Page 1
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
Page 2
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: 31-36-5493200 Fax: 31-36-5493209
عYanmar Asia (Singapore) Corporation Pte Ltd. (YASC)
4 Tuas Lane, Singapore 638613
Phone: 65-6595-4200 Fax: 65-6862-5189
3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki,
Hyogo, Japan 661-0001
Phone: 81-6-6428-3251 Fax: 81-6-6421-5549
عYanmar Engine (Shanghai). Co., Ltd.
10F, E-Block POLY PLAZA, No.18 Dongfang Road,
Pudong Shanghai, CHINA P.R.C 200120
Phone: 21-6880-5090 Fax: 21-6880-8090
عYanmar America Corporation (YA)
101 International Parkway
Adairsville, GA 30103, U.S.A.
Phone: 1-770-877-9894 Fax: 1-770-877-9009
Issued by : YANMAR CO.,LTD. Marine Operations Division
Edited by : YANMAR TECHNICAL SERVICE CO.,LTD.
Aug2009: 1st edition
Dec
2011: 2nd edition
3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE1, 4JH4-HTE
OPERATION MANUAL
Page 3
OPERATION MANUAL
MARINE ENGINES
3JH5E
4JH5E
4JH4-TE
4JH4-HTE1
4JH4-HTE
EN
English
Page 4
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.
Page 5
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
Page 6
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
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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
Page 8
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
Page 9
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.
Page 10
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
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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
Page 12
INTRODUCTION
This Page Intentionally Left Blank
4 JH Series Operation Manual
Page 13
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
Page 14
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
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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
Page 16
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
Page 17
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
Page 18
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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12/05
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
Page 20
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
Page 21
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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
Page 22
SAFETY
This Page Intentionally Left Blank
14 JH Series Operation Manual
Page 23
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
Page 24
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
Page 25
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
Page 26
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
Page 27
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
Page 28
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
Page 29
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
Page 30
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
Page 31
12/05
042563-00X00
4
213
043796-00X00
4
213
5
6
PRODUCT OVERVIEW
CONTROL EQUIPMENT
The equipment in the control room makes remote control operation possible. It consists of
the instrument panel, which is connected to the engine by a wire harness, and the remote
control handle, which is connected by control cables to the engine control lever and
marine gear.
Instrument Panel (Optional)
Equipment and Functions
The instrument panel is located in the cockpit. The following instruments enable you to
start or stop the engine and to monitor its condition during operation.
B20-Type
Figure 12
C30-Type
1 – Alarm lamp
2–Tachometer
3–LCD
Figure 13
4 – Switches (push-buttons)
5 – Coolant temperature gauge
6 – Engine oil pressure gauge
JH Series Operation Manual 23
Page 32
PRODUCT OVERVIEW
Meters
Instrument Function
Tachometer Shows engine rotation speed.
Hourmeter Shows number of operating hours. Can be used as a guide for periodic
maintenance checks. The hourmeter is located at the bottom of the
tachometer.
Coolant Temperature Gauge Shows the coolant temperature.
Engine Oil Pressure Gauge Shows the engine oil pressure.
Panel Lights When the power switch is pushed, the gauges will illuminate for easier viewing.
Note: The LCD on the instrument panel show hourmeter, display brightness and
battery voltage.
Coolant temperature and oil pressure display (option)
･B20-Type panels have a digital LCD screen inside the tachometer.
･C30-Type panels have an electric gauge with a needle.
24 JH Series Operation Manual
Page 33
12/05
042563-00X00
4
213
042564-00X00
042565-00X00
042566-00X00
042567-00X00
Instrument Panel
The formats for the instrument panel are shown below.
Figure 14
PRODUCT OVERVIEW
1 – Alarm lamp
2–Tachometer
Control panel switches
All switches are push-buttons.
Start switch
Pushing this switch
operates the starter and
starts the engine.
Stop switch
Pushing this switch stops
the engine.
3–LCD
4 – Switches (push-buttons)
Glow switch
Pushing this switch for the
specified time heats the air
heater on the air intake
manifold. It becomes
red-hot, facilitating fuel
ignition. This assists starting
in cold weather.
Power switch
Pushing this switch turns
on or off the power.
JH Series Operation Manual 25
Page 34
PRODUCT OVERVIEW
Indicators and Alarms (Optional)
When a sensor detects a problem during operation, the indicator on the instrument panel
will light and an alarm will sound. Indicators are located on the instrument panel and the
alarms are located on the back of the panel. Under normal operating conditions, the
indicators are off.
Battery Low Charge Indicator
When the alternator output is too low, the indicator will light. When
charging begins, the indicator will turn off.
Coolant High Temperature Indicator and Alarm
When coolant temperature reaches the maximum allowable temperature
(95°C [203°F] or higher), the indicator will light and the alarm will sound.
Continuing operation at temperatures exceeding the maximum limit will
result in damage and seizure. Check the load and troubleshoot the
cooling system.
Engine Oil Low Pressure Indicator and Alarm
When the engine oil pressure falls below normal, the oil pressure sensor
will send a signal to the indicator, causing it to light and the alarm to
sound. Stop operation to avoid damage to the engine. Check the oil level
and troubleshoot the lubrication system.
Water in Sail Drive Seal Indicator and Alarm
When water is detected between the seals of the sail drive, the indicator
will light and the alarm will sound.
Water in Fuel Filter Indicator and Alarm
- 4JH4-TE, 4JH4-HTE1 and 4JH4-HTE engines only -
When the water level in the fuel filter / water separator becomes too high,
the indicator will light and the alarm will sound. Drain the water from the
fuel filter / water separator. See Draining Fuel Filter / Water Separator on
page 76.
26 JH Series Operation Manual
Page 35
12/05
Scroll
Push and hold
(display will blink when
ready)
Scroll
100, 80, 60, 40, 20, 0
(value will be set after
3 seconds)
Return to hourmeter
EnglishMetric
EnglishMetric
043718-00E00
Press the power switch.
$IWHUVHFRQGVWKH/&'VKRZVWKH
hourmeter.
You can switch (scroll) between displays by pressing
the buttons on the bottom.
Ɣ6ZLWFKLQJVFUHHQVE\SUHVVLQJWKHULJKW
EXWWRQ3UHVVLQJWKHOHIWEXWWRQVZLWFKHV
WKHVFUHHQVLQWKHRSSRVLWHGLUHFWLRQ
Pressing the right button again shows the
/&'EULJKWQHVVVHWWLQJV
To set the brightness of the backlight:
Next, press the right button to show the
pressure display.
6HOHFWEHWZHHQ0HWULFXQLWV%$5DQG
Imperial units (PSI) at the "System Units
screen" on the next page.
Press again to show the battery voltage.
Pressing the button once more returns the
display to the initial hourmeter.
1RWH&RQWLQXRXVO\SUHVVLQJPHDQVKROGLQJWKH
button for approx. 2 seconds.
Press the left button continuously and
WKHGLJLWVRIWKH/&'VWDUWIODVKLQJ
In this condition, press the right button
to decrease the brightness and the left
button to increase the brightness.
(The brightness changes in 6 steps of 20 %.)
To set the desired brightness, do not
touch the buttons for 3 seconds.
Pressing the right button on the bottom of
WKH/&'VKRZVWKHWHPSHUDWXUHGLVSOD\
6HOHFWEHWZHHQ0HWULFXQLWV&DQG
Imperial units (°F) at the "System Units
screen" on the next page.
1 2 3
(QJLQHKRXU!PLQ-1
&RRODQWWHPSHUDWXUH
%DFNOLJKWLQJ%ULJKWQHVV
2LOSUHVVXUH
%DWWHU\YROWDJH
1
2
3
LCD control (hourmeter, coolant temperature, display brightness, oil
pressure, battery voltage)
Figure 1
PRODUCT OVERVIEW
JH Series Operation Manual 27
Page 36
PRODUCT OVERVIEW
Setting the temperature and pressure units
Setting the engine speed pulse value
Use the buttons on the bottom of the LCD
display to set the instrument panel.
Press the left button to switch between displays.
043719-00E00
Press and hold both buttons until
"SET UP" appears.
Press the left button to set the units for
the temperature and pressure display.
Next, press the right button to select
Metric units (°C, BAR). The display says
"METRIC".
The display says "UNIT".
Confirm that the display says "P10.29".
If not, press the left button and change the
set value.
Confirm that the display says
"ENGINE". Press the right button and
"P10.29" appears..
After confirming the display, press the
right button to re-start the panel and return
to the hourmeter display.
Note: This engine
panel
is pre-set to a speed
pulse of P10.29.
Press the left button to switch to Imperial
units (°F, PSI). The display says "ENGL".
Press the right button to select and go
back to the "UNIT" screen.
After confirming the above, press the right
button to return to the "ENGINE" screen.
Press the left button again to go from the
"ENGINE" screen to the "EXIT" screen.
1 2
14
4
2 3
1
5
2 3
1
2
1
2
3
Press the left button and go to the next
screen "ENGINE".
Confirm that the display says "ENGINE".
Pressing the right button shows the screen
for the engine speed pulse setting.
4
3
4
1
2
5
Engine type select
Select
Scroll
Imperial Metric
Select
Select
Exit setup
Select
Scroll
P 10.29
Return to previous
page LCD control
Scroll
Setup screen access and control
(Setting the temperature and pressure units and engine speed pulse)
28 JH Series Operation Manual
Page 37
12/05
PRODUCT OVERVIEW
Alarms
Checking the Warning Devices
Before and after engine start, make sure that the instruments and warning devices
operate correctly.
If the engine runs out of coolant or lubricating oil and the instruments and warning devices
fail, they can not give you warning to prevent accidents. This can also lead to incorrect
operation and cause further malfunctions of the engine.
Before Engine Start
1. Turn on the battery switch.
2. Push the power switch on.
• All alarm lamps light up for 4 seconds.
• After 4 seconds, the charge lamp and the lubricating oil pressure alarm lamp light up,
and the hourmeter is displayed.
• The alarm buzzer sounds until the engine starts.
After Engine Start
After engine start, make sure that the warning devices operate correctly and according to
“After start” in the below table.
• All alarm lamps turn off. The above check tells you whether the electric circuit for the
alarm lamps and alarm buzzer operate correctly. If they do not operate correctly,
inspection and repair are required. Consult your dealer or distributor for repairs.
Correct operation of the warning devices
Instrument panel (power switch) Power ON
Immediately After 2 seconds After 4 seconds
Before start After start
Starter switch OFF ON
Alarm buzzer ON OFF
Charge lamp ON ON ON OFF
Coolant temperature lamp ON ON OFF OFF
Engine lubricating oil pressure lamp ON ON ON OFF
LCD display Yanmar Full display Hourmeter
JH Series Operation Manual 29
Page 38
PRODUCT OVERVIEW
NOTICE
When the warning devices are activated and normal operation is impossible, stop the
engine and do not use it until the problem has been solved.
Accessory power output
The harness attached to the panel has a terminal where the signal that is synchronized to
the panel power supply can be taken off. (Figure 15) ( Refer to the Wiring Diagrams on
page 137.)
The maximum current of this output terminal is 3 A. Do not use a current higher than 3 A.
For the content of the output terminal, refer to the Wiring Diagrams on p138.
Figure 2
Buzzer
Figure 15
F1A - 3 AMP Fuse
ACC Output
043801-00E00
30 JH Series Operation Manual
Page 39
12/05
(2)
(1)
0004511
Single-Lever Remote Control Handle
Figure 3
(3)
(2)
PRODUCT OVERVIEW
(1)
(4)
0004504
Figure 16
Note: Direction of travel will vary
depending on installation
location.
1 – Low Speed - FWD or REV
2 – Low Speed - FWD or REV
3 – NEUTRAL - Power to the
propeller shaft is cut off and
the engine idles
4 – Maximum Engine Speed - FWD
or REV
5 – Maximum Engine Speed - FWD
or REV
(5)
Figure 17
Note: Yanmar recommends the use of
a single-lever type for the remote
control system. If only a
two-lever type is available in the
market, reduce engine speed to
1000 min
-1
or less before
engaging and disengaging the
marine gear clutch.
A single handle-type (Figure 16) should
be used to operate the marine gear clutch
(NEUTRAL, FORWARD and REVERSE)
and to control the engine speed.
The handle controls the direction of the
boat (ahead or astern) and also acts as an
accelerator by increasing engine speed as
the lever is pushed further in FORWARD
or REVERSE directions.
When the handle is pulled out
(Figure 17, (1)), the engine speed can be
controlled without engaging the clutch. The
clutch remains in NEUTRAL, no load
position. Turn the knob (Figure 17, (2))
counterclockwise to move the handle or
clockwise to lock the handle.
JH Series Operation Manual 31
Page 40
PRODUCT OVERVIEW
This Page Intentionally Left Blank
32 JH Series Operation Manual
Page 41
BEFORE YOU OPERATE
INTRODUCTION
This section of the Operation Manual
describes the diesel fuel, engine oil and
engine coolant specifications and how to
replenish them.
