Scribd Logo
Upload

Welcome to Scribd!

  • 54 views

    0fmpe En0037

    Uploaded by

    alex

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content

    You might also like

    0fmpe En0037

    Uploaded by

    alex
    54 views256 pages

    Original Title

    0FMPE-EN0037

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
    54 views256 pages

    0fmpe En0037

    Uploaded by

    alex

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
    of 256
    INSTALLATION MANUAL Volume 3 BY, LH, LP, LV, LY AY g (et California Proposition 65 Warning California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. ‘Wash hands after handling, 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 YANIMAR 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 - graph- ic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of YANMAR CO. LTD. MODEL BY, LH, LP, LV, LY Series CODE OFMPE-ENO037 INSTALLATION MANUAL, All Rights Reserved, Copyright YANMAR GO, LTD. REVISION HISTORY This manual will be revised whenever necessary. When the produet’s specification, structure, and maintenance essentials are changed, the revision will be made to the necessary parts of the manual. This is to always keep the manual in the newest state. When a revision is made, we will send you the new revised pages with the revision management chart, when necessary. Please replace them with the applying pages. Also, please dispose the pages and information that were replaced. In this way, information can be provided efficiently and quickly. Revision Control Table Revision date New page numbers Pedal nee sive Remarks Initiating Dept. ‘June 2006 all Re-release YMU Rev. 1 Dee. 2006 6BY220-2 Updated engine displacement YMU Rev. 2 eBY260-2 ‘Added KMH40 marine gear to marine gearistem drive specifications Dec. 2006 BY 150-1 6 | New table of contents YMU Rev.2 4BY 180-1, 6 | Changed intercooler to charge air cooler 6BY220-1, 6 | Updated fuel system specifications and 6BY260-1, 6 | added fuel system note Updated coolant overheat alarm operating temperature ‘Added classic control statement to lube oil low pressure alarm Corrected unit of measure for maximum fuel feed pump discharge volume Updated engine outlines Dec. 2006 4BY150-7, -10 and -11 ‘Added borg warner flange designation to. | YMU, Rev. 2 4BY 180-7, -10 and -11 flywheeltlywheel housing dimensions 6BY220-7, -10 and -11 ‘Added YANMAR starter code 6BY260-7, -10 and -11 ‘Added YANMAR alternator code Dec. 2006 4BY150-13,-14and-18 | Changed amperage of fuse FS YMU Rev. 2 4BY180-13, -14and-15 _| Added! additional information for fuses F7 and F8 ‘Added unit of measure to fuel consumption Updated TELEFLEX optional accessories Dec. 2006 @SY-1 and 2 New table of contents YMU Rev. 2 8SY-1 and -2 Updated marine gear specifications Dec. 2006 6SY-6 and 7 Updated engine outline YMU Rev. 2 8SY-5 and -7 Updated cooling system piping diagram Dec. 2006 SY-14 Removed air venting for V-drive applications | YMU Rev. 2 asY-15 - V-drive not available. Dec. 2006 6SY-STP2IESYE5S ‘Added new model numbers YMU Rev.2 YVANMAR iiaine nsataton tarual- Volume 3 Revision date New page numbers Revision number involved eae May 2007 GLPA-STP2/GLPA-STZP2 | Added new models YMU Rev. 3 ‘Aug. 2007 6sY ‘Added new models (6SY700, 6SY750) YMU Rev.3 asy ‘Oct, 2007 “ABY 150-4 New back pressure and intake depression | YMI Rev.3 BY 180-4 information. BY 220-4 BY 260-4 6LPA-STP2/6LPA-STZP2-2 6LPA-STP2/6LPA-STZP2-3 6LPA-STP2/6LPA-STZP2-4 6LPA-STP2/6LPA-STZP2-21 6LYS5 esy-9 asy-11 Dec. 2007 eLy3 Update airintake and exhaust specifications, | YMI Rev. 3 fuel system specifications, cooling system specifications, minimum battery capacity 6LY3-STP and 6LY3-UTP performance curves and change flow of layout to match the 6SY section “4BY 150-4 Update air intake and exhaust specifications | YMI BY 180-4 and note. BY 220-4 BY 260-4 esy-9 esy-11 77350 ‘Added new section for 27350 installation _ | YM information ‘Apr. 2008) 6CX530 section ‘Added new section for 6GX630 installation | YM Rev. 4 information (6CXS30-25 Updated engine mount