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
PRODUCT OVERVIEW
Alarms
Check that indicators and alarms are working normally when the key is turned to ON.
Key Switch OFF ⇒ ON START ⇒ ON
Engine Before start Running
Alarm Sound Stop
Indicators Battery Low Charge Indicator ON OFF
Coolant High Temperature Indicator OFF OFF
Engine Oil Low Pressure Indicator ON OFF
Water in Sail Drive Seal Indicator (if equipped) OFF OFF
JH4 Series Operation Manual 25
PRODUCT OVERVIEW
Single Lever Remote Control Handle
(3)
(1)
(4)
Figure 22
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
(2)
(5)
0004504
(2)
(1)
0004511
Figure 23
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 rpm to 1000
rpm or less before engaging and
disengaging the marine gear clutch.
A single handle-type (Figure 22) 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 23, (1)), the engine speed can be
controlled without engaging the clutch. The
clutch remains in NEUTRAL, no load
position. Turn the knob (Figure 23, (2))
counterclockwise to move the handle or
clockwise to lock the handle.
26 JH4 Series Operation Manual
BEFORE YOU OPERATE
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 checks.
DIESEL FUEL
Diesel Fuel Specifications
NOTICE: 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
EN590:96 European Union
ISO 8217 DMX International
BS 2869-A1 or A2 United Kingdom
JIS K2204 Grade No. 2 Japan
LOCATION
USA
JH4 Series Operation Manual 27
BEFORE YOU OPERATE
Additional Technical Fuel Requirements
• The fuel cetane number should be equal
to 45 or higher.
• The sulfur content must not exceed 0.5%
by volume. Less than 0.05% is preferred.
• 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.
0004512
Figure 1
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.
Handling of Diesel Fuel
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.
28 JH4 Series Operation Manual
BEFORE YOU OPERATE
Fuel Tank (Optional)
(4)
(3)
(1)
Figure 2
1 – Sediment Bowl
2 – Drain Cock
3 – To Engine
4 – Fuel Line
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)).
The fuel outlet should be positioned 20 - 30
mm (0.75 - 1.125 in.) above the bottom of
the tank so that only clean fuel is distributed
to the engine.
(2)
0004542
Fuel System - 3JH4E, 4JH4-TE and 4JH4-HTE
(1)
(2)
(3)
Figure 3
1 – Fuel Filter
2 – To Fuel Injection Pump
3 – Less than 500 mm (20.0 in.)
4 – Fuel Cock
5 – 20 - 30 mm (0.75 - 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.
(4)
(8)
(5)
0004489
(7)
(6)
JH4 Series Operation Manual 29
BEFORE YOU OPERATE
Fuel System - 4JH4AE
(5)
(6)
(4)
1 – Fuel Tank
2 – Fuel Cock
3 – Water Separator
4 – Fuel Feed Pump
5 – Fuel Filter
6 – To Fuel Injection Pump
7 – Fuel Return Line
8 – Drain Cock
9 – 20 - 30 mm (0.75 - 1.25 in.)
10 – Less than 400 mm (16.38 in.)
(10)
(3)
Figure 4
approximate
(7)
(1)
(9)
(2)
(8)
0004553
3. Fill the tank with clean fuel free of oil and
dirt. NOTICE: Hold the hose nozzle
firmly against the filler port while filling.
This prevents static electricity buildup
which could cause sparks and ignite
fuel vapors.
4. Stop fueling when the gauge shows the
fuel tank is full. NOTICE: NEVER overfill
the fuel tank.
5. Replace the fuel cap and hand-tighten.
Over-tightening the fuel cap will
damage it.
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.
Filling the Fuel Tank
Before filling fuel tank for the first time:
1. Rinse fuel tank with kerosene or diesel
fuel. Dispose of waste properly.
To fill the fuel tank:
NOTICE: 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.
30 JH4 Series Operation Manual
BEFORE YOU OPERATE
Bleeding the Fuel System - 3JH4E
(2)
(1)
(3)
(4)
(5)
5. Continue pumping until a solid stream
of fuel with no air bubbles begins to
flow.
6. Tighten the air bleed screw.
Note: After engine start-up, the automatic
air-bleeding device works to purge the air in
the fuel system.
Bleeding the Fuel System - 4JH4AE
(3)
(2)
(1)
(6)
Figure 6
(4)
(5)
0004555
(6)
0004554
Figure 5
1 – Fuel Injector
2 – Air Bleed Screw
3 – To Fuel Tank
4 – Fuel Filter
5 – Fuel Injection Pump
6 – Fuel Feed Pump
1. Check the fuel level in the fuel tank.
Refill if necessary.
2. Open the fuel cock of the fuel tank.
3. Loosen the air bleed screw
(Figure 5, (2)) 2 - 3 turns.
4. Push up and down on the priming pump
(Figure 5, (1)) to release air out of the
air bleed screw.
1 – Fuel Injector
2 – Fuel Filter
3 – Priming Pump
4 – Air Bleed Screw
5 – Fuel Feed Pump
6 – 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. Loosen the air bleed screw
(Figure 6, (4)) 2 - 3 turns.
4. Push up and down on the priming pump
(Figure 6, (3)) to release air out of the
air bleed screw.
5. Continue pumping until a solid stream
of fuel with no air bubbles begins to
flow.
6. Tighten the air bleed screw.
JH4 Series Operation Manual 31
BEFORE YOU OPERATE
Bleeding the Fuel System - 4JH4-TE and 4JH4-HTE
(1)
(2)
(3)
(4)
Figure 7
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.
3. Loosen the air bleed screw
(Figure 7, (2)) 2 - 3 turns.
4. Push up and down on the priming pump
(Figure 7, (1)) to release air out of the
air bleed screw.
5. Continue pumping until a solid stream
of fuel with no air bubbles begins to
flow.
6. Tighten the air bleed screw.
NOTICE: NEVER use an engine starting aid
such as ether. Engine damage will result.
0004494
ENGINE OIL
Engine Oil Specifications
NOTICE: 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.
Use an engine oil that meets or exceeds the
following guidelines and classifications:
• 3JH4E, 4JH4-TE and 4JH4-HTE: API
Service Categories CD or higher
• 4JH4AE: API Service Category CH-4
only
• SAE Viscosity: 10W30, 15W40. Engine
oil 10W30 and 15W40 can be used
throughout the year.
Note:
1. Be sure the engine oil, engine oil
storage containers, and engine oil filling
equipment are free of sediment or
water.
2. Change the engine oil after the first 50
hours of operation and then at every
250 hours thereafter.
3. Select the oil viscosity based on the
ambient temperature where the engine
is being operated. See the SAE Service
Grade Viscosity Chart (Figure 8).
4. Yanmar does not recommend the use
of engine oil “additives.”
Handling 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 engines life.
3. Engine oil should be replaced at the
specified intervals, regardless if the
engine has been operated.
32 JH4 Series Operation Manual
BEFORE YOU OPERATE
Engine Oil Viscosity
SAE 10W
SAE 20W
SAE 10W-30
SAE 15W-40
SAE 20
SAE 30
SAE 40
-4°F 14°F 32°F 50°F 68°F 86°F 104°F
(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)
0000005
Figure 8
Select the appropriate engine oil viscosity
based on the ambient temperature shown in
the SAE Service Grade Viscosity Chart in
Figure 8.
SAE 10W30 or SAE15W40 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.
Checking the Engine Oil
(1)
(2)
(3)
(4)
(5)
0004490
Figure 9
Note: 4JH4-TE shown. Other models are
similar.
1. It is recommended that the engine be
as level as possible before checking the
oil.
2. Remove dipstick (Figure 9, (3)) and
wipe with clean cloth.
3. Fully reinsert dipstick.
4. Remove dipstick. The oil level should
be between upper (Figure 9, (4)) and
lower (Figure 9, (5)) lines on the
dipstick.
5. Add oil if necessary. See Adding
Engine Oil on page 33.
6. Fully reinsert dipstick.
Adding Engine Oil
1. NOTICE: Prevent dirt and debris from
contaminating engine oil. Carefully
clean the dipstick and the surrounding
area before you remove the cap.
Remove the yellow oil filler port cap
from filler port (Figure 9, (1)) and fill
with engine oil.
2. Fill with oil to the upper limit
(Figure 9, (4)) on the dipstick
(Figure 9, (3)). NOTICE: NEVER
overfill the engine with engine oil.