SAFETY PRECAUTIONS
Before performing any operations within
this section, review the Safety section on
page 5.
JH Series Operation Manual 33
Page 42
BEFORE YOU OPERATE
WARNING
DIESEL FUEL
Diesel Fuel Specifications
Fire and Explosion Hazard.
Diesel fuel is flammable and explosive
under certain conditions.
Only use diesel fuels recommended by
Yanmar for the best engine performance,
to prevent engine damage and to comply
with EPA warranty requirements. Only use
clean diesel fuel.
Diesel fuel should comply with the
following specifications. The table lists
several worldwide specifications for diesel
fuels.
DIESEL FUEL
SPECIFICATION
No. 2-D, No. 1-D, ASTM
D975
EN590-2009 European Union
ISO 8217 DMX International
BS 2869-A1 or A2 United Kingdom
JIS K2204 Grade No. 2 Japan
Biodiesel Fuels
Yanmar approves the use of biodiesel fuels
that do not exceed a blend of 7%
non-mineral oil based fuel with 93%
standard diesel fuel. Such biodiesel fuels
are known in the marketplace as B7
biodiesel fuels. B7 biodiesel fuel can
reduce particulate matter and the emission
of “greenhouse” gases compared to
standard diesel fuel.
LOCATION
USA
B7 diesel fuels must meet certain
specifications.
The biodiesel fuels must meet the
minimum specifications for the country in
which they are used:
• In Europe, biodiesel fuels must comply
with the European Standard
EN590-2009.
• In the United States, biodiesel fuels must
comply with the American Standard
ASTM D-6751.
Biodiesel should be purchased only from
recognized and authorized diesel fuel
suppliers.
Precautions and concerns regarding
the use of biofuels:
• Biodiesel fuels have a higher content of
methyl-esters, which may deteriorate
certain metal, rubber and plastic
components of the fuel system. The
customer and / or boat builder are
responsible to verify the usage of
biodiesel compatible components on the
vessel fuel supply and return systems.
• Free water in biodiesel may result in
plugging of fuel filters and increased
bacterial growth.
• High viscosity at low temperatures may
result in fuel delivery problems, injection
pump seizures and poor injection nozzle
spray atomization.
• Biodiesel may have adverse effects on
some elastomers (seal materials) and
may result in fuel leakage and dilution of
the engine lubricating oil.
If the B7 biodiesel fuel used does not meet
the approved specifications, it will cause
abnormal wear of injectors, reduce the life
of the engine and it may affect the warranty
coverage of your engine.
34 JH Series Operation Manual
Page 43
12/05
WARNING
0004512
BEFORE YOU OPERATE
• Even biodiesel fuels that comply with a
suitable standard as delivered will
require additional care and attention to
maintain the quality of the fuel in the
equipment or other fuel tanks. It is
important to maintain a supply of clean,
fresh fuel. Regular flushing of the fuel
system, and / or fuel storage containers,
may be necessary.
• The use of biodiesel fuels that do not
comply with the standards as agreed to
by the diesel engine manufacturers and
the diesel fuel injection equipment
manufacturers, or biodiesel fuels that
have degraded as per the precautions
and concerns above, may affect the
warranty coverage of your engine.
Additional Technical Fuel
Requirements
• The fuel cetane number should be 45 or
higher.
• The sulfur content must not exceed 0.5%
by volume. Less than 0.05% is preferred.
Handling of Diesel Fuel
Fire and Explosion Hazard.
Only fill the fuel tank with diesel fuel.
Filling the fuel tank with gasoline may
result in a fire and will damage the
engine. NEVER refuel with the engine
running. Wipe up all spills immediately.
Keep sparks, open flames or any other
form of ignition (match, cigarette, static
electric source) well away when
refueling.
Fire and Explosion Hazard.
ALWAYS put the diesel fuel container
on the ground when transferring the
diesel fuel from the pump to the
container. Hold the hose nozzle firmly
against the side of the container while
filling it. This prevents static electricity
buildup which could cause sparks and
ignite fuel vapors.
• NEVER mix kerosene, used engine oil or
residual fuels with the diesel fuel.
• Water and sediment in the fuel should
not exceed 0.05% by volume.
• Keep the fuel tank and fuel-handling
equipment clean at all times.
• Ash content not to exceed 0.01% by
volume.
• Carbon residue content not to exceed
0.35% by volume. Less than 0.1% is
preferred.
• Total aromatics content should not
exceed 35% by volume. Less than 30%
is preferred.
• PAH (polycyclic aromatic hydrocarbons)
content should be below 10% by volume.
• Do not use Biocide.
• Do not use kerosene or residual fuels.
1. Water and dust in the fuel may cause
engine failure. When fuel is stored, be
sure that the inside of the storage
container is clean and dry, and that the
fuel is stored away from dirt or rain.
Figure 1
JH Series Operation Manual 35
Page 44
BEFORE YOU OPERATE
0004542
(3)
(1)
(2)
0004489
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
2. Keep the fuel container stationary for
several hours to allow any dirt or water
to settle to the bottom of the container.
Use a pump to extract the clear, filtered
fuel from the top of the container.
Fuel Tank (Optional)
Figure 2
1–Sediment Bowl
2 – Drain Cock
3 – Fuel Line to Engine
Install a drain cock (Figure 2, (2)) at the
bottom of the fuel tank to remove water
and contaminants from the sediment bowl
(Figure 2, (1)).
Fuel System - 4JH4-TE and
4JH4-HTE1, 4JH4-HTE
Figure 3
1 – Fuel Filter
2 – To Fuel Injection Pump
3 – Less than 500 mm (20.0 in.)
4–Fuel Cock
5 – 20 to 30 mm (0.75 to 1.125 in.)
Approximate
6 – Drain Cock
7 – Fuel Tank
8 – Fuel Return Line
Install the fuel line from the fuel tank to the
fuel injection pump as shown in Figure 3.
The recommended fuel / water separator
(optional) is installed at the center section
of that line.
The fuel outlet should be positioned 20 to
30 mm (0.75 to 1.125 in.) above the
bottom of the tank so that only clean fuel is
distributed to the engine.
36 JH Series Operation Manual
Page 45
12/05
WARNING
WARNING
WARNING
WARNING
027144-00X
BEFORE YOU OPERATE
Fuel System - 3JH5E and 4JH5E
(7)
(11)
(5)
(1)
(6)
(4)
(10)
(9)
(2)
(3)
Figure 4
1–Fuel Tank
2–Fuel Cock
3 – Water Separator
4 – Fuel Feed Pump
5 – Fuel Filter
6 – Fuel Injection Pump
7 – Fuel Return Line
8 – Drain Cock
9 – 20 to 30 mm (0.75 to 1.25 in.)
Approximate
10 – Less than 400 mm (16.38 in.)
11 – Orifice for Air Bleeding
Filling the Fuel Tank
(8)
To fill the fuel tank:
Fire and Explosion Hazard.
Operate bilge ventilation (blowers) for a
minimum of 5 minutes to purge fumes
from engine compartment after
refueling. Never operate bilge blower
while refueling. Doing so can pump
explosive fumes into the engine
compartment and result in an
explosion.
1. Clean the area around the fuel cap.
2. Remove the fuel cap from the fuel tank.
3. Fill the tank with clean fuel free of oil
and dirt.
Fire and Explosion Hazard.
Hold the hose nozzle firmly against
the filler port while filling. This
prevents static electricity buildup
which could cause sparks and ignite
fuel vapors.
Before filling fuel tank for the first
time:
Fire and Explosion Hazard.
NEVER refuel with the engine running.
Rinse fuel tank with kerosene or diesel
fuel. Dispose of waste properly.
4. Stop fueling when the gauge shows the
fuel tank is full.
Fire and Explosion Hazard.
NEVER overfill the fuel tank.
5. Replace the fuel cap and hand-tighten.
Over-tightening the fuel cap will
damage it.
JH Series Operation Manual 37
Page 46
BEFORE YOU OPERATE
WARNING
027141-00X
(1)
(2)
(3) (6)
(4)
(5)
(1)
(2)
(
3)
(4)
0004494
Bleeding the Fuel System
The fuel system has an automatic air
bleeding device that purges air from the
fuel system. No manual air bleeding is
required for normal operation. Bleeding
must be done if any fuel system
maintenance has been performed
(replacement of fuel filter, etc.) or if the
engine does not start after several
attempts.
Figure 5 applies to both 4JH5E and 3JH5E.
5. Continue pumping until a solid stream
of fuel with no air bubbles begins to flow
from the T-joint. Push the power switch
off.
6. Install the return side fuel hose onto the
T-joint. Tighten hose clamp.
Bleeding the Fuel System - 4JH4-TE
and 4JH4-HTE1, 4JH4-HTE
Figure 5
1 – Fuel Injector
2 – Fuel Filter
3 – Header (fuel filter)
4 – Electric Fuel Feed Pump
5 – Fuel Injection Pump
1. Check the fuel level in the fuel tank.
Refill if necessary.
2. Open the fuel cock of the fuel tank.
3. To bleed air from the fuel filter, loosen
the hose clamp on the return side fuel
hose (Figure 5, (4)) at the T-joint.
Remove the hose.
4. Push the power switch on to activate
the electric fuel feed pump.
Figure 6
1–Priming Pump
2 – Air Bleed Screw
3 – From Fuel Tank
4 – To Fuel Injection Pump
1. Check the fuel level in the fuel tank.
Refill if necessary.
2. Open the fuel cock of the fuel tank.
Exposure Hazard.
Always wear safety glasses when
bleeding the fuel system.
3. Loosen the air bleed screw
(Figure 6, (2)) two to three turns.
4. Push up and down on the priming
pump (Figure 6, (1)) to release air out
of the air bleed screw.
38 JH Series Operation Manual
Page 47
12/05
NOTICE
NOTICE
BEFORE YOU OPERATE
5. Continue pumping until a solid stream
of fuel with no air bubbles begins to
flow.
6. Tighten the air bleed screw.
NEVER use an engine starting aid such as
ether. Engine damage will result.
ENGINE OIL
Engine Oil Specifications
Using engine oil that does not meet or
exceed the following guidelines or
specifications may cause seizure of parts,
abnormal wear and shorten engine life.
Service Categories
Use an engine oil that meets or exceeds
the following guidelines and classifications:
• 4JH4-TE and 4JH4-HTE1, 4JH4-HTE:
API Service Categories CD, CF, CF-4
and CI-4.
• 3JH5E and 4JH5E:
API Service Category CF, CF-4 and
CI-4.
• SAE Viscosity:
10W30, 15W40. Engine oil 10W30 and
15W40 can be used throughout the year.
• Be sure the engine oil, engine oil storage
containers and engine oil filling
equipment are free of sediment or water.
• Change the engine oil after the first 50
hours of operation and then at every 250
hours thereafter.
• Select the oil viscosity based on the
ambient temperature where the engine
is being operated. See the SAE Service
Grade Viscosity Chart (Figure 7).
• Yanmar does not recommend the use of
engine oil “additives”.
JH Series Operation Manual 39
Page 48
BEFORE YOU OPERATE
NOTICE
(1)
(2)
(3)
(4)
(5)
0004490
Figure 7
Handling Engine Oil
Checking the Engine Oil
1. When handling and storing engine oil,
be careful not to allow dust and water to
contaminate the oil. Clean around the
filler port before filling.
2. Do not mix lube oils of different types or
brands. Mixing may cause the chemical
characteristics of the oil to change and
lubricating performance to decrease,
reducing the engine’s life.
3. Engine oil should be replaced at the
specified intervals, regardless if the
engine has been operated.
Engine Oil Viscosity
SAE 10W30 or SAE 15W40 are the
recommended oil viscosities.
If you operate your equipment at
temperatures outside the limits shown,
consult your authorized Yanmar dealer or
distributor for special lubricants or starting
aids.
Figure 8
Note: 4JH4-TE shown. Other models
are similar.
1. Make sure the engine is level.
2. Remove dipstick (Figure 8, (3)) and
wipe with clean cloth.
3. Fully reinsert dipstick.
4. Remove dipstick. The oil level should
be between upper (Figure 8, (4)) and
lower (Figure 8, (5)) lines on the
dipstick.
5. Add oil if necessary. See Adding
Engine Oil on page 40.
6. Fully reinsert dipstick.
Adding Engine Oil
1. Remove the yellow oil filler port cap
from filler port (Figure 8, (1)) and fill
with engine oil.
40 JH Series Operation Manual
Prevent dirt and debris from
contaminating engine oil. Carefully
clean the dipstick and the surrounding
area before you remove the cap.
Page 49
12/05
NOTICE
NOTICE
(1)
(2)
(3)
(4)
0004491
BEFORE YOU OPERATE
2. Fill with oil to the upper limit
(Figure 8, (4)) on the dipstick
(Figure 8, (3)).
