Yanmar 3JH5E Operation Manual
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Yanmar 3JH5E Operation Manual

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JH
Series
OPERATION MANUAL
3JH5E
4JH5E
4JH4-TE
4JH4-HTE
P/N: 0AJHM–G00200
MARINE
ENGINES

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Summary of Contents for Yanmar 3JH5E

  • Page 1 Series OPERATION MANUAL 3JH5E 4JH5E 4JH4-TE 4JH4-HTE P/N: 0AJHM–G00200 MARINE ENGINES...
  • Page 2 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.

  • Page 3: Table Of Contents

    Yanmar JH Series Features and Applications.....15 New Engine Break-In..........16 Component Identification..........17 Right Side (Viewed from Flywheel) - 3JH5E....17 Left Side (Viewed from Flywheel) - 3JH5E....17 Right Side (Viewed from Flywheel) - 4JH5E....18 Left Side (Viewed from Flywheel) - 4JH5E....18 Right Side (Viewed from Flywheel) - 4JH4-TE....
  • Page 4 The Importance of Periodic Maintenance ....57 Performing Periodic Maintenance ......57 The Importance of Daily Checks ....... 57 Keep a Log of Engine Hours and Daily Checks..... 57 Yanmar Replacement Parts ........57 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 5 TABLE OF CONTENTS Tools Required ............. 57 Ask Your Authorized Yanmar Marine Dealer or Distributor for Help..........57 Tightening Fasteners..........58 EPA Maintenance Requirements........59 EPA Requirements for USA and Other Applicable Countries............. 59 EPA Requirements ..........59 Conditions to Ensure Compliance with EPA Emission Standards ............
  • Page 6 TABLE OF CONTENTS Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only..............149 Your Warranty Rights and Obligations: ......150 Warranty Period: ..........150 Warranty Coverage: ..........150 Exclusions: ............151 Owner’s Responsibility: .........151 Customer Assistance: ...........151 Emission System Warranty..........153 Non-Road Emission System Warranty......153 Yanmar Co., Ltd.

  • Page 7: Introduction

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

  • Page 8: Jh Series Emission Control System Warranty-Usa, The Environmental Protection Agency (Epa) Only

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

  • Page 9: 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: JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 10 INTRODUCTION This Page Intentionally Left Blank JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 11: Safety

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

  • Page 12: Safety Precautions

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. Store any containers containing fuel or other • See your authorized Yanmar Marine flammable products in a well-ventilated dealer or distributor for additional training. area, away from any combustibles or source of ignition.
  • Page 13 Burn Hazard Some of the engine surfaces become very hot during operation and shortly after shutdown. Keep hands and other body parts away from hot engine surfaces. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 14 If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Installation Manuals,...
  • Page 15 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...

  • Page 16: 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 JH series marine engines. 3JH5E Engines WARNING Water Separator caution Drain off water at every 100hr. ISO10088 Diesel Fuel...
  • Page 17 1 – Part Number: 128377-07350 4 – Part Number: 128377-07150 2 – Part Number: 128990-07270 5 – Part Number: 120324-55751 3 – Part Number: 196630-12980 (fuel / water separator attached to the hull) JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 18 SAFETY 4JH4-TE Engines WARNING 128296-07300 008830-03X Figure 3 1 – Part Number: 128377-07350 3 – Part Number: 196630-12980 2 – Part Number: 128990-07270 4 – Part Number: 128296-07300 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 19 SAFETY 4JH4-HTE Engines WARNING 128296-07300 014387-01X Figure 4 1 – Part Number: 128377-07350 3 – Part Number: 128296-07300 2 – Part Number: 128990-07270 4 – Part Number: 196630-12980 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 20 SAFETY This Page Intentionally Left Blank JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 21: Product Overview

    (including the propeller) and other onboard systems. equipment, always observe the instructions and cautions given in the operation manuals The 3JH5E is 3-cylinder and naturally supplied by the shipyard and equipment aspirated. manufacturers. The 4JH5E is 4-cylinder and naturally The JH series engines are designed to be aspirated.

  • Page 22: New Engine Break-In

    Once past the initial 10 hours until 50 hours, lifetime. the engine should be used over its full A new Yanmar diesel engine must be operating range, with special emphasis on operated at suitable speeds and power running at relatively high power settings.

