Yanmar 3JH4E Operation Manual
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Yanmar 3JH4E Operation Manual

Jh4 series marine engines
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See also: Service Manual , Installation Manual
JH4
series
OPERATION MANUAL
3JH4E
4JH4AE
4JH4-TE
4JH4-HTE
P/N: 0AJH4–G00102
MARINE
ENGINES

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Summary of Contents for Yanmar 3JH4E

  • Page 1 OPERATION MANUAL 3JH4E 4JH4AE 4JH4-TE 4JH4-HTE P/N: 0AJH4–G00102 MARINE ENGINES...
  • Page 2 / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

  • Page 3: Table Of Contents

    ......... Before You Operate ......... During Operation and Maintenance ..... Location of Safety Decals ........Product Overview ............. 13 Yanmar JH4 Features and Applications ..... New Engine Break-In ........Component Identification ........Service Side - 3JH4E ........Non-Service Side - 3JH4E .......
  • Page 4 TABLE OF CONTENTS Filling the Fuel Tank ........Bleeding the Fuel System ........ Engine Oil ............Engine Oil Specifications ......... Engine Oil Viscosity ........Checking the Engine Oil ........Adding Engine Oil .......... Marine Gear or Sail Drive Oil ........Marine Gear Oil Specifications ......
  • Page 5 ......Keep a Log of Engine Hours and Daily Checks ..Yanmar Replacement Parts ......Tools Required ..........Ask Your Authorized Yanmar Marine Dealer or Distributor For Help ........Tightening Fasteners ........EPA Maintenance Requirements ......EPA Requirements for USA and Other Applicable Countries .............
  • Page 6 ..........System Diagrams ........... 101 Piping Diagrams ..........Wiring Diagrams ..........EPA Warranty USA Only .......... 129 Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only ........... Your Warranty Rights and Obligations: ....Warranty Period: .......... Warranty Coverage: ........

  • Page 7: Introduction

    This manual should be considered a permanent part of the To help you enjoy your Yanmar JH4 series engine and remain with it. engine for many years to come, please follow these recommendations: •...

  • Page 8: Record Of Ownership

    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: JH4 Series Operation Manual...

  • Page 9: Safety

    SAFETY Yanmar considers safety of great DANGER importance and recommends that anyone Indicates a hazardous situation which, if that comes into close contact with its not avoided, will result in death or products, such as those who install, serious injury.

  • Page 10: Safety Precautions

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. JH4 Series Operation Manual...
  • Page 11 SAFETY Sever Hazard WARNING Rotating parts can cause The safety messages that follow have severe injury or death. NEVER WARNING level hazards. wear jewelry, unbuttoned cuffs, ties or loose fitting Explosion Hazard clothing and ALWAYS tie long Avoid serious personal injury hair back when working near moving / or equipment damage.
  • Page 12 ALWAYS use tools appropriate for the task hands. ALWAYS use a piece of wood or at hand and use the correct size tool for cardboard. Have your authorized Yanmar loosening or tightening machine parts. marine dealer or distributor repair the damage.
  • Page 13 Immediately throttle back to approximately 2/3 throttle or to a setting where the engine If a Yanmar Marine Engine is installed at an performs normally. Failure to do so may angle that exceeds the specifications stated...

  • Page 14: Location Of Safety Decals

    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 WARNING 196630-12980 0004550 Figure 1 1 – Part Number: 128377–07350 2 – Part Number: 128377–07260 3 –...
  • Page 15 SAFETY 4JH4AE Engines WARNING 0004551 Figure 2 1 – Part Number: 128377–07350 2 – Part Number: 128377–07260 3 – Part Number: 196630–12980 4 – Part Number: 128377–07150 JH4 Series Operation Manual...
  • Page 16 SAFETY 4JH4-TE Engines WARNING 128296-07300 0003632 Figure 3 1 – Part No.: 128377-07350 2 – Part No.: 128377-07260 3 – Part No.: 196630-12980 4 – Part No.: 128296-07300 JH4 Series Operation Manual...
  • Page 17 SAFETY 4JH4-HTE Engines WARNING 128296-07300 0004552 Figure 4 1 – Part No.: 128377-07350 2 – Part No.: 128377-07260 3 – Part No.: 128296-07300 4 – Part No.: 196630-12980 JH4 Series Operation Manual...
  • Page 18 SAFETY This Page Intentionally Left Blank JH4 Series Operation Manual...