specification YM (6CX530-26 Updated flexible mount distortion Yaa (6CXS30-27 Updated torsional vibration Yul ‘6CXS30-29 to 6CX530-30 _| Updated optional accessories Yu 6CX530-6 Updated fuel system specifications YM (6CX530-28 Updated installation specifications Yu “4BY2 section ‘Added new section for 4BY2 installation | YM information (replace 4BY section) @BY2 section ‘Added new section for 6BY2 installation | YMI information (replace 6BY section) Marine installation Manuel -Voume s W/L RE ALAR Revision date New page numbers Reterto “OFZTD-G00100 (2T350 installation manual)” Revision number involved eee ‘Apr. 2009 6CXE30-5 Updated flywheeliywheel housing YM Rev. 4 dimensions 6SY section Updated engine, fuel system, cooling YM system, air intake and exhaust specifications. Updated performance curves. Updated mode! number throughout section, SY section Updated model number throughout whole | YM section Page 2, 4,5 andé Updated disclaimer and Rev. log and YM updated tabs 750 section Update corning in spring/summer 2009___[ YMII ‘June 2009 4BY2, 6BY2, 6CX530, ZT360 | Ree-release of Rev. 4 with updated 2350 | YMI Rev. 4 section, 6CX530 24 V diagram, BY2 safety Update, and engine room space specifications @LPASTP23 Fixed drawing aspect ratio GLPA-STP2-4 Corrected specification for maximum fuel feed pump discharge volume Dec. 2010 ‘LVS20(Z) ‘Added new models, Marine Rev. 5 8LV350(Z) Operations Div. 8LV370(Z) July 2012 4BY3 ‘Added new models Marine Rev. 6 eBy3 Operations Div. 21350 Delete YVANMAR iiaine nsataton tarual- Volume 3 Revision date New page numbers Remarks ing Dept. Revision number involved Feb. 2015 ALHA-HTP-3 Revised Marine Gear Specifications Large Power Rev.7 ALHA-HTP Revised Altemator data Products ALHA-HTP-10, 11 Revised Wiring diagrams Operations ALHA-HTP-18 Revised Optional Accessories Business 4LHADIPS Revised Marine Gear Specifications ALHA-DTP-2, 9 Revised Altemator data ALHA-DTP-10, 11, 12 Revised Wiring diagrams ALHA-DTP-19 Revised Optional Accessories aLHASTP-S Revised Marine Gear Specifications ALHA-STP-2, 9 Revised Altemator data ALHA-STP-10, 11, 12 Revised Wiring diagrams ALHA-STP-19 Revised Optional Accessories GLPA-STP2/6LPA-STZP2-3_| Revised Marine Gear Specifications GLPA-STP2/6LPA-STZP2-22 | Revised Optional Accessories @LY3s Revised Marine Gear Specifications 6LY3-10 Revised Altemator data 6LY3-11 Revised Wiring diagrams 6LY3-20 Revised Optional Accessories avs Revised Marine Gear Specifications aLV-5, 8, 10 Revised Engine Outline Drawing aLv-21 Revised Altemator data aLv-29 ‘Added Power take off aLv-34 Revised Optional Accessories GLY2A-4 Revised Marine Gear Specifications 6LY2A-15 Revised Altemator data 6LY2A-UTP Added new model “aBY2 Deleted old models eBy2 6LPA-DTP 6LPA-STP 6CXM-GTE2 6CX530 6sY sy June, 2076 eLv440 ‘Added new models Marine Rev. 8 eLY400 Recreational GLYA-STP Delete old model Eromotion! Division Marine installation Manuel -Voume s W/L RE ALAR SAFETY YANMAR is concerned for your safety and the condition of your marine engine. Safety statements are one of the primary ways to call your attention to the potential hazards associated with YANMAR, marine engines. Follow the precautions listed throughout the manual before operation, during operation and during periodic maintenance procedures for your safety, the safety of others and to protect the performance of your marine engine. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. Also, it you need to replace a part that has a decal attached to it, make sure you order the new part and decal at the same time. This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol. ADANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. ACAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. lezelel NOTICE indicates a situation which can cause damage to the machine, personal property and/or the environment or cause the equipment to operate improperly. YVAINMIAR vevine instataton Manuel-Votune 3 SAFETY SAFETY PRECAUTIONS There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance. Pees Avoid injury or equipment