Yanmar JH4 Operations Manual
JH4
series
OPERATION MANUAL
3JH4E
4JH4AE
4JH4-TE
4JH4-HTE
P/N: 0AJH4–G00102
MARINE
ENGINES
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 Marine International.
© 2006 Yanmar Marine International
1006
ii JH4 Series Operation Manual
TABLE OF
CONTENTS
Page
Introduction .............................................................. 1
Record of Ownership .............................................. 2
Safety ....................................................................... 3
Safety Precautions ................................................. 4
General Information ......................................... 4
Before You Operate ......................................... 4
During Operation and Maintenance ..................... 4
Location of Safety Decals ........................................ 8
Product Overview ..................................................... 13
Yanmar JH4 Features and Applications ..................... 13
New Engine Break-In ...................................... 13
Component Identification ........................................ 15
Service Side - 3JH4E ...................................... 15
Non-Service Side - 3JH4E ............................... 15
Service Side - 4JH4AE .................................... 16
Non-Service Side - 4JH4AE ............................. 16
Service Side - 4JH4-TE ................................... 17
Non-Service Side - 4JH4-TE ............................. 17
Service Side - 4JH4-HTE ................................. 18
Non-Service Side - 4JH4-HTE .......................... 18
Location of Nameplates .......................................... 19
Function of Major Components ................................ 20
Control Equipment ................................................ 21
Instrument Panel (Optional) .............................. 21
Single Lever Remote Control Handle .................. 26
Before You Operate .................................................. 27
Diesel Fuel .......................................................... 27
Diesel Fuel Specifications ................................ 27
JH4 Series Operation Manual iii
TABLE OF CONTENTS
Filling the Fuel Tank ........................................ 30
Bleeding the Fuel System ................................ 30
Engine Oil ........................................................... 32
Engine Oil Specifications ................................. 32
Engine Oil Viscosity ........................................ 33
Checking the Engine Oil .................................. 33
Adding Engine Oil .......................................... 33
Marine Gear or Sail Drive Oil ................................... 34
Marine Gear Oil Specifications .......................... 34
Sail Drive Oil Specifications - SD50 .................... 34
Checking Marine Gear Oil ................................ 35
Adding Marine Gear Oil ................................... 35
Checking and Adding Sail Drive Oil .................... 35
Engine Coolant ..................................................... 36
Engine Coolant Specifications ........................... 36
Coolant (Closed Cooling System) ...................... 36
Checking and Adding Coolant ........................... 36
Cranking the Engine .............................................. 39
Daily Checks ....................................................... 40
Visual Checks ............................................... 40
Checking Diesel Fuel, Engine Oil and Engine
Coolant Levels .............................................. 41
Checking and Refilling Marine Gear Oil ............... 41
Checking the Battery Electrolyte Level ................ 41
Checking the Alternator Belt ............................ 41
Checking the Remote Control Handle ................. 41
Checking the Alarm Indicators ........................... 41
Preparing Fuel, Oil and Coolant in Reserve .......... 41
Engine Operation ...................................................... 43
Starting the Engine ................................................ 44
Restarting After Starting Failure ......................... 45
Starting at Low Temperatures ........................... 45
After the Engine Has Started ............................. 46
Remote Control Handle Operation ............................ 46
Acceleration and Deceleration .......................... 46
Shifting the Engine ......................................... 46
Switching to Trolling (KMH4A only) .................... 47
Shutting Down the Engine ....................................... 48
Emergency Shutdown ..................................... 48
Checking the Engine After Operation ......................... 49
Periodic Maintenance ................................................ 51
Safety Precautions ................................................ 51
iv JH4 Series Operation Manual
TABLE OF CONTENTS
Precautions ......................................................... 53
The Importance of Periodic Maintenance ............. 53
Performing Periodic Maintenance ...................... 53
The Importance of Daily Checks ........................ 53
Keep a Log of Engine Hours and Daily Checks ..... 53
Yanmar Replacement Parts .............................. 53
Tools Required .............................................. 53
Ask Your Authorized Yanmar Marine Dealer or