NEVER overfill the engine with engine
oil.
3. Insert the dipstick fully to check the
level.
ALWAYS keep the oil level between
upper and lower lines on the oil cap /
dipstick.
4. Hand-tighten the filler port cap
securely.
MARINE GEAR OR SAIL
DRIVE OIL
Marine Gear Oil Specifications
Use marine gear oil that meets or exceeds
the following guidelines and classifications:
KM35P, KM35A, KM35A2, KM4A1,
KM4A2, KMH4A:
• API Service Categories CD or higher
• SAE Viscosity #20 or #30
ZF30M, ZF25A:
• ATF (Automatic Transmission Fluid)
Sail Drive Oil Specifications
Refer to the Operation Manual of the sail
drive for the procedure to fill or replace the
sail drive oil.
3JH5E, 4JH5E (SD50):
• Quick Silver
Lube
® 1
High Performance Gear
4JH4-TE (SD50-4T):
• Only use Quick Silver
Performance Gear Lube.
Checking Marine Gear Oil
1
Quick Silver is a registered trademark of Brunswick ® Corporation.
®
Figure 9
High
JH Series Operation Manual 41
Page 50
BEFORE YOU OPERATE
NOTICE
Note: 4JH4-TE with KMH4A marine
gear shown.
1. Make sure engine is level.
2. Remove the filler cap (Figure 9, (1)) at
the top of the housing.
3. Remove dipstick (Figure 9, (2)) and
wipe with clean cloth.
4. Fully reinsert dipstick.
5. Remove dipstick. The oil level should
be between upper (Figure 9, (3)) and
lower (Figure 9, (4)) lines on the
dipstick.
6. Fully reinsert dipstick.
Adding Marine Gear Oil
1. Make sure the engine is level.
2. Remove the filler cap (Figure 9, (1)) at
the top of the housing.
ENGINE COOLANT
Engine Coolant Specifications
Note: In the U.S., LLC is required for
the warranty to be valid.
• Texaco Long Life Coolant (LLC), both
standard and premixed, product code
7997 and 7998
• Havoline Extended Life
Antifreeze / Coolant, product code 7994
Following the manufacturer’s
recommendations, use a proper LLC which
will not have any adverse effects on the
materials (cast iron, aluminum, copper,
etc.) of the engine’s cooling system.
ALWAYS use the mixing ratios specified by
the antifreeze manufacturer for the
temperature range.
3. Fill with oil to the upper limit on the
dipstick (Figure 9, (3)). See Marine
Gear Oil Specifications on page 41.
NEVER overfill the marine gear with oil.
4. Fully reinsert dipstick.
5. Tighten the filler port cap by hand.
Checking and Adding Sail Drive
Oil
Refer to the operation manual for SD50-T
for the procedure to check and fill the sail
drive oil.
42 JH Series Operation Manual
Page 51
12/05
NOTICE
026099-00X
(1)
(2)
(4)
(3)
(3)
(2)
(1)
026100-00X
BEFORE YOU OPERATE
Coolant (Closed Cooling System)
ALWAYS add LLC to soft water especially
when operating in cold weather. NEVER
use hard water. Water should be clean and
free from sludge or particles. Without LLC,
cooling performance will decrease due to
scale and rust in the coolant system. Water
alone may freeze and form ice; it expands
approximately 9% in volume. Use the
proper amount of coolant concentrate for
the ambient temperature as specified by
the LLC manufacturer. LLC concentration
should be a minimum of 30% to a
maximum of 60%. Too much LLC will
decrease the cooling efficiency. Excessive
use of antifreeze also lowers the cooling
efficiency of the engine. NEVER mix
different types or brands of LLC, as a
harmful sludge may form. Mixing different
brands of antifreeze may cause chemical
reactions, and may make the antifreeze
useless or cause engine problems.
Checking and Adding Coolant
3JH5E
Figure 10
1 – Coolant Pump
2 – Seawater Drain from Seawater
Pump Cover
3 – Coolant Drain Cock
4 – Coolant Tank (heat exchanger)
JH Series Operation Manual 43
Figure 11
1 – Flywheel Housing
2 – Coolant Drain Cock
3 – Stop Solenoid
Page 52
BEFORE YOU OPERATE
027140-00X
(2)
(3)
(4)
(5)
(1)
026115-00X
(1)
(4)
(3)
(2)
(1)
0004514
(1)
0004559
(2)
(3)
4JH5E
Figure 12
1 – Coolant Pump
2 – Seawater Drain from Seawater
Pump Cover
3 – Coolant Tank (heat exchanger)
4 – Coolant Drain Cock
5 – Flywheel Housing
4JH4-TE
Figure 14
1 – Coolant Tank (heat exchanger)
2 – Coolant Pump
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock (2 used)
Figure 13
1 – Coolant Drain Cock
44 JH Series Operation Manual
Figure 15
1 – Coolant Drain Cock
2 – Seawater Drain Cock
3 – Marine Gear Cooler
Page 53
12/05
WARNING
(1)
(2)
(6)
(5)
(3)
(4)
0004560
0004561
(1)
(2)
(3)
(2)
(1)
(4)
(3)
0004492
BEFORE YOU OPERATE
4JH4-HTE1 / 4JH4-HTE
Figure 16
1 – Coolant Tank (heat exchanger)
2 – Coolant Pump
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock
5 – Intercooler
6 – Seawater Drain Cock
1. Ensure all drain cocks are closed.
Note: The drain cocks are opened
before shipping from the factory.
Marine gear ZF25A does not
have a drain cock on the clutch
cooler.
2. Loosen the filler cap of reservoir to
relieve the pressure, then remove the
filler cap.
Burn Hazard.
NEVER remove the coolant filler cap
if the engine is hot. Steam and hot
engine coolant will spray out and
seriously burn you. Allow the engine
to cool down before you attempt to
remove the cap.
Figure 1
Figure 17
1 – Coolant Drain Cock
2 – Seawater Drain Cock
3 – Marine Gear Cooler
JH Series Operation Manual 45
Figure 18
1 – Coolant Filler Cap
2 – Filler Cap Tabs
3 – Filler Port Notches
4 – Coolant Tank
3. Pour coolant slowly into reservoir
(Figure 18, (4)) to avoid air bubbles. Fill
until coolant overflows from the filler
port.
Page 54
BEFORE YOU OPERATE
NOTICE
NOTICE
NOTICE
LOW
FULL
(4)
(1)
(2)
(3)
0004493
NEVER pour cold coolant into a hot
engine.
4. Align filler cap tabs (Figure 18, (2))
with filler port notches (Figure 18, (3))
and tighten filler cap (Figure 18, (1))
firmly.
ALWAYS tighten reservoir cap securely
after checking reservoir. Steam can
spray out during engine operation if the
cap is loose.
Note: The coolant level rises in the
reservoir during operation. After
stopping the engine, the coolant
will cool down and the extra
coolant will return to reservoir.
6. Remove reservoir cap (Figure 19, (4))
to add coolant if necessary. Do not add
water.
7. Replace filler cap and tighten it firmly.
Failure to do so will cause water
leakage.
Reservoir Capacity
0.8 L (0.85 qt)
8. Check the rubber hose (Figure 19, (1))
connecting the reservoir to
reservoir / heat exchanger. Replace if
damaged.
Note: If the coolant runs low too often
or the coolant level in reservoir
drops without any change in the
level in the reservoir, there may
be water or air leaks in the
cooling system. See your
authorized Yanmar dealer or
distributor.
Figure 19
5. Check the coolant level in the reservoir.
The level should be at the FULL mark
(Figure 19, (2)). Add coolant if
necessary.
NEVER pour cold coolant into a hot
engine.
46 JH Series Operation Manual
Page 55
12/05
NOTICE
2
1
027092-00X
(2)
(1)
0004488
BEFORE YOU OPERATE
CRANKING THE ENGINE
When the engine has not been used for a
long period of time, engine oil will not be
distributed to all of the operating parts.
Using the engine in this condition will lead
to seizure. After a long period of no use,
distribute engine oil to each part by
cranking. Perform in accordance with the
following procedures before beginning
operation.
1. Open seacock.
2. Open fuel cock.
3. Put remote control shift lever in
NEUTRAL. See Starting the Engine on
page 51.
Crank the engine 5 seconds.
3JH5E / 4JH5E models:
Figure 20
4JH4-TE / 4JH4-HTE1 / 4JH4-HTE models:
4. Tur n on the batt ery swi tch (if
equipped).
5. Crank the engine.
1- Push the power switch on the
instrument panel and turn on the
power.
2- 3JH5E/4JH5E models:
Operate the starter while pushing in
the emergency stop button
(Figure 20, (1)) on the back of the
fuel pump. This stops the fuel supply.
4JH4-TE / 4JH4-HTE1 / 4JH4-HTE
models:
Operate the starter while moving
and holding (Figure 21, (1)) the stop
lever (Figure 21, (2)) on the govenor
to stop fuel flow.
When you push the start switch on the
instrument panel while the emergency
button is pushed in, the starter operates
and the engine cranks.
Figure 21
6. Continue cranking the engine for about
5 seconds, checking for abnormal
sounds.
If you cannot find any abnormal
sounds, push the power switch and turn
off the engine.
JH Series Operation Manual 47
Page 56
BEFORE YOU OPERATE
WARNING
Start switch
Power switch
042590-00E00
Figure 22
Never touch or allow your
clothes to touch the moving
parts of the engine during
operation. If a part of your
body or clothing is caught in
the front drive shaft, V-belt, propeller shaft,
etc. serious injury may result.
Check to see that no tools, pieces of
cloth, etc. are left on or around the
engine.
48 JH Series Operation Manual
Page 57
ENGINE OPERATION
INTRODUCTION
This section of the Operation Manual
describes the diesel fuel, engine oil and
engine coolant specifications and how to
replenish them. It also describes the daily
engine checkout.
SAFETY PRECAUTIONS
Before performing any operations within
this section, review the Safety section on
page 5.
JH Series Operation Manual 49
Page 58
ENGINE OPERATION
WARNING
NOTICE
Fire and Explosion
Hazard
NEVER jump-start the
engine. Sparks caused by
shorting the battery to the
starter terminals may cause
a fire or explosion.
ONLY use the start switch
on the instrument panel to
start the engine.
Sudden Movement Hazard
Be sure the boat is in open water away
from other boats, docks or other
obstructions before increasing engine
speed. Avoid unexpected equipment
movement. Shift the marine gear into
the NEUTRAL position any time the
engine is at idle.
If the alarm indicater with audible alarm
fails to display and go out about 3 seconds
after the ignition switch is turned on, see
your authorized Yanmar Marine dealer or
distributor for service before operating the
engine
If the vessel is equipped with a water lift
(water lock) muffler, excessive cranking
could cause seawater to enter the
cylinders and damage the engine. If the
engine does not start after cranking for 10
seconds, close the thru-hull water intake
valve to avoid filling the muffler with water.
Crank for 10 seconds at a time until the
engine starts. When the engine does start,
stop the engine immediately and turn off
the switch.
Be sure to re-open the seacock and restart
the engine. Operate the engine normally.
To prevent accidental equipment
movement, NEVER start the engine in
gear.
Sever Hazard
Keep children and pets away
while the engine is operating.
If any indicator illuminates during engine
operation, stop the engine immediately.
Determine the cause and repair the
problem before you continue to operate the
engine.
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature engine
wear:
• Avoid operating in extremely dusty
conditions.
• Avoid operating in the presence of
chemical gases or fumes.
• NEVER run the engine if the ambient
temperature is above +40°C (+104°F) or
below -16°C (+5°F).
• If the ambient temperature exceeds
+40°C (+104°F), the engine may
overheat and cause the engine oil to
break down.
• If the ambient temperature is below
-16°C (+5°F), rubber components such
as gaskets and seals will harden causing
premature engine wear and damage.
50 JH Series Operation Manual
Page 59
12/05
NOTICE
Start switch
Power switch
042590-00E00
ENGINE OPERATION
STARTING THE ENGINE
• Contact your authorized Yanmar Marine
engine dealer or distributor if the engine
will be operated outside of this standard
temperature range.
NEVER engage the starter motor while the
engine is running. Damage to the starter
motor pinion and / or ring gear will result.
1. Open the seacock (if equipped).
2. Open the fuel tank cock.
3. Put remote control handle in
NEUTRAL.
Note: Safety equipment should make it
impossible to start the engine in
any other position than
NEUTRAL.
Figure 1
Figure 1
4. Turn on the battery switch (if equipped).
Do not turn off the battery switch during
engine operation. Also, turn it off when
the engine does not operate.
5. If the alarm buzzer and all alarm lamps
operate when you turn on the power
switch on the instrument panel, the
warning devices operate correctly.
6. Pushing the start switch turns on the
engine. Release the switch after the
engine starts. If the alarm lamps and
the alarm buzzer stops operating, the
warning devices operate correctly.
