Yanmar 3JH5E, 4JH4-HTE1, 4JH4-HTE, 4JH5E, 4JH4-TE Operation Manual

http://www.yanmar.co.jp

0AJHM-M00201

PRINTED IN JAPAN

MARINE ENGINES

MARINE ENGINES

3JH5E
4JH5E
4JH4-TE
4JH4-HTE1
4JH4-HTE

OPERATION MANUAL

EN

English

FR

French

PT

Portuguese

ES

Spanish

DA

Danish

DE

German

EL

Greek

FI

Finnish

IT

Italian

NL

Dutch

NO

Norwegian

SV

Swedish

MARINE ENGINES

3JH5E 4JH5E 4JH4 -TE 4JH4-H TE1 4JH4-H TE

OPERATION MANUAL

3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE1, 4JH4-HTE

Model

OPERATION MANUAL

0AJHM-M00201Code

All Rights Reserved, Copyright

عYanmar (Head office)

1-32, Chayamachi, Kita-ku, Osaka, Japan 530-8311

Marine Operations Division

Quality Assurance Dept.

ع

Overseas Office

عYanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Phone: [phone] Fax: [phone]

عYanmar Asia (Singapore) Corporation Pte Ltd. (YASC)

4 Tuas Lane, Singapore 638613
Phone: [phone] Fax: [phone]

3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki,
Hyogo, Japan 661-0001
Phone: [phone] Fax: [phone]

عYanmar Engine (Shanghai). Co., Ltd.

10F, E-Block POLY PLAZA, No.18 Dongfang Road,
Pudong Shanghai, CHINA P.R.C 200120
Phone: [phone] Fax: [phone]

عYanmar America Corporation (YA)

101 International Parkway
Adairsville, GA 30103, U.S.A.
Phone: [phone] Fax: [phone]

Issued by : YANMAR CO.,LTD. Marine Operations Division

Edited by : YANMAR TECHNICAL SERVICE CO.,LTD.

Aug2009: 1st edition
Dec

2011: 2nd edition

3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE1, 4JH4-HTE

OPERATION MANUAL

OPERATION MANUAL

MARINE ENGINES

3JH5E
4JH5E
4JH4-TE
4JH4-HTE1
4JH4-HTE

EN

English

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 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 ­graphic, electronic, or mechanical, including photocopying, recording, taping, or
information storage and retrieval systems - without the written permission of
YANMAR CO., LTD.

TABLE OF

CONTENTS

INTRODUCTION .............................................................. 1

JH SERIES EMISSION CONTROL SYSTEM
WARRANTY-USA, THE ENVIRONMENTAL

PROTECTION AGENCY (EPA) ONLY ...................... 2

RECORD OF OWNERSHIP ...................................... 3

SAFETY ........................................................................... 5

SAFETY PRECAUTIONS .......................................... 6

General Information ............................................. 6

Before You Operate............................................. 6

During Operation and Maintenance..................... 6

LOCATION OF SAFETY DECALS .......................... 10

PRODUCT OVERVIEW ................................................. 15

YANMAR JH SERIES FEATURES AND

APPLICATIONS ....................................................... 15

New Engine Break-In......................................... 16

Page

COMPONENT IDENTIFICATION ............................ 17

Right Side (Viewed from Flywheel) - 3JH5E...... 17

Left Side (Viewed from Flywheel) - 3JH5E ........ 17

Right Side (Viewed from Flywheel) - 4JH5E...... 18

Left Side (Viewed from Flywheel) - 4JH5E ........ 18

Right Side (Viewed from Flywheel) - 4JH4-TE .. 19

Left Side (Viewed from Flywheel) - 4JH4-TE..... 19

Right Side (Viewed from Flywheel)

- 4JH4-HTE1 / 4JH4-HTE .................................. 20

Left Side (Viewed from Flywheel)

