Yanmar BY3 - OPM - 0ABY0-G00301

OPERATION MANUAL
MARINE ENGINES
4BY3-150
4BY3-150Z
4BY3-180
4BY3-180Z
6BY3-220
6BY3-220Z
6BY3-260
6BY3-260Z
en English
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 CO., LTD.
4BY3-150, 4BY3-150Z, 4BY3-180, 4BY3-180Z

Model
OPERATION MANUAL 6BY3-220, 6BY3-220Z, 6BY3-260, 6BY3-260Z
Code 0ABY0-G00301
All Rights Reserved, Copyright

BY3_OM.book i ページ２０１２年１１月８日　木曜日　午前９時１５分
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 ........................................................... 11
Product Overview ......................................................... 13
YANMAR BY3-Series Features and Applications .... 13
New Engine Break In ......................................... 14
Component Identification ......................................... 15
Left Side (as Viewed from Flywheel) - 4BY3 ..... 15
Right Side (as Viewed from Flywheel) - 4BY3... 15
Top View - 4BY3................................................ 16
Left Side - 6BY3 ................................................ 16
Right Side - 6BY3 .............................................. 17
Top View - 6BY3................................................ 17
Location of Nameplates ........................................... 18
Function of Major Components ................................ 19
Fuses and Relays .................................................... 21
Engine Cover ........................................................... 22
Before You Operate...................................................... 23
Introduction .............................................................. 23
Safety Precautions ................................................... 23
Diesel Fuel ............................................................... 24
Diesel Fuel Specifications ................................. 24
Filling the Fuel Tank .......................................... 27
Bleeding the Fuel System.................................. 28
BY3 Series Operation Manual i

BY3_OM.book ii ページ２０１２年１１月８日　木曜日　午前９時１５分
TABLE OF CONTENTS
Engine Oil ................................................................. 28
Engine Oil Specifications ................................... 28
Acceptable Engine Oil........................................ 30
Checking Engine Oil........................................... 33
Adding Engine Oil .............................................. 33
Marine Gear or Stern Drive Oil ................................. 34
Marine Gear Oil Specifications........................... 34
Stern Drive Oil Specifications............................. 34
Power Steering Fluid Specifications ......................... 34
Checking Power Steering Fluid Level ................ 34
Engine Coolant ......................................................... 35
Acceptable Engine Coolant................................ 35
Engine Operation .......................................................... 37
Introduction............................................................... 37
Starting the Engine ................................................... 38
Starting at Low Temperatures............................ 38
Shutting Down the Engine ........................................ 39
Emergency Shut Down ...................................... 39
Checking the Engine After Operation ....................... 39
Periodic Maintenance ................................................... 41
Introduction............................................................... 41
Precautions............................................................... 42
The Importance of Periodic Maintenance .......... 42
Performing Periodic Maintenance ...................... 42
The Importance of Daily Checks ........................ 42
Keep a Log of Engine Hours and Daily Checks . 42
YANMAR Replacement Parts ............................ 42
Tools Required................................................... 42
Ask Your Authorized YANMAR Marine Dealer
or Distributor For Help........................................ 42
Tightening Fasteners ......................................... 42
EPA Maintenance Requirements ............................. 44
EPA Requirements for USA and Other
Applicable Countries .......................................... 44
EPA Requirements............................................. 44
Conditions to Ensure Compliance with EPA
Emission Standards ........................................... 45
Inspection and Maintenance .............................. 46
Installation of Exhaust Sampling Port ................ 46
Periodic Maintenance Schedule ............................... 47
Inspection and Maintenance of EPA
Emission-Related Parts...................................... 51
ii BY3 Series Operation Manual

BY3_OM.book iii ページ２０１２年１１月８日　木曜日　午前９時１５分
12/05
TABLE OF CONTENTS
Periodic Maintenance Procedures ........................... 51
Daily Checks...................................................... 51
Visual Checks .................................................... 51
Checking Diesel Fuel, Engine Oil and Engine
Coolant Levels ................................................... 52
Checking the Battery Electrolyte Level .............. 52
Checking the Alarm Indicators........................... 52
Preparing Fuel, Oil and Coolant in Reserve ...... 52
Checking Power Steering Fluid ......................... 52
Draining the Fuel/Water Separator .................... 52
After Initial 50 Hours of Operation ..................... 53
Every 50 Hours of Operation ............................. 54
Every 250 Hours of Operation ........................... 55
Every 500 Hours of Operation ........................... 60
Every 1000 Hours of Operation ......................... 61
Every 2000 Hours of Operation ......................... 62
Troubleshooting ........................................................... 63
Troubleshooting After Starting ................................. 64
Troubleshooting Information .................................... 65
Troubleshooting Chart.............................................. 66
Starting Trouble ................................................. 66
Smoke Color ...................................................... 67
Vibration - Drive Disengaged............................. 67
Vibration - Drive Engaged ................................. 68
Engine Knocks................................................... 68
Low Power Output ............................................. 68
Engine Overheat................................................ 69
Engine Runs Cold.............................................. 69
Coolant Loss...................................................... 69
Diagnostic Trouble Codes........................................ 70
Diagnostic Trouble Code Table ......................... 71
Long-Term Storage ...................................................... 75
Prepare Engine for Long-Term Storage................... 75
Draining the Seawater Cooling System ............. 76
Specifications ............................................................... 77
Engine Specifications............................................... 77
BY3 Series Operation Manual iii

BY3_OM.book iv ページ２０１２年１１月８日　木曜日　午前９時１５分
TABLE OF CONTENTS
EPA Warranty USA Only............................................... 81
YANMAR Co., Ltd. Limited Emission Control
System Warranty - USA Only ................................... 81
Your Warranty Rights and Obligations:.............. 81
Warranty Period: ................................................ 82
Warranty Coverage: ........................................... 82
Exclusions: ......................................................... 82
Owner’s Responsibility:...................................... 82
Customer Assistance: ........................................ 83
Maintenance Log................................................ 84
iv BY3 Series Operation Manual

BY3_OM.book 1 ページ２０１２年１１月８日　木曜日　午前９時１５分
BY3 Series Operation Manual
INTRODUCTION
Welcome to the world of YANMAR Marine! • Constant efforts are made to improve the
YANMAR Marine offers engines, drive quality and performance of YANMAR
systems and accessories for all types of products, so some details included in
boats, from runabouts to sailboats, and this Operation Manual may differ slightly
from cruisers to mega yachts. In marine from your engine. If you have any
leisure boating, the worldwide reputation of questions about these differences,
YANMAR Marine is second to none. We please contact your authorized
design our engines to respect nature. This YANMAR marine dealer or distributor.
means quieter engines, with minimal
• The specifications and components
vibrations, cleaner than ever. All of our
(instrument panel, fuel tank, etc.)
engines meet applicable regulations,
described in this manual may differ from
including emissions, at the time of
ones installed on your vessel. Please
manufacture.
refer to the manual provided by the
To help you enjoy your YANMAR BY3 manufacturer of these components.
engine for many years to come, please
• Refer to the YANMAR Limited Warranty
follow these recommendations:
Handbook for a complete warranty
• Read and understand this Operation description.
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.
BY3 Series Operation Manual 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 BY3 Series Operation Manual

SAFETY
YANMAR considers safety of great
importance and recommends that anyone DANGER
that comes into close contact with its DANGER indicates a hazardous
products, such as those who install, situation which, if not avoided, will
operate, maintain or service YANMAR result in death or serious injury.
products, exercise care, common sense
and comply with the safety information in
this manual and on the machine's safety
WARNING
decals. Keep the labels from becoming WARNING indicates a hazardous
dirty or torn and replace them if they are situation which, if not avoided, could
lost or damaged. Also, if you need to result in death or serious injury.
replace a part that has a label attached to
it, make sure you order the new part and CAUTION
label at the same time.
CAUTION indicates a hazardous
This safety alert symbol situation which, if not avoided, could
appears with most safety result in minor or moderate injury.
statements. It means
A attention, become alert,

your safety is involved!
NOTICE
NOTICE indicates a situation which can
Please read and abide by
cause damage to the machine, personal
the message that follows
property and/or the environment or cause
the safety alert symbol.
the equipment to operate improperly.

SAFETY
SAFETY PRECAUTIONS During Operation and
Maintenance
General Information
There is no substitute for common sense
DANGER
and careful practices. Improper practices Crush Hazard
or carelessness can cause burns, cuts, • Never stand under
mutilation, asphyxiation, other bodily injury hoisted engine. If the
or death. This information contains general hoist mechanism fails,
safety precautions and guidelines that the engine will fall on
must be followed to reduce risk to personal you.
safety. Special safety precautions are
listed in specific procedures. Read and • If the engine needs to be transported
understand all of the safety precautions for repair, have a helper assist you
before operation or performing repairs or attach it to a hoist and load it on a
maintenance. truck.
• The engine lifting eyes are engineered
Before You Operate to lift the weight of the marine engine
only. Always use the engine lifting
WARNING eyes when lifting the engine.
• Never permit anyone to • Additional equipment is necessary to
install or operate the lift the marine engine and marine gear
engine without proper together. Always use lifting
training. equipment with sufficient capacity to
lift the marine engine.
• Read and understand this Operation
Manual before you operate or service WARNING
the engine to ensure that you follow Explosion Hazard
safe operating practices and
While the engine is
maintenance procedures.
running or the battery is
• Safety signs and labels are additional charging, hydrogen gas is
reminders for safe operating and being produced and can
maintenance techniques. be easily ignited. Keep the
• Contact your authorized YANMAR area around the battery
Marine dealer or distributor for well-ventilated and keep
additional training. sparks, open flames and
any other form of ignition
out of the area.

12/05
SAFETY
WARNING WARNING
Fire and Explosion Hazard Sever Hazard
• Diesel fuel is flammable • Rotating parts can cause
and explosive under severe injury or death.
certain conditions. Never wear jewelry,
unbuttoned cuffs, ties or
loose fitting clothing and
• Never use a shop rag to catch the Always tie long hair back
fuel. when working near
moving/rotating parts
• Wipe up all spills immediately. such as the flywheel or
• Never refuel with the engine running. PTO shaft. Keep hands,
• Never use diesel fuel as a cleaning feet and tools away from
agent. all moving parts. Never
operate the engine
• Store any containers containing fuel without the guards in
or other flammable products in a place.
well-ventilated area, away from any
combustibles or sources of ignition. • Before you start the engine make sure
that all bystanders are clear of the
• Never jump-start the engine. Sparks area. Keep children and pets away
caused by shorting the battery to the while the engine is operating.
starter terminals may cause a fire or
explosion. Only use the key switch to • Check the engine that any tools or
start the engine. shop rags used during maintenance
have been removed from the area.
WARNING
WARNING
Fire Hazard
Alcohol and Drug Hazard
• Undersized wiring
systems can cause an Never operate the engine
electrical fire. while under the influence
of alcohol or drugs or
feeling ill.
• Store any equipment in a designated

area away from moving parts.
• Never use the engine compartment WARNING
for storage.
Exposure Hazard
Always wear personal
protective equipment
including appropriate
clothing, gloves, work
shoes, eye and hearing
protection as required by
the task at hand.

SAFETY
WARNING WARNING
Entanglement Hazard Burn Hazard
• Never leave the key in Some of the engine
the key switch when you surfaces become very hot
are servicing the engine. during operation and
Someone may shortly after shut-down.
accidentally start the Keep hands and other
engine and not realize body parts away from hot
you are servicing it. engine surfaces.
• Never operate the engine while
wearing a headset to listen to music WARNING
or radio because it will be difficult to Sudden Movement Hazard
hear the warning signals.
• Always stop the engine before
beginning service.
WARNING
• Be sure the boat is in open water
Piercing Hazard away from other boats, docks or other
• Avoid skin contact with obstructions before increasing
high-pressure diesel fuel engine speed. Avoid unexpected
spray caused by a fuel equipment movement. Shift the
system leak such as a marine gear into the NEUTRAL
broken fuel injection position any time the engine is at idle.
line. High-pressure fuel • To prevent accidental equipment
can penetrate your skin movement, Never start the engine in
and result in serious gear.
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. Contact your authorized
YANMAR Marine dealer or distributor
repair the damage.

12/05
SAFETY
WARNING WARNING
Exhaust Hazard Shock Hazard
• Never block windows, • Always turn off the
vents or other means of battery switch (if
ventilation if the engine is equipped) or disconnect
operating in an enclosed the negative battery
area. All internal cable before servicing
combustion engines the equipment.
create carbon monoxide • Always keep the electrical connectors
gas during operation and and terminals clean. Check the
special precautions are electrical harnesses for cracks,
required to avoid carbon abrasions, and damaged or corroded
monoxide poisoning. connectors.
• Always ensure that all connections • Never use undersized wiring for the
are tightened to specifications after electrical system.
repair is made to the exhaust system.
All internal combustion engines
create carbon monoxide gas during
WARNING
operation and special precautions are Never remove the coolant filler cap if
required to avoid carbon monoxide the engine is hot. Steam and hot engine
poisoning. coolant will spray out and seriously
burn you. Allow the engine to cool
WARNING down before you attempt to remove the
cap.
Welding Hazard
• Always turn off the battery switch (if CAUTION
equipped) or disconnect the negative
battery cable and the leads to the Poor Lighting Hazard
alternator when welding on the Ensure that the work area is adequately
equipment. illuminated. Always install wire cages
• Remove the engine control unit on portable safety lamps.
multi-pin connector. Connect the weld
clamp to the component to be welded CAUTION
and as close as possible to the Tool Hazard
welding point.
Always use tools appropriate for the
• Never connect the weld clamp to the
task at hand and use the correct size
engine or in a manner which would
tool for loosening or tightening
allow current to pass through a
machine parts.
mounting bracket.
• When welding is completed,
reconnect the alternator and engine
control unit prior to reconnecting the
batteries.