Distributor For Help ........................................ 53
Tightening Fasteners ...................................... 54
EPA Maintenance Requirements .............................. 55
EPA Requirements for USA and Other Applicable
Countries ..................................................... 55
EPA Requirements ......................................... 55
Conditions to Ensure Compliance with EPA
Emission Standards ........................................ 55
Inspection and Maintenance ............................. 56
Periodic Maintenance Schedule ............................... 57
Inspection and Maintenance of EPA Emission-
Related Parts ................................................ 60
Periodic Maintenance Procedures ............................ 61
After Initial 50 Hours of Operation ...................... 61
Every 50 Hours of Operation ............................. 65
Every 250 Hours of Operation ........................... 67
Every 500 Hours of Operation ........................... 73
Every 1000 Hours of Operation ......................... 74
Troubleshooting ....................................................... 77
Troubleshooting After Starting ................................. 77
Troubleshooting Chart ........................................... 79
Troubleshooting Information .................................... 82
Long-Term Storage ................................................... 83
Prepare Engine for Long-Term Storage ...................... 83
Drain Seawater Cooling System ............................... 84
Specifications .......................................................... 87
Principal Engine Specifications ................................ 87
3JH4E Engine Specifications ............................ 87
3JH4E Marine Gear Specifications ..................... 89
4JH4AE Engine Specifications .......................... 90
4JH4AE Marine Gear or Sail Drive
Specifications ................................................ 94
4JH4-TE Engine Specifications ......................... 96
4JH4-HTE Engine Specifications ....................... 98
JH4 Series Operation Manual v
TABLE OF CONTENTS
4JH4-TE and 4JH4-HTE Marine Gear or Sail Drive
Specifications .............................................. 100
System Diagrams ................................................... 101
Piping Diagrams ................................................. 101
Wiring Diagrams ................................................. 116
EPA Warranty USA Only .......................................... 129
Yanmar Co., Ltd. Limited Emission Control System
Warranty - USA Only ........................................... 129
Your Warranty Rights and Obligations:
Warranty Period: .......................................... 130
Warranty Coverage: ...................................... 131
Exclusions: ................................................. 131
Owner’s Responsibility: ................................. 131
Customer Assistance: ................................... 132
Emission System Warranty ...................................... 133
Non-Road Emission System Warranty ..................... 133
Yanmar Co., Ltd. Limited Emission Control
System Warranty - USA Only .......................... 133
..............
130
vi JH4 Series Operation Manual
INTRODUCTION
Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and from
cruisers to mega yachts. In marine leisure
boating, the worldwide reputation of Yanmar
Marine is second to none. We design our
engines to respect nature. This means
quieter engines, with minimal vibrations,
cleaner than ever. All of our engines meet
applicable regulations, including emissions,
at the time of manufacture.
To help you enjoy your Yanmar JH4 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.
• 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.
JH4 Series Operation Manual 1
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:
2 JH4 Series Operation Manual
SAFETY
!
!
!
!
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,
your safety is involved! Please
read and abide by the message
that follows the safety alert
symbol.
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or
serious injury.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and / or the environment or cause the
equipment to operate improperly.
JH4 Series Operation Manual 3
!
!
SAFETY
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
DANGER
The safety messages that follow have
WARNING level hazards.
NEVER permit anyone to
install or operate the
engine without proper
training.
During Operation and Maintenance
DANGER
The safety message that follows has
DANGER level hazards.
Crush Hazard
NEVER stand under hoisted
engine. If the hoist mechanism
fails, the engine will fall on you.
• 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.
4 JH4 Series Operation Manual
!
SAFETY
WARNING
The safety messages that follow have
WARNING level hazards.
Explosion Hazard
Avoid serious personal injury
or equipment damage. 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 use a shop rag to catch the fuel.
Wipe up all spills immediately.
NEVER refuel with the engine running.
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 feeling ill.
Exposure Hazard
To avoid injury, ALWAYS
wear personal protective
equipment including
appropriate clothing, gloves,
work shoes, eye and hearing
protection as required by the task at hand.