- 4JH4-HTE1 / 4JH4-HTE .................................. 20

NAMEPLATES ......................................................... 21

FUNCTION OF MAJOR COMPONENTS ................ 22

JH Series Operation Manual i

TABLE OF CONTENTS

CONTROL EQUIPMENT.......................................... 23

Instrument Panel (Optional) ............................... 23

Single-Lever Remote Control Handle ................ 31

BEFORE YOU OPERATE .............................................. 33

INTRODUCTION ...................................................... 33

SAFETY PRECAUTIONS......................................... 33

DIESEL FUEL........................................................... 34

Diesel Fuel Specifications .................................. 34

Filling the Fuel Tank........................................... 37

Bleeding the Fuel System .................................. 38

ENGINE OIL ............................................................. 39

Engine Oil Specifications .................................. 39

Engine Oil Viscosity ........................................... 40

Checking the Engine Oil..................................... 40

Adding Engine Oil .............................................. 40

MARINE GEAR OR SAIL DRIVE OIL ...................... 41

Marine Gear Oil Specifications........................... 41

Sail Drive Oil Specifications ............................... 41

Checking Marine Gear Oil .................................. 41

Adding Marine Gear Oil...................................... 42

Checking and Adding Sail Drive Oil ................... 42

ENGINE COOLANT ................................................. 42

Engine Coolant Specifications ........................... 42

Coolant (Closed Cooling System) ...................... 43

Checking and Adding Coolant............................ 43

CRANKING THE ENGINE........................................ 47

ENGINE OPERATION .................................................... 49

INTRODUCTION ...................................................... 49

SAFETY PRECAUTIONS......................................... 49

STARTING THE ENGINE ........................................ 51

If the Engine Fails to Start.................................. 52

Starting at Low Temperatures............................ 52

After the Engine has Started .............................. 53

REMOTE CONTROL HANDLE OPERATION .......... 54

Acceleration and Deceleration ........................... 54

Shifting the Engine ............................................. 54

Switching to Trolling (KMH4A Only)................... 54

CAUTIONS DURING OPERATION.......................... 55

ii JH Series Operation Manual

12/05

TABLE OF CONTENTS

SHUTTING DOWN THE ENGINE ........................... 57

Normal Shutdown .............................................. 57

Emergency Shutdown ....................................... 58

CHECKING THE ENGINE AFTER OPERATION .... 58

PERIODIC MAINTENANCE........................................... 59

INTRODUCTION...................................................... 59

SAFETY PRECAUTIONS ........................................ 59

PRECAUTIONS ....................................................... 61

The Importance of Periodic Maintenance .......... 61

Performing Periodic Maintenance ..................... 61

The Importance of Daily Checks ....................... 61

Keep a Log of Engine Hours and Daily Checks 61

Yanmar Replacement Parts .............................. 61

Tools Required .................................................. 61

Ask Your Authorized Yanmar Marine Dealer

or Distributor for Help ........................................ 61

EPA MAINTENANCE REQUIREMENTS................. 63

EPA Requirements for USA and

Other Applicable Countries................................ 63

EPA Requirements ............................................ 63

Installation of Exhaust Sampling Port................ 65

PERIODIC MAINTENANCE SCHEDULE ................ 66

PERIODIC MAINTENANCE PROCEDURES .......... 70

Daily Checks...................................................... 70

After Initial 50 Hours of Operation ..................... 71

Every 50 Hours of Operation ............................. 76

Every 250 Hours of Operation ........................... 79

Every 500 Hours of Operation ........................... 87

Every 1000 Hours of Operation ......................... 87

TROUBLESHOOTING ................................................... 89

SAFETY PRECAUTIONS ........................................ 89