JH Series Operation Manual 51
Page 60
ENGINE OPERATION
NOTICE
NOTICE
NOTICE
If the Engine Fails to Start
Before pushing the start switch again, be
sure to confirm that the engine has
stopped completely. If an attempt to restart
is made while the engine is running, the
pinion gear of the starter motor will be
damaged.
NEVER hold for longer than 15 seconds or
the starter motor will overheat.
NEVER attempt to restart the engine if the
engine has not stopped completely. Pinion
gear and starter motor damage will occur.
Note: Push and hold the start switch
for a maximum of 15 seconds. If
the engine does not start the
first time, wait for about 15
seconds before trying again.
If the vessel is equipped with a water lift
(water lock) muffler, excessive cranking
could cause seawater to enter the
cylinders and damage the engine. If the
engine does not start after cranking for 15
seconds, close the thru-hull water intake
valve to avoid filling the muffler with water.
Crank for 10 seconds at a time until the
engine starts. When the engine does start,
stop the engine immediately and turn off
the power switch. Be sure to re-open the
seacock and restart the engine. Operate
the engine normally.
Air Bleeding the Fuel System After
Starting Failure
If the engine does not start after several
attempts, there may be air in the fuel
system. If air is in the fuel system, fuel
cannot reach the fuel injection pump.
Bleed the air out of the system. See
Bleeding the Fuel System on page 38.
Starting at Low Temperatures
Comply with local environmental
requirements. Use engine heaters to avoid
starting problems and white smoke. Do not
use starting aids.
NEVER use an engine starting aid such as
ether. Engine damage will result.
To limit white smoke, run the engine at low
speed and under moderate load until the
engine reaches normal operating
temperature. A light load on a cold engine
provides better combustion and faster
engine warm-up than no load.
Avoid running the engine at idling speed
any longer than necessary.
52 JH Series Operation Manual
Page 61
12/05
NOTICE
NOTICE
ENGINE OPERATION
Starting with Air Heater
(If Equipped)
1. Open the seacock (if equipped).
2. Open the fuel tank cock.
3. Put remote control handle in
NEUTRAL.
4. Turn the battery switch on (if equipped).
5. Push the power switch on. Ensure that
the instrument panel indicators light
and the alarm sounds. This shows that
indicators and alarm are working
correctly.
Note: The coolant high temperature
alarm indicator does not come
on during start-up.
6. Push and hold the glow switch for 15
seconds.
7. Push the start switch. Release the start
switch when the engine has started.
The alarm should stop and the
indicators should go out.
NEVER hold the start switch for longer
than 15 seconds or the starter motor will
overheat.
After the Engine has Started
After the engine has started, check the
following items at a low engine speed:
1. Check that the gauges, indicators and
alarm are normal.
• Normal coolant operating temperature
is approximately 76° to 90°C (169° to
194°F).
• Normal oil pressure at 3000 min
0.28 to 0.54 MPa (41 to 78 psi).
2. Check for water, fuel or oil leakage from
the engine.
3. Check that the smoke color, engine
vibration and sound are normal.
4. When there are no problems, keep the
engine at low speed with the boat still
stopped to distribute engine oil to all
parts of the engine.
5. Check that sufficient cooling water is
discharged from the seawater outlet.
Operation with inadequate seawater
discharge will damage the impeller of
the seawater pump. If seawater
discharge is too low, stop the engine
immediately. Identify the cause and
repair.
-1
is
The engine will seize if it is operated
when seawater discharge is too small or
if load is applied without any warming up
operation.
For troubleshooting assistance, see
Troubleshooting After Starting on page
89 or Troubleshooting Chart on page 91
. If necessary, see your authorized
Yanmar dealer or distributor.
JH Series Operation Manual 53
Page 62
ENGINE OPERATION
WARNING
NOTICE
NOTICE
REMOTE CONTROL
HANDLE OPERATION
Acceleration and Deceleration
(2)
(1)
(4)
Figure 2
1 – FORWARD or REVERSE
2 – NEUTRAL
3 – REVERSE or FORWARD
4 – Throttle Handle / Shifting
Handle
Note: Direction of travel will vary
depending on installation
location.
Use the throttle handle (Figure 2, (4)) to
control acceleration and deceleration.
Move the handle slowly.
(3)
0004513
Shifting the marine gear while operating at
high speed or not pushing the handle fully
into position (partial engagement) will
result in damage to marine gear parts and
abnormal wear.
1. Before using the marine gear, be sure
to move the throttle handle to a low idle
position (less than 1000 min
the throttle handle slowly to a higher
speed position after completing marine
gear engagement.
2. When moving the handle between
FORWARD (Figure 2, (1 or 3)) and
REVERSE (Figure 2, (3 or 1)), bring
the handle to NEUTRAL (Figure 2, (2))
and pause before slowly shifting to the
desired position. NEVER shift abruptly
from FORWARD to REVERSE or vice
versa.
• NEVER shift the marine gear at high
engine speed. During normal
operation, the marine gear should only
be shifted with the engine at idle.
-1
). Move
• When sailing, set the remote control
Shifting the Engine
handle in NEUTRAL. Not doing so
WILL introduce slippage or any
damage and void your warranty.
Sudden Movement Hazard.
The boat will start to move when the
marine gear is engaged:
• Ensure the boat is clear of all
obstacles forward and aft.
• Quickly shift to the FORWARD
position then back to the NEUTRAL
position.
• Observe whether the boat moves in
the direction you expect.
54 JH Series Operation Manual
Switching to Trolling (KMH4A
Only)
Use the trolling handle to begin trolling.
When changing from FORWARD or
REVERSE to trolling, the speed of the
propeller revolution will be reduced to a
minimum.
Page 63
12/05
NOTICE
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
0004498
ENGINE OPERATION
CAUTIONS DURING
OPERATION
Engine trouble can arise if the engine is
operated for a long time under overloaded
conditions with the control handle in the full
throttle position (maximum engine speed
position), exceeding the continuous rated
output engine speed. Operate the engine
-1
lower than the full
Figure 3
at about 100 min
throttle engine speed.
Note: If the engine is in the first 50
hours of operation, see New
Engine Break-In on page 16 .
1–Cable Fitting
2 – Trolling Lever
3 – Low Speed (trolling)
4 – High Speed
5 – Loosen
6 – Tighten
7 – Normal Operation (high speed)
8 – Trolling (low speed)
1. Operation continues at low engine
speed of 1000 min
-1
or less.
2. Reduce the speed by moving the
trolling handle from high speed (H)
(Figure 3, (4)) to low speed (L)
(Figure 3, (3)). Adjust the speed to the
desired rate and secure the trolling
handle in place.
3. Before returning to normal operation,
be sure to put the trolling handle in
high-speed (H) position.
4. Increase engine speed and continue
normal operation.
Always be on the lookout for problems
during engine operation.
Pay particular attention to the following:
• Is sufficient seawater being discharged
from the exhaust and seawater outlet
pipe?
If the discharge is small, stop the engine
immediately; identify the cause and
repair.
• Is the smoke color normal?
The continuous emission of black
exhaust smoke indicates engine
overloading. This shortens the engines
life and should be avoided.
JH Series Operation Manual 55
Page 64
ENGINE OPERATION
NOTICE
NOTICE
NOTICE
NOTICE
• Are there abnormal vibrations or noise?
Excessive vibration may cause damage
to the engine, marine gear, hull and
onboard equipment. In addition, it
causes able passenger and crew
discomfort.
Depending on the hull structure, engine
and hull resonance may suddenly
become great at a certain engine speed
range, causing heavy vibrations. Avoid
operation in this speed range. If you hear
any abnormal sounds, stop the engine
and inspect.
• Alarm buzzer sounds during operation.
Racing the engine: With the gear in
NEUTRAL, accelerate from the
low-speed position to the high-speed
position and repeat this process about
five times. This is done to clean out
carbon from the cylinders and the fuel
injection valve. Neglecting to race the
engine will result in poor smoke color
and reduce engine performance.
• If possible, periodically operate the
engine at near maximum engine speed
while underway. This will generate higher
exhaust temperatures, which will help
clean out hard carbon deposits,
maintaining engine performance and
prolonging the life of the engine.
If any alarm indicator with audible alarm
sound appears on the display during
engine operation, stop the engine
immediately. Determine the cause and
repair the problem before you continue
to operate the engine.
• Is there water, oil or fuel leakage, or are
there any loose bolts?
Check the engine room periodically for
any problems.
• Is there sufficient diesel fuel in the diesel
fuel tank?
Replenish diesel fuel before leaving the
dock to avoid running out of fuel during
operation.
• When operating the engine at low speed
for long periods of time, race the engine
once every 2 hours.
NEVER turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electric
system will result.
56 JH Series Operation Manual
Page 65
12/05
NOTICE
NOTICE
NOTICE
Start switch
Stop switch
Power switch
042590-00E02
SHUTTING DOWN THE
ENGINE OPERATION
ENGINE
Normal Shutdown
1. Reduce engine speed to low idle and
put remote control handle in NEUTRAL.
2. Accelerate from low speed to high
speed and repeat five times. This will
clean out the carbon from the cylinders
and the fuel injection nozzles.
3. Allow engine to run at low speed
(approximately 1000 min
for 5 minutes.
For maximum engine life, Yanmar
recommends that when shutting the
engine down, you allow the engine to
idle, without load, for 5 minutes. This will
allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
-1
) without load
Continue to hold the stop switch in until
the engine is completely stopped. If the
switch is released before the engine
has completely stopped, it may restart.
If the engine does not shut down, see
Emergency Shutdown on page 58 .
5. Turn off the battery switch (if equipped).
6. Close the fuel cock.
7. Close the seacock (if equipped).
•Be sure to close the seacock.
Neglecting to close the seacock could
allow water to leak into the boat and
may cause it to sink.
•If seawater is left inside the engine, it
may freeze and damage parts of the
cooling system when the ambient
temperature is below 0°C (32°F).
Figure 4
4. Push and hold the stop switch.
After the engine has stopped, push the
power switch off.
JH Series Operation Manual 57
Page 66
ENGINE OPERATION
NOTICE
WARNING
2
1
027092-00X
(2)
(1)
0004488
Emergency Shutdown
NEVER use the emergency stop switch for
a normal engine shutdown. Use this switch
only when stopping the engine suddenly in
an emergency.
If the engine cannot be shut down by the
stop switch on the panel, stop the engine
by moving the stop lever (Figure 6, (2)) by
hand to the left (Figure 6, (1)). The lever is
attached to the fuel injection pump.
3JH5E / 4JH5E
Figure 5
If the engine cannot be shut down by the
stop switch on the panel, stop the engine
by pushing the button (Figure 5, (1)) at the
back of the stop solenoid (Figure 5, (2)).
4JH4-TE / 4JH4-HTE1 / 4JH4-HTE
Sever Hazard.
ALWAYS keep hands, body parts and
loose-fitting clothes away from moving /
rotating parts such as the flywheel or
PTO shaft.
CHECKING THE ENGINE
AFTER OPERATION
• Check that the power switch is off and
that the battery switch (if equipped) is
turned to off.
• Fill the fuel tank. See Filling the Fuel
Tank on page 37.
• Close seawater cock(s).
• If there is a risk of freezing, check that
the cooling system contains enough
coolant. See Engine Coolant
Specifications on page 42.
Figure 6
58 JH Series Operation Manual
• If there is a risk of freezing, drain the
seawater system. See Drain Seawater
Cooling System on page 94.
• At temperatures below 0°C (32°F), drain
seawater system and connect the engine
heater (if equipped).
Page 67
PERIODIC
WARNING
MAINTENANCE
INTRODUCTION
This section of the Operation Manual
describes the procedures for proper care
and maintenance of the engine.
SAFETY PRECAUTIONS
Before performing any maintenance
procedures within this section, read the
following safety information and review the
Safety section on page 5.
Crush Hazard
If the engine needs to be
transported for repair, have a
helper assist you attach it to a
hoist and load it on a truck.
The engine lifting eyes are engineered
to lift the weight of the marine engine
only. ALWAYS use the engine lifting
eyes when lifting the engine.
Additional equipment is necessary to
lift the marine engine and marine gear
together. ALWAYS use lifting equipment
with sufficient capacity to lift the marine
engine.
JH Series Operation Manual 59
Page 68
PERIODIC MAINTENANCE
WARNING
NOTICE
Welding Hazard
• ALWAYS turn off the battery switch (if
equipped) or disconnect the negative
battery cable and the leads to the
alternator when welding on the
equipment.
• Remove the engine control unit
multi-pin connector. Connect the weld
clamp to the component to be welded
and as close as possible to the
welding point.
• NEVER connect the weld clamp to the
engine or in a manner which would
allow current to pass through a
mounting bracket.
• When welding is completed,
reconnect the alternator and engine
control unit prior to reconnecting the
batteries.