  • Page 19: Product Overview

    (including the propeller) and other onboard equipment, always observe the instructions The 3JH4E is 3-cylinder and naturally and cautions given in the operation manuals aspirated. supplied by the shipyard and equipment The 4JH4AE is 4-cylinder and naturally manufacturers.
  • Page 20 PRODUCT OVERVIEW A new Yanmar diesel engine must be Perform this procedure in open waters: operated at suitable speeds and power • With the clutch in NEUTRAL, accelerate settings during the break in period to make from the low speed position to the high the sliding parts, such as piston rings, break speed position briefly.

  • Page 21: Component Identification

    PRODUCT OVERVIEW COMPONENT Non-Service Side - 3JH4E IDENTIFICATION (10) 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. (11) (10) 0004544 Figure 2 1 –...

  • Page 22: Service Side - 4Jh4Ae

    PRODUCT OVERVIEW Service Side - 4JH4AE Non-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. 0004546 Figure 4 (10) 1 – Engine Nameplate (on rocker arm cover) (11) 2 –...

  • Page 23: Service Side - 4Jh4-Te

    PRODUCT OVERVIEW Service Side - 4JH4-TE Non-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) (11) (10) 0004547 Figure 6 1 – Engine Nameplate (on rocker arm cover) 2 –...

  • Page 24: Service Side - 4Jh4-Hte

    PRODUCT OVERVIEW Service Side - 4JH4-HTE Non-Service Side - 4JH4-HTE Figure 7 and Figure 8 illustrate a typical (10) version of a 4JH4–HTE engine. Your engine may have different equipment from that illustrated. (11) (12) (10) 0004549 Figure 8 1 – Engine Nameplate (on rocker arm cover) 2 –...

  • Page 25: Location Of Nameplates

    Check the marine gear's model, gear ratio, oil used, oil quantity and serial number The nameplates of Yanmar JH4 series engines are shown in Figure 9 and MODE L Figure 10. Check the engine's model,...

  • Page 26: Function Of Major Components

    PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of Component Function Fuel Filter Removes dirt and water from the fuel. Drain the filter periodically. The filter element should be replaced periodically. The water separator (if equipped) should be drained periodically. See Draining Fuel Filter / Water Separator on page 65. Fuel Feed Pump Pumps fuel from the tank to the fuel injection system.

  • Page 27: Control Equipment

    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.
  • Page 28 PRODUCT OVERVIEW C-Type (13) (12) (11) (10) 0004503 Figure 14 1 – Coolant High Temperature Indicator 8 – Key Switch 2 – Coolant Temperature Gauge 9 – Stop Button 3 – Engine Oil Low Pressure Indicator 10 – Battery Low Charge Indicator 4 –...
  • Page 29 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.
  • Page 30 PRODUCT OVERVIEW Figure 16 Figure 19 Battery Low Charge Indicator Water in Sail Drive Seal Indicator and Alarm (Figure 16) - When the alternator output is (Figure 19) - When water is detected too low, the indicator will light. When between the seals of the sail drive, the charging begins, the indicator will turn off.
  • Page 31 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 Coolant High Temperature Indicator Engine Oil Low Pressure Indicator Water in Sail Drive Seal Indicator (if equipped) JH4 Series Operation Manual...

  • Page 32: Single Lever Remote Control Handle

    PRODUCT OVERVIEW Single Lever Remote Control Handle 0004511 Figure 23 Note: Yanmar recommends the use of a 0004504 Figure 22 single-lever type for the remote control system. If only a two-lever type is available Note: Direction of travel will vary depending in the market, reduce engine rpm to 1000 on installation location.

  • Page 33: Before You Operate

    Diesel Fuel Specifications replenish them. It also describes the daily NOTICE: Only use diesel fuels engine checks. recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. Only use clean diesel fuel.

  • Page 34: Handling Of Diesel Fuel

    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.
  • Page 35 BEFORE YOU OPERATE Fuel Tank (Optional) Fuel System - 3JH4E, 4JH4-TE and 4JH4-HTE 0004489 Figure 3 0004542 1 – Fuel Filter Figure 2 2 – To Fuel Injection Pump 1 – Sediment Bowl 3 – Less than 500 mm (20.0 in.) 2 –...