TROUBLESHOOTING AFTER STARTING ............. 89

TROUBLESHOOTING INFORMATION ................... 90

TROUBLESHOOTING CHART................................ 91

LONG-TERM STORAGE ............................................... 93

PREPARE ENGINE FOR LONG-TERM STORAGE 93

DRAIN SEAWATER COOLING SYSTEM ............... 94

RETURNING THE ENGINE TO SERVICE .............. 96

JH Series Operation Manual iii

TABLE OF CONTENTS

SPECIFICATIONS .......................................................... 97

PRINCIPAL ENGINE SPECIFICATIONS................. 97

3JH5E Engine .................................................... 98

3JH5E Marine Gears.......................................... 99

4JH5E Engine .................................................. 100

4JH5E Marine Gear or Sail Drive ..................... 102

4JH4-TE Engine............................................... 103

4JH4-HTE1 Engine .......................................... 104

4JH4-HTE Engine ............................................ 105

4JH4-TE, 4JH4-HTE1 and 4JH4-HTE

Marine Gear or Sail Drive ................................ 106

SYSTEM DIAGRAMS................................................... 107

PIPING DIAGRAMS ............................................... 107

WIRING DIAGRAMS .............................................. 137

EPA WARRANTY USA ONLY ..................................... 149

YANMAR CO., LTD. LIMITED EMISSION CONTROL

SYSTEM WARRANTY - USA ONLY...................... 149

Your Warranty Rights and Obligations:............ 150

Warranty Period: .............................................. 150

Warranty Coverage: ......................................... 151

Exclusions: ....................................................... 151

Owner’s Responsibility:.................................... 151

Customer Assistance: ...................................... 151

EMISSION SYSTEM WARRANTY............................... 153

NON-ROAD EMISSION SYSTEM WARRANTY .... 153

Yanmar Co., Ltd. Limited Emission Control

System Warranty - USA Only........................... 153

Maintenance Log.............................................. 156

iv JH Series Operation Manual

INTRODUCTION

Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and
from cruisers to mega yachts. In marine
leisure boating, the worldwide reputation of
Yanmar Marine is second to none. We
design our engines to respect nature. This
means quieter engines, with minimal
vibrations, cleaner than ever. All of our
engines meet applicable regulations,
including emissions, at the time of
manufacture.

To help you enjoy your Yanmar JH series
engine for many years to come, please
follow these recommendations:

• Read and understand this Operation
Manual before you operate the machine
to ensure that you follow safe operating
practices and maintenance procedures.

• Keep this Operation Manual in a
convenient place for easy access.

•If this Operation Manual is lost or
damaged, order a new one from your
authorized Yanmar Marine dealer or
distributor.

• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
engine and remain with it.

• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in
this Operation Manual may differ slightly
from your engine. If you have any
questions about these differences,
please contact your authorized Yanmar
Marine dealer or distributor.

JH Series Operation Manual 1

• The specifications and components
(instrument panel, fuel tank, etc.)
described in this manual may differ from
ones installed on your vessel. Please
refer to the manual provided by the
manufacturer of these components.

• Refer to the Yanmar Limited Warranty
Handbook for a complete warranty
description.

INTRODUCTION

JH SERIES EMISSION CONTROL SYSTEM
WARRANTY-USA, THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) ONLY

JH series engines come with an emission control system warranty. In all states, 2009 and
later compression-ignition engines must be designed, built and equipped to meet the
United States EPA emissions standards. Yanmar warrants the emission control system on
your JH series engine for the periods of time listed below.

Emission Control Certification

Model Year 2011 2012 2013

3JH5E EPA marine CI Tier 3 (Non-road Tier 2)

4JH5E / 4JH4-TE EPA marine CI Tier 3 intermediate

4JH4-HTE1 - EPA marine CI Tier 3 intermediate

4JH4-HTE EPA marine CI Tier 2 -

Note: Since 2012, the 4JH4-HTE does not comply with the EPA regulation.

2 JH Series Operation Manual

12/05

INTRODUCTION

RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar for
service, parts or literature.