damage due to engine falling. Always secure the engine solidly to prevent the engine from falling during service. (Ly * Read and understand this manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures. + Never permit anyone to install or ‘operate the engine without proper training. * Safety signs and labels are additional reminders for safe operating and maintenance techniques. * See your authorized YANMAR marine dealer or distributor for additional training. Explosion Hazard Avoid serious personal injury or equipment damage. While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flame and any other form of ignition out of the area. Avoid serious personal injury or equipment damage. Always turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the equipment. Avoid unexpected equipment movement. Shift the marine gear into the NEUTRAL position any time the engine is at idle. Mi + Keep fire extinguishers handy in case of fire. Clearly indicate the location of the fire extinguishers with a safety sign. + Ensure that the type of fire extinguishers are appropriate for material that might catch fire. Check with local authorities. Fire Hazard * Avoid personal injury or equipment damage. Have appropriate safety equipment available. + Have all fire extinguishers checked periodically for proper operation and/or readiness. + Post evacuation routes prominently. Periodically conduct fire drills. Avoid personal injury. Always read and follow safety-related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Wipe up all spills immediately. Marine installation Manuel -Voume s W/L RE ALAR SAFETY Entanglement Hazard Rotating parts can cause severe injury or death, Never wear jewelry, @ unbuttoned cuffs, ties or loose ‘¢/%t fitting clothing and always tie long hair back when working near moving/rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. Avoid personal injury. Always stop the engine before beginning service. Avoid personal injury. Never leave the key in the key switch when servicing the engine. Attach a “Do Not Operate” tag near the key switch while performing maintenance on the equipment. Sever Hazard Avoid personal injury. The propeller th may rotate during towing or if the ic} engine is running at idle speed. fr& Never service the engine while being towed or when the engine is running. Avoid personal injury. If the vessel has more than one engine, never service an engine if either of the engines are running. In multi- engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running. Rotating parts can cause severe injury or death. Never operate the engine without the guards in place. Avoid personal injury. Never operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals. + Make welding repairs safely. + Always turn off the battery switch (if equipped) or disconnect the negative battery cable and the leads to the alternator when welding on the equipment. + Remove the multi-pin connector to the engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point. + Never connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket. + When welding is completed, reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries. Exhaust Hazard Avoid serious injury or death. Never @ block windows, vents, or other means of ventilation if the engine is AR operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning. Burn Hazard Avoid serious injury. Some of the engine surfaces become very hot during operation and shortly after shut-down. Keep hands and other body parts away from hot engine ‘surfaces. Handle hot components with heat-resistant gloves. YVANMAR iiaine nsataton tarual- Volume 3 SAFETY WARNING Sudden Movement Hazard Avoid personal injury or equipment damage. The engine lifting eyes are engineered to lift the weight of the marine engine only. Always use the engine lifting eyes when lifting the engine. To prevent accidental equipment movement, never start the engine in gear. ing Hazard Avoid serious personal injury. Additional equipment is necessary to lift the marine engine and marine gear together. Always use