Store any containers containing fuel in a
well-ventilated area, away from any
combustibles or sources of ignition.
NEVER place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shut down.
Fire Hazard
Avoid injury or equipment
damage from fire. Undersized
wiring systems can cause an
electrical fire.
Entanglement Hazard
NEVER leave the key in the
key switch when you are
servicing the engine.
Someone may accidentally
start the engine and not realize
you are servicing it.
Avoid personal injury. NEVER operate the
engine while wearing a headset to listen to
music or radio because it will be difficult to
hear the warning signals.
Stop the engine before you begin to service
it.
If you must service the engine while it is
operating, remove all jewelry, tie back long
hair, and keep your hands, other body parts
and clothing away from moving / rotating
parts.
JH4 Series Operation Manual 5
!
!
SAFETY
WARNING
Piercing Hazard
Avoid skin contact with highpressure 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 the
damage.
Burn Hazard
Avoid serious injury. Some of
the engine surfaces become
very hot during operation and
shortly after shut-down. Keep
hands and other body parts
away from hot engine
surfaces.
Sudden Movement Hazard
Avoid personal injury. ALWAYS stop the
engine before beginning service.
Exhaust Hazard
Avoid serious injury or death.
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.
CAUTION
The safety messages that follow have
CAUTION level hazards.
Poor Lighting Hazard
Avoid personal injury or equipment damage.
Ensure that the work area is adequately
illuminated. ALWAYS install wire cages on
portable safety lamps.
Tool Hazard
Avoid personal injury or equipment damage.
ALWAYS use tools appropriate for the task
at hand and use the correct size tool for
loosening or tightening machine parts.
Flying Object Hazard
Avoid personal injury. ALWAYS wear eye
protection when servicing the engine or
when using compressed air or highpressure 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 Long Life engine
coolant. If contact with the
eyes or skin should occur,
flush eyes and wash immediately with clean
water.
6 JH4 Series Operation Manual
SAFETY
NOTICE
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.
If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the nonrunning 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 thruhull (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.
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 rpm, 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.
JH4 Series Operation Manual 7
SAFETY
LOCATION OF SAFETY DECALS
Figure 1, Figure 2, Figure 3 and Figure 4 show the location of safety decals on Yanmar
JH4 series marine engines.
3JH4E Engines
(1)
(3)
(2)
WARNING
196630-12980
Figure 1
1 – Part Number: 128377–07350
2 – Part Number: 128377–07260
3 – Part Number: 196630–12980
8 JH4 Series Operation Manual
0004550
4JH4AE Engines
SAFETY
(3)
(4)
(1)
(2)
WARNING
1 – Part Number: 128377–07350
2 – Part Number: 128377–07260
3 – Part Number: 196630–12980
4 – Part Number: 128377–07150
JH4 Series Operation Manual 9
0004551
Figure 2
SAFETY
(1)
4JH4-TE Engines
(2)
WARNING
(3)
(4)
1 – Part No.: 128377-07350
2 – Part No.: 128377-07260
3 – Part No.: 196630-12980
4 – Part No.: 128296-07300
128296-07300
0003632
Figure 3
10 JH4 Series Operation Manual
(1)
WARNING
(2)
SAFETY
4JH4-HTE Engines
(3)
128296-07300
1 – Part No.: 128377-07350
2 – Part No.: 128377-07260
3 – Part No.: 128296-07300
4 – Part No.: 196630-12980
JH4 Series Operation Manual 11
(4)
0004552
Figure 4
SAFETY
This Page Intentionally Left Blank
12 JH4 Series Operation Manual
PRODUCT OVERVIEW
YANMAR JH4 FEATURES AND APPLICATIONS
The JH4 series are four-stroke direct
injection diesel engines equipped with liquid
coolant systems.
The 3JH4E is 3-cylinder and naturally
aspirated.
The 4JH4AE is 4-cylinder and naturally
aspirated.
The 4JH4–TE is 4-cylinder and
turbocharged.
The 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
- 200 rpm above the fuel stop power rpm to
allow for some added weight and hull
resistance.