JH4 Series Operation Manual 33
BEFORE YOU OPERATE
3. Insert the dipstick fully to check the
level. NOTICE: ALWAYS keep the oil
level between upper and lower lines on
the oil cap / dipstick.
4. Tighten the filler port cap securely by
hand.
MARINE GEAR OR SAIL DRIVE OIL
Marine Gear Oil Specifications
Use marine gear oil that meets or exceeds
the following guidelines and classifications:
KM4A2, KMH4A:
• API Service Categories CD or higher
• SAE Viscosity #20 or #30
ZF30M, ZF25A:
• ATF (Automatic Transmission Fluid)
Sail Drive Oil Specifications SD50
Refer to the operation manual of the sail
drive for the procedure to fill or replace the
sail drive oil.
3JH4E, 4JH4AE:
• SAE Viscosity #90 or 80W90
• QuickSilver® 1 High Performance Gear
Lube.
4JH4-TE:
• Only use QuickSilver® High Performance
Gear Lube.
1
QuickSilver is a registered trademark of Brunswick Corporation.
34 JH4 Series Operation Manual
BEFORE YOU OPERATE
Checking Marine Gear Oil
(1)
(3)
(4)
Figure 10
Note: 4JH4-TE with KMH4A marine gear
shown.
1. Make sure engine is level.
2. Remove the filler cap (Figure 10, (1))
at the top of the housing.
3. Remove dipstick (Figure 10, (2)) and
wipe with clean cloth.
4. Fully reinsert dipstick.
5. Remove dipstick. The oil level should
be between upper (Figure 10, (3)) and
lower (Figure 10, (4)) lines on the
dipstick.
6. Fully reinsert dipstick.
(2)
0004491
Adding Marine Gear Oil
1. Make sure the engine is level.
2. Remove the filler cap at the top of the
housing (Figure 10, (1)).
3. Fill with oil to the upper limit on the
dipstick (Figure 10, (3)). See Marine
Gear Oil Specifications on page 34.
NOTICE: 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.
JH4 Series Operation Manual 35
BEFORE YOU OPERATE
ENGINE COOLANT
Engine Coolant Specifications
• Texaco Long Life Coolant (LLC), both
standard and premixed, product code
7997 and 7998.
• Havoline Extended Life
Antifreeze / Coolant, product code 7994.
Note: In the U.S., LLC is required for the
warranty to be valid.
Coolant (Closed Cooling System)
NOTICE: Always add LLC to soft
water - especially when operating in cold
weather. Without LLC, cooling performance
will decrease due to scale and rust in the
cooling 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 also. Do not
mix different types or brands of LLC or a
harmful sludge may form. Do not use hard
water. Water should be clean and free from
sludge or particles. 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 fresh
water cooling system. See Engine Coolant
Specifications on page 36. Excessive use of
antifreeze also lowers the cooling efficiency
of the engine. Be sure to use the mixing
ratios specified by the antifreeze
manufacturer for the temperature range.
Replace engine coolant periodically,
according to the maintenance schedule in
this Operation Manual. Remove scale from
the cooling system periodically by flushing
the system. Do not mix different brands of
antifreeze. Chemical reactions may make
the antifreeze useless and engine problems
may result.
Checking and Adding Coolant
3JH4E
(4)
(3)
(5)
1 – Coolant Tank (Heat Exchanger)
2 – Seawater Drain Cock
3 – Coolant Drain Cock (located behind
the V-belt cover) - 3JH4E Only
4 – Coolant Pump (Fresh Water)
5 – Seawater Drain from Seawater
Pump Cover
6 – Coolant Drain Cock
(1)
1 – Coolant Drain Cock
2 – Flywheel Housing
3 – Stop Solenoid
(1)
Figure 11
3JH4E
(2)
Figure 12
(6)
(2)
0004556
0004664
36 JH4 Series Operation Manual
0004569
(3)
(4)
(5)
(6)
(1)
(2)
BEFORE YOU OPERATE
4JH4AE
Figure 13
1 – Coolant Pump (Fresh Water)
2 – Seawater Drain from Seawater
Pump Cover
3 – Coolant Tank (Heat Exchanger)
4 – Coolant Drain Cock
5 – Seawater Drain Cock
6 – Flywheel Housing
4JH4AE
4JH4-TE
(1)
(2)
(3)
Figure 15
1 – Coolant Tank (Heat Exchanger)
2 – Coolant Pump (Fresh Water)
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock (2 used)
4JH4-TE
(2)
0004514
(4)
(1)
Figure 14
1 – Coolant Drain Cock
JH4 Series Operation Manual 37
0004558
(3)
Figure 16
1 – Coolant Drain Cock
2 – Seawater Drain Cock
3 – Marine Gear Cooler
(1)
0004559
0004561
(1)
(2)
(3)
BEFORE YOU OPERATE
4JH4-HTE
(1)
(2)
(3)
Figure 17
1 – Coolant Tank (Heat Exchanger)
2 – Coolant Pump (Fresh Water)
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock
5 – Intercooler
6 – Seawater Drain Cock
4JH4-HTE
(4)
(5)
0004560
(6)
2. Loosen the filler cap of the coolant tank
to relieve the pressure then remove the
filler cap.
(1)
(2)
(3)
(4)
0004492
Figure 19
1 – Coolant Filler Cap
2 – Filler Cap Tabs
3 – Filler Port Notches
4 – Coolant Tank
3. Pour coolant slowly into the coolant
tank (Figure 19, (4)) to avoid air
bubbles. Fill until coolant overflows
from the filler port.
4. Align filler cap tabs (Figure 19, (2))
with filler port notches
(Figure 19, (3)) and tighten filler cap
(Figure 19, (1)).
Note: The coolant level rises in the coolant
recovery tank during operation. After
stopping the engine, the coolant will cool
down and the extra coolant will return to the
coolant tank.
Figure 18
1 – Coolant Drain Cock
2 – Seawater Drain Cock
3 – Marine Gear Cooler
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. Ensure all drain cocks are closed.
38 JH4 Series Operation Manual
BEFORE YOU OPERATE
5.
(1)
(2)
FULL
(4)
(3)
LOW
0004493
Figure 20
Check the coolant level in the coolant
recovery tank. The level should be at
the FULL mark (Figure 20, (2)). Add
coolant if necessary. NOTICE: NEVER
pour cold coolant into a hot engine.
6. Remove coolant recovery tank cap
(Figure 20, (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.
Coolant Recovery Tank Capacity
0.8 L (1.7 pt)
8. Check the rubber hose
(Figure 20, (1)) connecting the coolant
recovery tank to the coolant tank / heat
exchanger. Replace if damaged.
Note: If the coolant runs low too often or only
the coolant level in the coolant tank drops
without any change in the level in the coolant
recovery tank, there may be water or air
leaks in the cooling system. See your
authorized Yanmar dealer or distributor.
CRANKING THE ENGINE
When performing engine break-in or if 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 non-use, distribute
engine oil to each part by cranking the
engine. Perform the following procedure
before beginning operation:
1. Open seacock.
2. Open fuel cock.
3. Put remote control shift lever in
NEUTRAL.
4. Turn battery switch to ON (if equipped).
(1)
Note: If the engine has not been operated for
a long period of time, check that the key can
be moved from START to ON positions
smoothly.
5. Turn key to ON (Figure 21, (3)).
6. 3JH4E / 4JH4AE models:
a. While pushing the STOP button on
the control panel, turn the key to
the START position
(Figure 21, (4)). NOTICE:
NEVER hold the key in the START
position for longer than 15
seconds or the starter motor will
overheat.
(2)
(3)
(4)
0003622
Figure 21
JH4 Series Operation Manual 39
BEFORE YOU OPERATE
b. When the key is in the START
position, the engine will begin
cranking. Continue cranking for
about 5 seconds and listen for
abnormal noise during that time.
Note: If the STOP button is released during
the cranking procedure, the engine will start.
Do not start the engine in this mode.
7. 4JH4-TE / 4JH4-HTE models:
(2)
(1)
0004488
Figure 22
a. Move and hold (Figure 22, (1))
the stop lever (Figure 22, (2)) on
the governor to stop fuel flow while
cranking.
Note: 4JH4-TE /4JH4-HTE models: Do
not use the STOP button on the control
panel for cranking procedure.
b. Hold key in START position for
about 5 seconds and listen for
abnormal noise during that time.