lifting equipment with sufficient capacity to lift the marine engine. If you need to transport an engine for repair, have a helper assist you in attaching it to a hoist and load it on a truck. Alcohol and Drug Hazard Never operate the engine while you are under the influence of alcohol or drugs or are feeling ill. Exposure Hazard To avoid injury, Always wear personal protective equipment including appropriate clothing, MM loves, work shoes, eye and hearing protection as required by the task at hand. Tool Hazard Avoid personal injury or equipment damage. Always remove any tools or shop rags used during maintenance from the area before operation. ACAUTION Avoid personal injury. Always wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Poor Lighting Hazard Avoid personal injury or equipment damage. Ensure that the work area is adequately illuminated. Always install wire cages on portable safety lamps. Tool Hazard Avoid personal injury or equipment damage. Always use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts. Marine installation Manuel -Voume s W/L RE ALAR SAFETY NOTICE Lez Ele ‘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. Always tighten components to the specified torque. Loose parts can cause equipment damage or ‘cause it to operate improperly. Only use replacement parts specified. Other replacement parts may affect warranty coverage. Never attempt to modify the engine design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control. Modifications may impair the engine's safety and performance characteristics and shorten the engine's life. Any alterations to this engine may void its warranty. Be sure to use YANMAR genuine replacement parts. * Always be environmentally responsible. + Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility + Never dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways. If any indicator illuminates during engine operation, stop the engine immediately. Determine the cause and repair the problem before you continue to operate the engine. Make sure the engine is installed on a level surface. Ifa YANMAR marine engine is installed at an angle that exceeds the specifications stated in the YANMAR marine installation manuals, engine oil may enter the combustion chamber causing excessive engine speed, white exhaust smoke and serious engine damage. This applies to engines that run continuously or those that run for short periods of time. YVANMAR iiaine nsataton tarual- Volume 3 SAFETY This Page Intentionally Left Blank : Name netaton Mawl-Voume's | WALNEAL 4BY3 Page Engine Specifications sense we Engine Room Space for Safety, Service and Correct Operation... 3 Marine Geari/Stem-Drive Specifications ...nnnsnrnnesiennesns 5 6 7 8 9 10 4BY3 (Inboard) 4BY8 (Stem-Drive) Flywheel Housing Dimensions (For Inboard) .... Flywheel Housing Dimensions (For Stemn-Drive) Fuel System Specifications Piping Diagram... : Cooling System Specifications " Air Intake and Exhaust Specifications 13, Mixing Elbow .. ‘Alarm System Specifications Remote Control System Electrical System Performance Curves. Engine Mount Installation Specifications Cold Starting Aids. Water Heater Tank Connection. Heat Insulation Requirements Optional Accessories YVAINMIAR vevine instataton Manuel-Votune 3 4BYS-1 4BY3 4BY3-150, 4BY3-180 Please refer to the Safety section at the beginning of this manual. Engine Specifications Parameter Data 4BY3-150 “ABY3-180 Configuration 4-cyole diesel, 15° inolined, dual overhead camshaft Crankshaft rotation (viewed from flywheel) Counterclockwise ‘Combustion system Direct injection Aspiration Turbocharger with charge air cooler Number of cylinders In-line 4 Bore x stroke ‘84 mm x 90 mm (8.307 in. x 3.543 in) Displacement 1.995 L (121.7 cuin,) Continuous rating oulput at crankshaft (at 3876 min* (epm)) 100 kW (136 hp) 120 KW (163 hp) Maximum output at crankshaft (at 4000 rin® (rpm) 110 KW (150 hp) 182 KW (180 hp) Maximum torque ‘320 Nem (236 ft-lb) ‘360 Nem (265 ft-lb) High idiing speed ‘4600 min” (tpm) Low idling speed (at 88 °C (190 °F) 750 min" (rpm)"" Firing