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

Date Purchased: ________________________________________________________

Dealer: ________________________________________________________________

Dealer Phone: __________________________________________________________

JH Series Operation Manual 3

INTRODUCTION

This Page Intentionally Left Blank

4 JH Series Operation Manual

SAFETY

DANGER

WARNING

CAUTION

NOTICE

Yanmar considers safety of great
importance and recommends that anyone
that comes into close contact with its
products, such as those who install,
operate, maintain or service Yanmar
products, exercise care, common sense
and comply with the safety information in
this manual and on the machine’s safety
decals. Keep the labels from becoming
dirty or torn and replace them if they are
lost or damaged. Also, if you need to
replace a part that has a label attached to
it, make sure you order the new part and
label at the same time.

This safety alert symbol
appears with most safety
statements. It means
attention, become alert,

A

your safety is involved!
Please read and abide by
the message that follows
the safety alert symbol.

Indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.

Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.

Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.

Indicates a situation which can cause
damage to the machine, personal property
and / or the environment, or cause the
equipment to operate improperly.

JH Series Operation Manual 5

SAFETY

DANGER

WARNING

SAFETY PRECAUTIONS

General Information

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.

Before You Operate

The safety messages that follow have
DANGER level hazards.

During Operation and
Maintenance

The safety messages that follow have
WARNING level hazards.

Explosion Hazard

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
flames and any other form of ignition
out of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosive
under certain conditions.

NEVER permit anyone to
install or operate the engine
without proper training.

Read and understand this
Operation Manual before you operate or
service the engine to ensure that you
follow safe operating practices and
maintenance procedures.

• Safety signs and labels are additional

reminders for safe operating and
maintenance techniques.

• See your authorized Yanmar Marine

dealer or distributor for additional
training.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Fire Hazard

Undersized wiring systems
can cause an electrical fire.

Store any containers containing fuel or
other flammable products in a
well-ventilated area, away from any
combustibles or source of ignition.

Store any equipment in a designated
area away from moving parts.

NEVER use the engine compartment for
storage.

6 JH Series Operation Manual

12/05

WARNING

Sever Hazard

Rotating parts can cause
severe injury or death.
NEVER wear jewelry,
unbuttoned cuffs, ties or

loose-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.

Alcohol and Drug Hazard

NEVER operate the engine
while under the influence of
alcohol or drugs, or when
feeling ill.

SAFETY

Exhaust Hazard

NEVER block windows,
vents or other means of
ventilation if the engine is

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.

Exposure Hazard

ALWAYS wear personal
protective equipment
including appropriate

clothing, gloves, work
shoes, and eye and hearing protection
as required by the task at hand.

Sudden Movement Hazard

NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the warning signals.

Burn Hazard

Some of the engine
surfaces become very hot
during operation and
shortly after shutdown.
Keep hands and other body

parts away from hot engine surfaces.

JH Series Operation Manual 7

SAFETY

CAUTION

NOTICE

The safety messages that follow have
CAUTION level hazards.

Poor Lighting Hazard

Ensure that the work area is adequately
illuminated. ALWAYS install wire cages
on portable safety lamps.

Tool Haz ard

ALWAYS use tools appropriate for the
task at hand and use the correct size
tool for loosening or tightening
machine parts.

Flying Object Hazard

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.

Coolant Hazard

Wear eye protection and
rubber gloves when you

handle engine coolant. If
contact with the eyes or skin should
occur, flush eyes and wash immediately
with clean water.

The safety messages that follow have
NOTICE level hazards.

It is important to perform daily checks as
listed in the Operation Manual. Periodic
maintenance prevents unexpected
downtime, reduces the number of
accidents due to poor engine performance
and helps extend the life of the engine.

See your authorized Yanmar Marine dealer
or distributor if you need to operate the
engine at high altitudes. At high altitudes
the engine will lose power, run rough and
produce exhaust gases that exceed the
design specifications.

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 a 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.

8 JH Series Operation Manual

12/05

NOTICE

If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the
non-running engine(s) should be closed.
This will prevent water from being forced
past the seawater pump and eventually
finding its way into the engine. The result
of water entering the engine could cause
seizure or other serious problems.