Note: If the governor lever is released
during the cranking procedure, the
engine will start.
DAILY CHECKS
Before you start for the day, make sure the
Yanmar engine is in good operating
condition. CAUTION! It is important to
perform 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
1. Check for engine oil leaks.
2. Check for fuel leaks.
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 65. If you have to
drain the fuel filter / water separator
frequently, drain the fuel tank and check
for water in your fuel supply. See
Draining the Fuel Tank on page 67.
CAUTION! If any problem is noted
during the visual check, the necessary
corrective action should be taken before
you operate the engine.
40 JH4 Series Operation Manual
Checking Diesel Fuel, Engine Oil and Engine Coolant Levels
Follow the procedures in Filling the Fuel
Tank on page 30, Checking the Engine Oil
on page 33 and Checking Diesel Fuel,
Engine Oil and Engine Coolant Levels on
page 41 to check these levels.
Checking and Refilling Marine Gear Oil
See Checking Marine Gear Oil on page 35.
Checking the Battery Electrolyte Level
Check the battery electrolyte level before
use. See Checking the Battery Electrolyte
Level (Serviceable Batteries Only) on page
66.
Checking the Alternator Belt
Check the belt tension before use. See
Checking and Adjusting the Alternator VBelt Tension on page 62 .
BEFORE YOU OPERATE
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 63.
Checking the Alarm Indicators
Check the instruments and alarm indicators
at regular intervals.
Preparing Fuel, Oil and Coolant in Reserve
Prepare sufficient fuel for the day’s
operation. Always store engine oil and
coolant in reserve (for at least one refill) on
board, to be ready for emergencies.
JH4 Series Operation Manual 41
BEFORE YOU OPERATE
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42 JH4 Series Operation Manual
ENGINE OPERATION
!
WARNING
Fire and Explosion Hazard
Avoid serious personal injury.
NEVER jump-start the engine.
Sparks caused by shorting the
battery to the starter terminals
may cause a fire or explosion.
ONLY use the key switch 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 rpm. Avoid unexpected
equipment movement. Shift the marine gear
into the NEUTRAL position any time the
engine is at idle.
To prevent accidental equipment
movement, NEVER start the engine in gear.
Sever Hazard
Keep children and pets away
while the engine is operating.
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.
JH4 Series Operation Manual 43
ENGINE OPERATION
NOTICE
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.
If the alarm window with audible alarm fails
to display and go out about 3 seconds later
when the ignition switch is in the ON
position, see your authorized Yanmar
marine dealer or distributor for service
before operating 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.
• 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.
STARTING THE ENGINE
NOTICE: If the vessel is equipped with a
water lift (water lock) muffler, excessive
cranking could cause sea water 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 or until the engine
starts. When the engines does start, stop the
engine immediately and press the switch to
the OFF position.
1. Open the seacock (if equipped).
2. Open the fuel 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.
(1)
4. Turn the battery master switch (if
equipped) to ON.
5. Turn key switch to ON (Figure 1, (3)).
Ensure that the instrument panel
indicators light and the alarm sounds.
This indicates that indicators and alarm
are working correctly.
Note: The coolant high temperature alarm
indicator does not come on during start-up.
(2)
(3)
(4)
0003622
Figure 1
44 JH4 Series Operation Manual
ENGINE OPERATION
6. Turn key switch to START
(Figure 1, (4)). Release the key switch
when the engine has started. NOTICE:
NEVER hold the key in the START
position for longer than 15 seconds or
the starter motor will overheat.
7. The alarm should stop and the
indicators should go out. NOTICE: If
any indicator fails to illuminate when the
key switch is in the ON position, see
your authorized Yanmar marine dealer
or distributor for service before
operating the engine.
Note: When the engine has not been used
for a long period of time, check that the key
can move from the START position to the
ON position smoothly.
Restarting After Starting Failure
Before turning the key 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.
NOTICE: NEVER hold the key in the START
position for longer than 15 seconds or the
starter motor will overheat.
NOTICE: NEVER attempt to restart the
engine if the engine has not stopped
completely. Pinion gear and starter motor
damage will occur.
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 30.
Starting at Low Temperatures
Comply with local environmental
requirements. Use engine heaters to avoid
starting problems and white smoke. Do not
use starting aids. NOTICE: 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.
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 master switch (if
equipped) ON.
5. Turn key switch to GLOW for 15
seconds.
6. Turn key switch to 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.
7. Turn key switch to START. Release the
key switch when the engine has started.
The alarm should stop and the
indicators should go out. NOTICE:
NEVER hold the key in the START
position for longer than 15 seconds or
the starter motor will overheat.
JH4 Series Operation Manual 45
ENGINE OPERATION
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.
2. Check for water, fuel or oil leakage from
the engine.
3. Check that the exhaust 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
pipe. 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. NOTICE: The engine will
seize if it is operated when cooling
seawater discharge is inadequate or if
load is applied without any warm-up
operation.
For troubleshooting assistance, see
Troubleshooting After Starting on page
77 or Troubleshooting Chart on page
79.
If necessary, see your authorized
Yanmar dealer or distributor.
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 / Clutch 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.
Shifting the Engine
NOTICE: 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.
(3)
0004513
1. Before using the marine gear, be sure
to move the throttle handle to a low idle
position (less than 1000 rpm). Move the
throttle handle slowly to a higher speed
position after completing clutch
engagement.
46 JH4 Series Operation Manual
ENGINE OPERATION
2. NOTICE: NEVER shift the marine gear
at high engine speed. During normal
operation, the marine gear should only
be shifted with the engine at idle. When
moving the handle between
FORWARD (Figure 2, (1)) and
REVERSE (Figure 2, (3)), bring the
clutch to NEUTRAL (Figure 2, (2)) and
pause before slowly shifting to the
desired position. Do not shift abruptly
from FORWARD to REVERSE or vice
versa.
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.
NOTICE: When trolling, do not increase
engine speed above 1000 rpm. This may
cause premature wear and damage to the
clutch.
(6)
(8)
(1)
(2)
(3)
(4)
(7)
0004498
Figure 3
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)
(5)
1. Operation continues at low engine
speed of 1000 rpm 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.
JH4 Series Operation Manual 47
ENGINE OPERATION
SHUTTING DOWN THE ENGINE
NOTICE: Avoid engine damage. Do not stop
engine abruptly during operation. Yanmar
recommends that when shutting the engine
down, allow the engine to run, without load,
for 5 minutes. This will allow the engine
components that operate at high
temperatures, such as the exhaust system,
to cool slightly before the engine itself is shut
down.
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 rpm) without load
for 5 minutes.
(1)
6. Turn off the battery master switch (if
equipped).
7. Close the fuel cock.
8. Close the seacock (if equipped).
NOTICE: 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.
Emergency Shutdown
NOTICE: NEVER use the emergency stop
switch for a normal engine shutdown. Use
this switch only when stopping the engine
suddenly in an emergency.
3JH4E / 4JH4AE
(1)
(2)
Figure 5
If the engine cannot be shut down by the
0004487
STOP button on the panel, stop the engine
by pushing the button (Figure 5, (1)) at the
Figure 4
4. With the key in the ON position, push
and hold the stop button
back of the stop solenoid (Figure 5, (2)).
4JH4-TE / 4JH4-HTE
(Figure 4, (1)). After the engine has
stopped, turn the key switch to OFF.
Note: Continue to hold the stop button in
until the engine is completely stopped. If the
button is released before the engine has
completely stopped, it may restart. If the
engine does not shut down, see Emergency
(1)
Shutdown on page 48.
5. Remove the key and cover the key
switch with the moisture cap.
Figure 6
48 JH4 Series Operation Manual
0003624
(2)
0004488
ENGINE OPERATION
If the engine cannot be shut down by the
STOP button 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.
CHECKING THE ENGINE AFTER OPERATION
• Check that the key switch is in the OFF
position and battery master switch (if
equipped) is turned to OFF.
• Fill the fuel tank. See Filling the Fuel
Tank on page 30.
• 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 36.
• If there is a risk of freezing, drain the
seawater system. See Drain Seawater
Cooling System on page 84.
• At temperatures below 0˚C (32˚F), drain
seawater system and connect the engine
heater (if equipped).
JH4 Series Operation Manual 49
ENGINE OPERATION
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50 JH4 Series Operation Manual
PERIODIC MAINTENANCE
!