Failure to do so can lead to reduced vessel
performance, lead to increased smoke
levels and cause permanent damage to your
engine.
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 onboard
equipment, always observe the instructions
and cautions given in the operation manuals
supplied by the shipyard and equipment
manufacturers.
The JH4 series engines are designed to be
operated at maximum throttle
(3000 - 3200 rpm) for less than 5% of total
engine time (30 minutes out of every 10
hours) and cruising speed (2800 rpm 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 Yanmar's local
subsidiary in your region or your authorized
Yanmar marine dealer or distributor.
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.
JH4 Series Operation Manual 13
PRODUCT OVERVIEW
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˚ - 87˚C (160˚ - 190˚F).
During the first 10 hours of operation, the
engine should be run at maximum rpm
minus 400 - 500 rpm (approximately
60 - 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.
NOTICE: Do not operate at WOT (wide open
throttle) for more than a minute at a time
during the first 10 hours of operation.
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 lube oil
consumption may increase. Low idle speed
does not allow break-in of sliding parts.
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 rpm most of the
time (approximately 70% load), with a 10
minute run at maximum minus 200 rpm
(approximately 80% load) every 30 minutes
and a 4-5 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 maintenance procedures.
See Periodic Maintenance Schedule on
page 57.
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.
14 JH4 Series Operation Manual
PRODUCT OVERVIEW
COMPONENT IDENTIFICATION
Service Side - 3JH4E
Figure 1 and Figure 2 illustrate a typical
version of a 3JH4E engine. Your engine may
have different equipment from that
illustrated.
(1)
(2)
(3)
Figure 1
1 – Intake Silencer (Air Cleaner)
2 – Shift Lever
3 – Marine Gear
4 – Oil Cooler
5 – Engine Oil Filter
6 – Fuel Feed Pump
7 – Engine Oil Filler Cap
8 – Fuel Injection Pump
9 – Fuel Filter
10 – Engine Oil Dipstick
11 – Intake Manifold
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
0004543
Non-Service Side - 3JH4E
(1)
(2)
(3)
(4)
(5)
Figure 2
1 – Coolant Filler Cap
2 – Engine Nameplate (on rocker arm
cover)
3 – Fresh Water Pump
4 – Belt Cover
5 – Seawater Pump
6 – Starter Motor
7 – Mixing Elbow
8 – Exhaust Manifold
9 – Alternator
10 – Coolant Tank / Heat Exchanger
(10)
(9)
(8)
(7)
(6)
0004544
JH4 Series Operation Manual 15
PRODUCT OVERVIEW
Service Side - 4JH4AE
Figure 3 and Figure 4 illustrate a typical
version of a 4JH4AE engine. Your engine
may have different equipment from that
illustrated.
(5)
(1)
(2)
(3)
(4)
Figure 3
1 – Air Heater
2 – Intake Silencer
3 – Shift Lever
4 – Marine Gear
5 – Engine Oil Dipstick
6 – Fuel Priming Pump
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)
(12)
0004545
Non-Service Side - 4JH4AE
(1)
(2)
(3)
(4)
Figure 4
1 – Engine Nameplate (on rocker arm
cover)
2 – Fresh Water Pump
3 – Belt Cover
4 – Seawater Pump
5 – Coolant Filler Cap
6 – Coolant Tank / Heat Exchanger
7 – Exhaust Manifold
8 – Starter Motor
9 – Alternator
(5)
(6)
(7)
(8)
(9)
0004546
16 JH4 Series Operation Manual
PRODUCT OVERVIEW
Service Side - 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
Non-Service Side - 4JH4-TE
(1)
(2)
(3)
(4)
(5)
Figure 6
1 – Engine Nameplate (on rocker arm
cover)
2 – Coolant Filler Cap
3 – Fresh Water Pump
4 – Belt Cover
5 – Seawater Pump
6 – Alternator
7 – Starter Motor
8 – Exhaust / Water Mixing Elbow
9 – Coolant Tank / Heat Exchanger
(9)
(8)
(7)
(6)
0004547
JH4 Series Operation Manual 17
PRODUCT OVERVIEW
Service Side - 4JH4-HTE
Figure 7 and Figure 8 illustrate a typical
version of a 4JH4–HTE engine. Your engine
may have different equipment from that
illustrated.