SAFETY
CAUTION NOTICE
Flying Object Hazard Contact your authorized YANMAR Marine
dealer or distributor if you need to operate
Always wear eye protection when
the engine at high altitudes. At high
servicing the engine or when using
altitudes the engine will lose power, run
compressed air or high-pressure water.
rough and produce exhaust gases that
Dust, flying debris, compressed air,
exceed the design specifications.
pressurized water or steam may injure
your eyes.
NOTICE
CAUTION Always be environmentally
Coolant Hazard responsible.
Wear eye protection and
rubber gloves when you
handle Long Life engine
coolant. If contact with the Follow the guidelines of the EPA or other
eyes or skin should occur, governmental agencies for the proper
flush eyes and wash disposal of hazardous materials such as
immediately with clean engine oil, diesel fuel and engine coolant.
water. Consult the local authorities or reclamation
facility.
NOTICE
CAUTION Never dispose of hazardous materials by
• Do not drain the coolant system. A dumping them into a sewer, on the ground
full coolant system will prevent or into ground water or waterways.
corrosion and frost damage.
• If seawater is left inside of the engine, NOTICE
it may freeze and damage parts of the If a YANMAR Marine Engine is installed at
cooling system when the ambient an angle that exceeds the specifications
temperature is below 0 °C (32 °F). stated in the YANMAR Marine Installation
manuals, engine oil may enter the
NOTICE combustion chamber causing excessive
engine speed, white smoke and serious
It is important to perform daily checks as
engine damage. This applies to engines
listed in the Operation Manual. Periodic
that run continuously or those that run for
maintenance prevents unexpected
short periods of time.
downtime, reduces the number of
accidents due to poor engine performance
and helps extend the life of the engine.

12/05
SAFETY
NOTICE NOTICE
If you have an installation with two or three New Engine Break In: On the initial engine
engines, and only one engine is operating, start-up, check for proper engine oil
please note that if the propeller shaft pressure, diesel fuel leaks, engine oil
thru-hull (stuffing box) is lubricated by leaks, coolant leaks, and for proper
engine water pressure and the engines are operation of the indicators and/or gauges.
interconnected, care must be taken that During the first 50 hours of operation
water from the running engine does not operate your new engine under a
enter the exhaust of the non-running substantial load at all times. For best
engine(s). This water could cause seizure break-in results operate the engine at
of the non-running engine(s). Contact your various speeds. Operating the engine in
authorized YANMAR Marine dealer or NEUTRAL must be avoided. During the
distributor for a complete explanation of first 50 hours, avoid operation below
this condition. 2000 min-1. During the break-in period,
carefully observe the engine oil pressure
NOTICE and engine temperature. During the
break-in period, check the engine oil and
If you have an installation with two or three coolant levels frequently.
engines, and only one engine is operating,
the water pickup (thru-hull) of the NOTICE
non-running engine(s) should be closed.
This will prevent water from being forced If any indicator illuminates during engine
past the seawater pump and eventually operation, stop the engine immediately.
finding its way into the engine. The result Determine the cause and repair the
of water entering the engine could cause problem before you continue to operate
seizure or other serious problems. the engine. Contact your authorized
YANMAR Marine dealer or distributor for
NOTICE service before operating the engine.
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 speed,
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.

SAFETY
NOTICE NOTICE
Observe the following environmental Modifications may impair the engine’s
operating conditions to maintain engine safety and performance characteristics
performance and avoid premature engine and shorten the engine’s life. Any
wear: alterations to this engine may void its
• Avoid operating in extremely dusty warranty. Be sure to use YANMAR
conditions. genuine replacement parts.
• Avoid operating in the presence of
chemical gases or fumes.
• Never run the engine if the ambient
temperature is above +40 °C (+104 °F)
or below -16 °C (+3 °F).
• If the ambient temperature exceeds
+40 °C (+104 °F), the engine may
overheat and cause the engine oil to
break down.
• If the ambient temperature is below
-16 °C (+3 °F), rubber components such
as gaskets and seals will harden causing
premature engine wear and damage.
• Contact your authorized YANMAR
Marine engine dealer or distributor if the
engine will be operated outside of this
standard temperature range.
NOTICE
Never engage the starter motor while the
engine is running. Damage to the starter
motor pinion and/or ring gear will result.
NOTICE
Any part which is found defective as a
result of inspection, or any part whose
measured value does not satisfy the
standard or limit, must be replaced.

12/05
SAFETY
SAFETY DECALS
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SAFETY
This Page Intentionally Left Blank

04-Product_Overview.fm 13 ページ２０１２年１１月８日　木曜日　午後１時２分
PRODUCT OVERVIEW
YANMAR BY3-SERIES The engine must be installed correctly with
coolant lines, exhaust gas lines and
FEATURES AND electrical wiring. Any auxiliary equipment
APPLICATIONS attached to the engine should be easy to
use and accessible for service. To handle
The BY3-series engines are in-line 4- and the drive equipment, propulsion systems
6-cylinder direct injection diesel engines. (including the propeller) and other
The engines are turbocharged and on-board equipment, always observe the
equipped with a liquid cooling system. instructions and cautions given in the
These engines are designed for pleasure operation manuals supplied by the
craft use. shipyard and equipment manufacturers.
It is recommended that new vessels be The BY3 series engines are designed to
propped so the engines can operate at 50 be operated at maximum throttle (4000
to 100 min-1 above the fuel stop power min-1) for less than 5 % of total engine time
engine speed to allow for some added (30 minutes out of every 10 hours) and
weight and hull resistance. cruising speed (3600 - 3700 min-1 or less).
Failure to do so can lead to reduced vessel The laws of some countries may require
performance, lead to increased smoke hull and engine inspections, depending on
levels and cause permanent damage to the use, size and cruising area of the boat.
your engine. The installation, fitting and surveying of
this engine all require specialized
knowledge and engineering skills. See
YANMARs local subsidiary in your region
or your authorized YANMAR Marine dealer
or distributor.

PRODUCT OVERVIEW
New Engine Break In If operating engine at low speed and light
load, you must race the engine to clean the
As with all reciprocating engines, the way carbon from the cylinders and fuel injection
your engine is operated during its first 50 valve.
hours of operation plays a very significant
role in determining how long it will last and Perform this procedure in open waters:
how well the engine will perform over its • With the clutch in NEUTRAL, accelerate
lifetime. from the low-speed position to the
A new YANMAR diesel engine must be high-speed position briefly.
operated at suitable speeds and power • Repeat this process five times.
settings during the break-in period to make
the sliding parts, such as piston rings, Once past the initial 10 hours until 50
break-in properly and to stabilize engine hours, the engine should be used over its
combustion. full operating range, with special emphasis
on running at relatively high power
During the break-in period, carefully settings. This is not the time for an
observe the engine oil pressure and extended cruise at idle or low speed. The
engine temperature. boat should be run at maximum speed
During the first 10 hours of operation, the minus 400 min-1 most of the time
engine should be run at maximum engine (approximately 70 % load), with a 10
speed minus 400 to 500 min-1 minute run at maximum minus 200 min-1
(approximately 60 to 70 % of load) most of (approximately 80 % load) every
the time. This will ensure the sliding parts 30 minutes and a 4 to 5 minute period of
break in properly. During this period, avoid operation at WOT (wide open throttle)
operating at maximum engine speed and once each 30 minutes. During this period,
load to avoid damaging or scoring sliding be sure not to operate your engine at low
parts. speed and light load for more than 30
minutes. If operating engine at low speed
NOTICE and light load by necessity, just after the
low idle operation, be sure to race the
Do not operate at WOT (wide open engine.
throttle) for more than a minute at a time
To complete engine break-in, perform
during the first 10 hours of operation.
After Initial 50 Hours of Operation
maintenance procedures. See After Initial
Do not operate the engine at low idle or at 50 Hours of Operation on page 53.
low speed and light load for more than 30
minutes at a time. Since unburned fuel and
engine oil will adhere to the piston rings
when operating at low speeds for long
periods, this will interfere with proper
movement of the rings and the engine oil
consumption may increase. Low idle
speed does not allow break-in of sliding
parts.

12/05
PRODUCT OVERVIEW
COMPONENT Right Side (as Viewed from
IDENTIFICATION Flywheel) - 4BY3
Figure 1, Figure 2 and Figure 3 illustrate 3 4

a typical version of a 4BY3 engine. Your 5
engine may have different equipment from
that illustrated.
Left Side (as Viewed from

Flywheel) - 4BY3 2
1
1
6
7
9
8 K0006559
1 – Zinc anode
2 2 – Zinc anode
3 – Exhaust/water mixing elbow
4 – Coolant drain cock
5 – Heat exchanger
6 – Seawater pump
3 K0006557
7 – Seawater drain cock
8 – Hydraulic oil cooler
1 – Engine oil dipstick
9 – Coolant drain plug
2 – E-Box panel
3 – High pressure fuel pump Figure 2
Figure 1

PRODUCT OVERVIEW
Top View - 4BY3 Figure 4, Figure 5 and Figure 6 illustrate
a typical version of a 6BY3 engine. Your
2 engine may have different equipment from
3 4 that illustrated.
1 Left Side - 6BY3
1
7
5 2
6 K0006560 3
1 – Fuel fine filter K0006558
2 – Intake air manifold 1 – Engine oil dipstick

3 – Engine oil filter 2 – E-Box panel
4 – Power steering filler port (if 3 – High pressure fuel pump
equipped)
5 – Engine oil filler port Figure 4
6 – Coolant filler port
7 – Air filter
Figure 3
Note: YANMAR supplies a
water-separating pre-filter for
mounting by the installer. The engine
is equipped with an on-engine fine
filter (1, Figure 3).

12/05
PRODUCT OVERVIEW
Right Side - 6BY3 Top View - 6BY3
3 4 2
5
3 4
1
2
7
5
6
1
7
9 8 6 K0006562
K0006561
1 – Zinc anode 1 – Fuel fine filter

2 – Zinc anode 2 – Intake air manifold
3 – Exhaust/water mixing elbow 3 – Engine oil filter
4 – Coolant drain cock 4 – Power steering filler port (if
5 – Heat exchanger equipped)
6 – Seawater pump 5 – Engine oil filler port
7 – Seawater drain cock 6 – Coolant filler port
8 – Hydraulic oil cooler 7 – Air filter
9 – Coolant drain plug Figure 6
Figure 5
Note: YANMAR supplies a
water-separating pre-filter for
mounting by the installer. The engine
is equipped with an on-engine fine
filter (1, Figure 6).

PRODUCT OVERVIEW
LOCATION OF 6BY3
NAMEPLATES Model
Gear Model EMISSION CONTROL INFORMATION RCD - ENGINE FAMILY NAME
BY
THIS MARINE ENGINE COMPLIES WITH U.S.EPA REGULATIONS FOR
Continuous power kW kW/ ｎ-１
ｍｉ G .ULTRA LOW SULFUR DIESEL FUEL ONLY.
ENGINE FAMILY : A ENGINE MODE : C
Speed of prop.shaft ｎ-１
ｍｉ STANDARDS NOx+HC:5.8g/kW-hr CO:5.0g/kW-hr PM:0.15g/kW-hr
The engine data and drive information Fuel stop power kW

ENG.No.
MFG.DATE
/
/
ｎ-１
ｍｉ
APPLICATION:VARIABLE-SPEED PROPULSION ENGINES USED
WITH FIXED-PITCH PROPELLERS.
EMISSION CONTROL SYSTEM: DFI
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS.
YANMAR CO.,LTD.
INSTALLING THIS RECREATIONAL ENGINE IN A COMMERCIAL VESSEL
OR USING THE VESSEL FOR COMMERCIAL PURPOSES MAY VIOLATE
FEDERAL LAW SUBJECT TO CIVIL PENALTY. (40 CFR 1042.601)
YANMAR CO.,LTD.
nameplates on YANMAR BY3 series BSO/SAV-EXHAUST GAS TYPE TEST
ENGINE FAMILY BY
CERTIFICATION No. M140130652
engines are shown in Figure 7, Figure 8

and Figure 9. Replace if damaged or lost.
The typical location of the engine name
plate is shown for YANMAR 4BY3 Series
marine engines (Figure 7) and 6BY3
engines (Figure 8).
4BY3
Model
INSTALLING THIS RECREATIONAL ENGINE IN A COMMERCIAL VESSEL
OR USING THE VESSEL FOR COMMERCIAL PURPOSES MAY VIOLATE
044343-01X00
Gear Model
FEDERAL LAW SUBJECT TO CIVIL PENALTY. (40 CFR 1042.601)
Continuous power kW kW/ ｎ-１
ｍｉ
YANMAR CO.,LTD.
Speed of prop.shaft ｎ-１
ｍｉ
RCD - ENGINE FAMILY NAME Fuel stop power kW / ｎ-１
ｍｉ EMISSION CONTROL INFORMATION
BY ENG.No.
MFG.DATE /
THIS MARINE ENGINE COMPLIES WITH U.S.EPA REGULATIONS FOR
G .ULTRA LOW SULFUR DIESEL FUEL ONLY.
ENGINE FAMILY : A ENGINE MODE : C
STANDARDS NOx+HC:5.8g/kW-hr CO:5.0g/kW-hr PM:0.15g/kW-hr
Figure 8
APPLICATION:VARIABLE-SPEED PROPULSION ENGINES USED
WITH FIXED-PITCH PROPELLERS.
EMISSION CONTROL SYSTEM: DFI
REFER TO OWNER'S MANUAL FOR MAINTENANCE
The engine block information is etched into

SPECIFICATIONS AND ADJUSTMENTS.
YANMAR CO.,LTD.
BSO/SAV-EXHAUST GAS TYPE TEST
ENGINE FAMILY BY
CERTIFICATION No. M140130652 the cylinder block behind the engine oil
cooler near the end of the starting motor
(Figure 9).
MERCRUISER
DIVISION OF MERCURY MARINE
STILLWATER, OK, U.S.A. MODEL:
SERIAL NUMBERS TRANSOM ASSEMBLY
ENGINE AND STERN DRIVE
SERIAL NUMBER DECAL
TRANSOM
STRIPS TO THE
RESPECTIVE BLANK
DRIVE
ON THIS DECAL.
044342-01X00
4 BY N
1085 N 075
Figure 7 1100 7 824 951
K0006567
Figure 9

12/05
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
(not supplied by YANMAR) periodically. See Replacing fuel filter/water separator element on page 57. The
water separator should be drained periodically. See Draining the Fuel/Water
Separator on page 52.
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 53.
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 The centrifugal coolant pump circulates coolant inside the engine. The circulating
pump pump is driven by a poly V-belt.
Seawater pump Pumps seawater from outside vessel to the engine. The seawater pump is
belt-driven 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 reservoir. When the engine becomes cool
and the pressure inside the coolant tank drops, the vacuum valve in the filler cap
opens and the coolant in the reservoir returns to the heat exchanger through the
hose and filler cap. This minimizes coolant consumption.
Reservoir The coolant fill cap valve releases vapor and hot water overflow to the reservoir.
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 reservoir. 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.