This section of the Operation Manual
describes the procedures for proper care
and maintenance of the engine.
SAFETY PRECAUTIONS
WARNING
Crush Hazard
If you need to transport an
engine for repair, have a
helper assist you attach it
to a hoist and load it on a
truck.
Avoid personal injury or equipment damage.
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.
Avoid serious personal injury. 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.
JH4 Series Operation Manual 51
!
PERIODIC MAINTENANCE
WARNING
Welding Hazard
Make welding repairs safely.
• 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 multi-pin connector to the
engine control unit. 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 leads to the alternator and engine
control unit prior to reconnecting the
batteries.
Exhaust Hazard
Avoid serious injury or death.
ALWAYS ensure that all
connections are tightened to
specifications after repair is
made to the exhaust system.
All internal combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning.
NOTICE
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.
Shock Hazard
Avoid serious personal
injury or equipment
damage. ALWAYS turn
off the battery switch (if
equipped) or disconnect
the negative battery cable before servicing
the equipment.
Avoid personal injury or equipment damage.
ALWAYS keep the electrical connectors
and terminals clean. Check the electrical
harnesses for cracks, abrasions, and
damaged or corroded connectors.
52 JH4 Series Operation Manual
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
WARNING! 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.
Perform periodic maintenance procedures
in an open, level area free from traffic. If
possible, perform the procedures indoors to
prevent environmental conditions such as
rain, wind, or snow from damaging the
engine.
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.
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.
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.
The Importance of Daily Checks
The Periodic Maintenance Schedule
assume that the daily checks are performed
on a regular basis. Make it a habit of
performing daily checks before the start of
each operating day. See Daily Checks on
page 40.
JH4 Series Operation Manual 53
PERIODIC MAINTENANCE
Tightening Fasteners
Use the correct amount of torque when you
tighten fasteners on the machine. Applying
excessive torque may damage the fastener
or component and not enough torque may
cause a leak or component failure.
Bolt diameter x pitch
(mm)
N·m 11.0 ± 1.0 26.0 ± 3.0 50.0 ± 5.0 90.0 ± 10.0 140.0 ± 10.0 230.0 ± 10.0
Tightening
Torque
kgf-m 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0
lb-ft — 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2
lb-in. 96 ± 9.0 — — — — —
M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 1.5 M16 x 1.5
NOTICE: The 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.
54 JH4 Series Operation Manual
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
57 and the Periodic Maintenance
Procedures on page 61.
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 55.
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 adapted 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.
Conditions to Ensure Compliance with EPA Emission Standards
The 3JH4E, 4JH4AE, 4JH-TE and
4JH4-HTE 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.
• Ambient temperature: -20˚ to +40˚C
(-4˚ to +104˚F)
• Relative humidity: 80% or lower
• 3JH4E and 4JH4AE: Permissible value
for intake negative pressure: 4.0 kPa (400
mmAq) or lower
• 4JH4-TE and 4JH4-HTE: Permissible
value for intake negative pressure: 2.0
kPa (200 mmAq) or lower
• 3JH4E and 4JH4AE: Permissible value
for exhaust back pressure: 15.0 kPa
(1500 mmAq) or lower
• 4JH4-TE and 4JH4-HTE: Permissible
value for exhaust back pressure: 20.0 kPa
(2000 mmAq) 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:
• 3JH4E, 4JH4-TE and 4JH4-HTE: Type
API, Class CD or higher
• 4JH4AE: Type API, Class CH-4 only
Be sure to perform inspections as outlined
in Periodic Maintenance Procedures on
page 61 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.
The operating conditions should be as
follows:
JH4 Series Operation Manual 55
PERIODIC MAINTENANCE
Inspection and Maintenance
See Inspection and Maintenance of EPA
Emission-Related Parts on page 60 for the
EPA emission-related parts. Inspection and
maintenance procedures not shown in the
Inspection and Maintenance of EPA
Emission-Related Parts section are covered
in Periodic Maintenance Schedule on page
57.
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.
56 JH4 Series Operation Manual
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. CAUTION!
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at 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 ●.
PERIODIC MAINTENANCE
JH4 Series Operation Manual 57
PERIODIC MAINTENANCE
○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor
System Item Periodic Maintenance Interval
Whole Visual inspection of engine
Fuel
System
Lubricating
System
Cooling
System
exterior
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
*
pattern
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 two
Clean and check the
seawater passages
Engine ○
Marine
Gear
Engine ◊
Marine
Gear
Engine ◊
Marine
Gear
(if
equipped)
Daily Every 50
hours or
monthly
which-
ever
comes
first
○
○
○
Initial 50
○
◊
●
●
○
Initial 50
◊
Initial 50
Initial 50
◊
Initial 50
During
Oper-
ation
○ ◊
years. See Engine Coolant Specifications on page 36.
●
Every
250
hours or
one year
which-
ever
comes
first
○
◊
◊
◊
◊
Every
500
hours or
2 years
which-
ever
comes
first
Every
1000
hours or
4 years
which-
ever
comes
first
*
58 JH4 Series Operation Manual
PERIODIC MAINTENANCE
○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor
System Item Periodic Maintenance Interval
Air Intake
and
Exhaust
System
Electrical
System
Engine
Cylinder
Head and
Block
Miscellaneous Items
Daily Every 50
Clean intake silencer (air
cleaner) element
Clean or replace the
exhaust / water mixing
elbow
Clean the turbocharger* 4JH4-TE or 4JH4-HTE only
Check diaphragm assembly
3JH4E / 4JH4AE 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
coolant
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)
○
○
After
starting
○ ○
Replace every 2 years or every 2000 hours, whichever comes
hours or
monthly
which-
ever
comes
first
○
○ ◊
●
●
○
○
Initial 50
●
●
Initial 50
Initial 50
●
Initial 50
Every
250
hours or
one year
which-
ever
comes
first
○ ◊
●
●
●
first.
Every
500
hours or
2 years
which-
ever
comes
first
hours or
Every
1000
4 years
which-
ever
comes
first
*
For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 60.
Note: These procedures are considered normal maintenance and are performed at the
owner’s expense.
JH4 Series Operation Manual 59
PERIODIC MAINTENANCE
Inspection and Maintenance of EPA Emission-Related Parts
• Marine diesel engines less than 37 kW: 3JH4E is certified as EPA non-road engine
• Marine diesel engines greater than 37 kW: 4JH4AE, 4JH4-TE and 4JH4-HTE 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 to be performed at your Yanmar
dealer or distributor.
60 JH4 Series Operation Manual
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE PROCEDURES
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)
• Adjusting the Alternator V-Belt
Tension
• Adjusting Intake / Exhaust Valve
Clearance
• Checking and Adjusting the Remote
Control Cable
• Adjusting Propeller Shaft Alignment
Draining the Fuel Tank
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 effective to drain the
engine oil after operation while the engine is
still warm. WARNING! 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.
1. Turn the engine OFF.
2. NOTICE: Prevent dirt and debris from
contaminating engine oil. Carefully
clean the dipstick and the surrounding
area before you remove the dipstick.
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.
3. Turn the engine oil filter (Figure 2)
counterclockwise with a wrench.
4. Remove the engine oil filter.
(4)
(3)
(1)
Figure 1
Note: Optional fuel tank shown. Actual
equipment may differ.
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.
JH4 Series Operation Manual 61
(2)
0004542
0004508
Figure 2
Note: 4JH4-TE shown.
5. Install a new filter element and tighten
by hand until the seal touches the
housing.
PERIODIC MAINTENANCE
6. Turn filter an additional 3/4 turn with a
box wrench. Tighten to 20 - 24 N·m
(177 - 212 in.-lb).
7. Fill with new engine oil. See Adding
Engine Oil on page 33. NOTICE:
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.
8. Perform a trial run and check for oil
leaks.
9. Approximately 10 minutes after
stopping the engine, remove the oil
dipstick and check the oil level. Add oil
if the level is too low.
Replace the Marine Gear Oil Filter (If Equipped) and Change the Marine Gear Oil
(1)
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 (Figure 3, (5))
and tighten side cover bolts.
3. Fill marine gear with clean marine gear
oil. See Marine Gear Oil
Specifications on page 34.
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
NOTICE: NEVER get any oil on the belt(s).
Oil on the belt causes slipping and
stretching. Replace the belt if it is damaged.
