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Personal details for engine registration and service history.
General guidelines and warnings for safe operation, maintenance, and handling.
Specific safety measures during engine operation and maintenance tasks.
Identification and explanation of safety warning labels affixed to the engine.
Overview of BY3-series engine features, design, and intended use in pleasure craft.
Procedures for initial engine operation to ensure proper break-in and longevity.
Diagrams and labels identifying key components of the 4BY3 and 6BY3 engines.
Component identification on the left side of the 4BY3 engine, viewed from the flywheel.
Component identification on the right side of the 4BY3 engine, viewed from the flywheel.
Component identification from the top view of the 4BY3 engine.
Component identification on the left side of the 6BY3 engine.
Component identification on the right side of the 6BY3 engine.
Component identification from the top view of the 6BY3 engine.
Illustrations showing the location of engine data and drive information nameplates.
Explanation of the function of key engine components like filters, cooling systems, and turbochargers.
Diagram and list of fuses and relays in the E-Box, detailing their functions and ratings.
Instructions for removing the engine cover for access to internal components.
Overview of the section covering fuel, oil, coolant specs and replenishment.
Reminder to review the general Safety section before performing operations.
Information on diesel fuel requirements, specifications, and safety warnings.
Details on approved biodiesel blends, precautions, and concerns regarding their use.
Technical specifications for diesel fuel including cetane number, sulfur content, and water limits.
Safety warnings and procedures for handling diesel fuel, including refueling practices.
Diagram illustrating typical fuel system installation and requirements for suction resistance.
Instructions for installing a drain cock and positioning the fuel outlet in the fuel tank.
Step-by-step instructions for filling the fuel tank, including safety precautions and ventilation.
Procedures for bleeding the fuel system after maintenance or running out of fuel.
Information regarding engine oil specifications and maintenance requirements.
Guidelines and classifications for selecting appropriate engine oil.
Chart showing recommended engine oil viscosity based on ambient temperature.
List of acceptable engine oils under LongLife 01 and 04 categories.
Step-by-step guide with diagrams on how to check the engine oil level using the dipstick.
Instructions on how to add engine oil, including warnings and procedures.
Information and specifications for marine gear oil and stern drive oil.
Specifications for power steering fluid and checking its level.
Information on acceptable engine coolants and recommendations for use.
List of acceptable engine coolants with their trade names and manufacturers.
Detailed steps for adding engine coolant, including safety warnings and procedures.
Overview of the section covering fuel, oil, coolant replenishment and daily checks.
Reminder to review the general Safety section before performing operations.
Step-by-step guide for starting the engine, including pre-start checks and key switch operation.
Advice on starting the engine in cold conditions, including use of glow plugs and warm-up.
Procedures for normal and emergency engine shutdown, including post-shutdown checks.
Checks to perform after the engine has been shut down, including fuel tank and seawater cock.
Overview of the section describing engine care and maintenance procedures.
Reminder to review the general Safety section before performing maintenance.
Important considerations before performing periodic maintenance tasks.
Explanation of why periodic maintenance is crucial for engine longevity and performance.
General warning about ventilation during maintenance and ensuring connections are tight.
Emphasis on performing daily checks as a basis for periodic maintenance.
Guidance on maintaining logs for engine hours, daily checks, and service history.
Recommendation to use genuine YANMAR parts for maintenance and repair.
Advice to ensure all necessary tools are available before starting maintenance procedures.
Encouragement to seek professional help from YANMAR dealers for maintenance.
Guidance on proper torque for fasteners to prevent damage or leaks.
Table of standard torque values for hexagon bolts and nuts of various sizes.
Specifications for hose clamp torque, and a note on not reusing clamps.
Importance of following EPA regulations for optimum performance and compliance.
Conditions for operating the BY3-series engines to meet EPA emission standards.
Procedures for inspecting and maintaining EPA emission-related parts and other components.
Instructions for installing an exhaust sampling port as per federal regulations.
Summary of maintenance items and their intervals for keeping the engine in good operating condition.
Checks for engine exterior, leaks, damage, and loose/missing parts.
Procedure for draining water and sediment from the fuel filter/water separator.
Maintenance procedures to perform after the first 50 hours of engine operation.
Detailed steps for changing engine oil and replacing the oil filter element.
Maintenance procedures to perform every 50 hours or monthly, whichever comes first.
Maintenance procedures to perform every 250 hours of operation or yearly.
Procedure for draining the fuel tank to remove water and sediment.
Steps for replacing the fuel fine filter element, including pre-filling and bleeding.
Instructions for replacing the fuel filter/water separator element, including sensor disconnection.
Reference to procedures for changing engine oil and replacing the oil filter.
Procedure for checking and replacing seawater pump and alternator belts.
Procedure for inspecting and replacing zinc anodes in the seawater cooling system.
Steps for removing and replacing the air filter element.
Maintenance to perform every 500 hours of operation or every 2 years.
Procedure for draining and refilling the engine's closed cooling system.
Maintenance to perform every 1000 hours of operation or every 4 years.
Procedure for checking flexible engine mounts for wear or damage.
Maintenance to perform every 2000 hours of operation or every 8 years.
Procedure for replacing the seawater pump impeller.
Procedure for replacing the alternator belt.
Reminder to review the general Safety section before performing troubleshooting.
Checks to perform immediately after starting the engine to identify potential issues.
Information required when contacting a dealer for troubleshooting assistance.
Table listing problems, causes, and actions for diagnosing engine issues.
Table listing common starting problems, their causes, and recommended actions.
Table correlating smoke color with potential causes and corrective actions.
Causes and actions for engine roughness when the drive is disengaged.
Causes and actions for engine roughness when the drive is engaged.
Causes and actions for engine knocking noises.
Causes and actions for reduced engine power output.
Causes and actions for engine overheating.
Causes and actions for an engine running too cold.
Causes and actions for coolant loss.
Explanation of how the engine ECU generates fault codes and alarms.
Table of diagnostic trouble codes, their associated parts/systems, modes, and actions.
Measures to protect the engine from corrosion and rust during extended periods of non-use.
Procedure for draining the seawater cooling system to prevent freezing damage.
Detailed specifications for the YANMAR BY3 series marine engines.
Details of the EPA warranty for engines built after Jan 1, 2006, installed in US-flagged vessels.
Explanation of YANMAR's warranty coverage and the owner's responsibilities.
Defines the warranty start date and duration for pleasure use (5 years or 2000 hours).
Lists engine components covered by the limited emission control system warranty.
Lists failures and conditions not covered by the limited emission warranty.
Owner's responsibilities for performing maintenance and initiating warranty claims.
Contact information for YANMAR America Corporation, Marine Engine Division for warranty assistance.
A logbook format for recording engine maintenance dates, hours, and performed services.
Contact details for Yanmar's head office in Osaka, Japan.
Contact details for Yanmar's Marine Operations Division Quality Assurance Dept.
Contact information for various Yanmar overseas offices.
Contact details for Yanmar Europe B.V. in the Netherlands.
Contact details for Yanmar Asia (Singapore) Corporation Pte Ltd.
Contact details for Yanmar America Corporation in Adairsville, GA, USA.
Contact details for Yanmar Engine (Shanghai) Co., Ltd. in China.
Lists the YANMAR BY3 engine models covered by this operation manual.
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