If you have an installation with two or three
engines, and only one engine is operating,
please note that if the propeller shaft
thru-hull (stuffing box) is lubricated by
engine water pressure and the engines are
interconnected, care must be taken that
water from the running engine does not
enter the exhaust of the non-running
engine(s). This water could cause seizure
of the non-running engine(s). See your
authorized Yanmar Marine dealer or
distributor for a complete explanation of
this condition.

SAFETY

If you have an installation with two or three
engines, and only one engine is operating,
it is important to limit the amount of throttle
applied to the running engine. If you
observe black smoke or movement of the
throttle does not increase engine speed,
you are overloading the engine that is
running. Immediately throttle back to
approximately 2/3 throttle or to a setting
where the engine performs normally.
Failure to do so may cause the running
engine to overheat or cause excess carbon
buildup which may shorten the engine’s
life.

NEVER turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electrical
system will result.

JH Series Operation Manual 9

SAFETY

043811-00X00

LOCATION OF SAFETY DECALS

Figure 1, Figure 2, Figure 3 and Figure 4 show the location of safety decals on Yanmar

JH series marine engines.

3JH5E Engines

12

WARNING

3

196630-12980

Figure 1

1–Part Number: 128377-07350
2–Part Number: 128990-07270

3–Part Number: 196630-12980

10 JH Series Operation Manual

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SAFETY

4JH5E Engines

12

WARNING

3

196630-12980

4

043812-00X00

Figure 2

1–Part Number: 128377-07350
2–Part Number: 128990-07270

3–Part Number: 196630-12980
4–Part Number: 128377-07150

JH Series Operation Manual 11

SAFETY

4JH4-TE Engines

(1)

(2)

WARNING

(3)

(4)

Figure 3

1–Part Number: 128377-07350
2–Part Number: 128990-07270

3–Part Number: 196630-12980
4–Part Number: 128296-07300

128296-07300

008830-03X

12 JH Series Operation Manual

12/05

014387-01X

WARNING

128296-07300

(2)

(1)

(4)

(3)

SAFETY

4JH4-HTE1 / 4JH4-HTE Engines

Figure 4

1–Part Number: 128377-07350
2–Part Number: 128990-07270

3–Part Number: 128296-07300
4–Part Number: 196630-12980

JH Series Operation Manual 13

SAFETY

This Page Intentionally Left Blank

14 JH Series Operation Manual

PRODUCT OVERVIEW

YANMAR JH SERIES
FEATURES AND
APPLICATIONS

The JH series are four-stroke direct
injection diesel engines equipped with
liquid coolant systems.

The 3JH5E is 3-cylinder and naturally
aspirated.

The 4JH5E is 4-cylinder and naturally
aspirated.

The 4JH4–TE is 4-cylinder and
turbocharged.

The 4JH4–HTE1, 4JH4–HTE is 4-cylinder
and turbocharged with an intercooler.

The engines are equipped with a marine
gear or sail drive unit.

These engines are designed for pleasure
craft use.

It is recommended that new vessels be
propped so the engines can operate at 100
to 200 min
engine speed to allow for some added
weight and hull resistance.

-1

above the fuel stop power

The engine must be installed correctly with
coolant lines, exhaust gas lines and
electrical wiring. Any auxiliary equipment
attached to the engine should be easy to
use and accessible for service. To handle
the drive equipment, propulsion systems
(including the propeller) and other inboard
equipment, always observe the
instructions and cautions given in the
operation manuals supplied by the
shipyard and equipment manufacturers.

The JH series engines are designed to be
operated at maximum throttle
(3000 to 3200 min
total engine time (30 minutes out of every
10 hours) and cruising speed (2800 min
or less) for less than 90% of total engine
time (9 hours out of every 10 hours).

The laws of some countries may require
hull and engine inspections, depending on
the use, size and cruising area of the boat.
The installation, fitting and surveying of
this engine all require specialized
knowledge and engineering skills. See
Yanmars local subsidiary in your region or
your authorized Yanmar Marine dealer or
distributor.