(1)
(2)
(5)
(3)
(4)
0004495
Figure 3
Note: 4JH4-TE / 4JH4-HTE engines with
KMH4A marine gear shown. Refer to the
operation manual of marine gear or sail drive
for procedure.
1. Remove cap from the filler port and
attach an oil drain pump. Drain marine
gear oil.
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.
0004509
Figure 4
Note: 4JH4-TE shown.
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 - 10 mm (approximately
3/8 in.).
3. Loosen the alternator bolt and move the
alternator to adjust the V-belt tension.
62 JH4 Series Operation Manual
PERIODIC MAINTENANCE
4. Install the belt cover.
Note: If replacing the V-belt, loosen the
V-pulley of the coolant pump to remove Vbelt.
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.
Checking and Adjusting Remote Control Cables
Note: 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.
3JH4E / 4JH4AE
(1)
(6)
(5)
(3)
Figure 5
1 – Cable
2 – Fuel Injection Pump
3 – Adjustment Screw
4 – Low Speed Stop
5 – Control Lever
6 – High Speed Stop
4JH4-TE / 4JH4-HTE
(6)
(5)
(4)
6
(2)
(4)
0003625
(3)
(1)
(2)
0004496
Figure 6
1 – Cable
2 – Fuel Injection Pump
3 – Cable Fitting
4 – Low Speed Stop
5 – Control Lever
6 – High Speed Stop
1. To adjust, loosen the adjustment screw
or cable fitting (Figure 5, (3)) or
(Figure 6, (3)) for the remote control
cable on the engine side and adjust.
JH4 Series Operation Manual 63
0004562
(1)
(3)
(2)
0004563
(1)
(2)
(3)
PERIODIC MAINTENANCE
2. Adjust the high speed stop
(Figure 5, (6)) or (Figure 6, (6)),
position first and then adjust the low
speed stop (Figure 5, (4)) or
(Figure 6, (4)), with the adjustment
screw on the remote control lever
(Figure 5, (5)) or (Figure 6, (5)).
Adjusting Clutch Remote Control Cable
3JH4E / 4JH4AE
Figure 7
4JH4-TE / 4JH4-HTE
Adjusting Trolling Remote Control Handle - If Equipped
(6)
(8)
(7)
(1)
(2)
(3)
(4)
0004498
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)
(5)
Note: KMH4A marine gear shown.
1. Ensure that the trolling lever
(Figure 9, (2)) is in the high speed
(Figure 9, (4)) position when the
Figure 8
1. Ensure that the remote control lever
(Figure 7, (2)) (Figure 8, (2)) moves
to the correct position when the remote
control handle is in NEUTRAL,
FORWARD, and REVERSE positions.
Use the NEUTRAL position as the
standard for adjustment.
2. To adjust, loosen and retighten 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.
cable fitting (Figure 7, (1))
(Figure 8, (1)).
64 JH4 Series Operation Manual
PERIODIC MAINTENANCE
Adjusting Propeller Shaft Alignment
The flexible engine mounts are compressed
a little 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.
Every 50 Hours of Operation
After you complete the initial 50 hour
maintenance procedures, perform the
following procedures every 50 hours
thereafter or monthly, whichever comes
first.
• Draining Fuel Filter / Water Separator
• Checking Battery Electrolyte Level
Draining Fuel Filter / Water Separator
3JH4E and 4JH4AE (Attach to Hull)
(2)
(1)
Figure 10
1. Close the fuel cock of the fuel tank.
2. Loosen the drain plug (Figure 10, (1))
of water separator and drain off any
water or dirt collected inside.
3. After draining, tighten the air bleed
screw (Figure 10, (2)).
JH4 Series Operation Manual 65
0004564
0004565
(1)
(5)
(6)
(3)
(4)
PERIODIC MAINTENANCE
4. Be sure to bleed air from the fuel
system. See Bleeding the Fuel
System on page 30.
4JH4-TE and 4JH4-HTE
(2)
Figure 11
Note: 4JH4-TE shown. If no water or fuel
drains from the fuel filter / water separator,
loosen the air bleed screw on the fuel filter
2 - 3 times. This can occur when the fuel
level is lower than the position of the
fuel / water separator.
1. Make sure the fuel cock of the fuel tank
is closed.
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)).
4. Loosen the drain plug (Figure 11, (4))
at the bottom of the fuel filter / water
separator 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 61.
5. Tighten the drain plug.
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 30.
Checking the Battery Electrolyte Level (Serviceable Batteries Only)
WARNING! 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.
NOTICE: NEVER turn off the battery switch
(if equipped) or short the battery cables
during operation. Damage to the electric
system will result.
Note: Battery fluid tends to evaporate in high
temperatures, especially in summer. In such
conditions, inspect the battery earlier than
specified.
1. Turn the battery master switch to OFF
(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. NOTICE:
NEVER attempt to remove the covers
or fill a maintenance-free battery.
66 JH4 Series Operation Manual
PERIODIC MAINTENANCE
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.
(2)
UPPER LEVEL
LOWER LEVEL
(3)
(1)
0004566
Figure 12
Note: The maximum fill level is
approximately 10 - 15 mm
(3/8 - 9/16 in.) above the plates.
Every 250 Hours of Operation
Perform the following maintenance every
250 hours or one 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
• Changing the Coolant
• Cleaning Intake Silencer (Air Cleaner)
Element
• Cleaning the Exhaust / Water Mixing
Elbow
• Cleaning the Turbocharger (If
Equipped)
• Adjusting the Tension of the
Alternator V-Belt
• Checking the Wiring Connectors
• Tightening All Major Nuts and Bolts
Draining the Fuel Tank
See Draining the Fuel Tank on page 61.
Replacing the Fuel Filter Element
3JH4E / 4JH4AE
(1)
0003627
Figure 13
1. Close the fuel cock of the fuel tank.
JH4 Series Operation Manual 67
PERIODIC MAINTENANCE
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.
3. Apply a thin film of clean diesel fuel to
the sealing surface of the new filter
gasket.
Component Part No.
Fuel Filter - 3JH4E 129470-55703
Fuel Filter - 4JH4AE 119802–55801
4. Install new filter and tighten hand-tight.
Use a filter wrench and tighten to 20 24 N·m (14.75 - 17.7 ft-lb).
5. Install filter and tighten hand-tight.
6. Bleed the fuel system. See Bleeding
the Fuel System on page 30. Dispose
of waste properly.
4JH4-TE / 4JH4-HTE
(1)
(4)
(2)
(3)
0004500
Figure 14
1. Close the fuel cock of the fuel tank.
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.
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-HTE
129574-55711
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
tighten hand-tight until the gasket
comes into contact with the seat. Use a
filter wrench and tighten approximately
3/4 turn to 11.8 - 15.6 N·m
(104.4 - 138.1 in.-lb).
68 JH4 Series Operation Manual
PERIODIC MAINTENANCE
10. Install the fire-resistant cover and
tighten the hose clamp.
11. Bleed the fuel system. See Bleeding
the Fuel System on page 30.
12. Dispose of waste properly.
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 61.
Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter Element (If Equipped)
See Replace the Marine Gear Oil Filter (If
Equipped) and Change the Marine Gear
Oil on page 62.
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 replace
periodically (every 1000 hours) even if there
is no damage.
(1)
0004510
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
M18 x 1.5 M10 x 40 mm length
1. Remove the side cover of the seawater
pump.
2. Install puller (Figure 16, (A)) in the
impeller.
JH4 Series Operation Manual 69
PERIODIC MAINTENANCE
3. Turn the jack screw (Figure 16, (B))
clockwise to remove the impeller from
the pump body.
(1)
A
B
0004567
Figure 17
Puller B (Option) Part No. 129671-92100
(B)
(A)
0004502
Figure 19
A B
110 mm 140 mm
Replacing Coolant
Replace coolant every year.
Note: If Long Life coolant is used, replace
coolant every 2 years.
3JH4E
(4)
(1)
(6)
(3)
(5)
0004568
Figure 18
Note: When replacing a used impeller with
a new one, the impeller must have an M18 x
1.5 thread (Figure 17, (1)). Turn the M18
screw-side of the impeller to the cover side
and install (Figure 18).