NEVER use undersized wiring for the
electrical system.
To ol H aza rd
ALWAYS remove any tools or shop rags
used during maintenance from the area
before operation.
Any part which is found defective as a
result of inspection, or any part whose
measured value does not satisfy the
standard or limit, must be replaced.
Modifications may impair the engine’s
safety and performance characteristics
and shorten the engine’s life. Any
alterations to this engine may void its
warranty. Be sure to use Yanmar genuine
replacement parts.
Entanglement Hazard
NEVER leave the power
switch on when you are
servicing the engine.
Someone may accidentally
start the engine and not
realize you are servicing it.
Shock Hazard
ALWAYS turn off the battery
switch (if equipped) or
disconnect the negative
battery cable before servicing
the equipment.
ALWAYS keep the electrical connectors
and terminals clean. Check the
electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors.
60 JH Series Operation Manual
Page 69
12/05
WARNING
NOTICE
PERIODIC MAINTENANCE
PRECAUTIONS
The Importance of Periodic
Maintenance
Engine deterioration and wear occur in
proportion to the length of time the engine
has been in service and the conditions the
engine is subjected to during operation.
Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor machine
performance and helps extend the life of
the engine.
Performing Periodic
Maintenance
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.
Accumulation of this gas within an
enclosure could cause illness or even
death. Make sure that all connections
are tightened to specifications after
repair is made to the exhaust system.
Failure to comply could result in death
or serious injury.
Keep a Log of Engine Hours and
Daily Checks
Keep a log of the number of hours the
engine is run each day and a log of the
daily checks performed. Also note the
date, type of repair (e.g., replaced
alternator) and parts used for any service
needed between the periodic maintenance
intervals. Periodic maintenance intervals
are every 50, 250, 500 and 1000 engine
hours. Failure to perform periodic
maintenance will shorten the life of the
engine.
Failure to perform periodic maintenance
will shorten the life of the engine and may
void the warranty.
Yanmar Replacement Parts
Yanmar recommends that you use genuine
Yanmar parts when replacement parts are
needed. Genuine replacement parts help
ensure long engine life.
Tools Required
Before you start any periodic maintenance
procedure, make sure you have the tools
you need to perform all of the required
tasks.
The Importance of Daily Checks
The Periodic Maintenance Schedule
assumes that the daily checks are
performed on a regular basis. Make it a
habit to perform daily checks before the
start of each operating day. See Daily
Checks on page 70.
JH Series Operation Manual 61
Ask Your Authorized Yanmar
Marine Dealer or Distributor for
Help
Our professional service technicians have
the expertise and skills to help you with
any maintenance or service related
procedures you need help with.
Page 70
PERIODIC MAINTENANCE
NOTICE
Tightening Fasteners
Use the correct amount of torque when you tighten fasteners on the engine. Applying
excessive torque may damage the fastener or component and not enough torque may
cause a leak or component failure.
he tightening torque in the Standard Torque Chart should be applied only to the
bolts with a “7” head (JIS strength classification: 7T). Apply 60% torque to bolts
that are not listed. Apply 80% torque when tightened to aluminum alloy.
Bolt Diameter x
Pitch (mm)
Tightening
Torque
Taper Plugs 1/8 1/4 3/8 1/2
Tightening
Torque
N·m 10.8 ± 1.0 25.5 ± 3.0 49 ± 5.0 88.2 ± 10.0 140.0 ± 10.0 230.0 ± 10.0
ft-lb 8.0 ± 0.7 18.8 ± 2.2 36.2 ± 3.7 65.1 ± 7.4 103 ± 7.2 170 ± 7.2
N·m 9.8 19.6 29.4 58.8
ft-lb 7.4 14.5 21.7 43.2
M6x1.0 M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5
When lock adhesive is applied, decide separately.
Pipe Joint Bolts M8 M10 M12 M14 M16
Tightening
Torque
N·m 14.7 ± 2 22.5 ± 3 29.4 ± 5 14.1 ± 5 53.9 ± 5
ft-lb 10.9 ± 1.5 16.6 ± 2.2 21.7 ± 3.7 32.6 ± 3.7 69.8 ± 3.7
When seal washer applied, torque is 34 ± 5 N·m (25.1 ± 3.7 ft-lb).
Main Bolt and Nuts
Name
Head bolt M10x1.25 Yes 88.2 ± 3 (65.1 ± 2.2)
Con-rod bolt M9x1.0 Yes 44.1 to 49.1 (32.6 to 36.3)
Flywheel bolt M10x1.25 Yes 83.3 to 88.3 (61.5 to 65.2)
Metal cap bolt M12x1.5 Yes 98 ± 2 (72.3 ± 1.5)
Crank pulley bolt
(Material of pulley: FC300)
Nozzle fastening bolt M8x1.25 — 26.4 ± 2 (19.5 ± 1.5)
FIP gear
fastening
bolt
High pressure pipe nut M12x1.5 — 29.4 to 34.4 (21.7 to 25.4)
3JH5E, 4JH5E M8x1.0 — 34.3 ± 2 (25.3 ± 1.5)
4JH4-TE
4JH4-HTE1
4JH4-HTE
Starter relay nut M6x1 — 3.6 ± 0.6 (2.7 ± 0.4)
Thread Diameter
x Pitch
M14x1.5 Yes 88.2 ± 5 (65.1 ± 3.7)
M14x1.5 Yes 64 ± 5 (41.6 ± 3.7)
Lubricating Oil Application
(thread portion and
seat surface)
Torque N·m (ft-lb)
62 JH Series Operation Manual
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PERIODIC MAINTENANCE
EPA MAINTENANCE REQUIREMENTS
To maintain optimum engine performance and compliance with the Environmental
Protection Agency (EPA) Regulations for Engines, it is essential that you follow the
Periodic Maintenance Schedule on page 66 and the Periodic Maintenance Procedures on
page 70 .
EPA Requirements for USA and Other Applicable Countries
The following are the requirements for the EPA. Unless these requirements are met, the
exhaust gas emissions will not be within the limits specified by the EPA.
See Conditions to Ensure Compliance with EPA Emission Standards on page 64. Clean or
replace the air cleaner element if the air intake restriction exceeds the referenced
specifications.
EPA Requirements
The EPA emission regulation is applicable only in the USA and other countries that have
adopted the EPA requirements in part or in whole. Determine and follow the emission
regulations in the country where your engine will be operating to assist you in specified
compliance.
JH Series Operation Manual 63
Page 72
PERIODIC MAINTENANCE
Conditions to Ensure Compliance with EPA Emission Standards
The 3JH5E, 4JH5E, 4JH-TE and 4JH4-HTE1 are EPA-certified engines.
The following are the conditions that must be met in order to ensure that the emissions
during operation meet the EPA standards.
The operating conditions should be as follows:
• Ambient temperature: -20° to +40°C (-4°F to +104°F)
• Relative humidity: 80% or lower
The diesel fuel should be:
• ASTM D975 No. 1-D or No. 2-D, or equivalent (minimum of cetane No. 45)
The lubricating oil should be:
• 4JH4-TE and 4JH4-HTE1: Type API, Class CD, CF, CF-4 and CI-4
• 3JH5E and 4JH5E: Type API, Class CF, CF-4 and CI-4
Be sure to perform inspections as outlined in Periodic Maintenance Procedures on page
70 and keep a record of the results.
Pay particular attention to these important points:
• Replacing the engine oil
• Replacing the engine oil filter
• Replacing the fuel filter
• Cleaning the intake silencer (air cleaner)
Note: Inspections are divided into two sections in accordance with who is responsible for
performing the inspection: the user or the maker.
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
Note: Since 2012, the 4JH4-HTE does not comply with the EPA regulation.
64 JH Series Operation Manual
Page 73
12/05
PERIODIC MAINTENANCE
Inspection and Maintenance
See Inspection and Maintenance of EPA Emission-Related Parts on page 69 for the EPA
emission-related parts. Inspection and maintenance procedures not shown in Inspection
and Maintenance of EPA Emission-Related Parts on page 69 are covered in Periodic
Maintenance Schedule on page 66 .
This maintenance must be performed to keep the emission values of your engine in the
standard values during the warranty period. The warranty period is determined by the age
of the engine or the number of hours of operation.
Installation of Exhaust Sampling Port
All engines subject to emission standards shall be equipped with a connection in the
engine exhaust system that is located downstream of the engine, and before any point at
which the exhaust contacts water (or any other cooling / scrubbing medium), for the
temporary attachment of gaseous and / or particulate emissions sampling equipment. This
connection shall be internally threaded with standard pipe threads of a size not larger than
12.7 mm (0.5 in.), and shall be closed by a pipe plug when not in use. Equivalent
connections are allowed.
The instructions for the proper installation and location of the required sample port, in
addition to those specified above in the quoted federal regulation, are as follows:
1. The connection should be located as far downstream as reasonably practicable from
any sharp bend (of 30 degrees or more) in the exhaust pipe to help ensure that a
well-mixed exhaust flow sample may be taken;
2. The requirement that the connection be located before any point at which the exhaust
contacts water (or any other cooling / scrubbing medium) does not include contact with
water used to cool exhaust manifolds, unless the water is allowed to come into direct
contact with the exhaust gases;
3. To allow ready access to the sample port, the connection should be located, if possible
given the constraints of vessel design, approximately 0.6 to 1.8 m (2 to 6 ft) above a
deck or walkway;
4. To facilitate insertion and withdrawal of an exhaust sample probe, there should be no
obstructions for at least one and one-half exhaust pipe / stack diameters perpendicular,
i.e., 90 degrees, from the sample port; and
5. If a threaded connection is used, both the internal and external threads should be
coated with a high-temperature, anti-seize compound before the initial installation and
at every subsequent re-installation to facilitate removal of the connection for testing.
JH Series Operation Manual 65
Page 74
PERIODIC MAINTENANCE
NOTICE
PERIODIC MAINTENANCE SCHEDULE
Daily and periodic maintenance is important to keep the engine in good operating
condition. The following is a summary of maintenance items by periodic maintenance
intervals. Periodic maintenance intervals vary depending on engine application, loads,
diesel fuel and engine oil used and are hard to establish definitively. The following should
be treated only as a general guideline.
Establish a periodic maintenance plan according to the engine application and make sure
to perform the required periodic maintenance at the intervals indicated. Failure to follow
these guidelines will impair the engine’s safety and performance characteristics, shorten
the engine’s life and may affect the warranty coverage on your engine.
See your authorized Yanmar Marine dealer or distributor for assistance when checking
items marked with a ●.
66 JH Series Operation Manual
Page 75
12/05
: Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributor
System Item Periodic Maintenance Interval
Every 50
hours or
monthly
which- ever
comes first
Initial 50
Whole Visual inspection of engine
exterior
Fuel
System
Check the fuel level and refill
if necessary
Drain water and sediment
from fuel tank
Drain the fuel / water
separator
Replace the fuel filter
element
Check the fuel injection
timing
Check the fuel injector spray
For EPA requirements,
pattern
see Inspection and
Daily
See Daily
Checks
on
page 70.
PERIODIC MAINTENANCE
Every 500
hours or 2
which- ever
comes first
Every 250
hours or 1
year whichever comes
first
Maintenance of EPA
Emission-Related Parts
.
Engine
Marine Gear
Engine
Marine Gear
Engine
Marine Gear
(if equipped)
During
Operation
See Engine Coolant Specifications on page 42.
Initial 50
Initial 50
Initial 50
Initial 50
Lubricating
System
Cooling
System
on page 69
Check the
lube oil level
Replace the
lube oil
Replace the
oil filter
element
Seawater outlet
Check coolant level
Check or replace the
seawater pump impeller
Replace coolant Every year. When Long Life Coolant is used, replace every 2 years.
Clean and check the
seawater passages
years
Every 1000
hours or 4
years
which- ever
comes first
●
●*
●
JH Series Operation Manual 67
Page 76
PERIODIC MAINTENANCE
: Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributor
System Item Periodic Maintenance Interval
Every 500
hours or 2
which- ever
comes first
Air Intake
and
Exhaust
System
Electrical
System
Engine
Cylinder
Head and
Block
Miscellane
ous Items
Daily
See Daily
Checks
on
page 70.
Clean intake silencer (air
cleaner) element
Clean or replace the
exhaust / water mixing elbow
Clean the turbocharger
4JH4-TE, 4JH4-HTE1or
4JH4-HTE only
Check diaphragm assembly
3JH5E / 4JH5E only
Check the alarm and
indicators
Check the electrolyte level in
the battery
Adjust the tension of the
alternator V-belt or replace
V-belt
Check the wiring connectors
Check for leakage of fuel,
engine oil and engine coolantAfter
Tighten all major nuts and
bolts
Adjust intake / exhaust valve
clearance
Check the remote control
cable operation
Adjust the propeller shaft
alignment
Replace rubberized hoses
(fuel and water)
*
-
starting
Every 50
hours or
monthly
which- ever
comes first
Initial 50
● Initial 50 ●
Initial 50 ●
●Initial 50 ●
Every 250
hours or 1
year whichever comes
first
●
●
Replace every 2 years.
years
Every 1000
hours or 4
years
which- ever
comes first
●
* For EPA requirements, see
on page 69 .
