Part of the Yanmar Repair Manuals.
The first time a BY3 dies from a clogged fuel filter, the bleed sequence is what stands between a ten minute fix and an afternoon of cranking on a dead battery. This 96 page Yanmar operation manual, publication 0ABY0-G00301, covers the 4BY3-150, 4BY3-150Z, 4BY3-180, 4BY3-180Z, 6BY3-220, 6BY3-220Z, 6BY3-260 and 6BY3-260Z marine diesels, four and six cylinder versions of the same 84 mm x 90 mm block.
It walks through diesel fuel and oil specifications, bleeding the fuel system, starting at low temperatures, the full periodic maintenance schedule, troubleshooting charts for alarms and starting failures, and draining the seawater cooling system before storage. The Specifications section carries the numbers you otherwise end up guessing at: oil and coolant capacities, battery rating, idle speed.
Guessing an oil quantity or an anode torque is cheap right up until it isn't. Download it once and it is yours to keep, search and print for as long as the engine runs.
What's Inside This Yanmar 4BY3 / 6BY3 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 7-8 | Record of Ownership |
| Safety | 9-18 | Safety Precautions (Before You Operate, During Operation and Maintenance), Safety Decals |
| Product Overview | 19-28 | Yanmar BY3-Series Features and Applications, New Engine Break in |
| Before You Operate | 29-42 | Safety Precautions, Diesel Fuel (Specifications, Filling the Fuel Tank, Bleeding the Fuel System) |
| Engine Operation | 43-46 | Safety Precautions, Starting the Engine (Starting at Low Temperatures), Shutting Down the Engine, Emergency Shut Down, Checking the Engine After Operation |
| Periodic Maintenance | 47-68 | Safety Precautions |
| Troubleshooting | 69-80 | Safety Precautions, Troubleshooting After Starting, Troubleshooting Information |
| Long-Term Storage | 81-82 | Prepare Engine for Long-Term Storage, Draining the Seawater Cooling System |
| Specifications | 83-86 | Engine Specifications |
| EPA Warranty Usa Only | 87-96 | Yanmar Co. |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Zinc anode torque | 25 N·m (18 ft-lb) | p. 64 |
| Coolant temp alarm threshold | Over 110 °C (230 °F) | p. 77 |
| Maximum continuous operation at low idle or low speed and light load | 30 minutes at a time | p. 20 |
| Engine Oil Change Interval (after initial 50 hours) | 250 hours | p. 48 |
| M4 Hex bolt torque (grade 8.8 or 8) | 2.7 N·m (24 in.-lb) | p. 49 |
| M12 Hex bolt torque (grade 12.9 or 12) | 135 N-m (100 ft-lb) | p. 49 |
| 5 mm Hex head hose clamp torque | 1.0 - 1.5 N·m (8.9 - 13 in.-lb) | p. 49 |
| Bore x stroke | 84 mm x 90 mm (3.307 in. x 3.543 in.) | p. 83 |
| Compression ratio | 16.5:1 | p. 83 |
| 4BY3-150/150Z, 4BY3-180/180Z | ||
| Coolant capacity (approximate) | 10 l (10.6 qt) | p. 84 |
| 4BY3-150, 4BY3-150Z, 4BY3-180, 4BY3-180Z | ||
| Number of cylinders (4BY3-150, 4BY3-150Z, 4BY3-180, 4BY3-180Z) | 4 | p. 83 |
| 6BY3-220, 6BY3-220Z, 6BY3-260, 6BY3-260Z | ||
| Number of cylinders (6BY3-220, 6BY3-220Z, 6BY3-260, 6BY3-260Z) | 6 | p. 83 |
Yanmar 4BY3 / 6BY3 Series Common Problems This Manual Covers
Engine dies and will not restart
Air drawn into the fuel system after a filter change or a run-dry tank keeps these engines from firing until it is bled out properly. The Before You Operate section gives the diesel fuel specifications and the bleeding procedure step by step.
Manual Section: Before You Operate p. 29Hard starting after sitting
Weak batteries and corroded electrical connections are the usual culprits when a BY3 cranks slowly or starts intermittently after weeks on the mooring. The Troubleshooting section works through starting failures in order, so you test before you buy parts.
Manual Section: Troubleshooting p. 69Overheating and coolant temperature alarms
A restricted seawater path or low coolant pushes temperatures up fast, and the alarm trips above 110 degrees C (230 degrees F). The Troubleshooting section covers what to check after the alarm sounds and before you restart.
Manual Section: Troubleshooting p. 69Seawater circuit corrosion and anode wear
Zinc anodes sacrifice themselves to protect the seawater cooling circuit, and once they are gone the corrosion moves on to parts that cost real money. The Periodic Maintenance section covers inspection and replacement, with anodes torqued to 25 N·m (18 ft-lb).
Manual Section: Periodic Maintenance p. 47Oil consumption climbing after light-load running
Long stretches at low idle keep the rings from seating and oil consumption creeps up. The Product Overview section's break-in instructions set a hard limit of 30 minutes at a time for continuous low idle or light-load operation.
Manual Section: Product Overview p. 19Cold weather starting trouble
A diesel that fires instantly in July can balk when the water gets cold. The Engine Operation section includes a specific low-temperature starting procedure, so you are following a sequence instead of cranking and hoping.
Manual Section: Engine Operation p. 43Corrosion damage from improper winter layup
Seawater left in the cooling circuit over a layup freezes or eats the system from the inside. The Long-Term Storage section covers preparing the engine for storage and draining the seawater cooling system.
Manual Section: Long-Term Storage p. 81Frequently Asked Questions
Which engine models does this manual cover?
It covers eight Yanmar BY3 marine engines: the four cylinder 4BY3-150, 4BY3-150Z, 4BY3-180 and 4BY3-180Z, and the six cylinder 6BY3-220, 6BY3-220Z, 6BY3-260 and 6BY3-260Z. One manual serves the whole family, with model-specific values called out where they differ.
Is this a full workshop rebuild manual?
No, this is the factory operation manual, not a teardown and rebuild manual. You get operating procedures, break-in rules, fuel, oil and coolant specifications, the periodic maintenance schedule, troubleshooting charts, storage procedures and full engine specifications.
Does it list oil and coolant capacities?
Yes. The Specifications section lists the engine oil and coolant capacities for each model — the coolant figure for the 4BY3 engines is about 10 litres (10.6 qt), on page 84 — along with bore and stroke, compression ratio and cylinder count. p. 83
What is the engine oil change interval for the Yanmar 4BY3 / 6BY3 Series marine engines?
After the initial 50 hour service, oil changes come every 250 hours. The Periodic Maintenance section lays out the full service schedule along with standard hardware torque values. p. 47
What format is this manual in?
You get a 96-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Is this Yanmar 4BY3-150 & variants Operation Manual printable?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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