Yanmar 4LHA-HTP User manual

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Content
Section DescriptionDoc.no.Rev.
VOLUME 2
5.Operation/ UserInstructions,Continue:
Engine - Yanmar 4LHA-STP
Operation Manual
Parts Catalog
Service Manual
maritime partner as

OPERATIONMANUAL
YANMAR
YANMAR DIESEL
ENGINE
4LHA-HTP/-HTZP
4LHA-DTP/-DTZP
4LHA-STP/-STZP
Be suretoreadthismanualforsafeand
proper operation.
Storethismanualcarefully after use.

Congratulations on your choice of
YANMAR product from YANMAR DIESEL ENGINE CO., LTD.
This manual describes operation,periodicinspectionand
maintenanceservicingfortheENGINEmanufacturedby
YANMAR DIESEL ENGINE CO., LTD.
Please readthismanualcarefullybefore use, and operate
your engineproperlyunderthe optimum conditions, should
you have any questionsor concerns, please do nothesitateto
contact your nearestdealer.
California
Proposition 65 \\&ming
Diesel engine exhaust and some ofits
constitutionsare known tothe State of
California to cause cancer,birthdefects,
and other reproductiveharm.
California
Proposition 65Warning
T> ~4-4-~.*~.r « ^ r. • o fAvmtnalc ....
LJ m>i J * — ' ......--^—j
andrelated
accessoriescontainleadandlead
compounds,chemicalsknowntothe
State of California to cause cancerand
reproductiveharm.
Wash hand after handling

YANMAR
MARINE DIESEL ENGINE
MODELS: 4LHA-HTP/-HTZP/-DTP/-DTZP/-STP/-STZP
OPERATIONMANUAL
Thank youforpurchasingtheYANMAR Marine DieselEngine.
[INTRODUCTION]
•This OperationManualdescribestheoperation,maintenanceandinspection
ofthe 4LHA-HTP/-HTZP/-DTP/-DTZP/-STP/-STZP Yanmarmarinedieselengines.
•Read thisOperationManualcarefullybeforeoperatetheenginetoensure that
theengineisusedcorrectlyand that itstaysinthebestpossiblecondition.
•Keep thisOperationManualina convenientplaceforeasy access.
•ifthisOperationManualislostordamaged,ordera newonefromyourdealer
ordistributor.
•Make surethismanualistransferedtosubsequentowners.Thismanual
shouldbeconsidereda permanentpartoftheenginandremainit.
•ConstanteffortsaremadetoimprovethequalityandperformanceofYanmar
products,sosomedetailsincludedinthisOperationManualmaydifferslightly
fromyourengine.Ifyouhaveanyquestionsaboutsuchdifference,please
contactyourYanmarDealerorDistributor.
•For detailedinformationmarinegears,refertotheMarine Gear Operation
Manual.
OperationManual
(MarineEngine)
Models
4LHA-HTP/-H7ZP/-DTP/-DTZP/-STP/-STZP
OperationManual
(MarineEngine)
Code No. 49961-205430
-1-

INTRODUCTION £
INDEX • • "
1.FORSAFE OPERATION
4~8
1.1WarningSymbols4
1.2SafetyPrecautions5-6
1.3LocationofproductsafetyLabels""7~8
2. EXPLANATION OF PRODUCT 9~22
2.1Use,DrivingSystemetc.• • 9
2.2EngineSpecificitions• *10-12
2.3NamesofParts• - • 13-15
2.4MajorServicingParts• •*16
2.5ControiEquipment• 17-22
2.5.1Controlpanel •17-21
2.5.2RemoteControlHandle21-22
3.BEFORE OPERATION
3.1FuelOil,LubeOil& CoolingWater23-25
3.1.1Fueloil•23
3.1.2Lubeoil• •'•24
3.1.3CoolingWater• 24-25
3.2SupplyingFuel• • • ••••••26-27
3.2.1FillingtheFuelTank——26
3.2.2Bleedingthe FuelSystem•26-27
3.3SupplyingEnginelubeoil27
3.4SupplyingMarineDriveoil•••• • 28
3.5SupplyingCoolingWater- 29-30
oe o 1,:—30
o.vswiciiicxiiiy
3.7Checkingthe LubeOilandCoolingWater••31
4. HOWTO OPERATE 32-^
4.1 Inspection Before Starting Z2^m
4.2Checkingthe ControlPanelandAlarmDevices• •34
4.3Starting• ;34-35
4.3.1DailyStarting34
4.3.2StartingUnderLowTemperatureConditions•34
4.3.3RestartingAfterStartingFailure""35
4.3.4AftertheEnginehasStarted- 35
4.4Adjustingthe EngineSpeed• 36
4.5ClutchOperationforthe MarineDrive: ••••36
4.5.1Forward,Neutral,Reverse•36
4.6CheckDuringOperation; •"37
4.7StoppingtheEngine38
4.8OperationProcedure• 39
4.9Long-TermStorage• 40-41
4.9.1Beforestoringforlongperiodsof time •40^i
4.9.2 Checking the Engine for fteuse After a Long Storage Period •
-2-

5. MAINTENANCE & INSPECTION 42-54
5.1ListofPeriodicInspections•43
5.2PeriodicInspection Items 44-54
5.2.1Inspectionafter Initial 50 Hrs. Operation 44
5.2.2Inspection Every 50Hours •-45-47
5.2.3Inspection Every 250 Hrs. orlyr. ;48-51
5.2.4InspectionEvery 500 Hrs. or2 yrs. 52
5.2.5InspectionEvery 1000 Hrs. or 4 yrs. 52-53
5.2.6Inspection Every 2000Hrs. —•4 S3"54
6.TROUBLEANDTROUBLESHOOTING
55~56
7. SYSTEM DIAGRAMS s7"63
7.1PipingDiagram57-60
7.2WiringDiagram••"61~63
-3"

