4BY2 6BY2 SM 07Apr09, Instrukcje obsługi - Manuals, Yanmar, BY2

[ Pobierz całość w formacie PDF ]
BY
series
SERVICE MANUAL
BY Service Manual
4BY2
6BY2
P/N: 0BBY0-U00200
MARINE
ENGINES
This
Service Manual
has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in mind
and may not contain the necessary detail or safety statements that may be required for a non-professional to
perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service
professional before working on your Yanmar product.
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.
Yanmar and
are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or
other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without
the written permission of Yanmar Marine International.
© 2009 Yanmar Marine International
0409
ii
BY Service Manual
© 2009 Yanmar Marine International
 TABLE OF
CONTENTS
BY Service Manual
Page
Safety
.................................................................................................... 2-1
Safety Precautions .......................................................................... 2-2
General Service Information
.............................................................. 3-1
Safety Precautions .......................................................................... 3-3
Engine Outline Drawings................................................................. 3-4
4BY2 (Inboard) .......................................................................... 3-4
4BY2 (Stern Drive) .................................................................... 3-5
6BY2 (Inboard) .......................................................................... 3-6
6BY2 (Stern Drive) .................................................................... 3-7
Engine Piping Diagrams.................................................................. 3-8
4BY2.......................................................................................... 3-8
6BY2.......................................................................................... 3-9
Location of Nameplates................................................................. 3-11
Engine Nameplates (Typical) .................................................. 3-11
Diesel Fuel .................................................................................... 3-12
Diesel Fuel Specifications ....................................................... 3-12
Bleeding the Fuel System........................................................ 3-14
Engine Oil...................................................................................... 3-14
Engine Oil Specifications......................................................... 3-14
Acceptable Engine Oil ............................................................. 3-16
Recommended Marine Gear or Stern Drive Oil....................... 3-18
Recommended Power Steering Fluid...................................... 3-18
Engine Coolant.............................................................................. 3-19
Engine Coolant Specifications................................................. 3-19
Acceptable Engine Coolant ..................................................... 3-20
Principal Engine Specifications ..................................................... 3-21
BY Service Manual
iii
© 2009 Yanmar Marine International
TABLE OF CONTENTS
Tightening Torques for Standard Bolts and Nuts .......................... 3-23
Tightening Fasteners............................................................... 3-23
Hexagon Bolts and Nuts.......................................................... 3-23
Hose Clamps........................................................................... 3-23
Prepare Engine for Long-Term Storage ........................................ 3-24
Abbreviations and Symbols........................................................... 3-25
Abbreviations........................................................................... 3-25
Symbols................................................................................... 3-25
Unit Conversions ........................................................................... 3-26
Unit Prefixes ............................................................................ 3-26
Units of Length ........................................................................ 3-26
Units of Volume ....................................................................... 3-26
Units of Mass........................................................................... 3-26
Units of Force .......................................................................... 3-26
Units of Torque........................................................................ 3-26
Units of Pressure..................................................................... 3-26
Units of Power ......................................................................... 3-26
Units of Temperature............................................................... 3-26
Periodic Maintenance
......................................................................... 4-1
Safety Precautions .......................................................................... 4-3
Introduction...................................................................................... 4-3
The Importance of Periodic Maintenance.................................. 4-3
Performing Periodic Maintenance ............................................. 4-3
Yanmar Replacement Parts ...................................................... 4-3
Required EPA Maintenance ...................................................... 4-3
EPA Requirements.......................................................................... 4-3
Conditions to Ensure Compliance with
EPA Emission Standards .......................................................... 4-3
Inspection and Maintenance ..................................................... 4-4
Periodic Maintenance Schedule...................................................... 4-5
Periodic Maintenance Procedures .................................................. 4-9
After Initial 50 Hours of Operation ............................................. 4-9
Every 50 Hours of Operation................................................... 4-10
Every 250 Hours of Operation................................................. 4-11
Every 500 Hours of Operation................................................. 4-15
Every 1000 Hours of Operation............................................... 4-17
Every 2000 Hours of Operation............................................... 4-17
Engine
.................................................................................................. 5-1
Safety Precautions .......................................................................... 5-3
Introduction...................................................................................... 5-3
Specifications .................................................................................. 5-4
General Information................................................................... 5-4
Test and Adjustment Specifications .......................................... 5-4
Repair Specifications................................................................. 5-5
Special Torque Chart ...................................................................... 5-8
Special Service Tools.................................................................... 5-11
iv
BY Service Manual
© 2009 Yanmar Marine International
 TABLE OF CONTENTS
12/05
Measuring Instruments.................................................................. 5-12
Sealants and Compounds ............................................................. 5-13
Tests and Adjustments.................................................................. 5-14
Test Compression ................................................................... 5-14
Repair............................................................................................ 5-15
Cylinder Head................................................................................ 5-16
Cylinder Head Components .................................................... 5-16
General Guidelines.................................................................. 5-17
Remove and Install Cylinder Head Cover ............................... 5-17
Remove and Install Glow Plugs............................................... 5-19
Remove Cylinder Head ........................................................... 5-19
Disassemble Cylinder Head .................................................... 5-22
Clean Cylinder Head Components .......................................... 5-24
Pressure Test the Cylinder Head ............................................ 5-24
Inspect Cylinder Head Components........................................ 5-24
Replace Valve Stem Seals ...................................................... 5-25
Assemble Cylinder Head ......................................................... 5-26
Determine Cylinder Head Gasket Thickness........................... 5-26
Install Cylinder Head ............................................................... 5-27
Pistons and Cylinders.................................................................... 5-31
Remove and Disassemble Piston and Connecting Rod.......... 5-31
Inspect Pistons and Piston Rings ............................................ 5-32
Assemble Piston and Connecting Rod .................................... 5-33
Install Piston and Connecting Rod .......................................... 5-34
Flywheel and Flywheel Housing.................................................... 5-37
Remove and Install Flywheel Housing ................................... 5-37
Remove and Install Drive Coupling ......................................... 5-38
Remove Flywheel .................................................................... 5-39
Replace Rear Crankshaft Seal ................................................ 5-40
Install Flywheel ........................................................................ 5-41
Camshaft and Timing Gear Train .................................................. 5-42
Components ............................................................................ 5-42
Check and Adjust Camshaft Timing ........................................ 5-44
Remove and Install Vibration Damper - 4BY2......................... 5-46
Remove and Install Vibration Damper - 6BY2......................... 5-47
Remove Timing Case Cover ................................................... 5-48
Remove and Install Timing Chain............................................ 5-49
Install Timing Case Cover ....................................................... 5-49
Remove and Install Timing Chain Tensioner........................... 5-50
Remove Camshafts ................................................................. 5-51
Install Camshafts ..................................................................... 5-54
Cylinder Block and Crankshaft ...................................................... 5-56
Components ............................................................................ 5-56
Remove Crankshaft................................................................. 5-58
Measure Oil Clearance............................................................ 5-59
Inspect Crankshaft................................................................... 5-61
Inspect Cylinder Block ............................................................. 5-62
BY Service Manual
v
© 2009 Yanmar Marine International
  [ Pobierz całość w formacie PDF ]

  • zanotowane.pl
  • doc.pisz.pl
  • pdf.pisz.pl
  • styleman.xlx.pl

    		•