  • Page 23: Component Identification

    Left Side (Viewed from Flywheel) - 3JH5E IDENTIFICATION (10) Right Side (Viewed from Flywheel) - 3JH5E Figure 1 and Figure 2 illustrate a typical version of a 3JH5E engine. Your engine may have different equipment from that illustrated. (12) (11) (10) 026098-00X Figure 2 1 –...

  • Page 24: Right Side (Viewed From Flywheel) - 4Jh5E

    5 – Engine Oil Dipstick 6 – Header (fuel filter) 7 – Fuel Filter 8 – Fuel Injection Pump 9 – Engine Oil Filler Cap 10–Electric Fuel Feed Pump 11–Engine Oil Filter 12–Oil Cooler JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 25: Right Side (Viewed From Flywheel) - 4Jh4-Te

    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 JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 26: Right Side (Viewed From Flywheel) - 4Jh4-Hte

    10–Coolant Tank / Heat Exchanger 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 JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 27: Nameplates

    The marine gear nameplate (Figure 10) is attached to the marine gear. Check the marine gearʼs model, gear ratio, oil used, oil The nameplates of Yanmar JH series quantity and serial number. engines are shown in Figure 9. Check the engineʼs model, output, rpm and serial...

  • Page 28: Function Of Major Components

    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. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 29: Control Equipment

    7 – Water in Sail Drive Seal Indicator 3 – Moisture Cap for Key Switch 8 – Engine Oil Low Pressure 4 – Key Switch Indicator 5 – STOP Button 9 – Coolant High Temperature Indicator JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 30 6 – GLOW / STOP Switch 2 – Engine Oil Low Pressure 7 – Hourmeter Indicator 8 – Tachometer 3 – Water in Sail Drive Seal Indicator 4 – Battery Low Charge Indicator JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 31 12–Water in Fuel Filter Indicator (if 4 – Engine Oil Pressure Gauge equipped) 5 – Tachometer 13–Not Used on This Engine 6 – Hourmeter 7 – Moisture Cap for Key Switch JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 32 10–Tachometer 4 – Water in Fuel Filter Indicator 11–Engine Oil Pressure Gauge 5 – Water in Sail Drive Seal Indicator 12–Engine Oil Low Pressure 6 – Battery Low Charge Indicator Indicator JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 33 (if equipped) is turned on. key to OFF position. The air heater is standard on the 4JH5E and 3JH5E and optional on the 4JH4–TE and 4JH4–HTE models. When the key is released, the switch will automatically move to the ON position.
  • Page 34 Stop operation immediately to avoid damage to the engine. Check the oil level and troubleshoot the lubrication system. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 35 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) JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 36: Single-Lever Remote Control Handle

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

  • Page 37: Before You Operate

    This section of the Operation Manual Before performing any operations within this describes the diesel fuel, engine oil and section, review the Safety section on engine coolant specifications and how to page 5. replenish them. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 38: Diesel Fuel

    Biodiesel Fuels some elastomers (seal materials) and may result in fuel leakage and dilution of the Yanmar approves the use of biodiesel fuels engine lubricating oil. that do not exceed a blend of 5% non- mineral oil based fuel with 95% standard •...

  • Page 39: Handling Of Diesel Fuel

    Hold the hose nozzle firmly against the side of the container while filling it. This prevents static electricity buildup which could cause sparks and ignite fuel vapors. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 40 (0.75 to 1.125 in.) above the bottom of The recommended fuel / water separator the tank so that only clean fuel is distributed (optional) is installed at the center section of to the engine. that line. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 41: Filling The Fuel Tank

    BEFORE YOU OPERATE Filling the Fuel Tank Fuel System - 3JH5E and 4JH5E Before filling fuel tank for the first time: (11) WARNING! Fire and Explosion Hazard. NEVER refuel with the engine running. Rinse fuel tank with kerosene or diesel fuel.
  • Page 42 BEFORE YOU OPERATE Bleeding the Fuel System - 4JH4-TE Figure 5 shows 4JH5E and 3JH5E is and 4JH4-HTE similar. 0004494 Figure 6 1 – Priming Pump 2 – Air Bleed Screw 3 – From Fuel Tank 027141-00X Figure 5 4 – To Fuel Injection Pump 1 –...

  • Page 43: Engine Oil

    • 4JH4-TE and 4JH4-HTE: API Service engine has been operated. Categories CD or higher. Engine Oil Viscosity • 3JH5E and 4JH5E: API Service Category SAE 10W30 or SAE 15W40 are the CF-4 and CI-4. recommended oil viscosities. • SAE Viscosity: 10W30, 15W40. Engine oil...