-1

) for less than 5% of

-1

Failure to do so can lead to reduced vessel
performance, lead to increased smoke
levels and cause permanent damage to
your engine.

JH Series Operation Manual 15

PRODUCT OVERVIEW

NOTICE

New Engine Break-In

As with all reciprocating engines, the way
your engine is operated during its first 50
hours of operation plays a very significant
role in determining how long it will last and
how well the engine will perform over its
lifetime.

A new Yanmar diesel engine must be
operated at suitable speeds and power
settings during the break-in period to make
the sliding parts, such as piston rings,
break-in properly and to stabilize engine
combustion.

During the break-in period, the engine
coolant temperature gauge should be
monitored; temperature should be
between 71° and 87°C (160° and 190°F).

During the first 10 hours of operation, the
engine should be run at maximum engine
speed minus 400 to 500 min
(approximately 60 to 70% of load) most of
the time. This will ensure the sliding parts
break in properly. During this period, avoid
operating at maximum engine speed and
load to avoid damaging or scoring sliding
parts.

Do not operate at WOT (wide open throttle)
for more than a minute at a time during the
first 10 hours of operation.

-1

If operating engine at low speed and light
load, you must race the engine to clean the
carbon from the cylinders and fuel injection
valve.

Perform this procedure in open waters:

• With the clutch in NEUTRAL, accelerate

from the low-speed position to the
high-speed position briefly.

• Repeat this process five times.

Once past the initial 10 hours until 50
hours, the engine should be used over its
full operating range, with special emphasis
on running at relatively high power
settings. This is not the time for an
extended cruise at idle or low speed. The
boat should be run at maximum speed
minus 400 min

-1

most of the time
(approximately 70% load), with a 10
minute run at maximum minus 200 min

-1

(approximately 80% load) every
30 minutes and a 4 to 5 minute period of
operation at WOT (wide open throttle)
once each 30 minutes. During this period,
be sure not to operate your engine at low
speed and light load for more than
30 minutes. If operating engine at low
speed and light load by necessity, just after
the low idle operation, be sure to race the
engine.

To complete engine break-in, perform After
Initial 50 Hours of Operation maintenance
procedures. After Initial 50 Hours of
Operation on page 71.

Do not operate the engine at low idle or at
low speed and light load for more than
30 minutes at a time. Since unburned fuel
and engine oil will adhere to the piston
rings when operating at low speeds for
long periods, this will interfere with proper
movement of the rings and the engine oil
consumption may increase. Low idle
speed does not allow break-in of sliding
parts.

16 JH Series Operation Manual

12/05

(11)
(10)
(9)

(7)

(8)

(4) (5)

(6)

(12)

(1)

(2)

(3)

026097-00X

(2)

(1)

(10)

(9)

(8)

(7)

(3)

(4)

(5)

(6)

026098-00X

PRODUCT OVERVIEW

COMPONENT
IDENTIFICATION

Right Side (Viewed from
Flywheel) - 3JH5E

Figure 1 and Figure 2 illustrate a typical

version of a 3JH5E engine. Your engine
may have different equipment from that
illustrated.

Figure 1

1 – Intake Silencer (air cleaner)
2–Shift Lever

3–Marine Gear
4 – Oil Cooler
5 – Engine Oil Dipstick
6 – Engine Oil Filter
7 – Electric Fuel Priming Pump
8 – Fuel Feed Pump

9 – Engine Oil Filler Cap
10 – Fuel Injection Pump
11 – Fuel Filter
12 – Intake Manifold

Left Side (Viewed from Flywheel)

- 3JH5E

Figure 2

1 – Coolant Filler Cap
2 – Engine Nameplate (on rocker

arm cover)
3 – Coolant Pump
4 – Belt Cover
5–Alternator
6 – Seawater Pump
7 – Starter Motor
8 – Mixing Elbow
9 – Exhaust Manifold

10 – Coolant Tank / Heat Exchanger

JH Series Operation Manual 17

PRODUCT OVERVIEW

027143-00X

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

Right Side (Viewed from
Flywheel) - 4JH5E

Figure 3 and Figure 4 illustrate a typical

version of a 4JH5E engine. Your engine
may have different equipment from that
illustrated.