  • Page 36: Filling The Fuel Tank

    BEFORE YOU OPERATE Fill the tank with clean fuel free of oil and Fuel System - 4JH4AE 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.
  • Page 37 BEFORE YOU OPERATE Continue pumping until a solid stream Bleeding the Fuel System - 3JH4E of fuel with no air bubbles begins to flow. Tighten the air bleed screw. Note: After engine start-up, the automatic air-bleeding device works to purge the air in the fuel system.

  • Page 38: Engine Oil

    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 0004494...

  • Page 39: Engine Oil Viscosity

    If you operate your equipment at Remove dipstick (Figure 9, (3)) and temperatures outside the limits shown, wipe with clean cloth. consult your authorized Yanmar dealer or Fully reinsert dipstick. distributor for special lubricants or starting Remove dipstick. The oil level should aids.

  • Page 40: Marine Gear Or Sail Drive Oil

    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 High Performance Gear ®...

  • Page 41: Checking Marine Gear Oil

    BEFORE YOU OPERATE Checking Marine Gear Oil Adding Marine Gear Oil Make sure the engine is level. Remove the filler cap at the top of the housing (Figure 10, (1)). Fill with oil to the upper limit on the dipstick (Figure 10, (3)). See Marine Gear Oil Specifications on page 34.

  • Page 42: Engine Coolant

    Use the proper amount of coolant concentrate for the ambient temperature as 3 – Coolant Drain Cock (located behind the V-belt cover) - 3JH4E Only specified by the LLC manufacturer. LLC concentration should be a minimum of 30% 4 – Coolant Pump (Fresh Water) to a maximum of 60%.
  • Page 43 BEFORE YOU OPERATE 4JH4AE 4JH4-TE 0004514 Figure 15 0004569 1 – Coolant Tank (Heat Exchanger) Figure 13 2 – Coolant Pump (Fresh Water) 1 – Coolant Pump (Fresh Water) 3 – Seawater Drain from Seawater 2 – Seawater Drain from Seawater Pump Cover Pump Cover 4 –...
  • Page 44 BEFORE YOU OPERATE 4JH4-HTE Loosen the filler cap of the coolant tank to relieve the pressure then remove the filler cap. 0004560 Figure 17 0004492 1 – Coolant Tank (Heat Exchanger) Figure 19 2 – Coolant Pump (Fresh Water) 1 – Coolant Filler Cap 3 –...

  • Page 45: Cranking The Engine

    START to ON positions leaks in the cooling system. See your smoothly. authorized Yanmar dealer or distributor. Turn key to ON (Figure 21, (3)). 3JH4E / 4JH4AE models: While pushing the STOP button on...

  • Page 46: Daily Checks

    Continue cranking for Before you start for the day, make sure the about 5 seconds and listen for Yanmar engine is in good operating abnormal noise during that time. condition. CAUTION! It is important to perform daily checks as listed in this Note: If the STOP button is released during Operation Manual.

  • Page 47: Checking Diesel Fuel, Engine Oil And Engine Coolant Levels

    BEFORE YOU OPERATE 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.
  • Page 48 BEFORE YOU OPERATE This Page Intentionally Left Blank JH4 Series Operation Manual...

  • Page 49: Engine Operation

    ENGINE OPERATION Exhaust Hazard WARNING Avoid serious injury or death. Fire and Explosion Hazard NEVER block windows, vents Avoid serious personal injury. or other means of ventilation if NEVER jump-start the engine. the engine is operating in an Sparks caused by shorting the enclosed area.

  • Page 50: Starting The Engine

    • 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 0003622 engine dealer or distributor if the engine Figure 1...

  • Page 51: Restarting After Starting Failure

    ON position, see engine reaches normal operating your authorized Yanmar marine dealer temperature. A light load on a cold engine or distributor for service before provides better combustion and faster operating the engine.

  • Page 52: After The Engine Has Started

    NOTICE: Shifting the marine gear while If necessary, see your authorized operating at high speed or not pushing the Yanmar dealer or distributor. handle fully into position (partial engagement) will result in damage to marine gear parts and abnormal wear.

  • Page 53: Switching To Trolling (Kmh4A Only)

    ENGINE OPERATION 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.

  • Page 54: Shutting Down The Engine

    Close the seacock (if equipped). NOTICE: Avoid engine damage. Do not stop NOTICE: Be sure to close the seacock. engine abruptly during operation. Yanmar Neglecting to close the seacock could recommends that when shutting the engine allow water to leak into the boat and down, allow the engine to run, without load, may cause it to sink.