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) The electrical panel circuit breaker is installed in the positive (+) cable of the
circuit breaker 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.

12/05
PRODUCT OVERVIEW
FUSES AND RELAYS
2 4
1 3 6 8
5 7 10
13 9
11
14 12
15
K0004043
1 – Fuse F1 (3 A) - CAN switched 8 – Jumper fuse F8 (3 A) -

power CAN/Analog throttle selection,
2 – Fuse F2 (10 A) - Ignition* default is analog (fuse out). Insert
3 – Fuse F3 (15 A) - Fuel supply 3 A fuse to configure for CAN.
pump 9 – K1 - Starter relay
4 – Fuse F4 (30 A) - ECU switched 10 – K3 - Fuel supply pump relay
power 11 – K2 - Main power relay
5 – Fuse F5 (20 A) - Power to 12 – ECU
sensors and actuators 13 – Connector X1 - Communication
6 – Fuse F6 (10 A) - Auxiliary power to helm display
7 – Jumper fuse F7 (3 A) - Single/port 14 – Connector X21/1 - Engine wiring
selection, default is single/port harness
(fuse in). Remove fuse for 15 – Connector X22/1 - Fuel injector
starboard configuration. wiring harness
Figure 10
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, and must have a
circuit breaker installed in the B+ (red) lead.
* Never connect any additional devices to F2. F6 may be used however, it is not
switched.

PRODUCT OVERVIEW
ENGINE COVER
K0006552
Figure 11
To remove the cover from the engine,
remove all bolts, then lift cover from
engine.

BEFORE YOU OPERATE

INTRODUCTION
This section of the Operation Manual
describes the diesel fuel, engine oil and
engine coolant specifications and how to
replenish them.
SAFETY PRECAUTIONS
Before performing any operations within
this section, review the Safety section on
page 3.

BEFORE YOU OPERATE

DIESEL FUEL NOTICE
Diesel Fuel Specifications If the B7 biodiesel fuel used does not meet
the approved specifications, it will cause
WARNING abnormal wear of injectors, reduce the life
Fire and Explosion Hazard of the engine and it may affect the
warranty coverage of your engine.
Diesel fuel is flammable and explosive
under certain conditions.
B7 diesel fuels must meet certain
NOTICE specifications.
The biodiesel fuels must meet the
Only use diesel fuels recommended by minimum specifications for the country in
YANMAR for the best engine performance, which they are used:
to prevent engine damage and to comply
with EPA warranty requirements. Only use • In Europe, biodiesel fuels must comply
clean diesel fuel. with the European Standard
EN590-2009. EN14214
Diesel fuel should comply with the • In the United States, biodiesel fuels must
following specifications. The table lists comply with the American Standard
several worldwide specifications for diesel ASTM D-6751. D7467
fuels. Biodiesel should be purchased only from
recognized and authorized diesel fuel
Diesel fuel specification Location
suppliers.
ASTM D975 No. 2-D S15, USA
No. 1-D S15, D6751, D7467 Precautions and concerns regarding
EN590-2009, EN14214 European Union the use of biofuels:
ISO 8217 DMX International • Biodiesel fuels have a higher content of
BS 2869-A1 or A2 United Kingdom methyl-esters, which may deteriorate
JIS K2204 Grade No. 2 Japan certain metal, rubber and plastic
components of the fuel system. The
■ Biodiesel fuels customer and/or boat builder are
responsible to verify the usage of
YANMAR approves the use of biodiesel biodiesel compatible components on the
fuels that do not exceed a blend of 7 % vessel fuel supply and return systems.
non-mineral oil based fuel with 93 %
• Free water in biodiesel may result in
standard diesel fuel. Such biodiesel fuels
plugging of fuel filters and increased
are known in the marketplace as B7
bacterial growth.
biodiesel fuels. B7 biodiesel fuel can
reduce particulate matter and the emission • High viscosity at low temperatures may
of “greenhouse” gases compared to result in fuel delivery problems, injection
standard diesel fuel. pump seizures and poor injection nozzle
spray atomization.

05-Before_You_Operate.fm 25 ページ２０１２年１１月８日　木曜日　午後１時５分
12/05
BEFORE YOU OPERATE
• Biodiesel may have adverse effects on • Carbon residue content not to exceed
some elastomers (seal materials) and 0.35 % by volume. Less than 0.1 % is
may result in fuel leakage and dilution of preferred.
the engine lubricating oil.
• Total aromatics content should not
• Even biodiesel fuels that comply with a exceed 35 % by volume. Less than 30 %
suitable standard as delivered will is preferred.
require additional care and attention to
• PAH (polycyclic aromatic hydrocarbons)
maintain the quality of the fuel in the
content should be below 10 % by volume.
equipment or other fuel tanks. It is
important to maintain a supply of clean, • Do not use Biocide.
fresh fuel. Regular flushing of the fuel
system, and/or fuel storage containers, ■ Handling of diesel fuel
may be necessary.
WARNING
• The use of biodiesel fuels that do not
comply with the standards as agreed to Fire and Explosion Hazard
by the diesel engine manufacturers and • Only fill the fuel tank with diesel fuel.
the diesel fuel injection equipment Filling the fuel tank with gasoline may
manufacturers, or biodiesel fuels that result in a fire and will damage the
have degraded as per the precautions engine. Never refuel with the engine
and concerns above, may affect the running. Wipe up all spills
warranty coverage of your engine. immediately. Keep sparks, open
flames or any other form of ignition
■ Additional technical fuel (match, cigarette, static electric
requirements source) well away when refueling.
• The fuel cetane number should be 45 or • Always put the diesel fuel container
higher. on the ground when transferring the
diesel fuel from the pump to the
• The sulfur content must not exceed 15
container. Hold the hose nozzle firmly
ppm by volume.
against the side of the container while
A higher sulfur content fuel may cause
filling it. This prevents static
sulfuric acid corrosion in the cylinders of
electricity buildup which could cause
the engines.
sparks and ignite fuel vapors.
Especially in U.S.A. and Canada, Ultra
Low Sulfur fuel must be used.
1. Water and dust in the fuel may cause
• Never mix kerosene, used engine oil or
engine failure. When fuel is stored, be
residual fuels with the diesel fuel.
sure that the inside of the storage
• Water and sediment in the fuel should container is clean and dry, and that the
not exceed 0.05 % by volume. fuel is stored away from dirt or rain.
• Keep the fuel tank and fuel-handling
equipment clean at all times.
• Ash content not to exceed 0.01 % by
volume.

BEFORE YOU OPERATE

■ Diesel Fuel Lines
1 3
011213-00X-70
Figure 1
2
2. Keep the fuel container stationary for 7 6 5
several hours to allow any dirt or water K0003638A
to settle to the bottom of the container. 1 – To fuel feed pump

Use a pump to extract the clear, filtered 2 – Less than 500 mm (19.68 in.)
fuel from the top of the container. 3 – Fuel return line
4 – Fuel tank
■ Fuel tank (optional) 5 – Fuel tank drain cock
6 – 20 - 30 mm (0.75 - 1.125 in.)
7 – Fuel shutoff valve
Figure 3
Shown is a typical installation of a boat fuel
system. Fuel supply (2, Figure 3) and
return (4, Figure 3) lines connect to fittings
at the engine.
3 Total suction resistance shall be less than
0.1 bar (40 in.Aq). High resistance may
2 cause poor performance and reduce fuel
1 002875-02X01 system life.
1 – Sediment bowl Note: YANMAR supplies a water
2 – Drain cock separating pre-filter for mounting by
3 – Fuel line to engine the installer. The engine is also
Figure 2 equipped with an on-engine fine
filter.
Install a drain cock (2, Figure 2) at the
bottom of the fuel tank to remove water
and contaminants from the sediment bowl
(1, Figure 2).
The fuel outlet should be positioned 20 to
30 mm (0.75 to 1.125 in.) above the
bottom of the tank so that only clean fuel is
distributed to the engine.

12/05
BEFORE YOU OPERATE
Filling the Fuel Tank
WARNING
■ Before filling fuel tank for the first Fire and Explosion Hazard
time:
Never overfill the fuel tank.
WARNING
5. Replace the fuel cap and hand-tighten.
Fire and Explosion Hazard Over-tightening the fuel cap will
Never refuel with the engine running. damage it.
Rinse fuel tank with kerosene or diesel

fuel. Dispose of waste properly.
■ To fill the fuel tank:
WARNING
Fire and Explosion Hazard
Operate bilge ventilation (blowers) for a
minimum of 5 minutes to purge fumes
from engine compartment after
refueling. Never operate bilge blower
while refueling. Doing so can pump
explosive fumes into the engine
compartment and result in an
explosion.
1. Clean the area around the fuel cap.

2. Remove the fuel cap from the fuel tank.
3. Fill the tank with clean fuel free of oil
and dirt.
WARNING
Fire and Explosion Hazard
Hold the hose nozzle firmly against
the filler port while filling. This
prevents static electricity buildup
which could cause sparks and ignite
fuel vapors.
4. Stop fueling when the gauge shows the

fuel tank is full.

BEFORE YOU OPERATE

Bleeding the Fuel System ENGINE OIL
The fuel system needs to be bled under
Engine Oil Specifications
the following conditions:
Use a full-synthetic long-life engine oil that
• Before starting the engine for the first
meets or exceeds the following guidelines
time.
and classifications:
• After running out of fuel and fuel has
been added to the fuel tank. ■ Service categories
• After fuel system maintenance, such as • API Service Categories SM, SL, SJ,
changing the fuel filter and draining the SH/CF and CF
fuel filter/water separator, or replacing a • ACEA Service Categories A3, B3 and B4
fuel system component.
The fuel feed pump is ECU-controlled and ■ Definitions
will operate for only 10 seconds when the • API Classification (American Petroleum
key switch is turned ON while the engine is Institute)
not running or being started. For this
reason, the key switch must be repeatedly • ACEA Classification (Association des
turned ON then OFF to sufficiently bleed Constructeurs Européens
the fuel system. d’Automobilies)
1. Turn the key switch on and leave on for Note:

10 seconds. 1. Be sure the engine oil, engine oil
storage containers, and engine oil
NOTICE filling equipment are free of
Never hold the key in the START sediment and water.
position for longer than 10 seconds or 2. Change the engine oil after the first
the starter motor will overheat. 50 hours of operation and then at
every 250 hours thereafter.
2. Turn key switch OFF for 5 seconds, 3. Select the oil viscosity based on the
then turn key switch ON for 10 ambient temperature where the
seconds. engine is being operated. See the
3. Repeat steps 1 and 2 five more times. SAE Service Grade Viscosity Chart.
4. YANMAR does not recommend the
Note: The engine may run rough and
use of engine oil “additives”.
misfire for a few seconds when
first started until any remaining
air is purged from the fuel
system.
4. Attempt to start the engine. If the
engine does not start within a
reasonable time, repeat steps 1 and 2
until the engine starts and runs.
NOTICE
Never use an engine starting aid such
as ether. Engine damage will result.

12/05
BEFORE YOU OPERATE
■ Engine oil viscosity
Select the appropriate engine oil viscosity
based on the ambient temperature shown
in the SAE Service Grade Viscosity Chart
(Figure 4).
0W-30
5W-30
0W-40
5W-40
10W-30
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F

(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C)
K0000005B
Figure 4
Note: YANMAR recommends using
genuine YANMAR Marine Oil
specially formulated for the BY3
engine. Contact your authorized
YANMAR dealer or distributor.