(11)
(12)
(1)
(2)
(3)
(4)
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
(5)
(10)
(9)
(8)
(7)
(6)
0004548
Non-Service Side - 4JH4-HTE
(6)
(10)
(7)
(9)
(8)
0004549
(1)
(2)
(3)
(4)
(5)
Figure 8
1 – Engine Nameplate (on rocker arm
cover)
2 – Coolant Filler Cap
3 – Fresh Water Pump
4 – Belt Cover
5 – Seawater Pump
6 – Alternator
7 – Intercooler
8 – Starter Motor
9 – Exhaust Mixing Elbow
10 – Coolant Tank / Heat Exchanger
18 JH4 Series Operation Manual
PRODUCT OVERVIEW
LOCATION OF NAMEPLATES
The nameplates of Yanmar JH4 series
engines are shown in Figure 9 and
Figure 10. Check the engine's model,
output, rpm and serial number on the
nameplate. Please replace if damaged or
lost.
The engine nameplate is attached to the
engine rocker arm cover.
Model
Gear Model
Continuous power kW
Speed of prop shaft
Fuel stop power kW
ENG.No.
MADE IN JAPAN
Figure 9
min
-1
min
min
-1
-1
The marine gear nameplate (Figure 11) is
attached to the marine gear. Check the
marine gear's model, gear ratio, oil used, oil
quantity and serial number
MODE L KM
GEAR RATIO
OIL SAE20/30 HD
OIL QT Y. LTR.
NO.
0004529
Figure 11
The sail drive nameplate (Figure 12) is
attached to the sail drive. Check the sail
drive model and serial number.
MODEL
PASSED
MARK
MFG.NO.
Model
Gear Model
Continuous power kW
Speed of prop,shaf t
Fuel stop power kW
ENG.No.
MADE IN JAPAN
//
min
//
-1
min
-1
-1
min
0004574
Figure 12
0004575
Figure 10
JH4 Series Operation Manual 19
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
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
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 (fresh water) and
Closed Cooling
Circulation Pump
Seawater Pump Pumps seawater from outside vessel to the engine. The seawater pump is gear-
Coolant Filler Cap When the coolant temperature rises, the pressure inside the fresh water tank
Coolant Recovery Tank The pressure valve in the filler cap releases vapor and hot water overflow to the
Oil Cooler - Engine A heat exchanger that cools high temperature engine oil using coolant.
Oil Cooler - Marine Gear
(Optional)
Turbocharger (if
equipped)
Intercooler (if equipped) This heat exchanger cools the pressurized charging air from the turbocharger with
Intake Silencer (Air
Cleaner)
Nameplates Nameplates are provided on the engine and the marine gear and have the model,
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.
should be replaced periodically. The water separator (if equipped) should be
drained periodically. See Draining Fuel Filter / Water Separator on page 65.
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.
distributed to 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 69.
seawater. The engine is 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.
driven and has a replaceable rubber impeller. Do not operate it without seawater,
as this will damage the impeller.
increases and opens the pressure valve in the filler cap. When the pressure valve
in the filler cap is opened, hot water and steam pass through a rubber hose to the
coolant recovery tank. When the engine cools and the pressure inside the coolant
recovery tank drops, the vacuum valve in the filler cap opens and the coolant in
the coolant recovery tank returns to the water tank through the pipe and filler cap.
This minimizes coolant consumption.
coolant recovery tank. When the engine stops and the coolant cools, the pressure
in the coolant tank drops. The filler cap vacuum valve then opens to send water
back from the coolant recovery tank. This minimizes coolant consumptions. The
closed cooling system coolant level can easily be checked and refilled in this tank.
This heat exchanger that cools the marine gear (KMH4A) oil using seawater.
The turbocharger pressurizes the air coming into the engine. It is driven by a turbine
that is energized by exhaust gases.
seawater to increase the charging air quantity.