  • Page 55: Checking The Engine After Operation

    ENGINE OPERATION CHECKING THE ENGINE If the engine cannot be shut down by the STOP button on the panel, stop the engine AFTER OPERATION by moving the stop lever (Figure 6, (2)) by hand to the left (Figure 6, (1)). The lever is •...
  • Page 56 ENGINE OPERATION This Page Intentionally Left Blank JH4 Series Operation Manual...

  • Page 57: Periodic Maintenance

    PERIODIC MAINTENANCE SAFETY PRECAUTIONS This section of the Operation Manual describes the procedures for proper care and maintenance of the engine. 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.
  • Page 58 Any alterations to this engine may void its warranty. Be sure to • Remove the multi-pin connector to the use Yanmar genuine replacement parts. engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point.

  • Page 59: Precautions

    Yanmar Replacement Parts Performing Periodic Maintenance Yanmar recommends that you use genuine Yanmar parts when replacement parts are WARNING! NEVER block windows, needed. Genuine replacement parts help vents, or other means of ventilation if ensure long engine life.

  • Page 60: Tightening Fasteners

    PERIODIC MAINTENANCE Tightening Fasteners NOTICE: The tightening torque in the Standard Torque Chart Use the correct amount of torque when you should be applied only to the tighten fasteners on the machine. Applying bolts with a “7” head (JIS excessive torque may damage the fastener strength classification: 7T).

  • Page 61: Epa Maintenance Requirements

    • Ambient temperature: -20˚ to +40˚C REQUIREMENTS (-4˚ to +104˚F) • Relative humidity: 80% or lower • 3JH4E and 4JH4AE: Permissible value To maintain optimum engine performance for intake negative pressure: 4.0 kPa (400 and compliance with the Environmental mmAq) or lower Protection Agency (EPA) Regulations for •...

  • Page 62: Inspection And Maintenance

    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 This maintenance must be performed to keep the emission values of your engine in the standard values during the warranty...

  • Page 63: Periodic Maintenance Schedule

    See your authorized Yanmar marine dealer or distributor for assistance when checking items marked with a ●. JH4 Series Operation Manual...
  • Page 64 PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Every 50 Every Every Every hours or 1000 monthly hours or hours or hours or which- one year...
  • Page 65 PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Every 50 Every Every Every hours or 1000 monthly hours or hours or hours or which- one year...

  • Page 66: Inspection And Maintenance Of Epa Emission-Related Parts

    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...

  • Page 67: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE Changing the Engine Oil and Replacing the Engine Oil Filter PROCEDURES Element The engine oil on a new engine becomes After Initial 50 Hours of contaminated from the initial break-in of Operation internal parts. It is very important that the initial oil replacement is performed as Perform the following maintenance after the scheduled.
  • Page 68 PERIODIC MAINTENANCE Turn filter an additional 3/4 turn with a Hold the filter in place with the coil box wrench. Tighten to 20 - 24 N·m spring (Figure 3, (3)) and insert (177 - 212 in.-lb). into the case. Install a new O-ring (Figure 3, (4)) in the side cover.

  • Page 69: Control Cables

    Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage. See your authorized Yanmar marine dealer 0003625 or distributor to adjust the intake / exhaust Figure 5 valve clearance.
  • Page 70 (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 0004562 0004498 Figure 7 Figure 9 4JH4-TE / 4JH4-HTE 1 –...

  • Page 71: Every 50 Hours Of Operation

    Draining Fuel Filter / Water requires specialized knowledge and Separator techniques. Consult your authorized 3JH4E and 4JH4AE (Attach to Hull) Yanmar marine dealer or distributor. 0004564 Figure 10 Close the fuel cock of the fuel tank.
  • Page 72 PERIODIC MAINTENANCE Be sure to bleed air from the fuel Bleed air from the fuel system. See system. See Bleeding the Fuel Bleeding the Fuel System on page 30. System on page 30. Checking the Battery Electrolyte Level (Serviceable Batteries Only) 4JH4-TE and 4JH4-HTE WARNING! Batteries contain sulfuric acid.