  • Page 44: Adding Engine Oil

    Gear Lube. Checking Marine Gear Oil 0004491 Figure 9 Note: 4JH4-TE with KMH4A marine gear shown. 1. Make sure engine is level. QuickSilver is a registered trademark of Brunswick ® Corporation. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 45: Adding Marine Gear Oil

    LLC, as a harmful sludge may form. Mixing different brands of antifreeze may cause chemical reactions, and may make the antifreeze useless or cause engine problems. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 46: Checking And Adding Coolant

    4 – Coolant Tank (heat exchanger) 5 – Flywheel Housing 026100-00X Figure 11 1 – Flywheel Housing 026115-00X 2 – Coolant Drain Cock Figure 13 3 – Stop Solenoid 1 – Coolant Drain Cock JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 47 1 – Coolant Drain Cock 2 – Seawater Drain Cock 0004561 3 – Marine Gear Cooler Figure 17 1 – Coolant Drain Cock 2 – Seawater Drain Cock 3 – Marine Gear Cooler JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 48 Fill until coolant overflows from the filler port. 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) JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 49: Cranking The Engine

    See your Perform in accordance with the following authorized Yanmar dealer or distributor. procedures before beginning operation. 1. Open seacock. 2. Open fuel cock.
  • Page 50 BEFORE YOU OPERATE 6. 3JH5E / 4JH5E models: a. While pushing the STOP button on the control panel, turn the key to the START position (Figure 20, (4)). NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

  • Page 51: Engine Operation

    Before performing any operations within this describes the diesel fuel, engine oil and section, review the Safety section on engine coolant specifications and how to page 5. replenish them. It also describes the daily engine checkout. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 52 3 seconds after the key switch to start the engine. the ignition switch is turned to the ON position, see your authorized Yanmar Sudden Movement Hazard Marine dealer or distributor for service before operating the engine.

  • Page 53: Starting The Engine

    ENGINE OPERATION STARTING THE ENGINE NOTICE • Contact your authorized Yanmar Marine Before Starting the Engine engine dealer or distributor if the engine 1. Open the seacock (if equipped). will be operated outside of this standard 2. Open the fuel tank cock.

  • Page 54: If The Engine Fails To Start

    If air is in the fuel system, fuel cannot reach the starter motor will overheat. the fuel injection pump. Bleed the air out of the system. See Bleeding the Fuel System on page 35. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 55: After The Engine Has Started

    For troubleshooting assistance, see Troubleshooting After Starting on page 83 or Troubleshooting Chart on page 85. If necessary, see your authorized Yanmar dealer or distributor. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 56: Shifting The Engine

    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. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 57: Cautions During Operation

    Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 58: Shutting Down The Engine

    (approximately 1000 rpm) without load Emergency Shutdown for 5 minutes. NOTICE: For maximum NOTICE: NEVER use the emergency stop engine life, Yanmar recommends that switch for a normal engine shutdown. Use when shutting the engine down, you this switch only when stopping the engine allow the engine to idle, without load, for suddenly in an emergency.

  • Page 59: Checking The Engine After Operation

    WARNING! Sever Hazard. ALWAYS heater (if equipped). keep hands, body parts and loose-fitting clothes away from moving / rotating parts such as the flywheel or PTO shaft. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 60 ENGINE OPERATION This Page Intentionally Left Blank JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 61: Periodic Maintenance

    ALWAYS use the engine lifting eyes when lifting the engine. Additional equipment is necessary to lift the marine engine and marine gear together. ALWAYS use lifting equipment with sufficient capacity to lift the marine engine. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 62 Be sure to possible to the welding point. use Yanmar genuine replacement parts. • NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket.

  • Page 63: Precautions

    WARNING! Exhaust Hazard. NEVER Yanmar Replacement Parts block windows, vents, or other means of Yanmar recommends that you use genuine ventilation if the engine is operating in Yanmar parts when replacement parts are an enclosed area. All internal needed. Genuine replacement parts help combustion engines create carbon ensure long engine life.

