Yanmar 4BY3-180Z Specifications Page 1

MARINEENGINESBYseriesOPERATION MANUAL4BY26BY2P/N: 0ABY0-G00200

SAFETY PRECAUTIONSGeneral InformationThere is no substitute for common senseand careful practices. Improper practices orcarelessness can cause burns,

WARNINGThe safety messages that follow haveWARNING level hazards.Explosion HazardWhile the engine is running orthe battery is charging,hydrogen gas i

WARNINGPiercing HazardAvoid skin contact with high-pressure diesel fuel spraycaused by a fuel system leaksuch as a broken fuel injectionline. High-pr

NOTICEThe safety messages that follow haveNOTICE level hazards.It is important to perform daily checks aslisted in the Operation Manual. Periodicmaint

SAFETY DECALS0006620FULLLOW120650-07050120650-07040120650-07030• NEVER pour the engine oil across the full line.• Never remove the cap while the e

PRODUCT OVERVIEWYANMAR BY-SERIESFEATURES ANDAPPLICATIONSThe BY-series engines are in-line 4- and6-cylinder direct injection diesel engines.The engines

New Engine Break In• On the initial engine start-up, check forproper engine oil pressure, diesel fuelleaks, engine oil leaks, coolant leaks, andfor pr

COMPONENT IDENTIFICATIONFigure 1, Figure 2 and Figure 3 illustrate atypical version of a 4BY2 engine. Yourengine may have different equipment fromthat

Top View - 4BY2 0006560(1)(2)(3)(4)(5)(6)(7)Figure 31 – Fuel Fine Filter2 – Intake Air Manifold3 – Engine Oil Filter4 – Power Steering Filler Po

Right Side - 6BY2 0006561(6)(7)(3)(2)(4)(5)(8)(9)(1)Figure 51 – Zinc Anode2 – Zinc Anode3 – Exhaust / Water Mixing Elbow4 – Coolant Drain Cock5

Disclaimers:All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. T

LOCATION OFNAMEPLATESThe engine data and drive informationnameplates on Yanmar BY2 series enginesare shown in Figure 7, Figure 8 andFigure 9. Replace

00065674 B Y1 0 8 5 N 0 7 5 1 1 0 0 7 8 2 4 9 5 1NSERIAL NUMBERSENGINETRANSOMDRIVEMERCRUISERMODEL:TRANSOM ASSEMBLYAND STERN D

FUNCTION OF MAJOR COMPONENTSName of Component FunctionFuel Filter / Water Sepa-rator (not supplied byYanmar)Removes dirt and water from the fuel. The

Name of Component FunctionElectrical Panel (E-Box) The electrical panel houses the engine electrical system fuses, relays, and ECU.The ECU monitors da

FUSES AND RELAYS0004043(1)(2)(3)(4)(5)(6)(9)(10)(11)(12)(13)(14)(15)(7)(8)Figure 101 – Fuse F1 (3 A) - CAN SwitchedPower2 –Fuse F2 (10 A) - Ignition*3

ENGINE COVER0006552Figure 11To remove the cover from the engine,remove all bolts, then lift cover from engine.PRODUCT OVERVIEWBY Series Operation Manu

This Page Intentionally Left BlankPRODUCT OVERVIEW20 BY Series Operation Manual© 2008 Yanmar Marine International

BEFORE YOU OPERATEThis section of the Operation Manualdescribes the diesel fuel, engine oil, andengine coolant specifications and how toreplenish them

DIESEL FUELDiesel Fuel SpecificationsNOTICE: Only use diesel fuelsrecommended by Yanmar for the bestengine performance, to prevent enginedamage and to

Additional Technical FuelRequirements• The fuel cetane number should be equalto 48 or higher.• The sulfur content must not exceed 0.3%by volume. Less

TABLE OFCONTENTSPageIntroduction...1Record of Ownership...

Filling the Fuel TankNOTICE: Operate bilge ventilation(blowers) for a minimum of 5 minutes topurge fumes from engine compartment afterrefueling. Never

ENGINE OILEngine Oil SpecificationsUse a full-synthetic long-life engine oil thatmeets or exceeds the following guidelinesand classifications:Service

Acceptable Engine OilLongLife 01 OilsTrade name Producer/SupplierAddinol Super power MV 0537 Addinol Lube Oil GmbHAgip Formula LL B 01 ENI S.p.A. Refi

Trade name Producer/SupplierMobil 1 Spezial XS ExxonMobilMotorex Profile B-XL Bucher AGMotorex Select SP-X Bucher AGMotul Specific LL-01 Motul S.A.OMV