  • Page 73: Every 250 Hours Of Operation

    • 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 0003627 Figure 13 Close the fuel cock of the fuel tank. JH4 Series Operation Manual...
  • Page 74 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 0004500 Install new filter and tighten hand-tight. Figure 14 Use a filter wrench and tighten to 20 - Close the fuel cock of the fuel tank.
  • Page 75 Remove the side cover of the seawater continuously from the water drain line pump. below the seawater pump during Install puller (Figure 16, (A)) in the operation, replace the mechanical seal. impeller. See your authorized Yanmar marine dealer or distributor. JH4 Series Operation Manual...
  • Page 76 Note: When replacing a used impeller with 2 – Seawater Drain Cock a new one, the impeller must have an M18 x 3 – Coolant Drain Cock (3JH4E Only) - 1.5 thread (Figure 17, (1)). Turn the M18 Located behind the V-belt cover screw-side of the impeller to the cover side 4 –...
  • Page 77 PERIODIC MAINTENANCE 3JH4E 4JH4AE 0004570 0004557 Figure 23 Figure 21 1 – Coolant Drain Cock 1 – Stop Solenoid 2 – Stop Solenoid 2 – Coolant Drain Cock 4JH4-TE 3 – Flywheel Housing 4JH4AE 0004571 Figure 24 0004569 1 – Coolant Tank (Heat Exchanger) Figure 22 2 –...
  • Page 78 PERIODIC MAINTENANCE 4JH4-TE 4JH4-HTE 0004573 0004572 Figure 27 Figure 25 1 – Coolant Drain Cock 1 – Coolant Drain Cock 2 – Fuel Pump 2 – Fuel Pump 3 – Seawater Drain Cock 3 – Seawater Drain Cock 4 – Marine Gear Cooler 4 –...

  • Page 79: Every 500 Hours Of Operation

    500 hours or 2 years, whichever Inspect the gasket and replace if comes first, even if no damage is found. necessary. See your authorized Yanmar marine dealer Cleaning the Turbocharger (If or distributor. Equipped) Contamination of the turbocharger causes Replacing Rubber Hoses revolutions to drop and engine output to fall.

  • Page 80: Every 1000 Hours Of Operation

    • Replacing the Seawater Pump • Heat Exchanger Impeller • Pressure Cap • Cleaning and Checking the Seawater Passages See your authorized Yanmar marine dealer or distributor. • Checking Diaphragm Assembly (3JH4E / 4JH4AE only) Check Diaphragm Assembly • Replacing the Alternator V-Belt (3JH4E / 4JH4AE only) •...
  • Page 81 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.
  • Page 82 PERIODIC MAINTENANCE This Page Intentionally Left Blank JH4 Series Operation Manual...

  • Page 83: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING If a problem occurs, stop the engine immediately. Refer to the SYMPTOM AFTER STARTING column in the Troubleshooting Chart to identify the problem. 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? •...
  • Page 84 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.

  • Page 85: Troubleshooting Chart

    Filter Element on page 61 • Water in sail drive seal Rubber sail drive seal broken. See your authorized indicator comes on Yanmar marine dealer or distributor. • Coolant high Coolant / fresh water in coolant Check coolant level and See Checking temperature alarm tank is low.
  • Page 86 Electrolyte Level (Serviceable Batteries Only) on page 66 Alternator power generation See your authorized failure. Yanmar marine dealer or distributor. Starting Failures: • Starter turns but No fuel. Add fuel. Bleed fuel See Filling the engine does not start system.
  • Page 87 Symptom Probable Cause Measure Reference Abnormal Exhaust Color: • Black smoke Load increased. See your authorized Yanmar marine dealer or distributor. • Improper propeller matching. See your authorized Yanmar marine dealer or distributor. • Dirty intake silencer (air Clean element.

  • Page 88: Troubleshooting Information

    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 •...

  • Page 89: Long-Term Storage

    6 months. If it remains unused for longer prevent rusting during long-term storage. than this, please contact your authorized Yanmar marine dealer or distributor. Note: If the engine is close to a periodic maintenance interval, perform those maintenance procedures before putting the engine into long-term storage.

  • Page 90: Drain Seawater Cooling System

    Figure 1 3 – Stop Solenoid 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...
  • Page 91 LONG-TERM STORAGE 4JH4AE 4JH4-TE 0004569 0004571 Figure 3 Figure 5 1 – Coolant Pump (Fresh Water) 1 – Coolant Tank (Heat Exchanger) 2 – Seawater Pump 2 – Coolant Pump (Fresh Water) 3 – Coolant Tank (Heat Exchanger) 3 – Seawater Drain from Seawater Pump Cover 4 –...
  • Page 92 LONG-TERM STORAGE 4JH4-HTE 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).