  • Page 64: Tightening Fasteners

    M8x1.0 — 34.3 ± 2 (25.3 ± 1.5) High pressure pipe nut M12x1.5 — 29.4 to 34.4 (21.7 to 25.4) Starter relay nut M6x1 — 3.6 ± 0.6 (2.7 ± 0.4) JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 65: Epa Maintenance Requirements

    EPA requirements in part or in whole. Determine and follow the emission regulations in the country where your engine will be operating to assist you in specified compliance. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 66: Conditions To Ensure Compliance With Epa Emission Standards

    The lubricating oil should be: • 4JH4-TE and 4JH4-HTE: Type API, Class CD or higher • 3JH5E and 4JH5E: Type API, Class CH-4 and CI-4 only Be sure to perform inspections as outlined in Periodic Maintenance Procedures on page 66 and keep a record of the results.

  • Page 67: Inspection And Maintenance

    1. The connection should be located as far downstream as reasonably practicable from any sharp bend (of 30° or more) in the exhaust pipe to help ensure that a well-mixed exhaust flow sample may be taken; JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 68: Periodic Maintenance Schedule

    See your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a ●.
  • Page 69 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 See Dai- hours or 1000 monthly hours or hours or hours or...
  • Page 70 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 See Dai- hours or 1000 monthly hours or hours or hours or...

  • Page 71: 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: 3JH5E is certified as EPA CI marine engine and ARB non-road engine • Marine diesel engines greater than 37 kW: 4JH5E, 4JH4-TE and 4JH4-HTE are certified...

  • Page 72: Periodic Maintenance Procedures

    See Draining the Fuel Tank on Before you head out for the day, make sure page 67. the Yanmar engine is in good operating NOTICE: If any problem is noted during the condition. NOTICE: It is important to perform...

  • Page 73: After Initial 50 Hours Of Operation

    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. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 74 Drain marine gear oil. NOTICE: ALWAYS be environmentally responsible. 0004508 Figure 2 Note: 4JH4-TE shown. 4. Install a new filter element and tighten by hand until the seal touches the housing. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 75: Control Cables

    NOTICE: When there is too much tension in See your authorized Yanmar Marine dealer the V-belt, the belt will become damaged or distributor to adjust the intake / exhaust more quickly and the freshwater pump valve clearance.
  • Page 76 NEUTRAL, 4 – Low-Speed Stop FORWARD and REVERSE positions. 5 – Control Lever Use the NEUTRAL position as the 6 – High-Speed Stop standard for adjustment. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 77 This is considered normal maintenance and the adjustment requires specialized knowledge and techniques. Consult your authorized Yanmar Marine dealer or distributor. Check for any unusual noise and vibration in the engine / boat hull, while increasing and decreasing the engine speed gradually.

  • Page 78: Every 50 Hours Of Operation

    PERIODIC MAINTENANCE 3JH5E and 4JH5E (Attach to Hull) Every 50 Hours of Operation Perform the following procedures every 50 hours thereafter or monthly, whichever comes first. • Draining Fuel Filter / Water Separator • Checking Battery Electrolyte Level (Serviceable Batteries Only)
  • Page 79 See Draining the Fuel Tank on page 67. NOTICE: ALWAYS be environmentally responsible. Dispose of the collected water and dirt properly. 5. Tighten the drain plug. 6. Remove the drain tube. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 80: Every 250 Hours Of Operation

    Wipe up any spills immediately. WARNING! Exposure Hazard. Wear eye protection. The fuel system is under pressure and fuel could spray out when removing any fuel system component. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 81 5. Disconnect the electrical connectors and remove the alarm switch with a Component Part No. spanner wrench. Fuel Filter - 3JH5E / 119802–55801 4JH5E 6. Remove the filter housing 4. Install a new filter and hand-tighten. Use (Figure 14, (1)) with a filter wrench a filter wrench and tighten to 20 to 24 (Figure 14, (2)).
  • Page 82 Component Part No. See your authorized Yanmar Marine Fuel Filter - 4JH4- 129574-55711 dealer or distributor. TE / 4JH4-HTE Replacing the Seawater Pump Impeller 8.

  • Page 83: Changing The Coolant

    Note: When replacing a used impeller with a new one, the impeller must have an M18x1.5 thread (Figure 17, (1)). Turn the M18 screw side of the impeller to the cover side and install (Figure 18). JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 84 4 – Coolant Drain Cock 5 – Flywheel Housing 026100-00X Figure 21 1 – Flywheel Housing 2 – Coolant Drain Cock 026115-00X 3 – Stop Solenoid Figure 23 1 – Coolant Drain Cock JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 85 4 – Marine Gear Cooler 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. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 86 PERIODIC MAINTENANCE Checking the Wiring Connectors 1. Open all coolant drain cocks. See your authorized Yanmar Marine dealer 2. Allow to drain completely. Dispose of or distributor. waste properly. 3. Close all the drain cocks. Tightening All Major Nuts and Bolts 4.