BEFORE YOU OPERATE

Acceptable Engine Oil
LongLife 01 Oils
Trade name Producer/Supplier
Addinol Super power MV 0537 Addinol Lube Oil GmbH
Agip Formula LL B 01 ENI S.p.A. Refining and Marketing Division
Agip Sint 2000 Evolution ENI S.p.A. Refining and Marketing Division
Agip TECSINT SL ENI S.p.A. Refining and Marketing Division
ALPINE Longlife Mitan Mineralöl GmbH
Aral SuperTronic B Aral
Aral SuperTronic G Aral
AXCL S-Class Motor Oil AXCL Gulf FZE
BMW Quality Longlife 01 BMW
BP Visco 7000 BP Oil International
BP Visco 7000 GM BP Oil International
BP Visco 7000 Turbo Diesel BP Oil International
Castrol Edge Castrol Limited
Castrol Formula RS Power and Protection Castrol Limited
Castrol Formula SLX Castrol Limited
Castrol Formula SLX LL01 Castrol Limited
Castrol Formula SLX Long Tex Castrol Limited
Castrol Formula SLX Turbodiesel Castrol Limited
Castrol Syntec Castrol Limited
Castrol Syntec 0W-30 European Formula Castrol Limited
Castrol Super Racing 0W-40 Castrol Limited
Castrol TXT Softec LL01 Castrol Limited
Cepsa Star Mega Synthetic Cepsa Lubricantes S.A.
Divinol Syntholight Zeller+Gmelin
Elf Excellium Full-Tech Total
Elf Excellium LDX Total
Elf Excellium XLL Total
Esso Ultron FE ExxonMobil
Galp Formula XLD Petrogal SA
Gulf Formula TLX Total
Havoline Synthetic BM Chevron Texaco
Havoline Ultra BM Chevron Texaco
Igol Process Compact P Igol France S.A.
INA Futura Compact P INA Maziva Rijeka
Jet Top Level ConocoPhillips GmbH

12/05
BEFORE YOU OPERATE
Labo RC Fuchs Labo Auto S.A.
Liqui Moly Longtime High Tech Liqui Moly
Megol Motorenöl New Generation Meguin GmbH
Mobil 1 ExxonMobil
Mobil 1 Turbo Diesel ExxonMobil
Mobil 1 Spezial XS ExxonMobil
Motorex Profile B-XL Bucher AG
Motorex Select SP-X Bucher AG
Motul Specific LL-01 Motul S.A.
OMV full syn plus OMV AG
Opaljet Longlife Unil Opal
Panolin Exclusive BD Panolin AG
Pennzoil European Formula Ultra Pennzoil-Quaker State
Pentospeed 0W-30 VS* Deutsche Pentosin-Werke
Petronas Syntium 3000 LL Petronas
Q8 Formula Special Kuwait Petroleum
Quaker State European Formula Ultra Pennzoil-Quaker State
Ravenol HCL Ravensburger Schmierstoffvertrieb GmbH
Repsol Elite Common Rail Repsol YPF
Shell Helix Ultra AB Shell International Petroleum Company
Shell Helix Ultra AL Shell International Petroleum Company
Statoli LazerWay B Statoil Lubricants
Tecar Motorenöl Supersyn Techno-Einkauf GmbH
Titan Supersyn SL Fuchs Petrolub AG
Titan Supersyn SL Longlife Fuchs Petrolub AG
Tor Synthetic LL De Oliebron
Total Activa Expertise 9000 Total
Total Quartz Expertise 9000 Total
Valvoline SynPower MXL Valvoline
Veedol Powertron LL01 Veedol International
Veedol Syntron Veedol International
Veritas Syntolube Ölwerke Julius Schindler GmbH
Wako’s Super Synthe Wako Chemical Co.Ltd
Wintershall VIVA 1 Longlife SRS Schmierstoff Vertrieb GmbH
Yacco VX 1600 Yacco S.A.S.

BEFORE YOU OPERATE

LongLife 04 Oils
Addinol Super power MV 0537 Addinol Lube Oil GmbH
Agip Formula MS B04 ENI S.p.A.
Aral SuperTronic Aral
BMW Longlife-04 BMW
Castrol Edge Sport Castrol Limited
Castrol Edge Turbo Diesel Castrol Limited
Castrol Formula RS Castrol Limited
Castrol GTX Magnatec Castrol Limited
Castrol SLX LL-04 Castrol Limited
Castrol TXT LL-04 Castrol Limited
Elf Excellium LSX Total
Galp Energy Ultra LS Petrogal SA
Liqui Moly TopTec 4100 Liqui Moly
Midland ® Synova Oel-Brack AG
Midland ® Synova Oel-Brack AG
Mobil 1 ESP Formula ExxonMobil
Motorenöl Low Emission Meguin GmbH
Motul 1 Specific LL-04 Motul S.A.
OMV eco plus OMV AG
Repsol Elite Evolution Repsol YPF
Shell Helix Ultra AP Shell International Petroleum Company
Titan GT1 Fuchs Petrolub AG
Wintershall VIVA 1 topsynth alpha LS SRS Schmierstoff Vertrieb GmbH
York 848 Ginouves SAS

12/05
BEFORE YOU OPERATE
Checking Engine Oil Adding Engine Oil
1 K0006565
K0006568 Figure 7
Figure 5 Note: 4BY3 series shown. 6BY3 is similar.
Note: 4BY3 series shown. 6BY3 is similar. 1. Remove the oil filler port cap
(2, Figure 7) and pour engine oil into
NOTICE filler port. See Engine Oil Specifications
on page 28.
Prevent dirt and debris from contaminating
2. Fill with oil to the upper limit on the
engine oil. Carefully clean the dipstick and
dipstick (1, Figure 6).
the surrounding area before you remove
the cap.
NOTICE
1. Clean area around dipstick. Never overfill the engine with engine oil.
2. Remove dipstick (1, Figure 5) and wipe
with clean cloth. 3. Fully insert the dipstick to check the
level.
3. Fully reinsert dipstick.
4. Remove dipstick. The oil level should NOTICE
be between upper (1, Figure 6) and
lower lines (2, Figure 6) on the dipstick. Always keep the oil level between upper
and lower lines on the dipstick.
1 2
4. Tighten the fill port cap securely by
hand.
K0003826
Figure 6
5. Fully reinsert dipstick.

BEFORE YOU OPERATE

MARINE GEAR OR STERN POWER STEERING FLUID
DRIVE OIL SPECIFICATIONS
Note: Refer to the marine gear Refer to the stern drive manufacturer’s
manufacturer's operation manual for literature for power steering fluid
the marine gear oil specifications. specifications.
Refer to the manufacturer's
operation manual for marine gear or ■ Power steering oil (stern drive
stern drive oil specifications. only)
• QuickSilver® Power Trim and Steering
Marine Gear Oil Specifications
Fluid or Dexlone-II
Use marine gear oil that meets or exceeds
the following guidelines and classifications: ■ Power trim oil
• QuickSilver® Power Trim and Steering
■ KMH41A, KMH51A, KMH50V
Fluid or SAE 10W-30 or 10W-40 Engine
• API Service Categories CF Oil
• SAE Viscosity #30 Checking Power Steering Fluid
Stern Drive Oil Specifications Level
Use marine gear oil that meets or exceeds 1. Remove power steering filler cap.
the following guidelines and classifications: 2. Power steering fluid level must be
between the upper (1, Figure 8) and
■ ZT370 lower (2, Figure 8) level marks.
• GL-5 (SAE #80W90 or 75W90)
■ Mercruiser® Bravo
• QuickSilver®* High Performance Gear
Lube
2
K0004042
Figure 8
3. Add fluid if necessary.
* QuickSilver is a registered trademark of Brunswick Corporation.

12/05
BEFORE YOU OPERATE
ENGINE COOLANT
Acceptable Engine Coolant
Trade name Manufacturer
Addinol Antifreeze Super Addinol Lube Oil GmbH
Aral Antifreeze Extra Aral AG
AVIA Antifreeze APN AVIA Mineralöl AG
BMW Coolant BMW AG
BP anti-frost X 2270A BP Schmierstoff GMBH, Hamburg
Caltex CX Engine Coolant Caltex
Castrol ANTI-FREEZE NF Castrol International
Fridex G48 Velena s.a.
Glacelf Plus Total
GlycoShell Shell International
Glyco star Bremin Mineralöl GmbH & Co.
Glysantin G48-24 Engine Coolant UNICO Ltd.
Glysantin Protect Plus / G48 BASF
GUSOFROST LV 505 Chemische Industrielle Gesellschaft
Mobil Frostchutz 600 Mobil Schmierstoff GmbH
Havoline AFC (BD04) Chevron Texaco/Arteco
Mobil Frostschutz 600 ExxonMobil
OMV Kühlerfrostschutz OMV AG
Total Thermofreeze Plus Total
Note: YANMAR recommends using genuine YANMAR antifreeze/coolant. Contact your

authorized YANMAR dealer or distributor.

BEFORE YOU OPERATE

■ Adding engine coolant
1. Remove the pressure cap and pour
coolant mix slowly into the heat
exchanger to prevent the formation of
air pockets. Fill until the heat exchanger
is completely full.
NOTICE
Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and/or shorten
engine life. Prevent dirt and debris from
contaminating engine coolant. Carefully
clean the filler cap and the surrounding
area before you remove the cap. Never
mix different types of engine coolants.
This may adversely affect the properties
of the engine coolant.
2. Start the engine and allow to idle for

approximately 5 minutes.
3. Stop the engine and check the coolant
level. Add additional coolant if
necessary.
4. Install the pressure cap and tighten
firmly.
WARNING
Securely tighten the filler cap after
checking the coolant level. Steam
can escape during engine operation
if the cap is loose.
5. Remove the reservoir cap and fill with

coolant mix to approximately 50 mm (2
in.) below the full line. Replace cap.
Never fill to the full line.
6. After filling an empty cooling system,
test-run the engine for about five
minutes and check the engine coolant
level at the reservoir again.

ENGINE OPERATION
INTRODUCTION
describes the diesel fuel, engine oil and
engine coolant specifications and how to
replenish them. It also describes the daily
engine checkout.
SAFETY PRECAUTIONS
Before performing any operations within
this section, review the Safety section on
page 3.

ENGINE OPERATION
STARTING THE ENGINE Starting at Low Temperatures
1. Open the seacock (if equipped).
NOTICE
2. Open the fuel cock.
Never use an engine starting aid such as
3. Turn the battery switch (if equipped)
ether. Engine damage will result.
ON.
4. Put remote control handle in
NEUTRAL. Comply with local environmental
requirements. Use optional glow plugs (if
5. Ensure lanyard is connected to
equipped) to avoid starting problems and
emergency stop switch.
white smoke.
6. Attach lanyard to clothing.
To limit white smoke, run the engine at low
7. Turn key switch to ON. Ensure that the
speed and under moderate load until the
instrument panel indicators are
engine reaches normal operating
powered and working.
temperature. A light load on a cold engine
provides better combustion and faster
CAUTION engine warm-up than no load.
Never hold the key in the START Avoid running the engine at idling speed
position for longer than 10 seconds any longer than necessary.
or the starter motor will overheat.
8. Turn key switch to START. Release the

key switch when the engine has
started.
Note: Once the engine has started, the
ECU will raise the engine speed to
1080 min-1 to start alternator
charging, and then reduce to low
idle.

12/05
ENGINE OPERATION
SHUTTING DOWN THE CHECKING THE ENGINE
ENGINE AFTER OPERATION
Under normal operating conditions, shut • Check that the key switch is in the OFF
down the engine by turning the key switch position and battery switch (if equipped)
to OFF. is OFF.
There will be a delay of up to 3 seconds • Fill the fuel tank. Make sure that the fill
after turning the key to OFF. This is normal cap and the area around the fill opening
and allows the ECU computer to store are clean to avoid contamination of the
data. Wait at least 10 seconds after the fuel.
engine stops before turning the battery
• Close seawater cock(s).
switch to OFF.
• If there is a risk of freezing, check that
Emergency Shut Down the cooling system contains enough
coolant. See Engine Coolant on
NOTICE page 35.
Never use the emergency stop switch for a • If there is a risk of freezing, drain the
normal engine shut-down. Use this switch seawater system. See Draining the
only when stopping the engine suddenly in Seawater Cooling System on page 76.
an emergency
1. Ensure lanyard is connected to the

emergency stop switch.
2. Attach the lanyard to a secure place on
the operator’s clothing or life vest - not
where it might tear away.
NOTICE
• Do not cut or re-tie the lanyard. If it is
too long, shorten it by knotting or
looping it.
• Test the emergency engine shut off
switch before each outing.
3. Disconnecting the clip from the stop

switch will stop the engine.
NOTICE
Be sure to close the seacock. Neglecting
to close the seacock could allow water to
leak into the boat and may cause it to
sink.

ENGINE OPERATION

PERIODIC
MAINTENANCE
INTRODUCTION
describes the procedures for proper care
and maintenance of the engine.
SAFETY PRECAUTIONS
Before performing any maintenance
procedures within this section, read the
following safety information and review the
Safety section on page 3.

PERIODIC MAINTENANCE
PRECAUTIONS Keep a Log of Engine Hours and
Daily Checks
The Importance of Periodic
Keep a log of the number of hours the
Maintenance
engine is run each day and a log of the
Engine deterioration and wear occur in daily checks performed. Also note the
proportion to the length of time the engine date, type of repair (e.g., replaced
has been in service and the conditions the alternator), and parts used for any service
engine is subjected to during operation. needed between the periodic maintenance
Periodic maintenance prevents intervals. Periodic maintenance intervals
unexpected downtime, reduces the are every 50, 250, 500, 1000 and 2000
number of accidents due to poor machine engine hours. Failure to perform periodic
performance and helps extend the life of maintenance will shorten the life of the
the engine. engine.
Performing Periodic YANMAR Replacement Parts

Maintenance YANMAR recommends that you use
genuine YANMAR parts when
WARNING replacement parts are needed. Genuine
Never block windows, vents, or other replacement parts help ensure long engine
means of ventilation if the engine is life.
operating in an enclosed area. All
internal combustion engines create
Tools Required
carbon monoxide gas during operation. Before you start any periodic maintenance
Accumulation of this gas within an procedure, make sure you have the tools
enclosure could cause illness or even you need to perform all of the required
death. Make sure that all connections tasks.
are tightened to specifications after
repair is made to the exhaust system. Ask Your Authorized YANMAR
Failure to comply could result in death Marine Dealer or Distributor For
or serious injury. Help
Our professional service technicians have
The Importance of Daily Checks the expertise and skills to help you with
any maintenance or service related
Periodic Maintenance Schedules assume procedures.
that the daily checks are performed on a
regular basis. Make it a habit of performing Tightening Fasteners
daily checks before the start of each
Use the correct amount of torque when
operating day. See Periodic Maintenance
you tighten fasteners on the machine.
Procedures on page 51.
Applying excessive torque may damage
the fastener or component and not enough
torque may cause a leak or component
failure.