  • Page 93: Specifications

    SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS 3JH4E Engine Specifications Specification 3JH4E Marine Gear Model KM35P KM35A SD40/SD50 Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion system Direct injection Air charging Natural aspiration Number of cylinders Bore x stroke 88 mm x 90 mm (3.46 in. x 3.54 in.) Displacement 1.642 L (100.20 cu in.)
  • Page 94 SPECIFICATIONS Specification 3JH4E Marine Gear Model KM35P KM35A SD40/SD50 Bobtail Lubricating oil Rake angle at rake angle 8˚ at rake angle 0˚ capacity Total 5.0 ± 0.3 L 5.5 ± 0.3 L (engine) (5.3 ± 0.3 qt) (5.8 ± 0.3 qt) Oil pan only 4.5 ±...

  • Page 95: 3Jh4E Marine Gear Specifications

    SPECIFICATIONS 3JH4E Marine Gear Specifications Model KM35P KM35A SD40/SD50 (coupled at boat builder) Type Mechanical cone clutch Reduction ratio (Forward / 2.33/3.16 2.33/3.06 2.32 Reverse) Propeller speed (Forward / 1231/1114 1246/1103 1253 rpm 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)

  • Page 96: 4Jh4Ae Engine Specifications

    SPECIFICATIONS 4JH4AE Engine Specifications Engine Model 4JH4AE Marine Gear Model KM35P ZF30M KM35A2 KM4A1 Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion system Direct injection Air charging Natural aspiration Number of cylinders Bore x stroke 88 mm x 90 mm (3.46 in. x 3.54 in.) Displacement 2.190 L (133.64 cu in.) Continuous...
  • Page 97 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/cm at 15˚C.
  • Page 98 SPECIFICATIONS 4JH4AE Specifications (Continued) Engine Model 4JH4AE Marine Gear Model SD50 Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion system Direct injection Air charging Natural aspiration Number of cylinders Bore x stroke 88 x 90 mm (3.46 x 3.54 in.) Displacement 2.190 L 133.6 cu in.
  • Page 99 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/cm at 15˚C.

  • Page 100: 4Jh4Ae Marine Gear Or Sail Drive Specifications

    SPECIFICATIONS 4JH4AE Marine Gear or Sail Drive Specifications Model KM35P ZF30M Type Mechanical cone clutch Reduction ratio 2.36/3.16 2.61/3.16 2.15/2.64 2.70/2.64 (Forward / Reverse) Propeller speed 1232/921rpm 1114/921 rpm 1353/1103 1078/1103 (Forward / Reverse) Lubrication system Splash Lubricating oil capacity (Total) 0.5 L (0.5 qt) 1.1 L (1.2 qt) Lubricating oil capacity...
  • Page 101 SPECIFICATIONS This Page Intentionally Left Blank JH4 Series Operation Manual...

  • Page 102: 4Jh4-Te Engine Specifications

    SPECIFICATIONS 4JH4-TE Engine Specifications Engine Model 4JH4-TE Marine Gear Model ZF30M KM4A2 KMH4A ZF25A SD50-4T Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion system Direct injection Air charging Turbocharged Number of cylinders Bore x stroke 84 x 90 mm (3.31 x 3.54 in.) Displacement 1.995 L (121.74 cu in.) Continuous...
  • Page 103 SPECIFICATIONS Engine Model 4JH4-TE Marine Gear Model ZF30M KM4A2 KMH4A ZF25A SD50-4T Bobtail Engine Overall length 923 mm 903 mm 933 mm 1017 mm 782 mm 782 mm dimension (36.3 in.) (35.6 in.) (36.7 (40.0 in.) (30.8 in.) (30.8 in.) in.) Overall width 616 mm...

  • Page 104: 4Jh4-Hte Engine Specifications

    SPECIFICATIONS 4JH4-HTE Engine Specifications Engine Model 4JH4-HTE Marine Gear Model ZF30M KM4A2 KMH4A ZF25A Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion system Direct injection Air charging Turbocharged Number of cylinders Bore x stroke 84 x 90 mm (3.31 x 3.54 in.) Displacement 1.995 L (121.74 cu in.) Continuous...
  • Page 105 SPECIFICATIONS Engine Model 4JH4-HTE Marine Gear Model ZF30M KM4A2 KMH4A ZF25A Bobtail Engine Overall length 923 mm 903 mm 933 mm 1017 mm 782 mm dimension (36.3 in.) (35.6 in.) (36.7 in.) (40.0 in.) (30.8 in.) Overall width 616 mm (24.3 in.) Overall height 659 mm...