(5)

(1)

(2)

(12)

(3)

(4)

Figure 3

1 – Air Heater
2 – Intake Silencer

3–Shift Lever
4–Marine Gear
5 – Engine Oil Dipstick
6 – Header (fuel filter)
7 – Fuel Filter
8 – Fuel Injection Pump

9 – Engine Oil Filler Cap
10 – Electric Fuel Feed Pump
11 – Engine Oil Filter
12–Oil Cooler

(6)
(7)

(8)
(9)

(10)

(11)

027142-00X

Left Side (Viewed from Flywheel)

- 4JH5E

Figure 4

1 – Engine Nameplate (on rocker

arm cover)

2 – Coolant Pump
3 – Belt Cover
4 – Seawater Pump
5 – Coolant Filler Cap
6 – Coolant Tank / Heat Exchanger
7 – Exhaust Manifold
8–Starter Motor
9–Alternator

18 JH Series Operation Manual

12/05

(1)

(2)

(3)

(9)

(6)

(8)

(7)

(5)

(4)

0004547

PRODUCT OVERVIEW

Right Side (Viewed from
Flywheel) - 4JH4-TE

Figure 5 and Figure 6 illustrate a typical

version of a 4JH4-TE engine. Your engine
may have different equipment from that
illustrated.

(12)

(1)
(2)

(3)

(4)

Figure 5

1 – Intake Silencer (air cleaner)
2 – Turbocharger

3–Shift Lever
4 – Marine Gear (KMH4A shown)
5 – Engine Oil Cooler
6 – Engine Oil Filter
7 – Fuel Injection Pump
8 – Fuel Filter

9 – Fuel Priming Pump
10 – Engine Oil Dipstick
11 – Intake Manifold
12 – Engine Oil Filler Cap

(11)
(10)

(9)
(8)

(7)
(6)
(5)

0004516

Left Side (Viewed from Flywheel)

- 4JH4-TE

Figure 6

1 – Engine Nameplate (on rocker

arm cover)

2 – Coolant Filler Cap
3 – Coolant Pump
4 – Belt Cover
5 – Seawater Pump
6–Alternator
7 – Starter Motor
8 – Exhaust / Water Mixing Elbow
9 – Coolant Tank / Heat Exchanger

JH Series Operation Manual 19

PRODUCT OVERVIEW

(12)

(11)

(9)

(10)

(8)

(7)

(6)

(5)

(4)

(3)

(2)

(1)

0004548

Right Side (Viewed from
Flywheel) - 4JH4-HTE1 /
4JH4-HTE

Figure 7 and Figure 8 illustrate a typical

version of a 4JH4-HTE1, 4JH4-HTE
engine. Your engine may have different
equipment from that illustrated.

Figure 7

1 – Intake Silencer
2 – Turbocharger

3 – Shift Lever (KMH4A)
4 – Marine Gear (KMH4A)
5 – Engine Oil Cooler
6 – Engine Oil Filter
7 – Fuel Injection Pump
8 – Fuel Filter

9 – Fuel Priming Pump
10 – Engine Oil Dipstick
11 – Intake Manifold
12 – Engine Oil Filler Cap

Left Side (Viewed from Flywheel)

- 4JH4-HTE1 / 4JH4-HTE

(1)

(2)

(3)

(4)

(5)

Figure 8

1 – Engine Nameplate (on rocker

arm cover)

2 – Coolant Filler Cap
3 – Coolant Pump
4 – Belt Cover
5 – Seawater Pump
6–Alternator
7 – Intercooler
8–Starter Motor
9 – Exhaust Mixing Elbow

10 – Coolant Tank / Heat Exchanger

(10)

(9)

(8)

(7)

(6)

0004549

20 JH Series Operation Manual

12/05

/

/

Gear Model

ENG.No.

