Part of the Yanmar Repair Manuals.
Need the exact factory operating and maintenance procedures for your marine auxiliary engine? This 33-page Yanmar 4CHL-N, 4CHL-TN, 6CHL-N, 6CHL-TN, 6CHL-HTN Operation Manual PDF (OEM #49961-300040) covers every fluid check, startup sequence, and periodic servicing task. Inside, you get complete electric wiring diagrams, detailed fuel and cooling system layouts, and a full table of periodic checking intervals. Open to the supercharger section for proper handling and air cooler maintenance, or use the step-by-step air bleeding procedures to get your fuel system primed. Keep the fuel injection valve pressure dialed at 220±10 kg/cm² and make sure the cylinder head bolts are tightened to exactly 16±1 kg-m. A dead auxiliary engine leaves you stranded on the water. Download this bookmarked file right to your tablet, find your spec in seconds, and keep your vessel running.
What's Inside This Yanmar CHL Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Lntroduction | 2 | Operation, Maintenance and Inspection, Correct Engine Use, Engine Condition, Manual Accessibility, Manual Transfer, Product Improvements |
| Nomenclature | 5-6 | Pressure Cap, Suction Manifold, Lube Oil Filter Element, Instrument Panel, Exhaust Manifold, Alternator |
| Engine Specification | 7 | Model, Type, Combustion System, Cylinder Bore X Stroke, Rated Speed of Revolution, Firing Order |
| Instrument Panel・Adjustmetnt | 8-10 | - |
| Selection of Fuel Oil and Lubrications Oil | 11-12 | Selection and Handling of Fuel Oil, Selection of Lube Oil |
| Operation | 13-19 | Filling with Fuel Oil, Filling with Lube Oil, Filling with Cooling Water, Air Bleeding of Fuel System, Check Before Starting, Starting, Confirm Immediately After Starting |
| Handing of Supercharger | 20-21 | Check of Supercharger, Air Cooler (6CHL-Ht) |
| Periodic Checking and Servicing | 22-27 | Table of Periodic Checking and Servicing |
| System Diadrams | 28-33 | Fuel Oil System Diagram, Cooling Water System Diagram, Lube Oil System Diagram, Electric Wiring System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head bolt tightening torque | 16±1kg-m | p. 23 |
| Lube oil filter element replacement interval (first) | after 50 hours of operation (or one week) | p. 25 |
| Lube oil filter element replacement interval (subsequent) | every 500 hours of operation (or every 2 or 3 months) | p. 25 |
| Fuel valve tightening nut torque | 1±0.3 kg-m | p. 23 |
| Fuel injection valve pressure | 220±10kg/cm² | p. 23 |
| Air cooler draining interval | Every 50 hours (or weekly) | p. 21 |
| Exhaust manifold draining interval | Daily | p. 21 |
| Anticorrosive zinc plug change interval | Every 500 hours (or 2~3 months) | p. 21 |
| Normal lube oil pressure during operation | 3.5 – 4.5kg/cm² | p. 8 |
| Minimum lube oil pressure during warm-up | higher than 1.0kg/cm² | p. 17 |
| Cylinder Bore x Stroke | 105 x 125 mm | p. 7 |
| Starting System Voltage | DC24V | p. 7 |
Yanmar CHL Series Common Problems This Manual Covers
Yanmar 4CHL-N engine starts poorly with white smoke or stalls repeatedly after fuel filter service
Bleed air from the fuel system using the service procedures on page 15. Open the fuel filter vent and pump until bubbles stop. Check the fuel injection valve pressure on page 23 to ensure it meets the 220±10kg/cm² specification. Torque the tightening nut to 1±0.3kg-m.
Manual Section: 5. Operation p. 15Low oil pressure alarm sounding or gauge dropping during operation with abnormal bottom end noise
Verify lube oil pressure on the instrument panel gauge. Pressure must be higher than 1.0kg/cm² during warm-up on page 17, and register between 3.5 and 4.5kg/cm² during normal operation. Replace the lube oil filter element after the first 50 hours of operation as detailed on page 25.
Manual Section: 5. Operation p. 17Cooling water temperature alarm activates or engine overheats under load during normal marine operation
Inspect the cooling system and check the anticorrosive zinc plug. Replace the zinc plug every 500 hours as shown on page 21. For the 6CHL-HTN model, drain the air cooler every 50 hours to remove dirt and mud from the sea water system.
Manual Section: 6. Handing of Supercharger p. 21Weak compression on cylinders, hard starting, and white smoke emitting from the exhaust outlet
Inspect the exhaust elbow for water intrusion and check compression. Torque the cylinder head bolts to 16±1kg-m using the specifications on page 23. Verify the engine starting system receives DC24V as noted on page 7 to ensure adequate cranking speed for compression ignition.
Manual Section: 7. Periodic Checking and Servicing p. 23Frequently Asked Questions
What is the torque specification for the cylinder head bolts on marine diesel engines?
The tightening torque for the cylinder head bolts is specified as 16±1 kg-m. This precise torque is essential for proper engine assembly and to prevent issues during operation. p. 23
What are the replacement specifications for the fuel filter element?
The fuel filter element should be replaced every 250 hours of operation. This periodic maintenance is crucial for ensuring a clean fuel supply to the engine and maintaining optimal performance. p. 22
What do I get after purchasing this Yanmar 4CHL-N, 4CHL-TN, 6CHL-N, 6CHL-TN?
This is a 33-page searchable PDF (2 MB) ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print specific sections of this Yanmar 4CHL-N, 4CHL-TN, 6CHL-N, 6CHL-TN?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Are there wiring harness diagrams in this Yanmar 4CHL-N, 4CHL-TN, 6CHL-N?
Yes, this Yanmar 4CHL-N, 4CHL-TN, 6CHL-N, 6CHL-TN, 6CHL-HTN Operation Manual includes a wiring diagram for the electrical system.
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