LongLife 04 OilsTrade name Producer/SupplierAddinol Super power MV 0537 Addinol Lube Oil GmbHAgip Formula MS B04 ENI S.p.A.Aral SuperTronic AralBMW Lo

Checking Engine Oil(1)0006568Figure 3Note: 4BY2 series shown. 6BY2 is similar.1. NOTICE: Prevent dirt and debris fromcontaminating engine oil. Carefu

MARINE GEAR OR STERNDRIVE OILRefer to the instruction book for each marinegear or stern drive.POWER STEERING FLUIDSPECIFICATIONSRefer to the stern dri

ENGINE COOLANTAcceptable Engine CoolantTrade Name ManufacturerAddinol Antifreeze Super Addinol Lube Oil GmbHAral Antifreeze Extra Aral AGAVIA Antifree

Adding Engine Coolant1. Remove the pressure cap and pourcoolant mix slowly into the heatexchanger to prevent the formation ofair pockets. Fill until t

ENGINE OPERATION WARNINGFire and Explosion HazardAvoid serious personal injury.NEVER jump-start theengine. Sparks caused byshorting the battery to the

Adding Engine Oil... 29Marine Gear or Stern Drive Oil...30Power S

NOTICEIf any indicator illuminates during engineoperation, stop the engine immediately.Determine the cause and repair the problembefore you continue t

Starting at Low TemperaturesNOTICE: NEVER use an engine starting aidsuch as ether. Engine damage will result.Comply with local environmentalrequireme

CHECKING THE ENGINEAFTER OPERATION• Check that the key switch is in the OFFposition and battery master switch (ifequipped) is OFF.• Fill the fuel tank

PERIODIC MAINTENANCESAFETY PRECAUTIONS WARNINGCrush HazardIf you need to transport an enginefor repair, have a helper assist youattach it to a hoist a

WARNINGShock HazardAvoid serious personal injury orequipment damage. ALWAYSturn off the battery switch (ifequipped) or disconnect thenegative battery

PRECAUTIONSThe Importance of PeriodicMaintenanceEngine deterioration and wear occur inproportion to the length of time the enginehas been in service a

EPA REQUIREMENTSThe EPA emission regulation is applicableonly in USA.Conditions to EnsureCompliance with EPA EmissionStandardsThis product is an EPA-a

Standard Torque ValuesHexagon Bolts and NutsNominal Diameter Grade (Lubricated)8.8 or 8 10.9 or 10 12.9 or 12M4 2.7 N·m (24 in.-lb) 3.88 N·m (34.3 in.

PERIODIC MAINTENANCESCHEDULEDaily and periodic maintenance is importantto keep the engine in good operatingcondition. The following is a summary ofmai

○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributorSystem Item Periodic Maintenance Interval DailySee Daily

Every 1000 Hours of Operation... 56Every 2000 Hours of Operation... 57Troubleshooting...

○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributorSystem Item Periodic Maintenance Interval DailySee Daily

○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributorSystem Item Periodic Maintenance Interval DailySee Daily

Inspection and Maintenance ofEPA Emission-Related PartsParts IntervalCheck fuel injection nozzle(cleaning)1500 hoursCheck fuel injection nozzle(adjust

Checking Diesel Fuel, Engine Oiland Engine Coolant LevelsFollow the procedures in Filling the Fuel Tank on page 24 and Checking Engine Oil on page 29

PERIODIC MAINTENANCEPROCEDURESAfter Initial 50 Hours ofOperationPerform the following maintenanceprocedures after the initial 50 hours ofoperation.• C

8. Install a new filter element. Ensure thefilter fits snugly in the filter cap.9. Install the cap and filter assembly.Tighten cap by hand until the s

3. NOTICE: NEVER attempt to remove thecovers or fill a maintenance-free battery.Remove the caps and check theelectrolyte level in all cells.4. If the

Draining the Fuel Tank0004542(3)(1)(2)Figure 41 – Sediment Bowl2 – Drain Cock3 – Fuel Line to EngineNote: Typical fuel tank shown. Actualequipment ma

Replacing Fuel Filter / WaterSeparator ElementNote: Yanmar supplies a water separatingpre-filter separate from the engine. Locationand type of filter

14. Bleed air from the fuel system andcheck for leaks. See Bleeding the Fuel System on page 24.Changing the Engine Oil andReplacing Engine Oil Filter

This Page Intentionally Left BlankTABLE OF CONTENTSvi BY Series Operation Manual© 2008 Yanmar Marine International

Checking Exhaust / Water MixingElbowSee your authorized Yanmar dealer ordistributor.Replacing Air Filter Element1. Turn engine OFF.2. Remove engine co

Every 500 Hours of OperationPerform the following maintenance every500 hours of operation or every 2 years,whichever comes first.• Checking the Fuel P