  • Page 87: Every 500 Hours Of Operation

    500 hours or 2 years, whichever • Checking Diaphragm Assembly comes first, even if no damage is found. (3JH5E / 4JH5E Only) • Replacing the Alternator V-Belt See your authorized Yanmar Marine dealer • Adjusting Intake / Exhaust Valve or distributor. Clearance Replacing Rubber Hoses •...
  • Page 88 Adjusting Intake / Exhaust Valve Seawater Passages Clearance After prolonged use, clean the seawater See your authorized Yanmar Marine dealer passages to remove trash, scale, rust and or distributor. other contaminants that collect in the Checking the Remote Control Cable cooling water passages.

  • Page 89: Troubleshooting

    Is there water, oil or fuel leakage? Are there any loose bolts or connections? Check the engine room daily for any leaks or loose connections. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 90: Troubleshooting Information

    See Bleeding the Fuel System on to the Troubleshooting Chart on page 85 page 35. or see your authorized Yanmar Marine When operating the engine at low speed dealer or distributor. for long periods of time, race the engine Supply the authorized Yanmar Marine once every 2 hours.

  • Page 91: Troubleshooting Chart

    Check battery fluid level, See Checking specific gravity or the Battery Elec- replace battery. trolyte Level (Serviceable Batteries Only) on page 73 Alternator power generation See your authorized failure. Yanmar Marine dealer or distributor. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 92 Power lacking due to See your authorized Yanmar accessory drive being Marine dealer or distributor. engaged. • Engine cannot be Internal parts seized. See your authorized turned manually Yanmar Marine dealer or distributor. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 93 Yanmar Marine dealer or distributor. • Fuel injection timing off. See your authorized Yanmar Marine dealer or distributor. • Engine burning oil (excessive See your authorized consumption). Yanmar Marine dealer or distributor. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 94 TROUBLESHOOTING This Page Intentionally Left Blank JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 95: Long-Term Storage

    6 months. If it remains unused for longer than this, please contact your authorized 1. Wipe off any dust or oil from the outside Yanmar Marine dealer or distributor. of engine. Before performing any storage procedures 2. Drain water from fuel filters.

  • Page 96: Drain Seawater Cooling System

    3 – Coolant Drain Cock 4 – Coolant Tank (heat exchanger) 026115-00X 026100-00X Figure 2 Figure 4 1 – Flywheel Housing 1 – Coolant Drain Cock 2 – Coolant Drain Cock 3 – Stop Solenoid JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 97 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. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 98: Returning The Engine To Service

    5. Check fluid levels and check engine for cover of the seawater pump. Remove leaks. the cover and drain the seawater. 3. Install cover and tighten bolts. 4. Close all the drain cocks. JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 99: Specifications

    (5.3 ± 0.3 qt) Oil pan only 4.5 ± 0.3 L 5.0 ± 0.3 L (5.3 ± 0.3 qt) (4.8 ± 0.3 qt) Effective*** 1.1 L (1.2 qt) 1.2 L (1.3 qt) JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 100: 3Jh5E Marine Gear Specifications

    *** 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. Fuel temperature at the inlet of the fuel injection pump. 1 hp metric = 0.7355 kW 3JH5E Marine Gear Specifications Model KM35P KM35A...

  • Page 101: 4Jh5E Engine Specifications

    *** 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. Fuel temperature at the inlet of the fuel injection pump.1 hp metric = 0.7355 kW JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 102 *** 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. Fuel temperature at the inlet of the fuel injection pump. 1 hp metric = 0.7355 kW JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 103: 4Jh5E Marine Gear Or Sail Drive Specifications

    (effective) L(0.6 qt) Cooling System Air cooling by fan Seawater cooling Weight 13 kg (28 lb) 29.0 kg (64 lb) 40 kg (88 lb) At continuous power engine speed 2907 rpm JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 104: 4Jh4-Te Engine Specifications

    (36.7 (30.8 in.) (30.8 in.) in.) (40.0 in.) Overall width 616 mm (24.3 in.) Overall height 659 mm (25.9 in.) Flywheel Major Dimension D339 x 66 mm (13.3 x 2.6 in.) JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 105 *** 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. Fuel temperature at the inlet of the fuel injection pump. 1 hp metric = 0.7355 kW JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 106: 4Jh4-Hte Engine Specifications