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.
68 JH Series Operation Manual
Inspection and Maintenance of EPA Emission-Related Parts
Page 77
12/05
PERIODIC MAINTENANCE
Inspection and Maintenance of EPA Emission-Related Parts
• Marine diesel engines less than 37 kW: 3JH5E is certified as EPA CI marine engine and
CARB non-road engine
• Marine diesel engines greater than 37 kW: 4JH5E, 4JH4-TE and 4JH4-HTE1 are
certified as EPA CI marine engines
Inspection and Maintenance of EPA Emission-Related Parts for Non-Road
and CI Marine Engines
Parts Interval
Clean fuel injection nozzle 1500 hours
Check fuel injection nozzle pressure and spray pattern 3000 hours
Check fuel injection pump adjustment
Check turbocharger adjustment (if equipped)
Check electronic engine control unit and its associated sensors
and actuators (if equipped)
Note: The inspection and maintenance items shown above are to be performed at
your Yanmar Marine dealer or distributor.
JH Series Operation Manual 69
Page 78
PERIODIC MAINTENANCE
WARNING
NOTICE
WARNING
NOTICE
PERIODIC MAINTENANCE
PROCEDURES
Exposure Hazard.
ALWAYS wear personal protective
equipment when performing periodic
maintenance procedures.
Daily Checks
Before you head out for the day, make sure
the Yanmar engine is in good operating
condition.
It is important to perform the daily checks
as listed in this 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.
Make sure you check the following items.
Visual Checks
NEVER check for a fuel leak with your
hands.
ALWAYS use a piece of wood or
cardboard. Have your authorized
Yanmar Marine dealer or distributor
repair any damage.
3. Check for engine coolant leaks.
4. Check for damaged or missing parts.
5. Check for loose, missing or damaged
fasteners.
6. Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors.
7. Check hoses for cracks, abrasions, and
damaged, loose or corroded clamps.
8. Check the fuel filter / water separator
for presence of water and
contaminants. If you find any water or
contaminants, drain the fuel filter /
water separator. See Draining Fuel
Filter / Water Separator on page 76. If
you have to drain the fuel filter / water
separator frequently, drain the fuel tank
and check for the presence of water in
your fuel supply. See Draining the Fuel
Tank on page 71.
1. Check for engine oil leaks.
2. Check for fuel leaks.
Piercing Hazard.
Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak, such as
a broken fuel injection line.
High-pressure fuel can penetrate
your skin and result in serious injury.
If you are exposed to high-pressure
fuel spray, obtain prompt medical
treatment.
70 JH Series Operation Manual
If any problem is noted during the visual
check, the necessary corrective action
should be taken before operating the
engine.
Check Diesel Fuel, Engine Oil and
Engine Coolant Levels
Follow the procedures in Diesel Fuel on
page 34 , Engine Oil on page 39 and
Engine Coolant on page 42 to check these
levels.
Page 79
12/05
0004542
(3)
(1)
(2)
PERIODIC MAINTENANCE
Checking and Refilling Marine Gear
Oil
Refer to the Operation Manual for the
marine gear.
Checking the Battery Electrolyte
Level
Check the battery electrolyte level before
use. See Checking the Battery
Electrolyte Level (Serviceable Batteries
Only) on page 78.
Checking the Alternator Belt
Check the belt tension before use. See
Checking and Adjusting the Alternator
V-Belt Tension on page 73.
Checking the Remote Control
Handle
Check the operation of the remote control
handle and ensure it moves smoothly. If it
is hard to operate, grease the joints of the
remote control cable and lever bearings. If
the lever is too loose, adjust the remote
control cable. See Checking and Adjusting
Remote Control Cables on page 74.
After Initial 50 Hours of
Operation
Perform the following maintenance after
the initial 50 hours of operation.
• Draining the Fuel Tank
• Changing the Engine Oil and
Replacing the Engine Oil Filter
Element
• Changing the Marine Gear Oil and
Replacing the Marine Gear Oil Filter (If
Equipped)
• Checking and Adjusting the
Alternator V-Belt Tension
• Inspecting and Adjusting
Intake / Exhaust Valve Clearance
• Checking and Adjusting the Remote
Control Cables
• Adjusting Propeller Shaft Alignment
Draining the Fuel Tank
Checking the Alarm Indicators
When operating the start switch on the
instrument panel, check that there is no
alarm message on the display and the
alarm indicators work normally. See
Control Equipment on page 23.
Preparing Fuel, Oil and Coolant in
Reserve
Prepare sufficient fuel for the days
operation. Always store engine oil and
coolant in reserve (for at least one refill)
onboard, to be ready for emergencies.
Figure 1
Note: Optional fuel tank shown. Actual
equipment may differ.
JH Series Operation Manual 71
Page 80
PERIODIC MAINTENANCE
WARNING
NOTICE
NOTICE
NOTICE
0004508
1. Put a pan under the drain cock
(Figure 1, (2)) to catch fuel.
2. Open the drain cock and drain water
and sediment. Close the drain cock
when the fuel is clean and free of air
bubbles.
Changing the Engine Oil and
Replacing the Engine Oil Filter
Element
The engine oil on a new engine becomes
contaminated from the initial break-in of
internal parts. It is very important that the
initial oil replacement is performed as
scheduled.
It is easiest and most arailable to drain the
engine oil after operation while the engine
is still warm.
Burn Hazard.
If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being burned. ALWAYS wear
eye protection.
3. Remove the engine oil filter (Figure 2) with
a filter wrench (turn counterclockwise).
Figure 2
Note: 4JH4-TE shown.
4. Install a new filter element and tighten by
hand until the seal touches the housing.
5. Turn filter an additional 3/4 turn
clockwise with a box wrench. Tighten to
20 to 24 N·m (177 to 212 in.-lb).
6. Fill with new engine oil. See Adding
Engine Oil on page 40.
1. Turn the engine off.
2. Remove the engine oil dipstick. Attach
the oil drain pump (if equipped) and
pump out the oil.
For easier draining, remove the engine
oil fill cap. Dispose of used oil properly.
•Prevent dirt and debris from
contaminating engine oil. Carefully
clean the dipstick and the surrounding
area before removing the dipstick.
•ALWAYS be environmentally
responsible.
NEVER mix different types of engine oil.
This may adversely affect the lubricating
properties of the engine oil.
NEVER overfill. Overfilling may result in
white exhaust smoke, engine overspeed
or internal damage.
7. Perform a trial run and check for oil leaks.
8. Approximately 10 minutes after stopping the
engine, remove the oil dipstick and check the
oil level. Add oil if the level is too low.
Be careful not to get any oil on the
V-belt. Oil on the belt causes
slipping and stretching. Replace
the belt if it is damaged.
72 JH Series Operation Manual
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12/05
NOTICE
WARNING
NOTICE
(2)
(3)
(4)
(5)
(1)
0004495
0004509
(1)
PERIODIC MAINTENANCE
Changing the Marine Gear Oil and
Replacing the Marine Gear Oil Filter
(If Equipped)
Figure 3
Note: 4JH4-TE / 4JH4-HTE1 /
4JH4-HTE engines with KMH4A
marine gear shown. Refer to the
Operation Manual for the marine
gear or sail drive for procedure.
1. Remove cap from the filler port and
attach an oil drain pump. Drain marine
gear oil.
4. Perform a trial run and check for oil leaks.
5. Approximately 10 minutes after
stopping the engine, remove the oil
dipstick and check the oil level. Add oil
if the level is too low.
Checking and Adjusting the
Alternator V-Belt Tension
Sever Hazard. Perform this check with
the power switch off and the battery
switch turned off to avoid contact with
moving parts.
• When there is not enough tension in the
V-belt, it will slip and the coolant pump
will fail to supply coolant. Engine
overheating and seizure will result.
• When there is too much tension in the
V-belt, the belt will become damaged
more quickly and the coolant pump
bearing may be damaged.
ALWAYS be environmentally responsible.
2. KMH4A Marine Gear:
Wash the marine gear oil filter:
(a) Remove side cover (Figure 3, (5))
and remove the filter (Figure 3, (2)).
(b) Clean the filter thoroughly with
kerosene or clean diesel fuel.
(c) Hold the filter in place with the coil
spring (Figure 3, (3)) and insert into
the case. Install a new O-ring
(Figure 3, (4)) in the side cover.
(d) Install side cover and tighten side
cover bolts.
3. Fill marine gear with clean marine gear
oil. See Marine Gear Oil Specifications
on page 41.
• NEVER get any oil on the belt(s). Oil on
the belt causes slipping and stretching.
Replace the belt if it is damaged.
Figure 4
Note: 4JH4-TE shown.
JH Series Operation Manual 73
Page 82
PERIODIC MAINTENANCE
NOTICE
(1) (2)
(5)(6) (4) (3)
(1)
(2)
(3)
(4)
(5)
6
(6)
0004496
1. Remove the belt cover.
2. Check the belt by pushing on the
middle of the belt (Figure 4, (1)) with
your finger.
With proper tension, the belt should
deflect 8 to 10 mm (approximately
3/8 in.).
3. Loosen the alternator bolt and move
the alternator to adjust the V-belt
tension.
4. Install the belt cover.
Note: If replacing the V-belt, loosen the
V-pulley of the coolant pump to
remove V-belt.
Inspecting and Adjusting
Intake / Exhaust Valve Clearance
Proper adjustment is necessary to
maintain the correct timing for opening and
closing the valves. Improper adjustment
will cause the engine to run noisily,
resulting in poor engine performance and
engine damage. See your authorized
Yanmar Marine dealer or distributor to
adjust the intake / exhaust valve clearance.
3JH5E / 4JH5E
Figure 5
1 – Control Lever
2 – Fuel Injection Pump
3 – Low-Speed Stop
4 – Adjustment Screw
5 – High-Speed Stop
6–Cable
4JH4-TE / 4JH4-HTE1 / 4JH4-HTE
Checking and Adjusting Remote
Control Cables
Never adjust the high-speed stop bolt on
the governor. This will void the engine
warranty.
Adjusting Engine Speed Remote
Control Cable
Ensure the control lever on the engine side
moves to the high-speed stop position and
low-speed stop position when the remote
control lever is moved to HIGH and then to
LOW.
Figure 6
1–Cable
2 – Fuel Injection Pump
3–Cable Fitting
4 – Low-Speed Stop
5 – Control Lever
6 – High-Speed Stop
74 JH Series Operation Manual
Page 83
12/05
026101-00X
(1)
(2)
(3)
0004563
(1)
(2)
(3)
(1)
(2)
(
3)
(4)
(5)
(6)
(7)
(8)
0004498
PERIODIC MAINTENANCE
1. To adjust, loosen the adjustment screw
(Figure 5, (4)) or cable fitting
(Figure 6, (3)) for the remote control
cable on the engine side and adjust.
2. Adjust the high-speed stop
(Figure 5, (5)) or (Figure 6, (6))
position first and then adjust the
low-speed stop (Figure 5, (3)) or
(Figure 6, (4)), with the adjustment
screw on the remote control lever
(Figure 5, (1)) or (Figure 6, (5)).
Adjusting Clutch Remote Control Cable
3JH5E / 4JH5E
1. Ensure that the remote control lever
(Figure 7, (2)) or (Figure 8, (1)) moves
to the correct position when the remote
control handle is in the NEUTRAL,
FORWARD and REVERSE positions.
Use the NEUTRAL position as the
standard for adjustment.
2. To adjust, loosen and retighten the
cable fitting (Figure 7, (1)) or
(Figure 8, (2)).
Adjusting Trolling Remote Control
Handle - If Equipped
Figure 7
4JH4-TE / 4JH4-HTE1 / 4JH4-HTE
Figure 8
Figure 9
1–Cable Fitting
2 – Trolling Lever
3 – Low Speed (trolling)
4 – High Speed
5 – Loosen
6 – Tighten
7 – Normal Operation (high speed)
8 – Trolling (low speed)
Note: KMH4A marine gear shown.
JH Series Operation Manual 75
Page 84
PERIODIC MAINTENANCE
WARNING
1. Ensure that the trolling lever
(Figure 9, (2)) is in the high-speed
(Figure 9, (4)) position when the
trolling remote control handle is in
high-speed position (Figure 9, (7)).
2. Ensure that the trolling lever is in the
low-speed (Figure 9, (3)) position when
the trolling remote control handle is in
low-speed position (Figure 9, (8)).
3. To adjust, loosen the adjustment screw
of the cable fitting (Figure 9, (1)) and
adjust the position of the cable.
Adjusting Propeller Shaft Alignment
The flexible engine mounts are
compressed slightly during initial engine
operation and may cause misalignment
between the engine and the propeller
shaft.