MFG. DATE

/

Model

min

-1

min

-1

min

-1

Continuous power kW

Speed of prop. shaft

Fuel stop power kW

129670-07200

MODEL
GEAR RATIO
OIL

MFG. NO.

(177524-02902)

196450-02122

MODEL

PASSED
MARK

MFG.No.

MADE IN EU

PRODUCT OVERVIEW

NAMEPLATES

The nameplates of Yanmar JH series
engines are shown in Figure 9. Check the
engine’s model, output, min
number on the nameplate. Please replace
if damaged or lost.

The engine nameplate is attached to the
engine rocker arm cover.

-1

and serial

The marine gear nameplate (Figure 10) is
attached to the marine gear. Check the
marine gears model, gear ratio, oil used,
oil quantity and serial number.

Figure 10

The sail drive nameplate (Figure 11) is
attached to the sail drive. Check the sail
drive model and serial number.

Figure 9

Figure 11

JH Series Operation Manual 21

PRODUCT OVERVIEW

FUNCTION OF MAJOR COMPONENTS

Name of Component Function

Fuel Filter Removes dirt and water from the fuel. Drain the filter periodically. The filter element should be

Fuel Feed Pump Pumps fuel from the tank to the fuel injection system.

Fuel Priming Pump (if
equipped)

Engine Oil Filler Port Filler port for engine oil.

Engine Oil Filter Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is distributed to

Marine Gear Filler Port Filler port for marine gear lube oil. Located on top of the marine gear case.

Cooling System There are two cooling systems: closed cooling with coolant and seawater. The engine is

Closed Cooling Circulation
Pump

Seawater Pump Pumps seawater from outside vessel to the engine. The seawater pump is gear-driven and

Reservoir The pressure valve in the filler cap releases vapor and hot water overflow to the reservoir.

Oil Cooler - Engine A heat exchanger that cools high temperature engine oil using coolant.

Oil Cooler - Marine Gear
(Optional)

Turbocharger (if equipped) The turbocharger pressurizes the air coming into the engine. It is driven by a turbine that is

Intercooler (if equipped) This heat exchanger cools the pressurized charging air from the turbocharger with seawater

Intake Silencer (Air Cleaner) The intake silencer guards against dirt in the air and reduces the noise of air intake.

Nameplates Nameplates are provided on the engine and the marine gear and have the model, serial

Starter Starter motor for the engine. Powered by the battery.

Alternator Driven by belt and generates electricity and charges the battery.

Engine Oil Dipstick Gauge stick for checking the engine oil level.

replaced periodically. The water separator (if equipped) should be drained periodically. See
Draining Fuel Filter / Water Separator on page 76.

This is a manual fuel pump. Pushing the knob on the top of the fuel filter feeds the fuel. The
pump is also used to bleed air from the fuel system.

the engine’s moving parts. The filter is a cartridge type and the element should be replaced
periodically. See Changing the Engine Oil and Replacing the Engine Oil Filter Element on
page 82.

cooled by the closed cooling circuit. The closed circuit is cooled by seawater using a heat
exchanger. The seawater also cools the engine / marine gear oil and intake air (depending on
model) through the cooler(s) in an open circuit.

The centrifugal water pump circulates coolant inside the engine. The circulating pump is
driven by a V-belt.

has a replaceable rubber impeller. Do not operate it without seawater, as this will damage the
impeller.

When the engine stops and the coolant cools, the pressure in reservoir drops. The filler cap
vacuum valve then opens to send water back from the reservoir. This minimizes coolant
consumption. The closed cooling system coolant level can easily be checked and refilled in
this tank.

This heat exchanger cools the marine gear (KMH4A) oil using seawater.

energized by exhaust gases.

to increase the charging air quantity.

number and other data.

22 JH Series Operation Manual