12/05
■ Standard torque values
Hexagon bolts and nuts
Grade (lubricated)
Nominal diameter
8.8 or 8 10.9 or 10 12.9 or 12
M4 2.7 N·m (24 in.-lb) 3.88 N·m (34.3 in.-lb) 4.6 N·m (41 in.-lb)
M5 5.5 N·m (48.6 in.-lb) 8 N·m (71 in.-lb) 9.5 N·m (84 in.-lb)
M6 9.5 N·m (84 in.-lb) 13 N·m (115 in.-lb) 16 N·m (142 in.-lb)
M7 15 N·m (133 in.-lb) 22 N·m (195 in.-lb) 26 N·m (230 in.-lb)
M8 23 N·m (204 in.-lb) 32 N·m (24 ft-lb) 39 N·m (29 ft-lb)
M8  1 25 N·m (221 in.-lb) 35 N·m (26 ft-lb) 42 N·m (31 ft-lb)
M10 46 N·m (34 ft-lb) 64 N·m (47 ft-lb) 77 N·m (57 ft-lb)
M10  1.25 49 N·m (36 ft-lb) 68 N·m (50 ft-lb) 82 N·m (60 ft-lb)
M12 80 N·m (59 ft-lb) 110 N·m (81 ft-lb) 135 N·m (100 ft-lb)
M12  1.5 88 N·m (65 ft-lb) 125 N·m (92 ft-lb) 150 N·m (111 ft-lb)
Hose clamps
Note: Reuse and retightening is prohibited for all hose clamps. Always install new hose
clamps.
Size Specification
5 mm Hex head 1.0 - 1.5 N·m (8.9 - 13 in.-lb)
6 mm Hex head 2.5 - 3.5 N·m (22 - 31 in.-lb)

EPA MAINTENANCE REQUIREMENTS
To maintain optimum engine performance and compliance with the Environmental
Protection Agency (EPA) Regulations for Engines, it is essential that you follow the
Periodic Maintenance Schedule on page 47 and the Periodic Maintenance Procedures on
page 51 .
EPA Requirements for USA and Other Applicable Countries

The following are the requirements for the EPA. Unless these requirements are met, the
exhaust gas emissions will not be within the limits specified by the EPA.
See Conditions to Ensure Compliance with EPA Emission Standards on page 45. Clean or
replace the air cleaner element if the air intake restriction exceeds the referenced
specifications.
EPA Requirements
The EPA emission regulation is applicable only in the USA and other countries that have
adopted the EPA requirements in part or in whole. Determine and follow the emission
regulations in the country where your engine will be operating to assist you in specified
compliance.

12/05
Conditions to Ensure Compliance with EPA Emission Standards
The BY3-series are EPA-certified engines.
The following are the conditions that must be met in order to ensure that the emissions
during operation meet the EPA standards.
The operating conditions should be as follows:
• Ambient temperature: -16° to +40 °C (3° to 104 °F)
• Relative humidity: 80 % or lower
The fuel and lubricating oil used should be as follows:
• Diesel fuel: ASTM D975 No. 1-D S15 or No. 2-D S15, D6751, D7467 or equivalent
(minimum cetane No. 45)
• Lubricating oil: Type API, Class SM, SL, SJ, SH/CF and CF
Be sure to perform inspections as outlined in Periodic Maintenance Procedures on page
51 and keep a record of the results.
Pay particular attention to these important points:
• Replacing the engine oil
• Replacing the engine oil filter
• Replacing the fuel filter
• Cleaning the air filter
Note: Inspections are divided into two sections in accordance with who is responsible for
performing the inspection: the user or the maker.

Inspection and Maintenance
See Inspection and Maintenance of EPA Emission-Related Parts on page 51 for the EPA
emission-related parts. Inspection and maintenance procedures not shown in Inspection
and Maintenance of EPA Emission-Related Parts on page 51 are covered in Periodic
Maintenance Schedule on page 47 .
This maintenance must be performed to keep the emission values of your engine in the
standard values during the warranty period. The warranty period is determined by the age
of the engine or the number of hours of operation.
Installation of Exhaust Sampling Port

All engines subject to emission standards shall be equipped with a connection in the
engine exhaust system that is located downstream of the engine, and before any point at
which the exhaust contacts water (or any other cooling/scrubbing medium), for the
temporary attachment of gaseous and/or particulate emissions sampling equipment. This
connection shall be internally threaded with standard pipe threads of a size not larger than
12.7 mm (0.5 in.), and shall be closed by a pipe plug when not in use. Equivalent
connections are allowed.
The instructions for the proper installation and location of the required sample port, in
addition to those specified above in the quoted federal regulation, are as follows:
1. The connection should be located as far downstream as reasonably practicable from
any sharp bend (of 30 degrees or more) in the exhaust pipe to help ensure that a
well-mixed exhaust flow sample may be taken;
2. The requirement that the connection be located before any point at which the exhaust
contacts water (or any other cooling/scrubbing medium) does not include contact with
water used to cool exhaust manifolds, unless the water is allowed to come into direct
contact with the exhaust gases;
3. To allow ready access to the sample port, the connection should be located, if possible
given the constraints of vessel design, approximately 0.6 to 1.8 m (2 to 6 ft) above a
deck or walkway;
4. To facilitate insertion and withdrawal of an exhaust sample probe, there should be no
obstructions for at least one and one-half exhaust pipe/stack diameters perpendicular,
i.e., 90 degrees, from the sample port; and
5. If a threaded connection is used, both the internal and external threads should be
coated with a high-temperature, anti-seize compound before the initial installation and
at every subsequent re-installation to facilitate removal of the connection for testing.

12/05
PERIODIC MAINTENANCE SCHEDULE
Daily and periodic maintenance is important to keep the engine in good operating
condition. The following is a summary of maintenance items by periodic maintenance
intervals. Periodic maintenance intervals vary depending on engine application, loads,
diesel fuel and engine oil used and are hard to establish definitively. The following should
be treated only as a general guideline.
NOTICE
Establish a periodic maintenance plan according to the engine application and make sure
to perform the required periodic maintenance at the intervals indicated. Failure to follow
these guidelines will impair the engine’s safety and performance characteristics, shorten
the engine’s life and may affect the warranty coverage on your engine.
See your authorized YANMAR Marine dealer or distributor for assistance when checking
items marked with a ●.

: Check or Clean : Replace ●: Contact your authorized YANMAR marine dealer or distributor
Periodic maintenance interval
Every Every Every Every
Every 50
250 500 1000 2000
hours or
Daily hours or hours or hours or hours or
System Item monthly
See Daily one year 2 years 4 years 8 years
which-
Checks on which- which- which- which-
ever
page 51 ever ever ever ever
comes
comes comes comes comes
first
first first first first
Whole 
Visual inspection
Before
of engine exterior
starting
Fuel system 
Check for fuel
Before
leakage
starting
Check the fuel 
level and refill if Before
necessary starting
Drain water and
sediment from fuel 
tank
Drain the fuel 
filter/water
separator If
necessary
Replace the fuel

fine filter
Replace fuel
filter/water 
separator element
Check the fuel
pump and fuel ●
lines
Lubricating Check the engine 
system oil level and refill if Before
necessary starting
Change the
engine oil and 

replace the oil Initial 50
filter element
Cooling 
Visual inspection
system - Before
of cooling system
engine starting
coolant
Check coolant 
level and check Before
for leaks starting
Replace coolant When Long Life Coolant (LLC) is used, replace every two years.

12/05
Every 50
250 500 1000 2000
hours or
System Item monthly
which-
ever
comes
first
Cooling 
Visual inspection
system - Before
of cooling system
seawater starting
circuit

Check the
Before
seawater outlet
starting
Check seawater
pump belt for

wear, replace if
necessary
Check seawater
filter (if equipped) 
and inlet
Replace the

anodes*
Check or replace
the seawater ● ●
pump impeller
Air intake and 
exhaust Visual inspection Before
system starting
Replace
turbocharger heat 
shield
Check the

exhaust pipe
Check the air

intake system
Check the
exhaust/water ●
mixing elbow
Replace the air
●
filter element

Every 50
250 500 1000 2000
hours or
System Item monthly
which-
ever
comes
first
Electrical Check the
system electrolyte level in
the battery ●
(serviceable
batteries only)

Check the wiring
Before
connectors
starting
Check alternator
belt for wear,
 ●
replace if
necessary
Miscellane- Check the alarm
ous items and indicators (if 
equipped)
Check or change
power steering ● ●
fluid

Check for water or
Before
oil leakage
starting
Check shift cable ●
●
adjustment Initial 50
Adjust the
propeller shaft
●
alignment (if ●
Initial 50
equipped with
marine gear)
Check hydraulic
●
oil cooler
Check and
replace
●
rubberized hoses
(fuel and water)
Check flexible
 ●
engine mounts
* Check anodes periodically. Any anode having less than half its original size remaining should be
replaced - use this to establish a regular replacement interval.
Note: These procedures are considered normal maintenance and are performed at the
owner’s expense.

12/05
Inspection and Maintenance of PERIODIC MAINTENANCE
EPA Emission-Related Parts PROCEDURES
Parts Interval
Daily Checks
Check fuel injection nozzle 1500 hours
(cleaning) Before heading out for the day, make sure
Check fuel injection nozzle 3000 hours the YANMAR engine is in good operating
(adjustment) condition.
Check fuel injection pump
(adjustment) CAUTION
Check turbocharger
(adjustment) It is important to perform daily checks
as listed in this Operation Manual.
Check electronic engine
control unit (ECU) and its Periodic maintenance prevents
associated sensors and
unexpected downtime, reduces the
actuators
number of accidents due to poor engine
performance and helps extend the life
Note: The inspection and maintenance
of the engine.
items shown above are to be
performed at your YANMAR dealer
or distributor. Make sure you check the following items:
Visual Checks
• Check the exterior of the engine for
leaks, wear or damage.
• Check for engine oil leaks.
• Check for fuel leaks.
• Check for engine coolant leaks.
• Check for damaged or missing parts.
• Check for loose, missing, or damaged
fasteners.
• Check the seawater inlet and outlet for
blockage or damage.
• Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors.
• Check hoses for cracks, abrasions, and
damaged, loose or corroded clamps.

Draining the Fuel/Water
CAUTION
Separator
If any problem is noted during the
visual check, the necessary corrective Check the fuel filter/water separator for
action should be taken before you presence of water and contaminants. If
operate the engine you find any water or contaminants, drain
the fuel filter/water separator. If you have
to drain the fuel filter/water separator
Checking Diesel Fuel, Engine Oil frequently, drain the fuel tank and check
and Engine Coolant Levels for water in your fuel supply. See Draining
the fuel tank on page 56.
Follow the procedures in Filling the Fuel
Tank on page 27 and Checking Engine Oil 1. Turn engine OFF.
on page 33 to check these levels. 2. Ensure the fuel cock is closed.
3. Loosen the drain plug at the bottom of
Checking the Battery Electrolyte
the fuel filter/water separator and drain
Level off any water or sediment.
Check the battery electrolyte level before 4. Dispose of waste properly.
use. See Checking the battery electrolyte 5. Tighten the drain plug and open the fuel
level (serviceable batteries only) on cock.
page 54.
Checking the Alarm Indicators

Check the instruments and alarm
indicators at regular intervals.
Preparing Fuel, Oil and Coolant

in Reserve
Prepare sufficient fuel for the day’s
operation. Always store engine oil and
coolant in reserve (for at least one refill) on
board, to be ready for emergencies.
Checking Power Steering Fluid

See Checking Power Steering Fluid Level
on page 34.

12/05
3. Loosen the engine oil filter cap
After Initial 50 Hours of (2, Figure 1) 1 - 2 turns with a socket
Operation wrench. Allow to sit a few minutes to
allow oil to drain into crankcase.
Perform the following maintenance
procedures after the initial 50 hours of 2 1
operation.
• Changing the engine oil and replacing
the engine oil filter
• Checking shift cable adjustment
• Adjusting the propeller shaft
alignment (if equipped with marine
gear)
K0003653
■ Changing the engine oil and
replacing the engine oil filter Figure 1
The engine oil on a new engine becomes 4. Remove the engine oil dipstick
contaminated from the initial break-in of (1, Figure 1). Attach an oil drain pump
internal parts. It is very important that the and pump out the oil. Dispose of waste
initial oil replacement is performed as properly.
scheduled. 5. Remove the engine oil filter cap and
filter assembly.
It is easiest and most effective to drain the
engine oil after operation while the engine 6. Remove the filter element from stem.
is still warm. 7. Replace the three O-rings
(1, Figure 2) on the stem.
WARNING
1
If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being burned. Always wear
eye protection.
1. Turn engine OFF.

2. Remove engine cover.
NOTICE
Prevent dirt and debris from K0003652
contaminating engine oil. Carefully
clean the dipstick and the surrounding Figure 2
area before you remove the cap. 8. Install a new filter element. Ensure the
filter fits snugly in the filter cap.