    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. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 107 SPECIFICATIONS Note: Density of fuel: 0.842g/cm at 15°C. Fuel temperature at the inlet of the fuel injection pump. 1 hp metric = 0.7355 kW JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 108: 4Jh4-Te And 4Jh4-Hte Marine Gear Or Sail Drive Specifications

    Seawater cooling System Weight 27.5 kg (61 lb) 30 kg (66 lb) 31 kg (68 lb) 30 kg (66 lb) 42 kg (93 lb) At continuous power engine speed 2907 rpm JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 109: System Diagrams

    Diesel Fuel Piping Note: • Dimension of steel pipe: outer diameter x thickness. • Dimension of rubber pipe: inner diamter x thickness. • Fuel rubber pipes (marked *) satisfy EN / ISO7840. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 110 SYSTEM DIAGRAMS 3JH5E with KM35P, KM35A Marine Gear 026104-00X Figure 1 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 111 38–Detail of Part A 18–Seawater Inlet 39–Detail of Part B 19–25.4 x t4.3 Rubber Hose 40–Detail of Part C 20–Cooling Water Pump (seawater) 41–Detail of Part D 21–28 x t4 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 112 SYSTEM DIAGRAMS 3JH5E with KM4A1 Marine Gear 026114-00X Figure 2 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 113 40–To Camshaft 19–Lubricating Oil Inlet Filter 41–Detail of Part A 20–Main Bearing 42–Detail of Part B 21–Seawater Inlet 43–Detail of Part C 22–25.4 x t4.3 Rubber Hose 44–Detail of Part D JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 114 SYSTEM DIAGRAMS 3JH5E with SD50 Sail Drive 026105-00X Figure 3 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 115 17–Heat Exchanger 38–To Camshaft 18–Lubricating Oil Inlet Filter 39–Detail of Part B 19–Main Bearing 40–Detail of Part C 20–25.4 x t4.3 Rubber Hose 41–Detail of Part D 21–Cooling Water Pump (seawater) JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 116 SYSTEM DIAGRAMS 4JH5E with KM35P, KM35A2 Marine Gear 026106-00X Figure 4 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 117 38–Detail of Part A 18–Seawater Inlet 39–Detail of Part B 19–25.4 x t4.3 Rubber Hose 40–Detail of Part C 20–Cooling Water Pump (seawater) 41–Detail of Part D 21–28 x t4 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 118 SYSTEM DIAGRAMS 4JH5E with KM4A1 Marine Gear 026107-00X Figure 5 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 119 40–To Camshaft 19–Lubricating Oil Inlet Filter 41–Detail of Part A 20–Main Bearing 42–Detail of Part B 21–Seawater Inlet 43–Detail of Part C 22–25.4 x t4.3 Rubber Hose 44–Detail of Part D JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 120 SYSTEM DIAGRAMS 4JH5E with ZF30M Marine Gear 026108-00X Figure 6 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 121 18–Lubricating Oil Inlet Filter 39–Detail of Part A 19–Main Bearing 40–Detail of Part B 20–25.4 x t4.3 Rubber Hose 41–Detail of Part C 21–Cooling Water Pump (seawater) 42–Detail of Part D JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 122 SYSTEM DIAGRAMS 4JH5E with SD50 Sail Drive 026109-00X Figure 7 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 123 17–Heat Exchanger 38–To Camshaft 18–Lubricating Oil Inlet Filter 39–Detail of Part B 19–Main Bearing 40–Detail of Part C 20–25.4 x t4.3 Rubber Hose 41–Detail of Part D 21–Cooling Water Pump (seawater) JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 124 ( 28 ) ( 22 ) ( 23 ) ( 24 ) ( 55 ) ( 25 ) ( 20 ) ( 26 ) ( 27 ) ( 21 ) 0004181 Figure 8 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 125 24–Lubrication Oil Inlet Filter 54–Detail of Part C 25–25.4 x t4.3 Rubber Hose 55–Detail of Part D 26–25.4 x t4.3 Rubber Hose 27–7.5 x t2.5 Rubber Hose 28–25.4 x t4.3 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 126 ( 30 ) ( 25 ) ( 26 ) ( 58 ) ( 27 ) ( 21 ) ( 28 ) ( 22 ) ( 29 ) ( 23 ) 0004182 Figure 9 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 127 56–Detail of Part B 26–Lubrication Oil Inlet Filter 57–Detail of Part C 27–25.4 x t4.3 Rubber Hose 58–Detail of Part D 28–25.4 x t4.3 Rubber Hose 29–7.5 x t2.5 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 128 ( 28 ) ( 22 ) ( 23 ) ( 24 ) ( 55 ) ( 25 ) ( 20 ) ( 26 ) ( 21 ) ( 27 ) 0004183 Figure 10 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 129 24–Lubrication Oil Inlet Filter 54–Detail of Part C 25–25.4 x t4.3 Rubber Hose 55–Detail of Part D 26–25.4 x t4.3 Rubber Hose 27–7.5 x t2.5 Rubber Hose 28–25.4 x t4.3 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 130 ( 28 ) ( 27 ) ( 21 ) ( 22 ) ( 23 ) ( 24 ) ( 19 ) ( 25 ) ( 20 ) ( 26 ) 0004184 Figure 11 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 131 23–Lubrication Oil Inlet Filter 52–Detail of Part B 24–25.4 x t4.3 Rubber Hose 53–Detail of Part D 25–25.4 x t4.3 Rubber Hose 26–7.5 x t2.5 Rubber Hose 27–25.4 x t4.3 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 132 ( 22 ) ( 28 ) ( 62 ) ( 31 ) ( 23 ) ( 32 ) ( 24 ) ( 29 ) 0004591 ( 25 ) ( 33 ) Figure 12 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 133 59–Detail of Part A 27–Heat Exchanger 60–Detail of Part B 28–Main Bearing 61–Detail of Part C 29–Lubrication Oil Inlet Filter 62–Detail of Part B 30–25 x t2 C1201T 31–25.4 x t4.3 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 134 ( 28 ) ( 20 ) ( 26 ) ( 29 ) ( 21 ) ( 30 ) ( 22 ) ( 27 ) ( 31 ) ( 23 ) 0004592 Figure 13 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 135 57–Detail of Part B 26–Main Bearing 58–Detail of Part C 27–Lubrication Oil Inlet Filter 59–Detail of Part D 28–25 x t2 C1201T 29–25.4 x t4.3 Rubber Hose 30–25.4 x t4.3 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 136 ( 28 ) ( 26 ) ( 21 ) ( 29 ) ( 59 ) ( 22 ) ( 30 ) ( 27 ) ( 23 ) ( 31 ) 0004593 Figure 14 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 137 57–Detail of Part B 26–Main Bearing 58–Detail of Part C 27–Lubrication Oil Inlet Filter 59–Detail of Part D 28–25 x t2 C1201T 29–25.4 x t4.3 Rubber Hose 30–25.4 x t4.3 Rubber Hose JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 138 SYSTEM DIAGRAMS This Page Intentionally Left Blank JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 139: Wiring Diagrams