1 – Coolant Tank (Heat Exchanger)
2 – Seawater Drain Cock
3 – Coolant Drain Cock (3JH4E Only) -
Located behind the V-belt cover
4 – Coolant Pump (Fresh Water)
5 – Seawater Drain from Seawater
Figure 20
Pump Cover
6 – Coolant Drain Cock
70 JH4 Series Operation Manual
(2)
0004556
0004569
(3)
(4)
(5)
(6)
(1)
(2)
PERIODIC MAINTENANCE
3JH4E
(3)
(1)
(2)
Figure 21
1 – Stop Solenoid
2 – Coolant Drain Cock
3 – Flywheel Housing
4JH4AE
0004557
4JH4AE
Figure 23
1 – Coolant Drain Cock
2 – Stop Solenoid
4JH4-TE
(1)
(2)
(1)
(2)
0004570
(4)
Figure 22
1 – Coolant Pump (Fresh Water)
2 – Seawater Pump
3 – Coolant Tank (Heat Exchanger)
4 – Coolant Drain Cock
5 – Seawater Drain from Seawater
Pump Cover
6 – Flywheel Housing
JH4 Series Operation Manual 71
(3)
0004571
Figure 24
1 – Coolant Tank (Heat Exchanger)
2 – Coolant Pump (Fresh Water)
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock (2 used)
PERIODIC MAINTENANCE
4JH4-TE
(3)
(4)
(1)
0004572
Figure 25
1 – Coolant Drain Cock
2 – Fuel Pump
3 – Seawater Drain Cock
4 – Marine Gear Cooler
4JH4-HTE
(1)
(4)
(2)
(5)
(3)
0004560
Figure 26
1 – Coolant Tank (Heat Exchanger)
2 – Coolant Pump (Fresh Water)
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock
5 – Intercooler
6 – Seawater Drain from Seawater
Pump Cover
(6)
(2)
4JH4-HTE
(3)
(2)
(4)
(1)
0004573
Figure 27
1 – Coolant Drain Cock
2 – Fuel Pump
3 – Seawater Drain Cock
4 – Marine Gear Cooler
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 coolant recovery
tank with appropriate coolant. See
Engine Coolant Specifications on page
36 and See Checking and Adding
Coolant on page 36.
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.
3. Dry completely and reassemble.
72 JH4 Series Operation Manual
PERIODIC MAINTENANCE
Cleaning 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.
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.
Every 500 Hours of Operation
Perform the following maintenance every
500 hours or 2 years of operation, whichever
comes first.
• Replacing Exhaust / Water Mixing
Elbow
• Replacing Rubber Hoses
Replacing 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.
Adjusting the Alternator V-Belt Tension
See Checking and Adjusting the Alternator
V-Belt Tension on page 62.
Checking the Wiring Connectors
See your authorized Yanmar marine dealer
or distributor.
Tightening All Major Nuts and Bolts
See Tightening Fasteners on page 54 or see
your authorized Yanmar marine dealer or
distributor.
JH4 Series Operation Manual 73
PERIODIC MAINTENANCE
Every 1000 Hours of Operation
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
(3JH4E / 4JH4AE 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.
Clean and Check 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.
Check Diaphragm Assembly (3JH4E / 4JH4AE only)
NOTICE: If the diaphragm is damaged,
crankcase pressure control is affected.
Excessive crankcase pressure will cause
leaks at seals and mating part surfaces.
(2)
(3)
(4)
(1)
(5)
Checking the Fuel Injector Spray Pattern
(8)
(9)
(7)
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 69.
74 JH4 Series Operation Manual
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.
Figure 28
(6)
0003628
Replacing the Alternator V-Belt
See Checking and Adjusting the Alternator
V-Belt Tension on page 62.
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.
PERIODIC MAINTENANCE
JH4 Series Operation Manual 75
PERIODIC MAINTENANCE
This Page Intentionally Left Blank
76 JH4 Series Operation Manual
TROUBLESHOOTING
If a problem occurs, stop the engine
immediately. Refer to the SYMPTOM
column in the Troubleshooting Chart to
identify the problem.
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 exhaust color normal?
• The continuous emission of black exhaust
smoke indicates engine overloading. This
shortens the engine's 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.
Alarm sounds during operation.
• If the alarm sounds during operation,
lower the engine speed immediately,
check the warning lamps and stop the
engine for repairs.
Is there water, oil or fuel leakage? Are
there any loose bolts or connections?
JH4 Series Operation Manual 77
TROUBLESHOOTING
• 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 30.
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. NOTICE: Neglecting
the race the engine will result in poor
exhaust 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.
78 JH4 Series Operation Manual
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
Indicators Do Not Go On:
• When key is turned
ON
• When any trouble
occurs (oil pressure
etc.)
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.
Engine oil filter clogged. Replace engine oil filter.
Rubber sail drive seal broken. See your authorized
Coolant / fresh water in coolant
tank is low.
Insufficient seawater causing
temperature to rise.
Contamination inside cooling
system.
result if abnormalities are not identified due to faulty indicators or alarm.
No electrical current available.
Circuit broken or lamp burned
out.
Add or replace.
Replace engine oil.
Yanmar marine dealer or
distributor.
Check coolant level and
refill.
Check seawater system. -
See your authorized
Yanmar marine dealer or
distributor.
See your authorized
Yanmar marine dealer or
distributor.
See Checking
the Engine Oil on
page 33
See Changing
the Engine Oil
and Replacing
the Engine Oil
Filter Element on
page 61
-
See Checking
and Adding
Coolant on page
36
-
-
• One of the indicators
does not go out
Sensor switch is faulty. See your authorized
Yanmar marine dealer or
distributor.
JH4 Series Operation Manual 79
-
TROUBLESHOOTING
Symptom Probable Cause Measure Reference
• Battery low charge
indicator does not go
out during operation
Starting Failures:
• Starter turns but
engine does not start
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
V-belt is loose or broken. Replace V-belt or adjust
Battery is defective. Check battery fluid level,
Alternator power generation
failure.
No fuel. Add fuel. Bleed fuel
Fuel filter is clogged. Replace filter element. See Replacing
Improper fuel. Replace with
Problem with fuel injection. See your authorized
See your authorized Yanmar
marine dealer or distributor.
Faulty clutch position. Shift to NEUTRAL and
Insufficient battery charge. Check fluid level.
Cable terminal contact failure. Remove corrosion from
Faulty safety switch device. See your authorized
Faulty starter switch. See your authorized
See your authorized Yanmar
marine dealer or distributor.
Internal parts seized. See your authorized
tension.
specific gravity or
replace battery.
See your authorized
Yanmar marine dealer or
distributor.
system.
recommended fuel.
Yanmar marine dealer or
distributor.
-
start.
Recharge. Replace.
terminals. Tighten
battery cables.
Yanmar marine dealer or
distributor.
Yanmar marine dealer or
distributor.
-
Yanmar marine dealer or
distributor.
See Checking
and Adjusting the
Alternator V-Belt
Tension on page
62
See Checking
the Battery
Electrolyte Level
(Serviceable
Batteries Only)
on page 66
-
See Filling the
Fuel Tank on
page 30 and See
Bleeding the
Fuel System on
page 30
the Fuel Filter
Element on page
67
See Diesel Fuel
Specifications on
page 27
-
-
See Checking
the Battery
Electrolyte Level
(Serviceable
Batteries Only)
on page 66
-
-
-
-
80 JH4 Series Operation Manual
TROUBLESHOOTING
Symptom Probable Cause Measure Reference
Abnormal Exhaust Color:
• Black smoke Load increased. See your authorized
• Improper propeller matching. See your authorized
• Dirty intake silencer (air
cleaner).
• Improper fuel. Replace with
• Faulty spraying of fuel injector. See your authorized
• Incorrect
intake / exhaust valve
clearance.
See your authorized Yanmar
marine dealer or distributor.
Yanmar marine dealer or
distributor.
Yanmar marine dealer or
distributor.
Clean element. See Cleaning the
recommended fuel.
Yanmar marine dealer or
distributor.
-
-
-
Intake Silencer
(Air Cleaner)
Element on page
72
See Diesel Fuel
Specifications on
page 27
-
• White smoke Improper fuel. Replace with
• Faulty spraying of fuel injector. See your authorized
• Fuel injection timing off. See your authorized
• Engine burning oil (excessive
consumption).
recommended fuel.
Yanmar marine dealer or
distributor.
Yanmar marine dealer or
distributor.
See your authorized
Yanmar marine dealer or
distributor.