9. Install the cap and filter assembly.
Tighten cap by hand until the seal Every 50 Hours of Operation
touches the housing.
10.Tighten to 25 N·m (225 in.-lb). After you complete the initial 50 hour
maintenance procedures, perform the
11.Fill with new engine oil. See Adding
following procedures every 50 hours or
Engine Oil on page 33.
monthly, whichever comes first.
NOTICE • Checking seawater filter (if equipped)
and inlet
Never mix different types of engine oil.
This may adversely affect the lubricating • Checking the air intake system
properties of the engine oil. Never
• Checking battery electrolyte level
overfill. Overfilling may result in white
(serviceable batteries only)
smoke, engine overspeed or internal
damage. ■ Checking the seawater filter (if
equipped) and inlet
12.Perform a trial run and check for oil
leaks. Refer to boat builder’s literature for
information on the seawater filter.
13.Approximately 10 minutes after
stopping the engine, remove the oil ■ Checking the air intake system
dipstick and check the oil level. Add oil
if the level is too low. Check the air intake system for damage or
wear. If necessary, consult your authorized
■ Checking shift cable adjustment YANMAR dealer or distributor for repair.
See your authorized YANMAR dealer or ■ Checking the battery electrolyte
distributor.
level (serviceable batteries only)
■ Adjusting propeller shaft
alignment (if equipped with WARNING
marine gear) Batteries contain sulfuric acid. Never
The flexible engine mounts are slightly allow battery fluid to come in contact
compressed during initial engine operation with clothing, skin or eyes. Severe
and may cause misalignment between the burns could result. Always wear safety
engine and the propeller shaft. goggles and protective clothing when
servicing the battery. If battery fluid
This adjustment requires specialized contacts the eyes and/or skin,
knowledge and techniques. See your immediately flush the affected area with
authorized YANMAR dealer or distributor. a large amount of clean water and
obtain prompt medical treatment.

12/05
NOTICE Every 250 Hours of Operation

Never turn off the battery switch (if
equipped) or short the battery cables Perform the following maintenance every
during operation. Damage to the electric 250 hours of operation or yearly,
system will result. whichever comes first.
• Draining the fuel tank
1. Turn the battery master switch OFF (if • Replacing the fuel fine filter
equipped) or disconnect the negative
(-) battery cable. • Replacing the fuel filter/water
separator element
2. Do not operate with insufficient battery
electrolyte as the battery will be • Changing the engine oil and replacing
destroyed. the engine oil filter element
• Checking or replacing the seawater
NOTICE pump belt
Never attempt to remove the covers or • Replacing the anodes
fill a maintenance-free battery.
• Checking or replacing the seawater
3. Remove the caps and check the pump impeller
electrolyte level in all cells. • Replacing the turbocharger heat
4. If the level is lower than the minimum fill shield
level (1, Figure 3), fill with distilled
• Checking the exhaust/water mixing
water (2, Figure 3) (available locally)
elbow
up to the upper limit (3, Figure 3) of the
battery. • Replacing the air filter element
• Cleaning the turbocharger blower
• Checking or replacing the alternator
belt
• Changing the power steering fluid
3 2
1 • Checking the shift cable adjustment
K0002388
• Adjusting the propeller shaft
Figure 3 alignment
Note: The maximum fill level is • Checking the hydraulic oil cooler
approximately 10 - 15 mm (3/8 - 9/16 • Checking or replacing rubber hoses
in.) above the plates. Battery fluid
tends to evaporate in high • Checking flexible engine mounts
temperatures, especially in summer.
In such conditions, inspect the
battery more often.

■ Draining the fuel tank ■ Replacing the fuel fine filter
1. Disconnect the battery negative (-)
cable.
2. Close the fuel tank cock.
2 1
1 002875-02X01
1 – Sediment bowl
2 – Drain cock
3 – Fuel line to engine
Figure 4
Note: Typical fuel tank shown. Actual K0006638
equipment may differ. Figure 5

1. Turn engine OFF. 3. Unscrew and remove filter cartridge
2. Put a container under the drain cock (1, Figure 5).
(2, Figure 4) to catch fuel. 4. Replace rubber seal.
3. Open the drain cock and drain water 5. Replace filter.
and sediment. Close the drain cock
when the fuel is clean. NOTICE
4. Dispose of waste properly.
When replacing fuel filters, always
pre-fill them with fresh, clean fuel to
improve the system's ability to be bled.
6. Hand-tighten cartridge to filter.

7. Connect battery negative (-) cable.
8. Bleed the fuel system and check for
leaks. See Bleeding the Fuel System
on page 28.

12/05
■ Replacing fuel filter/water
separator element
Note: YANMAR supplies a water
separating pre-filter separate from
the engine. Location and type of
filter may vary.
3
1. Disconnect the battery negative (-)
cable.
2. Close the fuel tank cock.
3. Loosen the drain plug (4, Figure 6) on
the bottom of the fuel filter/water
separator and drain off any water or
sediment. 2
4. Disconnect water sensor connector
(1, Figure 6).
5. Turn the filter bowl (5, Figure 6)
counterclockwise to remove. 5
1
6. Remove the old filter element.
4
7. Clean the filter bowl. Inspect the water
sensor probe (1, Figure 6) for damage
if equipped. Inspect the bowl seal
(2, Figure 6).
K0003650
NOTICE Figure 6
When replacing fuel filters, always
pre-fill them with fresh, clean fuel to 8. Lubricate the seal at the top of the new
improve the system's ability to be bled. filter element (3, Figure 6) and install.
9. Lubricate the filter bowl seal
(2, Figure 6) and install the filter bowl
(5, Figure 6). Turn clockwise by hand
to tighten.
10.Ensure drain plug (4, Figure 6) is
securely tightened.
11.Connect water sensor connector
(1, Figure 6) if equipped.
12.Open the fuel cock.
13.Connect the battery negative (-) cable.
14.Bleed air from the fuel system and
check for leaks. See Bleeding the Fuel
System on page 28.

■ Changing the engine oil and ■ Replacing the zinc anodes
replacing engine oil filter element
To change engine oil and replace the
engine oil filter element, see Changing the
engine oil and replacing the engine oil filter
on page 53 .
■ Checking or replacing the

2
seawater pump and alternator
belts
1
K0006569
2 Figure 8
There are zinc anodes in the seawater
cooling system and they should be
inspected and replaced periodically.
Zinc anodes are located in the heat
exchanger (1, Figure 8) and the charge air
1 K0003662 cooler (2, Figure 8). An additional zinc
Figure 7 anode may also be located in the
exhaust/water mixing elbow.
NOTICE 1. Disconnect battery negative (-) cable.
Never get any oil on the belt(s). Oil on the 2. Remove each anode and inspect for
belt causes slipping and stretching. corrosion. Any anode having less than
Replace the belt if it is damaged. half its original size remaining should
be replaced.
1. Disconnect battery negative (-) cable NOTICE

from the battery. Never use thread sealer or thread
2. Remove belt guard. sealing tape when installing zinc
3. Check the seawater pump belt anodes. Anodes must make good
(1, Figure 7) and alternator belt metal-to-metal contact to perform
(2, Figure 7) for wear, cracks or properly.
damage.
4. Replace if necessary. See your 3. Install each anode using a new copper
authorized YANMAR dealer or gasket and tighten to 25 N·m (18 ft-lb).
distributor. 4. Start engine and check for water leaks.
5. Install belt guard and connect battery
negative (-) cable.

12/05
■ Checking or replacing the ■ Cleaning the turbocharger
seawater pump impeller blower
See your authorized YANMAR dealer or See your authorized YANMAR dealer or
distributor. distributor.
■ Replacing the turbocharger heat ■ Checking or replacing alternator
shield belt
See your authorized YANMAR dealer or See Checking or replacing the seawater
distributor. pump and alternator belts on page 58.
■ Checking exhaust/water mixing ■ Changing power steering fluid
elbow
See your authorized YANMAR dealer or
See your authorized YANMAR dealer or distributor.
distributor.
■ Checking shift cable adjustment
■ Replacing air filter element
See Checking shift cable adjustment on
1. Turn engine OFF. page 54.
2. Remove engine cover.
■ Adjusting the propeller shaft
3. Remove clamp (1, Figure 9).
alignment
2 1 See Adjusting propeller shaft alignment (if
equipped with marine gear) on page 54.
■ Checking hydraulic oil cooler

distributor.
■ Checking or replacing rubber

hoses
Check rubber water and fuel hoses for
wear or damage. See your authorized
YANMAR dealer or distributor for
K0006570
replacement.
Figure 9 ■ Checking or replacing flexible

engine mounts
4. Remove air filter (2, Figure 9).
5. Replace air filter. Check the flexible engine mounts for wear
or damage. See your authorized YANMAR
dealer or distributor for replacement.

5. Remove drain plug (1, Figure 10) from
Every 500 Hours of Operation the engine block. Allow coolant to drain
into a container of appropriate size.
Perform the following maintenance every
500 hours of operation or every 2 years, WARNING
whichever comes first.
Never remove the coolant filler cap if
• Checking the fuel pump and fuel lines the engine is hot. Steam and hot
• Draining and refilling closed cooling engine coolant will escape and
system (engine coolant) seriously burn you. Allow the engine
to cool before attempting to remove
■ Checking the fuel pump and fuel the filler cap.
lines
distributor. 1
■ Draining and refilling closed
cooling system (engine coolant)
1. Disconnect battery negative (-) cable.
2. Remove the engine cover.
3. Remove the coolant pressure cap from
heat exchanger.
4. Remove the heat exchanger to access
the cylinder block drain plug behind it. K0003660
Note: The charge air cooler has been Figure 10

removed for clarity of
(Figure 10). 6. Install cylinder block drain plug with a
new gasket.
7. Install heat exchanger. Ensure the
drain cock (1, Figure 11) on the heat
exchanger is closed.

12/05
Figure 1
1 2 Every 1000 Hours of Operation

1000 hours of operation or every 4 years,
• Checking flexible engine mounts
■ Checking flexible engine mounts

Check flexible engine mounts for damage,
cracks or wear. See your authorized
YANMAR marine dealer or distributor for
replacement.
K0006621
Figure 11
8. Remove the pressure cap
(2, Figure 11) from the heat exchanger.
9. Inspect the cap gasket and flange on
the filler neck for damage. Replace if
necessary.
10.Check the rubber hose connecting the
reservoir to the heat exchanger. Be
sure the hose is securely connected
and there is no damage.
11.Fill the heat exchanger and reservoir
with approved coolant mix.See Adding
engine coolant on page 36.

Every 2000 Hours of Operation

2000 hours of operation or every 8 years,
• Replacing seawater pump impeller
• Replacing alternator belt
■ Replacing seawater pump

impeller
See your authorized YANMAR marine
■ Replacing alternator belt

See your authorized YANMAR marine

TROUBLESHOOTING
SAFETY PRECAUTIONS
Before performing any troubleshooting
procedures within this section, review the
Safety section on page 3.
If a problem occurs, stop the engine
immediately. Refer to the Symptom
column in the Troubleshooting Chart to
identify the problem.

TROUBLESHOOTING
TROUBLESHOOTING AFTER STARTING
Just after the engine has started, check the following items at a low engine speed:
Is sufficient water being discharged from the seawater outlet pipe?
If the discharge is low, stop the engine immediately. Identify the cause and repair.
Is the smoke color normal?
The continuous emission of black smoke indicates engine overloading. This shortens the
engines life and should be avoided.
Are there abnormal vibrations or noise?
Depending on the hull structure, engine and hull resonance may suddenly increase at
certain engine speed ranges, causing heavy vibrations. Avoid operation in this speed
range. If any abnormal sounds are heard, stop the engine and inspect for cause.
Alarm sounds during operation.
If the alarm sounds during operation, lower the engine speed immediately, check the
alarm lamps and stop the engine for repairs.
Is there water, oil or fuel leakage? Are there any loose bolts or connections?
Check the engine room daily for any leaks or loose connections.
Is there sufficient fuel in the fuel tank?
Refill fuel in advance to avoid running out of fuel. If the tank runs out of fuel, bleed the fuel
system. See Bleeding the Fuel System on page 28.
When operating the engine at low speed for long periods of time, race the engine once
every 2 hours. Racing the engine with the clutch in NEUTRAL, accelerate from the
low-speed position to the high-speed position and repeat this process about five times.
This is done to clean out carbon from the cylinders and the fuel injection valves.
NOTICE
Neglecting to race the engine will result in poor smoke color and reduce engine
performance.
Periodically operate the engine near maximum speed while underway. This will generate
higher exhaust temperatures, which will help clean out hard carbon deposits, maintain
engine performance and prolong the life of the engine.