order 1-3-4-2-1" Engine lubrication system Enclosed, forced Engine oil capacity (0° incline) 8.0L (8.45 qh” Dry weight (without gear/drive or mixing elbow) For stem-drive: 273, 5 kg For marine gear: 262.5 kg Total air flow requirements 1850 mth (65832 f°7h) 1080 min’ (rpm) at startup for alternator excitation. “2: No. 1 cylinder is at the coolant pump end of the engine. “3: The engine oil capacity includes oil in the oil pan, channels, coolers, and filter. Note + Rating condition, ISO 8665 Fuel temperature: 40 °C (104 °F) #1 hp metric = 0.7355 KW 4BY3-2 Marine installation Manuel -Voume s W/L RE ALAR 4BY3 Engine Room Space for Safety, Service and Correct Operation | teeny coker Figure 1 The installer is responsible for ensuring that there is sufficient engine room space to access the engine for service and repair. Superstructures and connected components should be installed so that the engine can be removed, fitted and serviced without time being lost to any obstructions. The following components must be easy to access: + Fuel filter(s) + Fuel system components for bleeding the fuel system + Airfilter * Engine oil filter(s) * Oil fill port and dipstick + Engine oil drain plug + Marine gear or sail-drive oil fill port/dipstick. + Coolant tank fill port + Coolant drain cock(s) * Coolant pump + Heat exchanger + Complete seawater pump assembly (to access impeller and filter) * Zinc anodes + Batteries + Starter motor + Altemator + Turbocharger YVANMAR iiaine nsataton tarual- Volume 3 4BYS -3 4BY3 Marine Gear/Stern-Drive Specifications Use the KMH41A marine gear or ZT370 or Mercruiser Bravo 1, 2 or 3 stern-drive with the 4BY3 series engine. “ABY3-150 717370 or Mercruiser Brav KMH1A, 4BY3-180 Stem drive 1 Marine gear Fire Hazard * 27370 and Bravo stern-drive power steering hoses must be routed away from hot engine components. + Ensure the heat insulator is installed on the turbocharger. Note: See the marine gear/stern-drive ‘manufacturer's literature for additional information. 4BY3-4 Marine installation Manuel -Voume s W/L RE ALAR 4BY3 Figure 2 VANMAR sveroivsiasn ua. vanes ons 4BY3 ABY3 (Stern-Drive) me wean 4BY3-6 Marine instalation Manual -Vowume 3 WAM INTRA ARES Flywheel Housing Dimensions (For Inboard) iH Yoh \ Whee / {| — zsisas _—\.\\) {en Figure 4 4BY3 Unit mm fn) = 119 (4.89) = VANMAR storie inctataton Manual Volume 3 4BY3 -7 4BY3 Flywheel Housing Dimensions (For Stern-Drive) Unit fn) - 245 (9.65) Figure 5 4BY3-8 Marine Installation Manual-Voume s WAM INURE ARES Fuel System Specifications 4BY3 Parameter Data “ABY3-150 “ABY3-180 Maximum fuel feed pump suction head 7.0 m (89.37 in) Maximum fuel feed pump discharge volume 160.0 Uhr minimum (42.3 galfhr minimum) Maximum fuel feed pump discharge pressure Fuel inlet pipe connector thread 5 bar (72.5 psi) 3/8 NPT Maximum fuel inlet temperature 70°C (158 °F) Fuel consumption at rated output 31.6 Uhr (63 gah) ‘96.7 Uhr (9.7 gah) Fuel line (minimum size) Hose acc. [SO 7840 At (fire resistance hose) is requested Max length of hose between prefiter and engine depends on suction height of complete suction line. Inner diameter for inlet 8 mm (0.32 in.) Inner diameter for outlet 12 mm (0.47 in.) Note: YANMAR supplies a water separating pre-filter for mounting by the installer. The engine is also equipped with an on-engine fine fiter. Al Fire Hazard Always route fuel lines away from hot engine components, such as the exhaust manifold, turbocharger and exhaust hoses. Fuel lines must be secured to the hull with approved clamps every 100 om (4.3 in.). YVANMAR iiaine nsataton tarual- Volume 3 4BYS -9 4BY3 Piping Diagram ™ Fuel flow 10 14 16 1 Fuel inlet from tank 2 ~Fuel filter (10 micron) 8 ~Fuel feed pump 4 = Inlet fuel temperature sensor 5 —High-pressure fuel pump 6 —High-pressure fuel supply line 7 -High-pressure fuel common rail 8 —Fuel injection line 12 15 " a 13\ 9 —Fuel injector 10—Fuel injector return hose 11.