    (in. 15 (0.023) < 0.86 (0.26) 20 (0.031) < 1.3 (0.40) 30 (0.046) < 2.3 (0.70) 40 (0.062) < 2.8 (0.85) 50 (0.077) < 3.5 (1.07) 60 (0.093) < 4.1 (1.25) JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 140 SYSTEM DIAGRAMS 3JH5E / 4JH5E with C-Type Instrument Panel (Optional) 026648-00X Figure 15 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 141 SYSTEM DIAGRAMS 3JH5E / 4JH5E with C-Type Instrument Panel (Optional) 20–(Option) Controller (heater) Color Coding Engine Harness Assembly 21–Engine Stop Solenoid Black 22–Stop Relay White Ignition 23–Air Heater Blue Air Heater / Glow 24–Heater Relay (option) 25–Heater Controller Red / Black Alternator Exciter 26–Remove the connector of engine...
  • Page 142 SYSTEM DIAGRAMS 3JH5E / 4JH5E with 12V B and B x B Type Instrument Panel (Optional) 026110-00X Figure 16 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 143 SYSTEM DIAGRAMS 3JH5E / 4JH5E with 12V B and B x B Type Instrument Panel (Optional) 19–Procured by Customer Color Coding Engine Harness 20–Battery 21–Battery Switch Black 22–Engine Stop Solenoid White Ignition 23–Air Heater Blue Air Heater / Glow 24–Stop Relay (option) 25–Starter Relay...
  • Page 144 SYSTEM DIAGRAMS 3JH5E / 4JH5E with 12V C x B Type Instrument Panel (Optional) 026111-00X Figure 17 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 145 SYSTEM DIAGRAMS 3JH5E / 4JH5E with 12V C x B Type Instrument Panel (Optional) 19–Procured by Customer Color Coding Engine Harness 20–Battery 21–Battery Switch Black 22–Engine Stop Solenoid White Ignition 23–Air Heater Blue Air Heater / Glow 24–Stop Relay (option) 25–Starter Relay...
  • Page 146 SYSTEM DIAGRAMS 3JH5E / 4JH5E with Keyless B and B x B Type Instrument Panel (Optional) 026112-00X Figure 18 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 147 SYSTEM DIAGRAMS 3JH5E / 4JH5E with Keyless B and B x B Type Instrument Panel (Optional) 18–Wire Harness for Sub Panel Color Coding Engine Harness 19–Water in Sail Drive Seal Sensor Amplifier (sail drive only) Black 20–Procured by Customer White Ignition 21–Battery...
  • Page 148 SYSTEM DIAGRAMS 3JH5E / 4JH5E with Keyless C x B Type Instrument Panel (Optional) 026113-00X Figure 19 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 149 SYSTEM DIAGRAMS 3JH5E / 4JH5E with Keyless C x B Type Instrument Panel (Optional) 18–Wire Harness for Sub Panel Color Coding Engine Harness 19–Water in Sail Drive Seal Sensor Amplifier (sail drive only) Black 20–Procured by Customer White Ignition 21–Battery...
  • Page 150 SYSTEM DIAGRAMS 4JH4-TE / 4JH4-HTE with B x B Type Panel (Optional) Figure 20 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 151 12–Tachometer / Hourmeter 13–Instrument Panel (sub station) (option) 14–Instrument Panel (main station) (option) 15–Wire Harness 16–Relay 17–Wire Harness for Sub Panel 18–Water in Sail Drive Seal Sensor Amplifier (sail drive only) JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 152 SYSTEM DIAGRAMS 4JH4-TE / 4JH4-HTE with C x B Type Panel (Optional) 026653-00X Figure 21 JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 153 12–Tachometer / Hourmeter 13–Instrument Panel (sub station) (option) 14–Instrument Panel (main station) (option) 15–Wire Harness 16–Relay 17–Wire Harness for Sub Panel 18–Water in Sail Drive Seal Sensor Amplifier (sail drive only) JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 154 SYSTEM DIAGRAMS This Page Intentionally Left Blank JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 155: Epa Warranty Usa Only

    LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY. ENGINE FAMILY: 9YDXN1.64D3N DISPLACEMENT: 1.642 LITERS 129671-07710 Figure 2 ENGINE MODEL: 3JH5E EMISSION CONTROL SYSTEM: EM FUEL RATE: 32.5MM /STROKE @ 28.7kW / 3000RPM (19≤kW<37) 4JH4-HTE EPA Nameplate STANDARDS NOx+HC: 7.5g/kW-hr CO: 5.5g/kW-hr PM: 0.30g/kW-hr APPLICATION: VARIABLE-SPEED PROPULSION ENGINES USED WITH FIXED-PITCH PROPELL ERS.

  • Page 156: Your Warranty Rights And Obligations

    Obligations: whichever comes first. 4JH5E, 4JH4-TE (37 ≤ 60 months or 5,000 Yanmar warrants to the first user and each kW < 75) hours of use, subsequent purchaser the emission control whichever comes first. system on your engine for periods of time...

  • Page 157: Exclusions

    You are responsible for initiating the warranty process. You must present your marine engine to an authorized Yanmar dealer or distributor as soon as a problem exists. JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 158 EPA WARRANTY USA ONLY This Page Intentionally Left Blank JH Series Operation Manual © 2009 Yanmar Marine International...

  • Page 159: Emission System Warranty

    The Air Resources Board (ARB), the applicable warranty period, the part will be Environmental Protection Agency (EPA) replaced by Yanmar. and Yanmar Co., Ltd. hereafter referred to as Yanmar, are pleased to explain the Engine Model Warranty Period emission control system warranty on your 3JH5E (19 ≤...

  • Page 160: 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 161 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 America Corporation, Marine Engine Division for assistance. Yanmar America Corporation, Marine...

  • Page 162: Maintenance Log

    Maintenance Log Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 163 Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature JH Series Operation Manual © 2009 Yanmar Marine International...
  • Page 164 JH Series Operation Manual © 2009 Yanmar Marine International...

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