12/05
TROUBLESHOOTING
TROUBLESHOOTING INFORMATION
If the engine does not operate properly, refer to the Troubleshooting Chart on page 66 or
see your authorized YANMAR Marine dealer or distributor.
Supply the authorized YANMAR Marine dealer or distributor with the following information:
• Model name and serial number of your engine
• Boat model, hull material, size (tons)
• Use, type of boating, number of hours run
• Total number of operation hours (refer to hourmeter), age of boat
• The operating conditions when the problem occurs:
• Engine speed (min-1)
• Color of smoke
• Type of diesel fuel
• Type of engine oil
• Any abnormal noises or vibration
• Operating environment such as high altitude or extreme ambient temperatures, etc.
• Engine maintenance history and previous problems
• Other factors that contribute to the problem

TROUBLESHOOTING
TROUBLESHOOTING CHART
Starting Trouble
Problem/Symptom Cause Action
Engine will not crank Discharged battery Charge/replace battery
Blown fuse Replace fuse
Defective starter motor See your authorized YANMAR
dealer or distributor
Loose wiring connections Tighten connections
Electrical panel power circuit Reset circuit breaker
breaker is tripped
Engine cranks but will not start No fuel to engine Check fuel level in tank
See your authorized YANMAR
No fuel to cylinders Check fuel filter/water separator
Clean or replace clogged fuel fine
filter
Bleed air from fuel system
Replace blown fuse (F3)
Low ambient temperature See your authorized YANMAR
Oil high Replace with correct viscosity oil for
operating conditions

12/05
TROUBLESHOOTING
Smoke Color
White smoke Cold engine Allow engine to warm to operating
temperature
Incorrect fuel Replace fuel with correct type
Defective (leaking) fuel injector See your authorized YANMAR
Injection timing is incorrect
White smoke with water vapor Leaking cylinder head gasket See your authorized YANMAR
Leaking charge air cooler dealer or distributor
Cracked cylinder head

Cracked cylinder
Blue smoke Worn piston rings/cylinders See your authorized YANMAR
Oil leak in turbocharger (oil present
in intake manifold)
Damaged piston cooling nozzles
Black smoke under load Clogged intake air filter Replace or clean as necessary
Incorrect valve timing See your authorized YANMAR
Defective (leaking) fuel injector
Low charge air pressure Clean or replace clogged air filter
Excessive exhaust back pressure See your authorized YANMAR
Plugged intake port(s) See your authorized YANMAR
Vibration - Drive Disengaged

Rough at all engine speeds Air in fuel system Bleed fuel system
Faulty fuel injector See your authorized YANMAR
Leaking cylinder head gasket
Damaged intake or exhaust valves
Incorrect injection pressure

TROUBLESHOOTING
Vibration - Drive Engaged
Rough at all speeds Engine and propeller shaft See your authorized YANMAR
misaligned dealer or distributor
Bent propeller shaft
Rough at higher speeds Bent propeller See your authorized YANMAR
Slipping clutch/clutch dog
Incorrect injection pressure
Engine Knocks
Excess fuel injected Defective fuel injector See your authorized YANMAR
High fuel injection pressure
Noise changes with engine load Incorrect or poor quality fuel Drain and refill tank with proper fuel
Worn crankshaft/bearings See your authorized YANMAR
Broken piston/rings
Low Power Output

Miscellaneous Clogged air filter Replace air filter
Leaking cylinder head gasket See your authorized YANMAR
Damaged turbocharger
Incorrect propeller
Excessive exhaust back pressure
Fuel Plugged fuel filter(s) Replace as necessary
Faulty fuel supply pump See your authorized YANMAR
Low fuel injection pressure Defective fuel pressure See your authorized YANMAR
regulator/sensor dealer or distributor
Worn high-pressure fuel pump
Low engine speed at wide open Propeller pitch too great See your authorized YANMAR
throttle dealer or distributor
Engine overheated
Damaged turbocharger

12/05
TROUBLESHOOTING
Engine Overheat
Instrument shows high Clogged seawater inlet Clean
temperature Low coolant level Fill with coolant/inspect for leaks
Clogged seawater filter (if Clean
equipped)
Clogged hydraulic cooler See your authorized YANMAR dealer or
distributor
Seawater pump worn or damaged
Defective sensor/instrument
Defective thermostat
Damaged closed coolant pump
Combustion gas leakage (causes
loss of coolant)
Seawater pump belt slips or pump
pulley loose on pump shaft
Clogged heat exchanger
Engine Runs Cold

Instrument shows low Defective sensor/instrument See your authorized YANMAR dealer or
temperature Defective thermostat distributor
Cabin heater or boiler too large
Coolant Loss
Repeated low coolant level Defective cylinder head gasket See your authorized YANMAR dealer or
(external leakage) distributor
External leakage at connection
Coolant forced out of coolant Turbocharging pressure enters See your authorized YANMAR dealer or
recovery tank cooling system via leaking charge distributor
air cooler
Defective cylinder head gasket
(internal leakage)
White smoke when engine hot Crack in cylinder head (not cracks See your authorized YANMAR dealer or
indicates water vapor between valve seats) distributor
Cracked cylinder wall

TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODES
When certain faults occur, or when certain limits have been exceeded, the engine ECU
may generate a “Check Engine” warning or turn on a check engine light (if equipped).
Some of these faults may also generate a DTC or Diagnostic Trouble Code and an
audible alarm. If a DTC is generated, the engine ECU will store that code or codes for
reference. To read the DTC codes, a special tool is used by the technician. The technician
then can use a list to more quickly find the cause of the fault and correct it.
Some conditions will produce an alarm but do not generate a trouble code. An example is
engine overheat (over 108 °C) caused by an obstructed seawater inlet. The overheat
alarm will sound and the engine torque will be reduced to protect the engine, but no code
will be set.
Under some conditions, the warning alarm will sound until the fault code is checked and
corrected. Under other conditions, the alarm will be canceled if the engine is turned off and
then restarted.
For further information, please contact your authorized YANMAR distributor or dealer.

12/05
TROUBLESHOOTING
Diagnostic Trouble Code Table
Check
Run or engine
Code Part or system Mode engine
condition can start
alarm
No code Coolant temp Under 0 °C (32 °F) 1000 min-1 Yes No
No code Coolant temp Over 108 °C (226 °F) Reduce Yes No
No code Coolant temp Over 110 °C (230 °F) Reduce Yes Alarm
No code Charge air temp Over 110 °C (230 °F) Reduce Yes No
No code Boost pressure 4BY2 - over 1.9 bar (27.5 PSI) Reduce Yes Alarm
reading (relative*) or 2.9 bar (42.0 PSI)
(absolute**)
6BY2 - over 2.3 bar (33.3 PSI)
(relative*) or 3.3 bar (42.9 PSI)
(absolute**)
No code Fuel temperature Over 90 °C (194 °F) Reduce Yes No
No code Neutral switch Only in case of analog throttle No No Alarm
or in case of CAN-fault
(U0001), wrong configuration -
neutral position
P0001 Fuel metering unit Not connected Reduce Yes Alarm
P0003 Fuel metering unit Short circuit to ground No No Alarm
P0004 Fuel metering unit Short circuit to B+ Reduce Yes Alarm
P0087 Rail pressure governor Fuel rail pressure out of range Reduce or Depends Alarm
deviation shut off on fault
P0088 Rail pressure governor Fuel rail pressure out of range Reduce or Depends Alarm
deviation shut off on fault
P0089 Rail pressure governor Fuel rail pressure out of range Yes Yes Alarm
deviation
P0090 Fuel pressure control Not connected No No Alarm
valve
Rail pressure governor Fuel rail pressure out of range Reduce Yes Alarm
deviation
P0091 Fuel pressure control Short circuit to ground Reduce Yes Alarm
valve
P0092 Fuel pressure control Short circuit to B+ No No Alarm
valve
P0112 Charge air temp Over 125 °C (257 °F) Reduce Yes Alarm
Charge air temp Short circuit to B+ Reduce Yes Alarm
sensor
P0113 Charge air temp Under -20 °C (-4 °F) Reduce Yes Alarm
Charge air temp No connection/short circuit to Reduce Yes Alarm
sensor ground
P0117 Coolant temp sensor Short circuit to B+ Reduce Yes Alarm
P0118 Coolant temp sensor No connection/short circuit to Reduce Yes Alarm
ground

TROUBLESHOOTING
Check
Run or engine
condition can start
alarm
P0122 Throttle signal Both throttle signals are 1600 Yes Alarm
missing/short circuit to ground
Throttle signal Throttle signal 1 is Reduce Yes Alarm
P0123 Throttle signal Both throttle signals are short 1600 Yes Alarm
circuited to B+
Throttle signal Throttle signal 1 short circuit to Reduce Yes Alarm
B+
P0182 Fuel temperature Short circuit to B+ Reduce Yes Alarm
sensor
P0183 Fuel temperature No connection/short circuit to Reduce Yes Alarm
sensor Ground
P0192 Fuel rail pressure Short circuit to ground Reduce Yes Alarm
sensor
P0193 Fuel rail pressure No connection/short circuit B+ Reduce Yes Alarm
sensor
P0201 Injector No. 1 Open circuit/short circuit to Reduce Yes Alarm
Ground
Ground
Ground
Ground
Ground
Ground
P0222 Throttle signal Both throttle signals are 1600 Yes Alarm
missing/short circuit to Ground
Throttle signal Throttle signal 2 is Reduce Yes Alarm
P0223 Throttle signal Both throttle signals are short 1600 Yes Alarm
circuited to B+
Throttle signal Throttle signal 2 short circuited Reduce Yes Alarm
to B+
P0230 Fuel feed pump Not connected No No Alarm
P0231 Fuel feed pump Short circuit to ground Reduce Yes Alarm
P0232 Fuel feed pump Short circuit to B+ No No Alarm
P0236 Boost pressure Plausibility check with APS Reduce Yes Alarm
(ambient air pressure sensor)
fail

12/05
TROUBLESHOOTING
Check
Run or engine
condition can start
alarm
P0237 Boost pressure Under 0.5 bar (7.3 PSI) Reduce Yes Alarm
(absolute**)
Boost pressure sensor No connection/short circuit to Reduce Yes Alarm
ground
P0238 Boost pressure 4 bar (58.0 PSI) (absolute**) Reduce Yes Alarm
Boost pressure sensor Short circuit to B+ Reduce Yes Alarm
P0243 Turbocharger positive Leakage in the air routing (hole Yes Yes Alarm
boost pressure in the charge air pipe)
deviation
P0261 Injector No. 1 Short circuit to B+ Reduce Yes Alarm
P0299 Turbocharger negative Boost pressure actuator is Yes Yes Alarm
boost pressure sticking defect waste gate hose
deviation
P0344 Crankshaft speed Disagreement between No No Alarm
sensor camshaft speed sensor and
crankshaft speed sensor
P0380 Glow control relay Not connected, short circuit Yes Yes Alarm
actuator
P0562 System voltage low – Yes No Alarm
P0563 System voltage high – Yes Yes Alarm
P0602 Control module Overvoltage/undervoltage No No Alarm
programming error
(hwemon)
Shut off path Control module programming No No Alarm
error
P0607 Injector chip fault Injector control module No No Alarm
performance
P0642 Sensor supply Short circuit Reduce Yes Alarm
monitoring 1
monitoring 1
P0650 Check engine lamp Not connected, short circuit Yes Yes Alarm
monitoring 2
monitoring 3

TROUBLESHOOTING
Check
Run or engine
condition can start
alarm
P0670 Glow plug control Failure, short circuit, Yes Yes Alarm
module over-current
P0671 Glow system - glow Not connected, short circuit Yes Yes Alarm
spark No. 1
spark No. 2
spark No. 3
spark No. 4
spark No. 5
spark No. 6
P0689 Main relay Power relay sense short circuit No No Alarm
low
P0690 Main relay Power relay sense short circuit No No Alarm
high
P2049 4BY2 - Injector bank 1 Short circuit on high side to No No Alarm
ground/B+
6BY2 - Injector bank 1 Short circuit on high side to Reduce No Alarm
ground/B+
P2052 4BY2 - Injector bank 2 Short circuit on high side to Reduce Yes Alarm
ground/B+
6BY2 - Injector bank 2 Short circuit on high side to Reduce Yes Alarm
ground/B+
P2227 Atmospheric pressure Plausibility check with BPS Yes Yes Alarm
(boost pressure sensor) fail
P2228 Atmospheric pressure Short circuit low Yes Yes Alarm
P2229 Atmospheric pressure Short circuit high Yes Yes Alarm
P2614 Camshaft speed No connection/short circuit Reduce Yes Alarm
sensor
P2617 Crankshaft speed No connection/short circuit No No Alarm
sensor
U0001 CAN throttle signal No signal Idle Yes Alarm
U0106 Glow control unit No communication error Yes Yes Alarm
U0426 Immobilizer Manipulation error No No Alarm
* Relative value is the value read on a pressure gauge attached to the intake pipe.
** Absolute is the value reported by the ECU and displayed at the helm digital display.

LONG-TERM STORAGE
If the engine is not to be used for an PREPARE ENGINE FOR
extended period of time, special measures
should be taken to protect the coolant LONG-TERM STORAGE
system, fuel system and combustion
chambers from corrosion and the exterior NOTICE
from rusting. It is recommended that you
Do not drain closed cooling system for
see your authorized YANMAR marine
long-term storage. Antifreeze must be
dealer or distributor to prepare the engine
used to avoid freezing and damaging of
for long-term storage.
components. Antifreeze will prevent
The engine can normally stand idle for up rusting during long-term storage.
to six months. If it remains unused for
longer than this, please contact your
1. Change engine oil and filter.
authorized YANMAR marine dealer or
distributor. 2. Drain seawater cooling system. See
Draining the Seawater Cooling System
Winter Storage on page 76.
Drain water from fuel tank and fuel filters 3. Wipe off any dust or oil from the outside
before and after extended storage. of the engine.
To reduce the risk of condensation in the 4. Drain fuel tank or fill the tank to prevent
fuel tank during winter storage, fill the tank condensation.
with fuel and treat with diesel fuel 5. Grease the exposed areas and joints of
stabilizer. the remote control cables and the
bearings of the remote control handle.
6. Seal the intake silencer, exhaust pipe,
etc. to prevent moisture or
contamination from entering engine.
7. Completely drain bilge in hull bottom.
8. Waterproof the engine room to prevent
rain or seawater from entering.
9. Charge the battery once a month to
compensate for battery’s
self-discharge.