-Common rail return line 12—Return fuel tee with back pressure valve 13—Return fuel to fuel tank with over pressure valve 14-Fuel pressure sensor 15—Fuel pressure regulator (ECU-controlled) 46~Fuel measuring unit (ECU: controlled) Figure 6 4BY3-10 Marine installation Manuel -Voume s W/L RE ALAR Cooling System Spec! 4BY3 Parameter Data ‘4BY3-150 “4BY3-180 Cooling system Closed cooling with heat exchanger Coolant capacity (approximately) 0.0L (10.6 qd) Coolant capacity (Reservoir) TOL (0a) Maximum seawater pump flow rate at maximum rating 165 Umin. (174 qtimin.) Maximum seawater pump suction head 0.5 m (19.69 in.) ‘Seawater inlet pipe connector outer diameter 38.1 mm (1.5 in) Thermostat operating temperature (full open) 96°C (205 *F) ‘Thermostat operating temperature (opening) 88°C (190.4 °F) Maximum overflow pipe length (coolant reservoir to filler cap) 1.0 m (89.37 in) (Overflow pipe inner diameter (coolant reservoir to filler cap) 6 mm (0.250 in) ‘Water heater tank/eabin heater pipe inside diameter 10 mm (0.394 inn “1; Must have a minimum pressure rating of 1.5 bar (22 psi). eee The coolant hose from the heat exchanger to the sub-tank must be routed away from hot engine components. Never route coolant hoses over the flywheel side of the engine. YVANMAR iiaine nsataton tarual- Volume 3 aBys-11 4BY3 Cooling flow 2 7 9 2B 8 " 40 1 —Seawater supply 8 —Engine coolant pump 2 ~Seawater pump 9 - Thermostat 3 -Hydraulic oil cooler 10-Engine oil cooler 4 ~Charge oil cooler 11-Engine coolant passages 5 ~Engine heat exchanger 12—Coolant recovery tank 6 —Exhaust/seawater mixing elbow 13—Water cooled exhaust manifold 7 —Exhaust/seawater exit Figure 7 4BY3 -12 Marine Installation Manual-Voume s WAM INURE ARES Intake and Exhaust Specifications Check for leaks at initial start. 4BY3 Parameter Data 4BY3-150 “aBY3-180 Exhaust pipe outer diameter connection 102 mm (4.0in,) Air volume necessary for combustion at WOT (650 m'/h (22956 ft7h) Maximum air inlet depression 4.0 kPa, 408 mmAg (16.06 in.Aq) Maximum back pressure 45 kPa, 4589 mmAg (180.67 in.Aq) Maximum output exhaust temperature before turbocharger 650 °C (1202 °F) 710°C (1310 °F) EPA exhaust test port sizes Location: Mixing elbow G 1/4 19 BSPP™ or G 3/8 - 19 BSPP"! Maximum turbocharger boost pressure (min/max) 1650/1800 mbar 1700/1850 mbar (23.9/26.1 psi) (24.7/26.8 psi) Maximum engine room ambient temperature 60°C (140 °F) “1: Back pressure measured from EPA test port located on the mixing elbow. Neds let Test ports are British Standard Pipe Parallel (BSPP) not National Pipe Thread (NPT). BSPP and NPT threads are not compatible due to the thread pitch. Mixing can cause thread damage. YVANMAR iiaine nsataton tarual- Volume 3 aBYS- 13 4BY3 Mixing Elbow Transom exhaust (standard) '020082-13130 Riser exhaust (option) Figure 8 To install mixing elbow: 1. Torque V-clamp to 4.0 N-m (35.4 Ib-in.) 2. Lightly tap on mixing elbow with plastic hammer to center elbow. 3. Tighten V-clamp to final torque of 5.5 + 0.5 N-m (48.6 + 4.4 Ib-in.) Marine installation Manuel -Voume s W/L RE ALAR 4BY3-14 4BY3 Alarm System Specifications Data Parameter 4BY3-150 | 4BY3-180 ‘Coolant overheat alarm operating temperature 108°C (226 °F) Below 1500 min® (rpm) < 0.5 bar (7.25 psi) for Lube oiliow pressure | more than one second) alarm (alarm not available on classic controls) beve;1 500 calle an) < 20 bar (29 psi) for more than one second ‘Overspeed protection (fuel ah 4600 min” (rpm) Remote Control System ™ Panel The 4BY3 series utilizes YANMAR marine electronic control technology, incorporating an LCD multi-function display panel. Refer to the appropriate YANMAR electronic control system installation manual for detailed component specifications and options. YANMAR digital display 1 Tachometer 2 —Engine oll pressure meter 3 Multifunction meter Figure 9 YVANMAR iiaine nsataton tarual- Volume 3 aBYS- 15 4BY3 Electrical System § Starter specifications Check all electrical connections per the wiring ; Data c diagrams and ensure the bolts are tightened to the rameter qEYSAED | aBYSASD correct torque specifications. YANMAR code 16500-35760 1 Battery specifications Slarter model BOSCH came ous Voltage 12 “4BY3-150 | 4Bys-100 | | Quput 2.0 kW (2.7 