  • Page 106: 4Jh4-Te And 4Jh4-Hte Marine Gear Or Sail Drive Specifications

    SPECIFICATIONS 4JH4-TE and 4JH4-HTE Marine Gear or Sail Drive Specifications Model ZF30M KM4A2 KMH4A ZF25A SD50-4T (coupled at boat builder) Down angle 0˚ 7˚ 8˚ 8˚ Type Mechanical Mechanical cone Hydraulic wet Hydraulic Mechanical wet multiple clutch multiple disk wet multiple cone clutch disk clutch clutch...

  • Page 107: System Diagrams

    SYSTEM DIAGRAMS PIPING DIAGRAMS Notation Screw Joint (Union) Flange Joint Eye Joint Insertion Joint Drilled Hole Coolant Piping Cooling Seawater Piping Lubricating Oil Piping Fuel Oil Piping JH4 Series Operation Manual...
  • Page 108 SYSTEM DIAGRAMS 3JH4E with KM35P, KM35A Marine Gear 0004175 Figure 1 JH4 Series Operation Manual...
  • Page 109 SYSTEM DIAGRAMS 3JH4E with SD50 (SD40) Sail Drive 0004176 Figure 2 JH4 Series Operation Manual...
  • Page 110 SYSTEM DIAGRAMS 4JH4AE with KM35P, KM35A2 Marine Gear 0004177 Figure 3 JH4 Series Operation Manual...
  • Page 111 SYSTEM DIAGRAMS 4JH4AE with KM35P, KM35A2 Marine Gear 0004587 Figure 4 JH4 Series Operation Manual...
  • Page 112 SYSTEM DIAGRAMS 4JH4AE with KM4A1 Marine Gear Figure 5 JH4 Series Operation Manual...
  • Page 113 SYSTEM DIAGRAMS 4JH4AE with ZF30M Marine Gear 0004589 Figure 6 JH4 Series Operation Manual...
  • Page 114 SYSTEM DIAGRAMS 4JH4AE with SD50 Sail Drive 0004590 Figure 7 JH4 Series Operation Manual...
  • Page 115 SYSTEM DIAGRAMS 4JH4-TE with ZF30M 0004181 Figure 8 JH4 Series Operation Manual...
  • Page 116 SYSTEM DIAGRAMS 4JH4-TE with KM4A2 0004182 Figure 9 JH4 Series Operation Manual...
  • Page 117 SYSTEM DIAGRAMS 4JH4-TE with KM4A / ZF25A 0004183 Figure 10 JH4 Series Operation Manual...
  • Page 118 SYSTEM DIAGRAMS 4JH4-TE with SD50 (SD40) 0004184 Figure 11 JH4 Series Operation Manual...
  • Page 119 SYSTEM DIAGRAMS 4JH4-HTE with KM4A2 0004591 Figure 12 JH4 Series Operation Manual...
  • Page 120 SYSTEM DIAGRAMS 4JH4-HTE with KMH4A / ZF25A 0004592 Figure 13 JH4 Series Operation Manual...
  • Page 121 SYSTEM DIAGRAMS 4JH4-HTE with ZF30 0004593 Figure 14 JH4 Series Operation Manual...