1.FOR SAFE OPERATION
Following theprecautionsdescribedinthismanualwillenableyoutousethisengine with comple
satisfaction. Failuretoobserveanyoftherulesandprecautions,however,mayresultininjury,
bums, fires,andenginedamage. Read thismanualcarefullyandbesureyoufullyunderstandit
beforebeginningoperation.
Thesearethe warning signs which areusedin this manual andontheproducts.
Payspecial attention to them.
A DANGER DANGER-
indicates an imminently hazardous
situation which,ifnotavoided, WILL result in death
orserious injury.
A WARNING
WARNING- Indicates a potentially hazardous
situation which,ifnotavoided,COULD result in
death orserious injury.
mm
situation which,ifnotavoided,MAY result in minor
or moderate injury. Itmayalsobeusedto alert
against unsafe practices.
The descriptionscaptionedby[NOTICE]arefortheparticularlyimportantcautionsfor
handling. Ifyouignorethem,theperformanceofyourmachinemaydeteriorateleadingto
trouble.
-4-

1.2 Safety Precautions
(Observe theseinstructionsforyourownsafety.)
Precautions for Operation
44. DANGER
Burns from Scalding
#Neverremovethefillercapofthefreshwatercoolerwhiletheengineisstillhot.
Steam andhotwaterwillspurtoutandseriouslyburnyou.Wait until thewater
temperaturehas dropped, thenwrapa clotharoundthecapandloosenitslowly.
#After inspection, refastenthefillercapfirmly.Ifthecapisnot secure, steamor
scalding watermaybeemittedduringoperationcausingburns.
A DANGER
A DANGER
Proper Ventilation ofthe Battery Area
#Besuretheareaaroundthebatteryiswell-ventilatedandthere is nothingwhich
could starta fire.Duringoperationand charging, hydrogengasisemittedfrom
thebatteryandcanbeeasilyignited.
Fires from Oil Ignition
# Be suretousethecorrecttypeoffuelwhenrefueling.
Mistakenly filling with gasolineorthelikewillresultinignition.
#Besuretostoptheenginebeforerefueling.
Ifyouspillfuel,wipesuchspillagecarefully.
#Neverplaceoilsorotherflammablematerialclosetotheengineasthiscould
resultinignition.
A WARNING
Exhaust GasPoisoning
#Besuretoestablishgoodventilationintheengineroom with windows,vents,or
otherventilationequipment. Check againduringoperationtobesure that venti-
lationis good. Exhaustgascontainspoisonouscarbonmonoxideandshould
notbeinhaled.
A WARNING
Moving Parts
#Donottouchthemovingpartsoftheengine(propellershaft,V-belt,PTO-pulley,
etc.)duringoperationorletyourclothinggetcaughtinthémasthiscanresultin
injury.
#Neveroperatetheengine without thecoversonthemovingparts.
# Check beforestartingtheenginetosee that anytoolsorclothsusedinmainte-
nance havebeenremovedfromthe area.
A CAUTION
Burns from Contact with HotEngine Parts
•Thewholeengineishotduringoperationpndimmediatelyafterstopping.
The turbocharger,exhaustmanifold,exhaust pipe, andengineareveryhot.
Never touchtheseparts with yourbodyorclothing.
-5-

A WARNING
Alcohol
•Neveroperatetheenginewhileyouareundertheinfluenceofalcoholorwhen
youareillorfeelunwellasthisresultsinaccidents.
Safety Precautions for inspection
A DANGER
-AWAHNING-
AWARNING
A CAUTION
Battery Fluid
•Batteryfluidisdilutedsulfuric acid. Itcanblindyouifitgetsinyour eyes, orburn
your skin. Keep thefluidawayfromyourbody.Washitoffimmediately with a
largequantityoffreshwaterifyougetanyonyou.
Fire duetoElectric Short-Circuits
•Always turn offthebatteryswitchordetachtheearthcable(-)beforeinspecting
theelectricalsystem.Failuretodosocouldcauseshort-circuitingandfires.
Precautions for Moving Parts
•Stoptheenginebeforeyouserviceit.Ifyoumustinspectwhiletheengineis
operating,nevertouchmovingparts. Keep yourbodyandclothingwellclearof
allmovingpartsasthiscouldresultin injury.
Precautions for Removing HotOiland Water to
Prevent Burns
•Ifextractingoilfromtheenginewhileitisstillhot,donotlettheoilsplashonyou.
W wanunmtnelemperaiurenasaropptsuutsiuio IOIMOVHI^ ..—••——
enginetoavoidgetting scalded.
[NOTICE]^
Donot alter the diesel engine.
Rebuildingtheengineoralteringpartstoincreasethe speed ortheamountoffueldischarged,
etc.willmakeoperationunsafe,andresultindamageandshorteningofenginelife.
r-[NOTICE]-
Disposalof waste materials
•Put oilorliquidstobedisposedina container.Neverdisposeofwasteoilorotherfluids
outside,ina sewer,river,orthesea.
•Treatwastematerialssafelyobservingallregulationsandlaws.Aska wasterecovery
companytocollectanddisposeofit.
-6-