The intake silencer guards against dirt in the air and reduces the noise of air intake.
serial number and other data.
20 JH4 Series Operation Manual
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.
B-Type
(9)
(8)
(7)
(6)
(1)
(2)
1 – Tachometer
2 – Hourmeter
3 – Moisture Cap for Key Switch
4 – Key Switch
5 – Stop Button
(5)
(4)
(3)
0004486
Figure 13
6 – Battery Low Charge Indicator
7 – Water in Sail Drive Seal Indicator
8 – Engine Oil Low Pressure Indicator
9 – Coolant High Temperature Indicator
JH4 Series Operation Manual 21
PRODUCT OVERVIEW
(1)
(2)
(3)
C-Type
(13)
(12)
(11)
(10)
(9)
(4)
(5) (6)
Figure 14
1 – Coolant High Temperature Indicator
2 – Coolant Temperature Gauge
3 – Engine Oil Low Pressure Indicator
4 – Engine Oil Pressure Gauge
5 – Tachometer
6 – Hourmeter
7 – Moisture Cap for Key Switch
(8)
(7)
0004503
8 – Key Switch
9 – Stop Button
10 – Battery Low Charge Indicator
11 – Water in Sail Drive Seal Indicator
12 – Water in Fuel Filter Indicator (if
equipped)
13 – Insufficient Seawater Flow Indicator
22 JH4 Series Operation Manual
PRODUCT OVERVIEW
Meters
B-Type and C-Type panels use analog electric gauges with needle indicators.
Instrument Function
Tachometer Shows engine rotation speed.
Hourmeter Shows number of operating hours. Can be used as a guide for
Coolant Temperature Gauge (C-Type only) Shows the coolant temperature.
Engine Oil Pressure Gauge (C-Type only) Shows the engine oil pressure.
Panel Lights When turning the key switch to ON, the gauges will illuminate for
periodic maintenance checks. The hourmeter is located at the
bottom of the tachometer.
easier viewing.
Key Switch
(1)
The GLOW position (Figure 15, (1)) is the
start aid position. Electric current to the glow
plug or air heater (if equipped) is turned on.
The air heaters is standard on the 4JH4AE
and optional on the 3JH4E, 4JH4–TE and
4JH4–HTE models. When the key is
released, the switch will automatically move
to the ON position.
(2)
(3)
(4)
0003622
Figure 15
The ON position (Figure 15, (3)) allows
electrical current to the controls and
equipment and allows the engine to keep
running. To stop the engine, keep the key
switch in the ON position and push the stop
button. After stopping the engine, turn key to
OFF position.
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, the alarm is located on the back of the
panel. Under normal operating conditions,
the indicators are off.
The START position (Figure 15, (4)) allows
current to the starting motor. When starting
the engine, move the key to the START
position and release. The key will
automatically move to the ON position.
When the key is in the OFF position
(Figure 15, (2)) the electric current is off.
The key can be inserted or removed in this
position.
JH4 Series Operation Manual 23
PRODUCT OVERVIEW
Figure 16
Battery Low Charge Indicator
(Figure 16) - When the alternator output is
too low, the indicator will light. When
charging begins, the indicator will turn off.
No alarm will sound for low battery charge.
Figure 17
Coolant High Temperature Indicator and
Alarm (Figure 17) - 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.
Figure 18
Engine Oil Low Pressure Indicator and
Alarm (Figure 18) - 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 immediately to avoid
damage to the engine. Check the oil level
and troubleshoot the lubrication system.
Figure 19
Water in Sail Drive Seal Indicator and Alarm
(Figure 19) - When water is detected
between the seals of the sail drive, the
indicator will light and the alarm will sound.
Figure 20
Water in Fuel Filter Indicator and Alarm (CType only) - 4JH4-TE and 4JH4–HTE
engines only - (Figure 20) - 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 65.
Figure 21
Insufficient Seawater Flow Indicator and
Alarm (C-Type only) (Figure 21).
24 JH4 Series Operation Manual
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