After the first 50 hours of operation, the
alignment should be checked and
readjusted if necessary. This is considered
normal maintenance and the adjustment
requires specialized knowledge and
techniques. Consult your authorized
Yanmar Marine dealer or distributor.
Check for any unusual noise and vibration
in the engine / boat hull, while increasing
and decreasing the engine speed
gradually.
Every 50 Hours of Operation
Perform the following procedures every 50
hours thereafter or monthly, whichever
comes first.
• Draining Fuel Filter / Water Separator
• Checking Battery Electrolyte Level
(Serviceable Batteries Only)
Draining Fuel Filter / Water
Separator
Fire and Explosion Hazard.
When removing any fuel system
component to perform maintenance
(such as changing the fuel filter), put an
approved container under the opening
to catch the fuel.
NEVER use a shop rag to catch the fuel.
Vapors from the rag are flammable and
explosive. Wipe up any spills
immediately.
Exposure Hazard.
Wear eye protection. The fuel system is
under pressure and fuel could spray
out when removing any fuel system
component.
If there is unusual noise and / or vibration,
this maintenance requires specialized
knowledge and techniques. See your
authorized Yanmar Marine dealer or
distributor to adjust the propeller shaft
alignment.
76 JH Series Operation Manual
Page 85
12/05
NOTICE
NOTICE
1
2
043823-00X00
0004565
(1)
(5)
(6)
(3)
(4)
(2)
PERIODIC MAINTENANCE
3JH5E and 4JH5E (Attach to Hull)
Figure 10
1. Close the fuel tank cock.
2. Loosen the drain plug (Figure 10, (1))
of the water separator and drain off any
water or dirt collected inside. Dispose
of the collected water and dirt properly.
ALWAYS be environmentally
responsible.
3. After draining, tighten the air bleed
screw (Figure 10, (2)).
4JH4-TE and 4JH4-HTE1, 4JH4-HTE
Figure 11
Note: 4JH4-TE shown.
If the fuel filter / water separator is
positioned higher than the fuel
level in the fuel tank, water may
not drip out when the fuel filter /
water separator drain cock is
opened. If this happens, turn the
air vent screw on the top of the fuel
filter / water separator two to three
turns counterclockwise. Be sure to
tighten the air vent screw after the
water has drained out.
4. Be sure to bleed air from the fuel
system. See Bleeding the Fuel System
on page 38.
JH Series Operation Manual 77
1. Close the fuel tank cock.
2. Loosen the hose clamp and remove the
fire-resistant cover, which is installed to
the lower part of the fuel filter / water
separator to protect the water alarm
switch.
3. Attach a tube (Figure 11, (6)) to the
drain plug (Figure 11, (4)).
Page 86
PERIODIC MAINTENANCE
NOTICE
WARNING
NOTICE
NOTICE
4. Loosen the drain plug (Figure 11, (4))
at the bottom of the fuel filter / water
separator by turning counterclockwise
and drain off any water or sediment.
NOTE:If there is a large quantity of
water and sediment in the fuel
filter / water separator, also drain
the fuel tank. See Draining the
Fuel Tank on page 71.
ALWAYS be environmentally
responsible. Dispose of the collected
water and dirt properly.
5. Tighten the drain plug.
NEVER turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electric
system will result.
NEVER operate with insufficient battery
electrolyte. Operating with insufficient
electrolyte will destroy the battery.
Battery fluid tends to evaporate in high
temperatures, especially in summer. In
such conditions, inspect the battery earlier
than specified.
6. Remove the drain tube.
7. Install the fire-resistant cover and
tighten the hose clamp.
8. Bleed air from the fuel system. See
Bleeding the Fuel System on page 38.
Checking the Battery Electrolyte
Level (Serviceable Batteries Only)
Exposure Hazard. Batteries contain
sulfuric acid.
NEVER allow battery fluid to come in
contact with clothing, skin or eyes.
Severe burns could result. ALWAYS
wear safety goggles and protective
clothing when servicing the battery. If
battery fluid contacts the eyes and / or
skin, immediately flush the affected
area with a large amount of clean water
and obtain prompt medical treatment.
1. Turn off the battery switch (if equipped)
or disconnect the negative (-) battery
cable.
2. Do not operate with insufficient battery
electrolyte, as the battery will be
destroyed.
3. Remove the plugs and check the
electrolyte level in all cells.
NEVER attempt to remove the covers or
fill a maintenance-free battery.
4. If the level is lower than the minimum fill
level (Figure 12, (1)), fill with distilled
water (Figure 12, (2)) (available in the
grocery store) up to the upper limit
(Figure 12, (3)) of the battery.
78 JH Series Operation Manual
Page 87
12/05
UPPER LEVEL
LOWER LEVEL
(2)
(3)
(1)
0004566
PERIODIC MAINTENANCE
Every 250 Hours of Operation
Perform the following maintenance every
250 hours or 1 year of operation,
whichever comes first.
• Draining the Fuel Tank
• Replacing the Fuel Filter Element
• Changing the Engine Oil and
Replacing the Engine Oil Filter
Element
• Changing the Marine Gear Oil and
Replacing Marine Gear Oil Filter
Element (If Equipped)
• Checking or Replacing the Seawater
Impeller
Figure 12
Note: The maximum fill level is
approximately 10 to 15 mm
(3/8 to 9/16 in.) above the plates.
• Changing the Coolant
• Cleaning the Intake Silencer (Air
Cleaner) Element
• Cleaning the Exhaust / Water Mixing
Elbow
• Cleaning the Turbocharger (If
Equipped)
• Adjusting the Alternator V-Belt
Tension
• Checking the Wiring Connectors
• Tightening All Major Nuts and Bolts
Draining the Fuel Tank
See Draining the Fuel Tank on page 71.
JH Series Operation Manual 79
Page 88
PERIODIC MAINTENANCE
WARNING
WARNING
(1)
027094-00X
Replacing the Fuel Filter Element
Fire and Explosion Hazard.
When removing any fuel system
component to perform maintenance
(such as changing the fuel filter), put an
approved container under the opening
to catch the fuel.
NEVER use a shop rag to catch the fuel.
Vapors from the rag are flammable and
explosive. Wipe up any spills
immediately.
Exposure Hazard.
Wear eye protection. The fuel system is
under pressure and fuel could spray
out when removing any fuel system
component.
Figure 13
1. Close the fuel tank drain cock.
2. Remove the cartridge filter
(Figure 13, (1)) with a filter wrench.
Note: When removing the fuel filter,
hold the bottom of the fuel filter
with a cloth to prevent the fuel
from spilling. Wipe up any spilled
fuel immediately.
3JH5E / 4JH5E
When there is not enough tension in the
V-belt, it will slip and the coolant pump will
fail to supply coolant. Engine overheating
and seizure will result.
When there is too much tension in the
V-belt, the belt will become damaged more
quickly and the coolant pump bearing may
be damaged.
Sever Hazard.
Perform this check with the power
switch off and the battery switch turned
off to avoid contact with moving parts.
3. Apply a thin film of clean diesel fuel to
the sealing surface of the new filter
gasket.
Component Part No.
Fuel Filter -
3JH5E / 4JH5E
119802–55801
4. Install a new filter and hand-tighten.
Use a filter wrench and tighten to 20 to
24 N·m (14.75 to 17.7 ft-lb).
5. Bleed the fuel system. See Bleeding
the Fuel System on page 38. Dispose
of waste properly.
6. Check for fuel leaks.
80 JH Series Operation Manual
Page 89
12/05
WARNING
(1)
(2)
(3)
(4)
0004500
Piercing Hazard.
Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak, such as
a broken fuel injection line.
High-pressure fuel can penetrate
your skin and result in serious injury.
If you are exposed to high-pressure
fuel spray, obtain prompt medical
treatment.
NEVER check for a fuel leak with your
hands.
ALWAYS use a piece of wood or
cardboard. Have your authorized
Yanmar Marine dealer or distributor
repair any damage.
4JH4-TE / 4JH4-HTE1 / 4JH4-HTE
PERIODIC MAINTENANCE
5. Disconnect the electrical connectors
and remove the alarm switch with a
spanner wrench.
6. Remove the filter housing
(Figure 14, (1)) with a filter wrench
(Figure 14, (2)).
7. Clean the filter housing mounting
surface. Install new filter element in
filter housing.
Component Part No.
Fuel Filter -
4JH4-TE / 4JH4-HTE1 /
4JH4-HTE
8. Install the alarm switch to the fuel filter.
Apply clean fuel to the gasket of the
new fuel filter.
9. Install filter housing into engine and
hand-tighten until the gasket comes
into contact with the seat. Use a filter
wrench and tighten approximately 3/4
turn to 11.8 to 15.6 N·m (104.4 to 138.1
in.-lb).
129574-55711
Figure 14
1. Close the fuel tank drain cock.
2. Loosen the hose clamp and remove the
fire-resistant cover, which is installed to
the lower part of the fuel filter / water
separator to protect the water alarm
switch.
3. Attach a tube to the drain plug.
4. Loosen the drain plug and drain the fuel
from the drain plug.
10.Install the fire-resistant cover and
tighten the hose clamp.
11.Bleed the fuel system. See Bleeding
the Fuel System on page 38.
12.Dispose of waste properly.
JH Series Operation Manual 81
Page 90
PERIODIC MAINTENANCE
0004510
(1)
Changing the Engine Oil and
Replacing the Engine Oil Filter
Element
See Changing the Engine Oil and
Replacing the Engine Oil Filter Element on
page 72.
Changing the Marine Gear Oil and
Replacing the Marine Gear Oil Filter
Element (if equipped)
See Changing the Marine Gear Oil and
Replacing the Marine Gear Oil Filter (If
Equipped) on page 73.
Checking or Replacing Seawater
Pump Impeller
1. Loosen side cover bolts and remove
the side cover.
2. Inspect the inside of the seawater
pump with a flashlight. If any of the
following are found, disassembly and
maintenance are required:
• Impeller blades are cracked or nicked.
Edges or surfaces of the blades are
marred or scratched.
• Wear plate is damaged.
3. If no damage is found when inspecting
the inside of the pump, install the O-ring
and side cover.
4. If a large amount of water leaks
continuously from the water drain line
below the seawater pump during
operation, replace the mechanical seal.
See your authorized Yanmar Marine
dealer or distributor.
Replacing the Seawater Pump Impeller
Note: The impeller must be replaced
periodically (every 1000 hours)
even if there is no damage.
Figure 15
There are two types of special service
tools for removing the impeller:
Puller A (standard)
Part No. 129671-92110
(A)
(B)
0004501
Figure 16
Puller A Jack Screw B
M18x1.5 M10x40 mm length
1. Remove the side cover of the seawater
pump.
2. Install puller (Figure 16, (A)) in the
impeller.
3. Turn the jack screw (Figure 16, (B))
clockwise to remove the impeller from
the pump body.
82 JH Series Operation Manual
Page 91
12/05
CAUTION
NOTICE
0004567
(1)
A
B
0004568
PERIODIC MAINTENANCE
Puller B (option)
Part No. 129671-92100
(B)
(A)
0004502
Figure 19
Figure 17
AB
110 mm (4.33 in.) 140 mm (5.51 in.)
Figure 18
Note: When replacing a used impeller
with a new one, the impeller
must have an M18x1.5 thread
(Figure 17, (1)). Turn the M18
screw side of the impeller to the
cover side and install
(Figure 18).
Changing the Coolant
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.
Change the coolant every year.
NEVER mix different types and / or colors
of coolants.
Discard old coolant in an approved manner
according to environmental laws.
Note: If Long Life coolant is used,
replace coolant every 2 years.
JH Series Operation Manual 83
Page 92
PERIODIC MAINTENANCE
026099-00X
(1)
(2)
(4)
(3)
(3)
(2)
(1)
026100-00X
027140-00X
(2)
(3)
(4)
(5)
(1)
026115-00X
(1)
3JH5E
Figure 20
1 – Coolant Pump
2 – Seawater Drain from Seawater
Pump Cover
3 – Coolant Drain Cock
4 – Coolant Tank (heat exchanger)
4JH5E
Figure 22
1 – Coolant Pump
2 – Seawater Drain from Seawater
Pump Cover
3 – Coolant Tank (heat exchanger)
4 – Coolant Drain Cock
5 – Flywheel Housing
Figure 21
1 – Flywheel Housing
2 – Coolant Drain Cock
3 – Stop Solenoid
84 JH Series Operation Manual
Figure 23
1 – Coolant Drain Cock
Page 93
12/05
0004572
(2)
(1)
(4)
(3)
(1)
(2)
(6)
(5)
(3)
(4)
0004560
000457
3
(2)
(1)
(4)
(3)
PERIODIC MAINTENANCE
4JH4-TE
(1)
(2)
(3)
(4)
0004571
Figure 24
1 – Coolant Tank (heat exchanger)
2 – Coolant Pump
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock (two used)
4JH4-HTE1 / 4JH4-HTE
Figure 26
1 – Coolant Tank (heat exchanger)
2 – Coolant Pump
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock
5 – Intercooler
6 – Seawater Drain from Seawater
Pump Cover
Figure 25
1 – Coolant Drain Cock
2–Fuel Pump
3 – Seawater Drain Cock
4 – Marine Gear Cooler
JH Series Operation Manual 85
Figure 27
1 – Coolant Drain Cock
2 – Fuel Pump
3 – Seawater Drain Cock
4 – Marine Gear Cooler
Page 94
PERIODIC MAINTENANCE
Note: The drain cocks are opened
before shipping from the factory.