hp) | 12 V, 85 Ah, 680 CCA | | Direction of rotation Clockwise Battery size (minimum) (viewed trom pinion side) (cold cranking amps) Baitery voltage 2V Weight 35 kg (77 b) Nominal output 12 VA5OA Mimberol pionicettt 2 a egies ound No-load terminal voltage TeV Loaded terminal voltage 33V “1: No other device can be connected othe starting battery. Loaded maximum current 122A m Battery cable requirements Loaded torque 32.3 Nm (238 lbh) Battery cable | Battery cable ae length area 70-25m 30 mm 1 3-821) | (.08in3) 2.0-40m 70 mm (66 - 13.1 tt) (0.11 in) cal 25-50m 9 mm (2-16.41) | 018in9 se 325-65 m 720 mam a (io7-213%) | @.19in9 Always route battery cables away from hot engine components, such as the exhaust manifold, turbocharger and exhaust hoses. Install rubber protective caps on each battery terminal. 4By9-16 Manne nsataton Marua-voume © WAALNTIVAALAE 4BY3 Starter performance curve @ Standard alternator data Data Parameter 4BY3-150 | 4BY3-180 YANMAR code 165001-60020 Alternator model Valeo Alternator 12V, 150A IC regulator model 7 788 623.1 Fee Clckise Weight 6.9 kg (15.2 Ib) VANMAR storie inctataton Manual Volume 3 4BY3 -17 4BY3 1 Wiring diagram Figure 11 4BYS -18 Marine Installation Manual - Volume 3 W/L INE A A 4BY3 1 Engine Control Unit (ECU) 2 —Internal ECU sensors (operating voltage and ambient air pressure) 3 Fuse (F2) 10 A” - ignition 4 —Fuse (F1) 3 A - CAN switched power 5 —Fuse (F6) 10 A - auxiliary power 6 —Start signal from key switch 7 —Fuse (Fd) 30 A - ECU switched power 8 —Fuse (F3) 15 A- fuel supply pump 9 —Fuse (F5) 20 A - fuel pressure regulator, water-in-uel, camshatt sensor, and fuel volume regulator 410—Circuit breaker (boatbuilder installed) 11~Power to starter solenoid primary terminal 12—Starter relay K1 13-Main power relay K2 14—Fuel supply pump relay K3 15—Poweer to fuel supply pump 16~B+ to water-in-fuel sensor 17-Not used 418—Check engine indicator output 19~Fuel rail pressure control valve 20—Fuel volume control (high-pressure pump) 21—Fuel injector No. 4 (4BY3) or No. 6 (6BY3) 22—Fuel injector No. 2 (4BY3) or No. 2 (6BY3) 23—Fuel injector No. 3 (4BY3) or No. 5 (6BY3) 24—Fuel injector No. 1 (4BY3) or No. 3 (6BY3) 25~Fuel injector No. 1 (6BY3) 26—Fuel injector No. 4 (6BY3) 27-CAN signal - low 28—CAN signal - high 29—Panel, ECU, and CAN ground 30-K-line 31—Neutral start switch (NC in neutral) 32—Jumper fuse (F8) 3 A - CAN/analog throttle selection, default is analog (fuse oul), Insert 3 A fuse to configure for CAN 33—Jumper fuse (F7) 3 A - Single/port selection, default is single/port (fuse in). Remove fuse for starboard configuration. 84—Fuel rail pressure sensor 35 ~Fuel temperature sensor 36—Subthrottle sensor 2 37—Subthrottle sensor 1 38-Oil pressure sensor 39—Water-in-fuel sensor 40—Camshatt speed sensor 41—Crankshaft speed sensor 42—Charge air pressure sensor 43—Charge air temperature sensor 44—Engine coolant temperature sensor 45 Ignition power input from key switch (terminal X1-D) 46 — Auxiliary power output (terminal X1-G) 47—NMEA + power supply (X7-R) 48~Battery power to key switch (terminal X1-B) 49—CAN signal blocking diode 50-High bench 1 51—High bench 2 52-Oil pressure switch (X1-Q) 53-NMEA ground supply 54~Power resistor for the generator "1: Never connect any additional devices to F2. Fé may be used however, itis not switched. YVANMAR iiaine nsataton tarual- Volume 3 aBYS- 19 4BY3 Performance Curves i Power and torque 4BY3-150 00 0 210 120 sa 100 20 = < z Terave o 2 200 z g : é wo ® 10 100 “ Power 0 2 4 ° ‘oo 000 ——1600~—~—«OO0 ~~ ~COOS~C«OOO SC Figure 12 4BY3-180 soo 0 30 Terave a 200 400 250 E = 2 wo = J 20 : é 160 ° Power 100 aa s0 2 ° 0 Soo —vo00 4600 ——za00 2500 —~S000 =O) —a000— Figure 13 4BY3 -20 Marine installation Manuel -Voume s W/L RE ALAR ™ Fuel consumption 4BY3-150 200 200) 280) 210) 260) 260) 240) 230) ‘Specitcfuel consumption [ok 220) 210) 200) Fuel consumption 500 yo t600~=~« 0 ABY3-180 72500 Figure 14 30003500 200 t 280 t 20 240 Specific fuel consumption [oh] 20 Fuel consumption 210 200 Ce ae eT) "2500 Figure 15 3000 ~

    You might also like