ALWAYS be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. NEVER dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways. If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Installation manuals, engine oil may enter the combustion chamber causing excessive engine speed, white exhaust smoke and serious engine damage. This applies to engines that run continuously or those that run for short periods of time. BY Series Operation Manual If you have an installation with two or three engines and only one engine is operating, the water pickup (thru-hull) of the nonrunning engine(s) should be closed. This will prevent water from being forced past the seawater pump and eventually finding its way into the engine. The result of water entering the engine could cause seizure or other serious problems. If you have an installation with two or three engines, and only one engine is operating, please note that if the propeller shaft thruhull (stuffing box) is lubricated by engine water pressure and the engines are interconnected, care must be taken that water from the running engine does not enter the exhaust of the non-running engine (s). This water could cause seizure of the non-running engine(s). See your authorized Yanmar marine dealer or distributor for a complete explanation of this condition. If you have an installation with two or three engines, and only one engine is operating, it is important to limit the amount of throttle applied to the running engine. If you observe black smoke or movement of the throttle does not increase engine rpm, you are overloading the engine that is running. Immediately throttle back to approximately 2/3 throttle or to a setting where the engine performs normally. Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engine's life. 7

SAFETY SAFETY DECALS Never remove the cap while the engine is still hot. Hot water may spurt out and burn you. 60 0.5 ton 120650-07040 When lifting the engine, lift only as shown in diagram. Weight: 0.5 ton 120650-07030 FULL LOW NEVER pour the engine oil across the full line. 120650-07050 0004537 Figure 1 8 BY Series Operation Manual

PRODUCT OVERVIEW YANMAR BY-SERIES FEATURES AND APPLICATIONS The BY-series engines are in-line 4- and 6-cylinder direct injection diesel engines. The engines are turbocharged and equipped with a liquid cooling system. These engines are designed for pleasure craft use. In order to obtain full performance from your engine, it is imperative that you check the size and structure of the hull and use a propeller of the appropriate size. As new boats are used, owners add additional equipment and completely fill the fuel and water tanks adding to the overall displacement (weight) of the vessel. Extra canvas enclosures, bottom paint, and bottom fouling can add additional hull resistance. It is recommended that a new vessel be propped so the engine can operate at 100 rpm above maximum rpm to allow for some added weight and hull resistance. Failure to do so can lead to reduced vessel performance, increased smoke levels and cause permanent damage to your engine. BY Series Operation Manual The engine must be installed correctly with the seawater or cooling water piping, exhaust gas piping and electrical wiring. Any auxiliary equipment attached to the engine should be easy to use and accessible for service. To handle the drive equipment, propulsion systems (including the propeller) and other on-board equipment, be sure to observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers. The laws of some countries may require hull and engine inspections, depending on the use, size and cruising area of the boat. The installation, fitting and surveying of this engine all require specialized knowledge and engineering skills. See Yanmar's local subsidiary in your region or your authorized Yanmar marine dealer or distributor. This engine is designed for pleasure boat applications. The engine is designed to be operated at: maximum throttle for less than 5% of its total operation time (30 minutes out of every 10 hours). The engine should be operated at cruising speed (3200 - 3300 rpm) for less than 90% of its total operation time (9 hours out of every 10 hours). 9

PRODUCT OVERVIEW New Engine Break In On the initial engine start-up, check for proper engine oil pressure, diesel fuel leaks, engine oil leaks, coolant leaks, and for proper operation of the indicators and / or gauges. During the first 50 hours of operation, operate your new engine under a substantial load at all times. For best break-in results, operate the engine at various speeds. Operating the engine in NEUTRAL must be avoided. During the first 50 hours, avoid operation below 2000 rpm. During the break-in period, carefully observe the engine oil pressure and engine temperature. During the break-in period, check the engine oil and coolant levels frequently. 10 BY Series Operation Manual

PRODUCT OVERVIEW COMPONENT IDENTIFICATION Left Side - 4BY Right Side - 4BY Figure 1, Figure 2 and Figure 3 illustrate a typical version of a 4BY engine. Your engine may have different equipment from that illustrated. (1) (4) (5) (3) (2) (2) (1) (6) (7) (3) (9) (8) Figure 2 (4) 0003642 Figure 1 1– 2– 3– 4– Engine Oil Dipstick Fuel Filter / Water Separator E-Box Panel High Pressure Fuel Pump BY Series Operation Manual 1– 2– 3– 4– 5– 6– 7– 8– 9– 0003643 Zinc Anode Zinc Anode Exhaust / Water Mixing Elbow Coolant Drain Cock Heat Exchanger Seawater Pump Seawater Drain Cock Hydraulic Oil Cooler Water Drain Plug 11

PRODUCT OVERVIEW Top View - 4BY Left Side - 6BY (2) (3) (4) (1) Figure 4, Figure 5 and Figure 6 illustrate a typical version of a 6BY engine. Your engine may have different equipment from that illustrated. (7) (1) (2) (3) (5) (6) 0003644 (4) 0003645 Figure 3 1– 2– 3– 4– Fuel Fine Filter Intake Air Manifold Engine Oil Filter Power Steering Filler Port (if equipped) 5 – Engine Oil Filler Port 6 – Coolant Filler Port 7 – Air Filter 12 Figure 4 1– 2– 3– 4– Engine Oil Dipstick Fuel Filter / Water Separator E-Box Panel High Pressure Fuel Pump BY Series Operation Manual

PRODUCT OVERVIEW Right Side - 6BY Top View - 6BY (4)(5) (3) (2) (4) (1) (3) (2) (5) (7) (6) (1) (7) (9) (8) Figure 5 1– 2– 3– 4– 5– 6– 7– 8– 9– (6) 0003646 Zinc Anode Zinc Anode Exhaust / Water Mixing Elbow Coolant Drain Cock Heat Exchanger Seawater Pump Seawater Drain Cock Hydraulic Oil Cooler Water Drain Plug BY Series Operation Manual Figure 6 0003647 1– 2– 3– 4– Fuel Fine Filter Intake Air Manifold Engine Oil Filter Power Steering Filler Port (if equipped) 5 – Engine Oil Filler Port 6 – Coolant Filler Port 7 – Air Filter 13

PRODUCT OVERVIEW LOCATION OF NAMEPLATES The engine data and drive information nameplates on Yanmar BY series engines are shown in Figure 7. Replace if damaged or lost. The engine block information is etched into the cylinder block behind the engine oil cooler near the end of the starting motor (Figure 8). 4 BY N 1085 N 075 1100 7 824 951 The typical location of the engine name plate is shown for Yanmar 4BY Series marine engines (Figure 7). 6BY engines are similar. Model Gear Model min-1 Continuous Power KW Speed of Prop Shaft min-1 min-1 Fuel Stop Power KW ENG. No. MERCRUISER DIVISION OF MERCURY MARINE STILLWATER, OK, U.S.A. SERIAL NUMBERS ENGINE YANMAR CO. LTD. TRANSOM MADE IN AUSTRIA DRIVE MODEL: TRANSOM ASSEMBLY AND STERN DRIVE SERIAL NUMBER DECAL STRIPS TO THE RESPECTIVE BLANK ON THIS DECAL. 0003637 Figure 8 Figure 7 14 0003636A BY Series Operation Manual

PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of Component Function Fuel Filter / Water Separator Removes dirt and water from the fuel. The filter element should be replaced periodically. See Replacing Fuel Filter / Water Separator Element on page 48. The water separator should be drained periodically. See Draining the Fuel / Water Separator on page 30. Fuel Fine Filter Removes extremely fine contaminants from fuel prior to entering fuel injection system. Fuel Feed Pump Pumps fuel from the tank to the fuel injection system. Engine Oil Fill Port To add engine oil. Engine Oil Filter Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is distributed to the engine's moving parts. The filter is a cartridge type and the element should be replaced periodically. See Changing the Engine Oil and Replacing the Engine Oil Filter on page 44. Coolant System There are two cooling systems: 1) closed cooling with coolant and 2) seawater. The engine is cooled by the closed cooling system. The closed system coolant is cooled by seawater using a heat exchanger. The seawater also cools the marine gear or power steering oil, and the combustion intake air through cooler (s) in an open circuit. Closed Cooling Circulation Pump The centrifugal coolant pump circulates coolant inside the engine. The circulating pump is driven by a poly V-belt. Seawater Pump Pumps seawater from outside vessel to the engine. The seawater pump is beltdriven and has a replaceable rubber impeller. Avoid impeller damage, do not operate it without seawater. Coolant Fill Cap When the coolant temperature rises, the pressure inside the heat exchanger increases, causing the pressure valve in the filler cap to open, forcing hot water and steam through a rubber hose to the coolant recovery tank. When the engine becomes cool and the pressure inside the coolant recovery tank drops, the vacuum valve in the filler cap opens and the coolant in the coolant recovery tank returns to the heat exchanger through the hose and filler cap. This minimizes coolant consumption. Coolant Recovery Tank The coolant fill cap valve releases vapor and hot water overflow to the coolant recovery tank. When the engine stops and the coolant cools, the pressure in the heat exchanger drops. The fill cap valve then opens to send coolant back from the coolant recovery tank. This minimizes coolant consumption. The closed cooling system coolant level can easily be checked and refilled in this tank. Oil Cooler - Engine A heat exchanger that cools high temperature engine oil using engine coolant. Oil Cooler - Hydraulic A heat exchanger that cools the marine gear oil or power steering fluid using seawater. Turbocharger The turbocharger pressurizes the air coming into the engine. It is powered by a turbine that is driven by exhaust gases. Air Filter The air filter removes dirt from the intake combustion air reducing engine wear. Nameplates Nameplates are provided on the engine and the marine gear and have the model, serial number and other data. BY Series Operation Manual 15

PRODUCT OVERVIEW Name of Component Function Electrical Panel (E-Box) The electrical panel houses the engine electrical system fuses, relays, and ECU. The ECU monitors data from the various sensors and controls such functions as low-pressure fuel pump operation, fuel injection pressure, fuel injection system volume, and the timing and volume of fuel injected by the Bosch electronic fuel injectors. Throttle control is fly-by-wire meaning it is controlled by electric signals from the helm. The throttle control is either analog or digital depending on the level of control options installed. The ECU also uses sensor inputs to monitor engine condition and will set a trouble code if a system or sensor indicates a problem. In most cases, a Check Engine light will be displayed. The engine may or may not run normally depending on the fault. Not all inputs are monitored by the ECU. Low oil pressure and water in fuel are two examples. Either of these conditions will result in a warning indicator and possible audible alarm. Low oil pressure will also be indicated by the oil gauge at the helm (not available with Classic Controls). Electrical Panel (E-Box) Circuit Breaker 16 The electrical panel circuit breaker is installed in the positive ( ) cable of the electrical panel power lead, and provides overload protection for the electrical panel. The electrical panel power leads must be connected directly to the battery, and must have a breaker installed in the B (red) lead. BY Series Operation Manual

PRODUCT OVERVIEW FUSES AND RELAYS (13) (2) (4) (6) (8) (3) (10) (5) (7) (9) (11) (14) (12) (1) To access the fuse and relay panel, remove the four bolts from the E-Box cover and remove cover. NOTICE: The electrical panel cables must be connected directly to the battery,

INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from

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