8. Remove the pressure cap(Figure 11, (2)) from the heatexchanger.9. Inspect the cap gasket and flange on thefiller neck for damage. Replace ifnecessa

Every 2000 Hours of OperationPerform the following maintenance every2000 hours of operation or every 8 years,whichever comes first.• Replacing Seawate

This Page Intentionally Left BlankPERIODIC MAINTENANCE58 BY Series Operation Manual© 2008 Yanmar Marine International

TROUBLESHOOTINGIf a problem occurs, stop the engineimmediately. Refer to theProblem / Symptom column in theTroubleshooting Chart to identify theproble

TROUBLESHOOTING CHARTStarting TroubleProblem / Symptom Cause ActionEngine Will Not Crank Discharged battery Charge / replace batteryBlown fuse Replace

Exhaust ColorProblem / Symptom Cause ActionWhite Smoke Cold engine Allow engine to warm to operatingtemperatureSee your authorized Yanmar deal-er or d

Vibration - Drive EngagedProblem / Symptom Cause ActionRough at All Speeds Engine and propeller shaft mis-alignedSee your authorized Yanmar deal-er or

Engine OverheatProblem / Symptom Cause ActionInstrument Shows High Tem-peratureClogged seawater inlet CleanLow coolant level Fill with coolant / inspe

INTRODUCTIONWelcome to the world of Yanmar Marine!Yanmar Marine offers engines, drivesystems and accessories for all types ofboats, from runabouts to

DIAGNOSTIC TROUBLECODESWhen certain faults occur, or when certainlimits have been exceeded, the engine ECUmay generate a “Check Engine” warning orturn

Diagnostic Trouble Code TableCode Part or System Mode Run OrConditionEngineCanStartCheckEngineAlarmNoCodeCoolant Temp Under 0°C (32°F) 1000 rpm yes no

Code Part or System Mode Run OrConditionEngineCanStartCheckEngineAlarmP0122 Throttle Signal Both throttle signals are miss-ing / short circuit to Grou

Code Part or System Mode Run OrConditionEngineCanStartCheckEngineAlarmP0238 Boost Pressure4 bar (58.0 psi) (absolute**)reduce yes alarmBoost Pressure

Code Part or System Mode Run OrConditionEngineCanStartCheckEngineAlarmP0675 Glow System - GlowSpark No. 5Not connected, short circuit yes yes alarmP06

LONG-TERM STORAGEIf the engine is not to be used for anextended period of time, special measuresshould be taken to protect the coolantsystem, fuel sys

Draining the Seawater CoolingSystemCAUTION! DO NOT drain the coolantsystem. A full coolant system willprevent corrosion and frost damage.CAUTION! If s

SPECIFICATIONSENGINE SPECIFICATIONSEngine Model 4BY2-150 /150Z4BY2-180 /180Z6BY2-220 /220Z6BY2-260 /260ZApplication Design Models numbers with no suff

Engine Model 4BY2-150 /150Z4BY2-180 /180Z6BY2-220 /220Z6BY2-260 /260ZFuel Injection System Common rail (ECU-controlled)Fuel Injection Pressure Variabl

Engine Model 4BY2-150 /150Z4BY2-180 /180Z6BY2-220 /220Z6BY2-260 /260ZWeight (without marine gear) Dry (without mixingelbow)For Stern Drive: 273.5 kg

RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar forservice, parts or literature.Engine Model: Engine

This Page Intentionally Left BlankSPECIFICATIONS74 BY Series Operation Manual© 2008 Yanmar Marine International

EPA WARRANTYUSA ONLYYANMAR CO., LTD. LIMITEDEMISSION CONTROLSYSTEM WARRANTY - USAONLYThe following EPA Warranty only applies toengines built on or aft

Warranty Period:The warranty starts on either the date ofdelivery to the first end-user, or the date theunit is first leased, rented, or loaned.For Pl

Customer Assistance:If you have any questions regarding yourwarranty rights and responsibilities or wouldlike information on the nearest authorizedYan

Maintenance LogDate OperatingHoursMaintenance Performed Dealer Name Stamp or Signa-ture

Date OperatingHoursMaintenance Performed Dealer Name Stamp or Signa-ture

EPA WARRANTY USA ONLY80 BY Series Operation Manual© 2008 Yanmar Marine International

EPA WARRANTY USA ONLYBY Series Operation Manual 81© 2008 Yanmar Marine International

This Page Intentionally Left BlankEPA WARRANTY USA ONLY82 BY Series Operation Manual© 2008 Yanmar Marine International

SAFETYYanmar considers safety of greatimportance and recommends that anyonethat comes into close contact with itsproducts, such as those that install,