LONG-TERM STORAGE
10.Remove key from key switch and cover
key switch with moisture cap (if WARNING
equipped). Never drain the seawater cooling system
if the engine is hot. Steam and hot fluid
Draining the Seawater Cooling
will escape and seriously burn you. Allow
System the engine to cool before attempting to
opening the drain cocks.
CAUTION
• Do not drain the coolant system. A 1. Open the lower seawater drain cock
full coolant system will prevent (3, Figure 1) located in the piping
corrosion and frost damage. between the seawater pump and
hydraulic oil cooler. Allow to drain.
• If seawater is left inside of the engine,
it may freeze and damage parts of the 2. Open the drain cock (4, Figure 1) on
cooling system when the ambient the bottom of the charge air cooler.
temperature is below 0 °C (32 °F). 3. Remove the seawater pump cover. See
your authorized YANMAR dealer or
NOTICE distributor.
4. Remove zinc anodes from the heat
If water fails to drain from any open drain exchanger (2, Figure 1) and charge air
cock or port, remove the cock completely cooler (1, Figure 1) and allow water to
and probe the opening with a small piece drain from housings.
of wire to loosen debris.
5. Inspect condition of zinc anodes. Install
anodes. See Replacing the zinc anodes
on page 58.
NOTICE
Do not use thread sealer or thread
sealing tape when installing zinc
anodes. Anodes must make good
2 metal-to-metal contact to perform
properly.
1 6. Close all drain cocks.
3
4 K0006575
Figure 1

SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine model 4BY3-150/150Z 4BY3-180/180Z 6BY3-220/220Z 6BY3-260/260Z
Application design Models numbers with no suffix letter are used in marine gear applications.
Models having a “Z” suffix are used with stern drive.
Number of cylinders In-line 4 In-line 6
Type 15° inclined, water-cooled, dual overhead camshaft, 4-cycle diesel
Combustion system Direct injection
Aspiration Turbocharged with charge air cooler
Bore  stroke 84 mm  90 mm (3.307 in.  3.543 in.)
Displacement 1.995 l (122 cu in.) 2.993 l (183 cu in.)
Firing order* 1-3-4-2 1-5-3-6-2-4
Compression ratio 16.5:1 16.5:1
Continuous power (at
crankshaft**)/engine speed 100/3876 120/3876 148/3876 174/3876
kW/min-1
Fuel stop power (at
110/4000 132/4000 162/4000 191/4000
crankshaft**)/engine speed
(150 hp) (180 hp) (220 hp) (260 hp)
kW/min-1
Low idle speed (warm engine @
750 min-1 (ECU-controlled)*** 670 min-1 (ECU-controlled)***
88 °C [190 °F])
Cold start speed 1200 min-1 gradually decreasing to warm engine idle @ 88 °C (190 °F)
@ 20 °C (68 °F) (ECU-controlled)
High idle speed 4600 min-1
Rotation direction Counterclockwise (viewed from flywheel)
No. of valves per cylinder 4
Valve adjustment Hydraulic self-adjusting
Turbocharger MHI with pneumatic wastegate HOLSET with pneumatic wastegate
Charge air cooler Seawater cooled
Electrical system 12 V

SPECIFICATIONS
Starter 12 V/2 kW (2.7 hp)
Charging system 12 V/150 A
Battery capacity - recommended 12 V/85 Ah/680 CCA (cold cranking amps)
Fuel injection system Common rail (ECU-controlled)
Fuel injection pressure Variable depending on engine speed; 250 - 1600 bar (3626 - 23,206 PSI)
Injection timing Variable (ECU controlled)
ECU threshold voltage 7.8 V
Cooling system Closed cooling system with seawater heat exchanger
Coolant capacity
10 l (10.6 qt) 13 l (13.7 qt)
(approximate)
Seawater pump Rubber impeller, belt driven
Capacity 165 l/min at maximum rating
Maximum lift 2000 mm (78.75 in.)
Hydraulic oil cooler Seawater cooled
Lubrication system Totally enclosed, forced lube system
Oil cooler Engine coolant system
Engine oil pressure at 4000
3.5 - 6.0 bar (51 - 87 PSI)
min-1
Engine oil pressure at 1000
0.6 - 1.0 bar (8.7 - 14.5 PSI)
min-1
Engine oil capacity**** 8.0 l (8.5 qt)***** 11.0 l (11.5 qt)*****
Crankcase ventilation Closed, with filter
Drive options –
Stern drive ZT370 or MerCruiser Bravo-1, -2, -3
Marine gear KMH41A KMH51A, KMH50V
Operational angles –
Continuous Front-to-rear: -5 to 20°, Side-to-Side: 20°
Peak Front-to-rear: -5 to 25°, Side-to-Side: 30°
Height 721 mm (28.4 in.)
Length (without marine gear) –
Stern drive (front-to-middle of
736.5 mm (30.0 in.) 942 mm (37.1 in.)
engine mount)
Marine gear (front-to-marine
644 mm (25.4 in.) 827.5 mm (32.6in.)
gear mounting face)
Overall length 839.2 mm (33.0 in.) 1001 mm (39.4 in.)
Width 670 mm (26.4 in.) (local exceeding)

12/05
SPECIFICATIONS
Weight (without marine gear) –
Dry (without mixing elbow) For stern drive: 273.5 kg (603 lb) For stern drive: 338 kg (745 lb)
For marine gear: 262.5 kg (575.7 lb) For marine gear: 319 kg (703 lb)
* Cylinder numbering starts at the coolant pump end of the engine.
** Rating condition: ISO 8665. Temperature of fuel: 40 °C (104 °F) at engine inlet
1 hp (metric horsepower) = 0.7355 kW
Fuel condition: Density at 15 °C (59 °F) = 0.840 g/cm3
*** 1080 min-1 at startup for alternator excitation
**** The “Total Engine Lubricating Oil Capacity” includes oil in the oil pan, channels, coolers, and
filter. The “Effective Engine Lubricating Capacity” indicates the difference in maximum scale of
the dipstick and minimum scale.
***** Capacity may vary depending on installation angle.

SPECIFICATIONS

11-EPA_Warranty.fm 81 ページ２０１２年１１月８日　木曜日　午後１時８分
EPA WARRANTY
USA ONLY
YANMAR CO., LTD. LIMITED YANMAR warrants that the engine is
designed, built and tested using genuine
EMISSION CONTROL parts and equipped so as to conform to all
SYSTEM WARRANTY - USA applicable emission requirements of the
U.S. Environmental Protection Agency and
ONLY is free from defects in material and
The following EPA Warranty only applies workmanship which would cause this
to engines built on or after January 01, engine to fail to conform to the applicable
2006 and labeled with the proper emission regulations over its limited
nameplate. emission control system warranty period.
THIS EMISSION WARRANTY APPLIES Where a warrantable emissions condition

TO THE ENGINES CERTIFIED TO exists, YANMAR will repair your engine at
UNITED STATES EPA 40 CFR Part no charge to you for diagnosis, parts, and
1042.135 AND SOLD BY YANMAR THAT labor. Warranty service or repair will be
ARE INSTALLED IN VESSELS FLAGGED provided at authorized YANMAR marine
OR REGISTERED IN THE UNITED dealers or distributors.
STATES. It is recommended that any replacement
Your Warranty Rights and parts used for maintenance, repair or
replacement of emission control systems
Obligations: are YANMAR parts. The owner may elect
YANMAR warrants to the first user and to have maintenance, replacement or
each subsequent purchaser the emission repair of the emission control components
control system on your engine for periods and systems performed by any repair
of time listed below provided the engine establishment or individual and may elect
has been installed according to YANMAR to use parts other than YANMAR parts for
installation requirements and there has such maintenance, replacement or repair.
been no abuse, neglect, or improper However, the cost of such service or parts
maintenance of your YANMAR marine and subsequent failures from such service
engine. or parts will not be covered under this
emission control system warranty:

EPA WARRANTY USA ONLY

Warranty Period: Owner’s Responsibility:
The warranty starts on either the date of As the YANMAR marine engine owner,
delivery to the first end-user, or the date you are responsible for the performance of
the unit is first leased, rented, or loaned. the required maintenance listed in your
Operation Manual. YANMAR recommends
For Pleasure Use: The warranty period is
that you retain all documentation, including
five (5) years or 2000 hours of use,
receipts, covering maintenance on your
whichever occurs first. In the absence of a
marine engine, but YANMAR cannot deny
device to measure hours of use, the
warranty solely for the lack of receipts or
engine has a warranty period of five (5)
for your failure to ensure the performance
years.
of all scheduled maintenance.
Warranty Coverage: Your engine is designed to operate on
Repair or replacement of any warranted diesel fuel only. Use of any other fuel may
parts will be performed at an authorized result in your engine no longer operating in
YANMAR dealer or distributor. This limited compliance with applicable emission
emission control system warranty covers requirements. You are responsible for
engine components that are a part of the initiating the warranty process. You must
emission control system of the engine as present your marine engine to an
delivered by YANMAR to the original retail authorized YANMAR dealer or distributor
purchaser. Such components may include as soon as a problem exists.
the following:
1. Fuel injection system
2. Turbocharger system
3. Aftercooler
4. Electronic engine control units and its
associated sensor and actuators
Exclusions:
Failures other than those arising from
defects in material and/or workmanship
are not covered by this limited emissions
warranty. This warranty does not extend to
the following: malfunction caused by
abuse, misuse, improper adjustment,
modification, alteration, tampering,
disconnection, improper or inadequate
maintenance, improper storage or use of
non-recommended fuels and lubricating
oils, accident-caused damage, and
replacement of expendable and/or
consumable items made in connection
with scheduled maintenance.

11-EPA_Warranty.fm 83 ページ２０１２年１２月１４日　金曜日　午後２時１１分

12/05
Customer Assistance: Yanmar America Corporation,

Marine Engine Division
If you have any questions regarding your 101 International Parkway
warranty rights and responsibilities or Adairsville, GA 30103
would like information on the nearest USA Telephone: 770-877-9894
authorized YANMAR dealer or distributor, Fax: 770-877-7567
you should contact Yanmar America Website: us.yanmar.com
Corporation, Marine Engine Division for E-mail: [email protected]
assistance. Toll Free Telephone Numbers:
1-855-416-7091
1-800-872-2867


Maintenance Log
Stamp or
Date Operating hours Maintenance performed Dealer name
signature

12/05
Stamp or
Date Operating hours Maintenance performed Dealer name
signature

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11-EPA_Warranty.fm 87 ページ２０１２年１２月１９日　水曜日　午前１１時５０分

12/05


‫ڦ‬Yanmar (Head office)
Umeda Gate Tower 1-9 Tsurunocho, kita-ku, Osaka,
Japan 530-8311
‫ ڦ‬Marine Operations Division
Quality Assurance Dept.
3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki,
Hyogo, Japan 661-0001
Phone: +81-6-6428-3251 Fax: +81-6-6421-5549
Overseas Office
‫ڦ‬Yanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Phone: +31-36-5493200 Fax: +31-36-5493209
‫ڦ‬Yanmar Asia (Singapore) Corporation Pte Ltd. (YASC)

4 Tuas Lane, Singapore 638613
Phone: +65-6595-4200 Fax: +65-6862-5189
‫ڦ‬Yanmar America Corporation (YA)

101 International Parkway
Adairsville, GA 30103, U.S.A.
Phone: +1-770-877-9894 Fax: +1-770-877-9009
‫ڦ‬Yanmar Engine (Shanghai). Co., Ltd.

10F, E-Block POLY PLAZA, No.18 Dongfang Road,
Pudong Shanghai, CHINA P.R.C. 200120
Phone: +86-21-6880-5090 Fax: +86-21-6880-8090
OPERATION MANUAL
4BY3-150, 4BY3-150Z, 4BY3-180, 4BY3-180Z

6BY3-220, 6BY3-220Z, 6BY3-260, 6BY3-260Z
1st edition: May 2012

2nd edition: January 2013
Issued by: YANMAR CO., LTD. Marine Operations Div.

Edited by: YANMAR TECHNICAL SERVICE CO., LTD.
MARINE ENGINES
http://www.yanmar.com 0ABY0-G00301

Yanmar BY3 - OPM - 0ABY0-G00301

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OPERATION MANUAL

All Rights Reserved:

4BY3-150, 4BY3-150Z, 4BY3-180, 4BY3-180Z

All Rights Reserved, Copyright

BY3 Series Operation Manual i

ii BY3 Series Operation Manual

BY3 Series Operation Manual iii

iv BY3 Series Operation Manual

BY3 Series Operation Manual

BY3 Series Operation Manual 1

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

2 BY3 Series Operation Manual

BY3 Series Operation Manual

A attention, become alert,

BY3 Series Operation Manual 3

4 BY3 Series Operation Manual

• Store any equipment in a designated

BY3 Series Operation Manual 5

6 BY3 Series Operation Manual

BY3 Series Operation Manual 7

8 BY3 Series Operation Manual

If you have an installation with two or three

BY3 Series Operation Manual 9

10 BY3 Series Operation Manual

No. Part Number

BY3 Series Operation Manual 11

This Page Intentionally Left Blank

12 BY3 Series Operation Manual

BY3 Series Operation Manual

BY3 Series Operation Manual 13

14 BY3 Series Operation Manual

Figure 1, Figure 2 and Figure 3 illustrate 3 4

Left Side (as Viewed from

BY3 Series Operation Manual 15

2 – Intake air manifold 1 – Engine oil dipstick

16 BY3 Series Operation Manual

1 – Zinc anode 1 – Fuel fine filter

BY3 Series Operation Manual 17

The engine data and drive information Fuel stop power kW

nameplates on YANMAR BY3 series BSO/SAV-EXHAUST GAS TYPE TEST

engines are shown in Figure 7, Figure 8

The engine block information is etched into

BSO/SAV-EXHAUST GAS TYPE TEST

18 BY3 Series Operation Manual

BY3 Series Operation Manual 19

20 BY3 Series Operation Manual

1 – Fuse F1 (3 A) - CAN switched 8 – Jumper fuse F8 (3 A) -

BY3 Series Operation Manual 21

22 BY3 Series Operation Manual

BY3 Series Operation Manual

BEFORE YOU OPERATE

BY3 Series Operation Manual 23

BEFORE YOU OPERATE

24 BY3 Series Operation Manual

BY3 Series Operation Manual 25

BEFORE YOU OPERATE

to settle to the bottom of the container. 1 – To fuel feed pump

26 BY3 Series Operation Manual