Yanmar 3JH3(8)E User manual

I MARINE DIESEL ENGINE
MODELS:
3JH3(8)E, 3JH3(C)E*, 4JH3(8)E, 4JH3(C)E
*The 3JH3(C)E is an EPA Certified Engine.
It meets the low emission standards set bythe EPA.
OPERATION MANUAL
California
Proposition 65 Warning
Diesel engineexhaust and some of
its constituents are recognized by
the State of California to cause
cancer, birth defects, and other
reproductive harm.
•

Contents
CONTENTS
INTRODUCTION .............................................. 3
FOR YOUR SAFETY ................................... 4
1.1 Warning symbols................................ 4
1.2 Safety Precautions.............................. 4
1.3 Warning Labels................................... 7
2 PRODUCT EXPLANATION ......................... 8
2.1 Use, Driving System etc...................... 8
2.2 Engine Specifications ......................... 9
2.3 Names
of Parts..................................13
2.4 MajorServicing Parts.........................15
2.5 Control Equipment ............................16
2.5.1 Control Panel...........................16
2.5.2 Single Lever Remote
Control Handle ........................18
2.5.3 Stopping Equipment ...............18
3 OPERATION ..............................................19
3.1 Fuel Oil, Lube Oil & Cooling Water .....19
3.1.1 Fuel Oil ....................................19
3.1.2 Lube Oil ...................................20
3.1.3 Cooling Water..........................20
3.2 Before Initial Operation...................... 21
3.2.1 Supply Fuel Oil ........................ 21
3.2.2 Supply Engine Lube Oil .......... .21
3.2.3 Supply Clutch Lube Oil ........... 22
3.2.4 Supply Cooling Water............. 22
3.2.5 Cranking (Idling)...................... 23
3.2.6 Check and Resupply Lube
Oil and Cooling Water............. 24
3.3 Operating your Engine ...................... 25
3.3.1 Inspection Before Starting...... 25
3.3.2 How
to Startthe Engine .......... 26
2
3.3.3 Operation................................ 28
3.3.4 Cautionsduring Operation...... 29
3.3.5 Stopping the Engine ............... 29
3.4 Long term Storage............................ 30
4 MAINTENANCE & INSPECTION ............... 32
4.1 General Inspection Rules.................. 32
4.2 List of Periodic Inspection Items....... 33
4.3 Periodic Inspection Items ................. 35
4.3.1 Inspection on Initial 50 Hrs. of
Operation (or after 1 month).... 35
4.3.2 Inspection Every 50 Hours
(or monthly)............................. 35
4.3.3 Inspection Every 150 Hrs........ 37
4.3.4 Inspection Every 300 Hrs........ 37
4.3.5 Inspection Every 600 Hrs........ 38
4.4 EPA Requirements ........................... 40
4.4.1 EPA Certification Plate............ 40
4.4.2 Conditions to Insure
Compliance with Emission
Standards............................... 40
4.4.3 Inspection and Maintenance.... 41
5 TROUBLEAND TROUBLESHOOTING..... 42
6 PIPING DIAGRAMS...................................45
7 WIRING DIAGRAMS..................................46
APPENDIXA (Piping diagrams)..................... A-1
(See the back
of this Manual)
APPENDIX B (Wiring diagrams) .................... B-1
(See the back of this Manual)

Introduction
Thankyou for purchasing a YANMAR Marine Diesel Engine.
This Operation Manual describes the operation, maintenance and inspection of the
3JH3(8)E, 3JH3(C)E, 4JH3(8)E, 4JH3(C)E Yanmar Marine Diesel Engines.
Read this Operation Manual carefully before operating the engine
to ensure that it is used
correctlyand that it stays in the best possible condition.
Keep thisOperation Manual
in aconvenient placeforeasy access.
Ifthis Operation Manual is lostordamaged, order a new onefrom yourdealer or distributor.
Make sure this manual is transfered
to subsequent owners. It should be considered as a
permanent part
of theengine and remain so. E
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 anyquestions aboutthis, please contactyourYanmar dealerordistributor.
The marinegeardescribed
in this manual is Yanmar Model KM Series.
Models 3JH3(B)E, 3JH3(C)E, 4JH3(B)E, 4JH3(C)E
Operation Manual
(Marine Engine)
Code. No. 499613 -02780
The essentials of the sail drive are described in this manual. For further details on its use,
refer to the sail drive manual.
3

1. Foryour safety
1.1 WARNING SYMBOLS
Most operation, maintenance and inspection problems arise due to users' failure to comply
with the rules and precautions for safe operation described in this operation manual. Often,
users do not understand or recognize the signs of approaching problems. Improper
handling can cause burnsand otherinjuries and can result
in death.
Be sure
to read this operation manual carefully before operating the engine and observe all
of the instructionsand precautionsdescribed in this manual.
Below follow the warning signs used
in this manual. Pay special attention to parts
containing these wordsand signs.
A DANGER DANGER indicates
an imminently hazardous
situation which, if not avoided, WILL result in death
or serious injury.
A WARNING WARNING indicates a potentially hazardous situa-
tion which, if not avoided, COULD result in death or
serious injury.
A CAUTION CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury.
This sign is also be used to alert against unsafe
practices.
NOTICE
The descriptions captioned by are particularly important cautions for
handling. If you ignore them, the performance of your machine may deteriorate leading to
problems.
1.2 SAFETY PRECAUTIONS
(Observethese instructionsforyourown safety!)
Precautions for Operation
4
Filler
Cap of Fresh Water Tank
Never open the cap of the fresh water tank while the engine is still hot.
Steam and hot water will spurt out and burn you seriously. Wait until the
temperature of the fresh water tank has dropped, wrap a cloth around
the filler cap and loosen the cap slowly. After inspection, refasten the
cap firmly.

1. Foryoursafety
Battery
Never smoke or permit sparks near the battery, because it may emit
explosive hydrogen gas. Placethe battery in a well-ventilated place.
Fuel
Use only diesel oil. Never use other fuels, including gasoline, kerosene,
etc., because they could cause a fire. The wrong fuel could also cause
the fuel injection pump and injector
to fail due to lack of proper
lubrication. Be sure
to check that you have selected the correct diesel
fuel before filling thefuel tank.
Fire Prevention
Be sure to stop the engine and confirm that there are no open flames in
the vicinity before supplying fuel. If you do spill fuel, wipe such spillage
carefully and dispose ofthe wiping materials properly. Wash your hands
thorougly with soap and water.
Neverplace oil
or otherflammable material in the engine room.
Install a fire extinguisher near the engine room, and familiarize yourself ~
with its use. IiIiI
Exhaust Gas
Exhaust gas contains poisonous carbon monoxide and should not be
inhaled.
Be sure to install ventilation ports or ventilators in the engine room and
ensure good ventilation during engine operation.
Moving Parts
Do not touch or let your clothing get caught in the moving parts of the
engine, such as the front drive shaft, V-belt or propeller shaft, during
engine operation. You will be injured.
Neveroperate the engine withoutthe covers on the moving parts.
Burns
The whole engine is hot during operation and immediately after
stopping. The exhaust manifold, exhaust pipe and high pressure fuel
pipeare very hot. Nevertouch these parts with your body orclothing.
5

1. Foryour safety
Pi'!f.! ... I·U'
~
fl'·Wlij#;-
6
Alcohol
Neveroperate the engine while you are underthe influence of alcohol.
Neveroperate the engine when you are ill orfeeling unwell.
SAFETY PRECAUTIONS FOR INSPECTION
Battery Fluid
Battery fluid is dilute sulfuric acid. It can blind you if it gets in your eyes,
or burn your skin. