Yanmar 4BY2 Installation manual

MARINE
ENGINES
BY
series
OPERATION MANUAL
4BY2
6BY2
P/N: 0ABY0-G00200

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
the right to make any change at any time without notice. Yanmar and are
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.
© 2008 Yanmar Marine International
1108
ii BY Series Operation Manual
© 2008 Yanmar Marine International

TABLE OF
CONTENTS
Page
Introduction......................................................................1
Record of Ownership......................................................2
Safety...............................................................................3
Safety Precautions.........................................................4
General Information .................................................4
Before You Operate .................................................4
During Operation and Maintenance .............................4
Safety Decals................................................................8
Product Overview..............................................................9
Yanmar BY-Series Features and Applications......................9
New Engine Break In.............................................. 10
Component Identification...............................................11
Left Side (as viewed from flywheel) - 4BY2.................. 11
Right Side (as viewed from flywheel) - 4BY2................ 11
Top View - 4BY2 ................................................... 12
Left Side - 6BY2 .................................................... 12
Right Side - 6BY2 .................................................. 13
Top View - 6BY2 ................................................... 13
Location of Nameplates.................................................14
Function of Major Components........................................16
Fuses and Relays.........................................................18
Engine Cover..............................................................19
Before You Operate..........................................................21
Diesel Fuel..................................................................22
Diesel Fuel Specifications ....................................... 22
Filling the Fuel Tank ............................................... 24
Bleeding the Fuel System........................................ 24
Engine Oil...................................................................25
Engine Oil Specifications......................................... 25
Acceptable Engine Oil ............................................ 26
Checking Engine Oil............................................... 29
BY Series Operation Manual iii
© 2008 Yanmar Marine International

Adding Engine Oil.................................................. 29
Marine Gear or Stern Drive Oil.........................................30
Power Steering Fluid Specifications..................................30
Checking Power Steering Fluid Level......................... 30
Engine Coolant............................................................31
Acceptable Engine Coolant...................................... 31
Engine Operation.............................................................33
Starting the Engine.......................................................34
Starting at Low Temperatures .................................. 35
Shutting Down the Engine..............................................35
Emergency Shut Down ........................................... 35
Checking the Engine After Operation................................36
Periodic Maintenance.......................................................37
Safety Precautions.......................................................37
Precautions.................................................................39
The Importance of Periodic Maintenance .................... 39
Performing Periodic Maintenance ............................. 39
The Importance of Daily Checks ............................... 39
Keep a Log of Engine Hours and Daily Checks............. 39
Yanmar Replacement Parts ..................................... 39
Tools Required ..................................................... 39
Ask Your Authorized Yanmar Marine Dealer or
Distributor For Help................................................ 39
Required EPA Maintenance..................................... 39
EPA Requirements.......................................................40
Conditions to Ensure Compliance with EPA Emission
Standards............................................................ 40
Inspection and Maintenance .................................... 40
Tightening Fasteners.............................................. 40
Periodic Maintenance Schedule......................................42
Inspection and Maintenance of EPA Emission-Related
Parts................................................................... 46
Daily Checks...............................................................46
Visual Checks....................................................... 46
Checking Diesel Fuel, Engine Oil and Engine Coolant
Levels................................................................. 47
Checking the Battery Electrolyte Level ....................... 47
Checking the Alarm Indicators.................................. 47
Preparing Fuel, Oil and Coolant in Reserve ................. 47
Checking Power Steering Fluid................................. 47
Draining the Fuel / Water Separator ........................... 47
Periodic Maintenance Procedures....................................48
After Initial 50 Hours of Operation.............................. 48
Every 50 Hours of Operation .................................... 49
Every 250 Hours of Operation .................................. 50
Every 500 Hours of Operation .................................. 55
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© 2008 Yanmar Marine International

Every 1000 Hours of Operation................................. 56
Every 2000 Hours of Operation................................. 57
Troubleshooting..............................................................59
Troubleshooting Information........................................... 59
Troubleshooting Chart...................................................60
Starting Trouble .................................................... 60
Exhaust Color....................................................... 61
Vibration - Drive Disengaged.................................... 61
Vibration - Drive Engaged........................................ 62
Engine Knocks...................................................... 62
Low Power Output ................................................. 62
Engine Overheat ................................................... 63
Engine Runs Cold.................................................. 63
Coolant Loss ........................................................ 63
Diagnostic Trouble Codes..............................................64
Diagnostic Trouble Code Table ................................ 65
Long-Term Storage..........................................................69
Prepare Engine for Long-Term Storage.............................69
Draining the Seawater Cooling System....................... 70
Specifications..................................................................71
Engine Specifications....................................................71
EPA Warranty USA Only....................................................75
Yanmar Co., Ltd. Limited Emission Control System Warranty
- USA Only..................................................................75
Your Warranty Rights and Obligations: ....................... 75
Warranty Period: ................................................... 76
Warranty Coverage:............................................... 76
Exclusions: .......................................................... 76
Owner’s Responsibility: .......................................... 76
Customer Assistance: ............................................ 77
Maintenance Log................................................... 78
TABLE OF CONTENTS
BY Series Operation Manual v
© 2008 Yanmar Marine International

This Page Intentionally Left Blank
TABLE OF CONTENTS
vi BY Series Operation Manual
© 2008 Yanmar Marine International

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 BY2 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.
• 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.
• Refer to the Yanmar Limited Warranty
Handbook for a complete warranty
description.
BY Series Operation Manual 1
© 2008 Yanmar Marine International

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:
INTRODUCTION
2 BY Series Operation Manual
© 2008 Yanmar Marine International

SAFETY
Yanmar considers safety of great
importance and recommends that anyone
that comes into close contact with its
products, such as those that 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 labels. Keep
the labels 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
label attached to it, make sure you order the
new part and label 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.
DANGER
Indicates an 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 engine, personal property
and / or the environment or cause the
equipment to operate improperly.
BY Series Operation Manual 3
© 2008 Yanmar Marine International

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.
Before You Operate
DANGER
The safety message that follows has
DANGER 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 labels are additional
reminders for safe operating and
maintenance techniques.
• See your authorized Yanmar Marine
dealer or distributor for additional training.
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.
SAFETY
4 BY Series Operation Manual
© 2008 Yanmar Marine International