See Diesel Fuel
Specifications on
page 27
-
-
-
JH4 Series Operation Manual 81
TROUBLESHOOTING
TROUBLESHOOTING INFORMATION
If the engine does not operate properly, refer
to the Troubleshooting Chart on page 79 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:
• Engine rpm
• 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
82 JH4 Series Operation Manual
LONG-TERM STORAGE
If the engine will not be used for an extended
period of time, special measures should be
taken to protect the cooling system, fuel
system and combustion chamber from
corrosion and the exterior from rusting.
The engine can normally stand idle for up to
6 months. If it remains unused for longer
than this, please contact your authorized
Yanmar marine dealer or distributor.
PREPARE ENGINE FOR LONG-TERM STORAGE
NOTICE: Do not drain closed cooling
system for long-term storage. Antifreeze
must be used to avoid freezing and
damaging of components. Antifreeze will
prevent rusting during long-term storage.
Note: If the engine is close to a periodic
maintenance interval, perform those
maintenance procedures before putting the
engine into long-term storage.
1. Wipe off any dust or oil from the outside
of engine.
2. Drain water from fuel filters.
3. Drain fuel tank completely or fill the tank
to prevent condensation.
4. Grease the exposed areas and joints of
the remote control cables and the
bearings of the remote control handle.
5. Seal the intake silencer, exhaust pipe,
etc. to prevent moisture or
contamination from entering engine.
6. Completely drain bilge in hull bottom.
7. Waterproof the engine room to prevent
rain or seawater from entering.
8. Charge the battery once a month to
compensate for battery’s selfdischarge.
9. Remove key from key switch and cover
the key switch with moisture cap.
JH4 Series Operation Manual 83
LONG-TERM STORAGE
DRAIN SEAWATER COOLING SYSTEM
3JH4E
(4)
(3)
(5)
1 – Coolant Tank (Heat Exchanger)
2 – Seawater Drain Cock
3 – Coolant Drain Cock (3JH4E only)
4 – Coolant Pump (Fresh Water)
5 – Seawater Drain from Seawater
Pump Cover
6 – Coolant Drain Cock
(1)
(6)
(2)
0004556
Figure 1
3JH4E
(3)
(1)
(2)
Figure 2
1 – Coolant Drain Cock
2 – Flywheel Housing
3 – Stop Solenoid
0004557
84 JH4 Series Operation Manual
0004569
(3)
(4)
(5)
(6)
(1)
(2)
LONG-TERM STORAGE
4JH4AE
Figure 3
1 – Coolant Pump (Fresh Water)
2 – Seawater Pump
3 – Coolant Tank (Heat Exchanger)
4 – Coolant Drain Cock
5 – Seawater Drain from Seawater
Pump Cover
6 – Flywheel Housing
4JH4AE
4JH4-TE
(1)
(2)
(3)
0004571
Figure 5
1 – Coolant Tank (Heat Exchanger)
2 – Coolant Pump (Fresh Water)
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock (2 used)
4JH4-TE
(4)
Figure 4
1 – Coolant Drain Cock
2 – Stop Solenoid
JH4 Series Operation Manual 85
(1)
(2)
0004570
(2)
(3)
Figure 6
1 – Coolant Drain Cock
2 – Seawater Drain Cock
3 – Marine Gear Cooler
(1)
0004559
0004561
(1)
(2)
(3)
LONG-TERM STORAGE
4JH4-HTE
(1)
(4)
(2)
(5)
(3)
0004560
Figure 7
1 – Coolant Tank (Heat Exchanger)
2 – Coolant Pump (Fresh Water)
3 – Seawater Drain from Seawater
Pump Cover
4 – Coolant Drain Cock
5 – Intercooler
6 – Seawater Drain from Heat
Exchanger
4JH4-HTE
(6)
Note: The drain cocks are opened before
shipping from the factory. Marine gear
ZF25A does not have a drain cock on the
clutch cooler.
NOTICE: If seawater is left inside, it may
freeze and damage parts of the cooling
system (fresh water cooler, seawater pump,
etc.) when ambient temperature is below
32°F (0°C).
1. Open the seawater drain cock on the
clutch cooler (if equipped). Allow to
drain. Open the seawater drain cock on
the intercooler (4JH4-HTE only) and
drain.
If no water drains, use a stiff brush to
remove any debris.
2. Remove four bolts attaching the side
cover of the seawater pump. Remove
the cover and drain the seawater.
3. Install cover and tighten bolts.
4. Close all the drain cocks.
Figure 8
1 – Coolant Drain Cock
2 – Seawater Drain Cock
3 – Marine Gear Cooler
86 JH4 Series Operation Manual
SPECIFICATIONS
PRINCIPAL ENGINE SPECIFICATIONS
3JH4E Engine Specifications
Specification 3JH4E
Marine Gear Model KM35P KM35A SD40/SD50 Bobtail
Use Pleasure use
Type Vertical water cooled 4-cycle diesel engine
Combustion system Direct injection
Air charging Natural aspiration
Number of cylinders 3
Bore x stroke 88 mm x 90 mm (3.46 in. x 3.54 in.)
Displacement 1.642 L (100.20 cu in.)
Continuous
power
Fuel stop
power
Installation Flexible mounting
Fuel injection timing FIC 13 ± 1˚ BTDC (FID 12 ± 1 ˚ BTDC)
Fuel injection opening pressure 21.6 ± 0.5 MPa
Main power take off At flywheel end
Direction of
rotation
Cooling system Fresh water cooling with heat exchanger
Lubrication system Complete enclosed forced lubrication system
Cooling water capacity (fresh) Engine 4.5 L (4.8 qt), Coolant recovery tank: 0.8 L (0.8 qt)
Output at
crankshaft / Engine
speed
Output at
crankshaft / Engine
speed
Output at
propeller / Engine
speed
Crankshaft Counterclockwise viewed from stern
Propeller shaft
(Ahead)
28.0 kW (38.1 hp metric)/3000
27.4 kW (37.3 hp metric)/3000
Clockwise viewed from stern - -
26.7 kW (36.3 hp metric)/2907 rpm
29.4 kW (40.0 hp metric)/3000 rpm
28.7 kW (39.0 hp metric)/3000 rpm
- -
rpm*
rpm**
*
*
**
JH4 Series Operation Manual 87
SPECIFICATIONS
Specification 3JH4E
Marine Gear Model KM35P KM35A SD40/SD50 Bobtail
Lubricating oil
capacity
(engine)
Starting
system
Engine
dimension
Flywheel major dimension D300 x 66 mm (11.8 x 2.6 in.)
Engine dry mass (include marine
gear)
*
Rating Condition: Temperature of fuel; 25˚C at fuel pump inlet; ISO 3046-1
**
Rating Condition: Temperature of fuel; 40˚C at fuel pump inlet; ISO 8665
***
The “total” oil quantity includes oil in oil pan, channels, coolers and filter.
****
The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
Note: Density of fuel: 0.842g/cm3 at 15˚C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
Rake angle at rake angle 8˚ at rake angle 0˚ -
***
Total
Oil pan only 4.5 ± 0.3 L (4.8 ±
5.0 ± 0.3 L
(5.3 ± 0.3 qt)
5.5 ± 0.3 L
(5.8 ± 0.3 qt)
5.0 ± 0.3 L (5.3 ± 0.3 qt)
0.3 qt)
Effective
****
1.1 L (1.2 qt) 1.2 L (1.3 qt)
Type Electric
Starting motor DC 12 V - 1.4 kW
AC generator 12 V - 80 A (12 V - 60 A optional)
Overall length 777 mm
(30.6 in.)
776 mm (30.6 in.) 700 mm
(27.6 in.)
Overall width 539 mm (21.2 in.)
Overall height 623 mm (24.5 in.)