  • Page 122: Wiring Diagrams

    SYSTEM DIAGRAMS WIRING DIAGRAMS 3JH4E - B-Type Instrument Panel 0004185 Figure 15 JH4 Series Operation Manual...
  • Page 123 SYSTEM DIAGRAMS 3JH4E - B-Type Instrument Panel Color Description Starter Switch Coding Stop Switch Tachometer / Hourmeter Black Buzzer White Lubricating Oil Low Pressure Alarm Blue Coolant High Temperature Alarm Red / Black Water in Sail Drive Seal Alarm Blue / Black...
  • Page 124 SYSTEM DIAGRAMS 4JH4AE - B-Type Instrument Panel 0004594 Figure 16 JH4 Series Operation Manual...
  • Page 125 SYSTEM DIAGRAMS 4JH4AE - B-Type Instrument Panel Color Description Starter Switch Coding Stop Switch Tachometer / Hourmeter Black Buzzer White Lubricating Oil Low Pressure Alarm Blue Coolant High Temperature Alarm Red / Black Water in Sail Drive Seal Alarm Blue / Black Battery Low Charge Alarm Yellow / White Relay (for 2 station - Optional)
  • Page 126 SYSTEM DIAGRAMS 3JH4E - C-Type Instrument Panel 0004186 Figure 17 JH4 Series Operation Manual...
  • Page 127 SYSTEM DIAGRAMS 3JH4E - C-Type Instrument Panel Color Description Starter Switch Coding Stop Switch Tachometer / Hourmeter Black Buzzer White Lubricating Oil Low Pressure Alarm Blue Coolant High Temperature Alarm Red / Black Water in Sail Drive Seal Alarm Blue / Black...
  • Page 128 SYSTEM DIAGRAMS 4JH4AE - C-Type Instrument Panel 0004595 Figure 18 JH4 Series Operation Manual...
  • Page 129 SYSTEM DIAGRAMS 4JH4AE - C-Type Instrument Panel Color Description Starter Switch Coding Stop Switch Tachometer / Hourmeter Black Buzzer White Lubricating Oil Low Pressure Alarm Blue Coolant High Temperature Alarm Red / Black Water in Sail Drive Seal Alarm Blue / Black Battery Low Charge Alarm Yellow / White Relay (for 2 station - Optional)
  • Page 130 SYSTEM DIAGRAMS 4JH4-TE / 4JH4-HTE with B x B Type Panel 0004506 Figure 19 JH4 Series Operation Manual...
  • Page 131 SYSTEM DIAGRAMS 4JH4-TE / 4JH4-HTE with B x B Type Panel Color Coding Engine Option Harness Alarm Lamps Buzzer Black Oil Pressure White Ignition Coolant Temperature Blue Air heater / glow Sail Drive Seal (option) Battery Low Charge Alarm Red / Alternator Black exciter...
  • Page 132 SYSTEM DIAGRAMS 4JH4-TE / 4JH4-HTE with C x B Type Panel 0004507 Figure 20 JH4 Series Operation Manual...
  • Page 133 SYSTEM DIAGRAMS 4JH4-TE / 4JH4-HTE with C x B Type Panel Instrument panel (main station) Color Coding Engine (Option) Harness Wire Harness Relay Black Wire Harness for Sub Panel White Ignition Amplifier (Sail Drive Only) Blue Air heater / glow (option) Procured by Customer Red / Alternator...
  • Page 134 SYSTEM DIAGRAMS This Page Intentionally Left Blank JH4 Series Operation Manual...

  • Page 135: Epa Warranty Usa Only

    YANMAR CO., LTD. LIMITED 4JH4-TE EPA Nameplate EMISSION CONTROL SYSTEM WARRANTY - USA ONLY 3JH4E EPA and ARB Nameplate IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO 2006 M.Y.CALIFORNIA AND U.S.EPA REGULATIONS FOR OFF-ROAD C.I.ENGINES. 0004152 THIS ENGINE IS CERTIFIED TO OPERATE ON "TYPE2-D" FUEL.

  • Page 136: Your Warranty Rights And Obligations

    STATES EPA 40 CFR 94 AND SOLD BY replacement of emission control systems YANMAR THAT ARE INSTALLED IN are Yanmar parts. The owner may elect to VESSELS FLAGGED OR REGISTERED IN have maintenance, replacement or repair of THE UNITED STATES.

  • Page 137: Warranty Coverage

    You must present your marine engine to an authorized Failures other than those arising from Yanmar dealer or distributor as soon as a defects in material and / or workmanship are problem exists. not covered by this limited emissions warranty.

  • Page 138: Customer Assistance

    Customer Assistance: If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor, you should contact Yanmar Marine USA Corporation for assistance. Yanmar Marine USA Corporation 101 International Parkway...

  • Page 139: Emission System Warranty

    Agency (EPA) and Yanmar Co., Ltd. (25.5 hp ≤ and use, the engine has a hereafter referred to as Yanmar, are pleased less than < 49.6 warranty period of five (5) years. to explain the emission control system...

  • Page 140: Warranted Parts

    This warranty covers engine components the performance of all scheduled that are a part of the emission control system maintenance. of the engine as delivered by Yanmar to the original retail purchaser. Such components Yanmar may deny your warranty coverage may include the following:...
  • Page 141 Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor, you should contact Yanmar Marine USA Corporation for assistance. Yanmar Marine USA Corporation 101 International Parkway...
  • Page 142 JH4 Series Operation Manual...

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