Marine gear ZF25A does not
have a drain cock on the clutch
cooler.
1. Open all coolant drain cocks.
2. Allow to drain completely. Dispose of
waste properly.
3. Close all the drain cocks.
4. Fill coolant tank and reservoir with
appropriate coolant.
See Engine Coolant Specifications on
page 42 and Checking and Adding
Coolant on page 43 .
Cleaning the Intake Silencer (Air
Cleaner) Element
1. Disassemble the intake silencer (air
cleaner).
2. Remove element. Clean element and
housing with a neutral detergent.
Cleaning the Turbocharger (If
Equipped)
Contamination of the turbocharger causes
revolutions to drop and engine output to
fall.
If a significant drop in engine output is
noted (10% or more), clean the
turbocharger.
This should be done only by a trained and
qualified technician. See your authorized
Yanmar Marine dealer or distributor.
Adjusting the Alternator V-Belt
Tension
See Checking and Adjusting the Alternator
V-Belt Tension on page 73.
Checking the Wiring Connectors
See your authorized Yanmar Marine dealer
or distributor.
3. Dry completely and reassemble.
Cleaning the Exhaust / Water Mixing
Elbow
The mixing elbow is attached to the
turbocharger. The exhaust gas is mixed
with seawater in the mixing elbow.
1. Remove the mixing elbow.
2. Clean dirt and scale out of the exhaust
and seawater passages.
3. If the mixing elbow is damaged, repair
or replace. See your authorized Yanmar
Marine dealer or distributor.
4. Inspect the gasket and replace if
necessary.
Tightening All Major Nuts and Bolts
See Tightening Fasteners on page 62 or
see your authorized Yanmar Marine dealer
or distributor.
86 JH Series Operation Manual
Page 95
12/05
PERIODIC MAINTENANCE
Every 500 Hours of Operation Every 1000 Hours of Operation
Perform the following maintenance every
500 hours or 2 years of operation,
whichever comes first.
• Replacing the Exhaust / Water Mixing
Elbow
• Replacing Rubber Hoses
Replacing the Exhaust / Water
Mixing Elbow
Replace the mixing elbow with a new one
every 500 hours or 2 years, whichever
comes first, even if no damage is found.
See your authorized Yanmar Marine dealer
or distributor.
Replacing Rubber Hoses
Replace rubber hoses every 2000 hours or
2 years, whichever comes first.
See your authorized Yanmar Marine dealer
or distributor.
Perform the following maintenance every
1000 hours or 4 years of operation,
whichever comes first.
• Checking the Fuel Injection Timing
• Checking the Fuel Injector Spray
Pattern
• Replacing the Seawater Pump
Impeller
• Cleaning and Checking the Seawater
Passages
• Checking Diaphragm Assembly
(3JH5E / 4JH5E Only)
• Replacing the Alternator V-Belt
• Adjusting Intake / Exhaust Valve
Clearance
• Checking the Remote Control Cable
Operation
• Adjusting the Propeller Shaft
Alignment
Checking the Fuel Injection Timing
See your authorized Yanmar Marine dealer
or distributor.
Checking the Fuel Injector Spray
Pattern
See your authorized Yanmar Marine dealer
or distributor.
Replacing the Seawater Pump
Impeller
The seawater impeller must be replaced
every 1000 hours even if it is not damaged.
See Checking or Replacing Seawater
Pump Impeller on page 82.
JH Series Operation Manual 87
Page 96
PERIODIC MAINTENANCE
(7)
(8)
(6)
(5)
(1)
(2)
(3)
(4)
(9)
0003628
Cleaning and Checking the
Seawater Passages
After prolonged use, clean the seawater
passages to remove trash, scale, rust and
other contaminants that collect in the
cooling water passages. This can cause
declining cooling performance. The
following items need to be inspected:
• Heat Exchanger
• Pressure Cap
See your authorized Yanmar Marine dealer
or distributor.
Checking Diaphragm Assembly
(3JH5E / 4JH5E Only)
Replacing the Alternator V-Belt
See Checking and Adjusting the Alternator
V-Belt Tension on page 73.
Adjusting Intake / Exhaust Valve
Clearance
See your authorized Yanmar Marine dealer
or distributor.
Checking the Remote Control Cable
Operation
See your authorized Yanmar Marine dealer
or distributor.
Adjusting the Propeller Shaft
Alignment
See your authorized Yanmar Marine dealer
or distributor.
Figure 28
1 – Diaphragm Cover
2–Spring
3 – Center Plate
4 – Diaphragm
5 – Rocker Arm Cover
6 – Breather Baffle
7 – Baffle Plate
8 – Intake Silencer
9–Breather Pipe
See your authorized Yanmar Marine dealer
or distributor.
88 JH Series Operation Manual
Page 97
TROUBLESHOOTING
SAFETY PRECAUTIONS
Before performing any troubleshooting
procedures within this section, review the
Safety section on page
If a problem occurs, stop the engine
immediately. Refer to the Symptom column
in the Troubleshooting Chart to identify the
problem.
5.
TROUBLESHOOTING
AFTER STARTING
Just after the engine has started, check
the following items at a low engine speed:
Is sufficient water being discharged
from the seawater outlet pipe?
If the discharge is low, stop the engine
immediately. Identify the cause and repair.
Is the smoke color normal?
The continuous emission of black exhaust
smoke indicates engine overloading. This
shortens the engines life and should be
avoided.
Are there abnormal vibrations or noise?
Depending on the hull structure, engine
and hull resonance may suddenly increase
at certain engine speed ranges, causing
heavy vibrations. Avoid operation in this
speed range. If any abnormal sounds are
heard, stop the engine and inspect for
cause.
JH Series Operation Manual 89
Alarm sounds during operation.
If the alarm sounds during operation, lower
the engine speed immediately, check the
alarm lamps and stop the engine for
repairs.
Page 98
TROUBLESHOOTING
NOTICE
Is there water, oil or fuel leakage? Are
there any loose bolts or connections?
Check the engine room daily for any leaks
or loose connections.
Is there sufficient fuel in the fuel tank?
Refill fuel in advance to avoid running out
of fuel. If the tank runs out of fuel, bleed
the fuel system. See Bleeding the Fuel
System on page 38.
When operating the engine at low speed
for long periods of time, race the engine
once every 2 hours. Racing the engine
with the clutch in NEUTRAL, accelerate
from the low-speed position to the
high-speed position and repeat this
process about five times. This is done to
clean out carbon from the cylinders and
the fuel injection valves.
TROUBLESHOOTING
INFORMATION
If the engine does not operate properly,
refer to the
page 91 or see your authorized Yanmar
Marine dealer or distributor.
Supply the authorized Yanmar Marine
dealer or distributor with the following
information:
• Model name and serial number of your
engine
• Boat model, hull material, size (tons)
• Use, type of boating, number of hours
run
• Total number of operation hours (refer to
hourmeter), age of boat
• The operating conditions when the
problem occurs:
Troubleshooting Chart on
Neglecting to race the engine will result in
poor smoke color and reduce engine
performance.
Periodically operate the engine near
maximum speed while underway. This will
generate higher exhaust temperatures,
which will help clean out hard carbon
deposits, maintain engine performance
and prolong the life of the engine.
• Engine speed (min
• Color of exhaust smoke
• Type of diesel fuel
• Type of engine oil
• Any abnormal noises or vibration
• Operating environment such as high
altitude or extreme ambient
temperatures, etc.
• Engine maintenance history and
previous problems
• Other factors that contribute to the
problem
-1
)
90 JH Series Operation Manual
Page 99
12/05
TROUBLESHOOTING
TROUBLESHOOTING CHART
Symptom Probable Cause Measure Reference
Indicators light on the
instrument panel and alarm
sounds during operation
• Engine oil low pressure
alarm indicator comes on
• Water in sail drive seal
indicator comes on
• Coolant high temperature
alarm comes on
• Faulty Warning Devices Do not operate the engine if alarm devices are not repaired. Serious accidents may result if
Indicators Do Not Go On:
• The tachometer does not
turn on, even though the
power switch is turned on
• One of the indicators
does not go out
• Battery low charge
indicator does not go out
during operation
Starting Failures:
• Starter turns but engine
does not start
Shift to low-speed operation immediately, and check which indicator has come on. Stop the
engine and inspect. If no abnormality is identified and there is no problem with operation,
return to port at lowest speed and request repairs.
Engine oil level is low. Check engine oil level. Add
Engine oil filter clogged. Replace engine oil filter.
Rubber sail drive seal broken. See your authorized Yanmar
Coolant level is low. Check coolant level and refill. See Checking and
Insufficient seawater causing
temperature to rise.
Contamination inside cooling system. See your authorized Yanmar
abnormalities are not identified due to faulty indicators or alarm.
No electrical current available.
The battery switch is turned off, the
fuse (3 A) on the instrument panel is
burned out or the circuit is broken.
Sensor switch is faulty. See your authorized Yanmar
V-belt is loose or broken. Replace V-belt or adjust
Battery is defective. Check battery fluid level,
Alternator power generation failure. See your authorized Yanmar
No fuel. Add fuel. Bleed fuel system. See Filling the Fuel
Fuel filter is clogged. Replace filter element. See Replacing the
Improper fuel. Replace with recommended
Problem with fuel injection. See your authorized Yanmar
or replace.
Replace engine oil.
Marine dealer or distributor.
Check seawater system. -
Marine dealer or distributor.
See your authorized Yanmar
Marine dealer or distributor.
Marine dealer or distributor.
tension.
specific gravity or replace
battery.
Marine dealer or distributor.
fuel.
Marine dealer or distributor.
See Checking the
Engine Oil on
page 40
See Changing the
Engine Oil and
Replacing the
Engine Oil Filter
Element on page 72
-
Adding Coolant on
page 43
-
-
-
See Checking and
Adjusting the
Alternator V-Belt
Tension on page 73
See Checking the
Battery Electrolyte
Level (Serviceable
Batteries Only) on
page 78
-
Tank on page 37
and Bleeding the
Fuel System on
page 38
Fuel Filter Element
on page 80
See Diesel Fuel
Specifications on
page 34
-
JH Series Operation Manual 91
Page 100
TROUBLESHOOTING
Symptom Probable Cause Measure Reference
Compression leakage from
intake / exhaust valve.
• Starter does not turn or
turns slowly (engine can
be turned manually)
Power lacking due to
accessory drive being
engaged.
• Engine cannot be turned
manually
Abnormal Smoke Color:
• Black smoke Load increased. See your authorized Yanmar
• Incorrect intake / exhaust
valve clearance.
• White smoke Improper fuel. Replace with recommended
See your authorized Yanmar Marine
dealer or distributor.
Faulty clutch position. Shift to NEUTRAL and start. -
Insufficient battery charge. Check fluid level. Recharge.
Cable terminal contact failure. Remove corrosion from
Faulty safety switch device. See your authorized Yanmar
Faulty instrument panel. See your authorized Yanmar
See your authorized Yanmar Marine
dealer or distributor.
Internal parts seized. See your authorized Yanmar
Improper propeller matching. See your authorized Yanmar
Dirty intake silencer (air cleaner). Clean element. See Cleaning the
Improper fuel. Replace with recommended
Faulty spraying of fuel injector. See your authorized Yanmar
See your authorized Yanmar Marine
dealer or distributor.
Faulty spraying of fuel injector. See your authorized Yanmar
Fuel injection timing off. See your authorized Yanmar
Engine burning oil (excessive
consumption).
- -
Replace.
terminals. Tighten battery
cables.
Marine dealer or distributor.
Marine dealer or distributor.
- -
Marine dealer or distributor.
Marine dealer or distributor.
Marine dealer or distributor.
fuel.
Marine dealer or distributor.
- -
fuel.
Marine dealer or distributor.
Marine dealer or distributor.
See your authorized Yanmar
Marine dealer or distributor.
See Checking the
Battery Electrolyte
Level (Serviceable
Batteries Only) on
page 78
-
-
-
-
-
-
Intake Silencer (Air
Cleaner) Element on
page 86
See Diesel Fuel
Specifications on
page 34
-
See Diesel Fuel
Specifications on
page 34
-
-
-
92 JH Series Operation Manual
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