185 kg
(408 lb)
186 kg
(410 lb)
213 kg engine:
173 kg (470 lb)
173 kg
(467 lb)
(engine: 381 lb)
88 JH4 Series Operation Manual
SPECIFICATIONS
3JH4E Marine Gear Specifications
Model KM35P KM35A SD40/SD50 (coupled at boat
builder)
Type Mechanical cone clutch
Reduction ratio (Forward /
Reverse)
Propeller speed (Forward /
Reverse)
*
Lubrication system Splash - Oil bath
Lubricating oil capacity (Total) 0.5 L (0.5 qt) 0.65 L (0.69 qt) SD40 (Old type): 1.8 L (1.9 qt)
Lubricating oil capacity (Effective) 0.05 L (0.05 qt) 0.15 L (0.16 qt) -
Cooling system Air cooling by fan on flywheel -
Weight 12 kg (26.5 lb) 13 kg (28.7 lb) 39 kg
*
At continuous power engine speed 2907 rpm
2.33/3.16 2.33/3.06 2.32
1231/1114
rpm
1246/1103
rpm
1253 rpm
SD50: 2.2 L (2.3 qt)
Long Reach (58): 2.35 L (2.48 qt)
Long Reach (100): 2.45 L (2.59
qt)
(86.0 lb)
JH4 Series Operation Manual 89
SPECIFICATIONS
4JH4AE Engine Specifications
Engine Model 4JH4AE
Marine Gear Model KM35P ZF30M KM35A2 KM4A1
Use Pleasure use
Type Vertical water cooled 4-cycle diesel engine
Combustion system Direct injection
Air charging Natural aspiration
Number of cylinders 4
Bore x stroke 88 mm x 90 mm (3.46 in. x 3.54 in.)
Displacement 2.190 L (133.64 cu in.)
Continuous
power
Fuel stop
power
Output at
crankshaft / Engine speed
Output at
crankshaft / Engine speed
Output at propeller / Engine
speed
36.0 kW (48.9 hp metric)/2907 rpm
39.6 kW (53.8 hp metric)/3000 rpm
38.0 kW (51.7 hp metric) /
3000 rpm
*
- -
Installation Flexible mounting
Fuel injection timing FIR 5 ± 1° BTDC (at Fuel Stop Power)
FIT 18 ± 1° BTDC (at Plunger Lift 2.5)
Fuel injection opening pressure 19.6 - 20.6 MPa
Main power take off At flywheel end
Direction of
rotation
Crankshaft Counterclockwise viewed from stern
Propeller shaft (ahead) Clockwise viewed from stern
Cooling system Fresh water cooling with heat exchanger
Lubrication system Complete enclosed forced lubrication system
Cooling water capacity (fresh) Engine 6.0 L (6.3 qt)
Coolant recovery tank: 0.8 L (0.8 qt)
Lubricating oil
capacity
(engine)
Rake angle at rake angle 8˚ at rake angle 0˚
***
Total
5.0 ± 0.3 L (5.3 ± 0.3 qt) 5.5 ± 0.3 L (5.8 ± 0.3 qt)
Oil pan only 4.5 ± 0.3 L (4.8 ± 0.3 qt) 5.0 ± 0.3 L (5.3 ± 0.3 qt)
****
1.2 L (1.3 qt) 1.4 L (1.5 qt)
Starting
system
Effective
Type Electric
Starting motor DC 12 V - 1.4 kW
AC generator 12 V - 80 A
Engine
dimension
Overall length 871 mm
(34.3 in.)
950 mm
(37.4 in.)
864 mm
(34.0 in.)
Overall width 560 mm (22.0 in.)
Overall height 625 mm (24.6 in.)
Flywheel major dimension D300 x 66 mm (11.8 x 2.6 in.)
Engine dry mass (include marine gear) 213 kg
(470 lb)
229 kg
(505 lb)
214 kg
(472 lb)
*
***
922 mm
(36.3 in.)
230 kg
(507 lb)
*
Rating Condition: Temperature of fuel; 25˚C at fuel pump inlet; ISO 3046-1
90 JH4 Series Operation Manual
SPECIFICATIONS
**
Rating Condition: Temperature of fuel; 40˚C at fuel pump inlet; ISO 8665
***
The “total” oil quantity includes oil in oil pan, channels, coolers and filter.
****
The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
Note: Density of fuel: 0.842g/cm3 at 15˚C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
JH4 Series Operation Manual 91
SPECIFICATIONS
4JH4AE Specifications (Continued)
Engine Model 4JH4AE
Marine Gear Model SD50 Bobtail
Use Pleasure use
Type Vertical water cooled 4-cycle diesel engine
Combustion system Direct injection
Air charging Natural aspiration
Number of cylinders 4
Bore x stroke 88 x 90 mm (3.46 x 3.54 in.)
Displacement 2.190 L
133.6 cu in.
Continuous power Output at crankshaft / Engine
36.0 kW (48.9 hp)/2907 rpm
speed
Fuel stop power Output at crankshaft / Engine
39.6 kW (53.8hp)/3000 rpm
speed
Output at propeller / Engine
-
speed
Installation Flexible mounting
Fuel injection timing FIR 5 ± 1° BTDC (at Fuel Stop Power)
FIT 18 ± 1° BTDC (at Plunger Lift 2.5)
Fuel injection opening pressure 19.6 - 20.6 MPa
Main power take off At flywheel end
Direction of rotation Crankshaft Counterclockwise viewed from stern
Propeller shaft (Ahead) Clockwise viewed from stern
Cooling system Fresh water cooling with heat exchanger
Lubrication system Closed forced lubrication system
Cooling water capacity (fresh) Engine 6.0 L (6.3 qt)
Coolant recovery tank: 0.8 L (0.8 qt)
Lubricating oil capacity
(engine)
Rake angle at rake angle 0˚
***
Total
5.5 ± 0.3 L (5.8 ± 0.3 qt)
Oil pan only 5.0 ± 0.3 L (5.3 ± 0.3 qt)
Effective
****
1.4 L (1.5 qt)
Starting system Type Electric
Starting motor DC 12 V - 1.4 kW
AC generator 12 V - 80 A
Engine dimension Overall length 795 mm (31.3 in.)
Overall width 560 mm (22.0 in.)
Overall height 625 mm (24.6 in.)
Flywheel major dimension D300 x 66 mm (11.8 x 2.6 in.)
Engine dry mass (include marine gear) 241 kg engine: 201 kg
201 kg (443 lb)
(531 lb)
(engine: 443 lb)
*
***
92 JH4 Series Operation Manual
SPECIFICATIONS
*
Rating Condition: Temperature of fuel; 25˚C at fuel pump inlet; ISO 3046-1
**
Rating Condition: Temperature of fuel; 40˚C at fuel pump inlet; ISO 8665
***
The “total” oil quantity includes oil in oil pan, channels, coolers and filter.
****
The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
Note: Density of fuel: 0.842g/cm3 at 15˚C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
JH4 Series Operation Manual 93
SPECIFICATIONS
4JH4AE Marine Gear or Sail Drive Specifications
Model KM35P ZF30M
Type Mechanical cone clutch
Reduction ratio
(Forward / Reverse)
Propeller speed
(Forward / Reverse)
*
Lubrication system Splash
Lubricating oil capacity (Total) 0.5 L (0.5 qt) 1.1 L (1.2 qt)
Lubricating oil capacity
(Effective)
Cooling system Air cooling by fan Seawater cooling
Weight 12 kg (26 lb) 27.5 kg (61 lb)
*
At continuous power engine speed 2907 rpm
**
ZF30M Lubricating oil: ATF
Model KM35A2 KM4A1 SD50
Type Mechanical cone clutch
Reduction ratio
(Forward / Reverse)
Propeller speed
(Forward / Reverse)
*
Lubrication system Splash - Oil bath
Lubricating oil capacity
(Total)
Lubricating oil capacity
(Effective)
Cooling system Air cooling by
Weight 13 kg (28 lb) 29.0 kg (64 lb) 40 kg
2.36/3.16 2.61/3.16 2.15/2.64 2.70/2.64
1232/921rpm 1114/921 rpm 1353/1103
rpm
1078/1103
rpm
**
0.05 L (0.05 qt) 0.2 L (0.2 qt)
(coupled
at boat
builder)
2.33/
3.06
1246/
955
rpm
2.64/
3.06
1103/
955
rpm
1.47/
1.47
1983/
1993
rpm
2.14/
2.14
1360/
1360
rpm
2.63/
2.63
1106/
1106
rpm
3.30/
3.30
882/
882
rpm
2.32
1253 rpm
0.65 L (0.69 qt) 2.3 L (2.4 qt) SD50: 2.1 L
(2.2 qt)
0.15 L (0.16 qt) 0.20 L (0.21 qt) SD50: 0.5 L
(0.6 qt)
Seawater cooling -
fan
(88 lb)
*
At continuous power engine speed 2907 rpm
94 JH4 Series Operation Manual
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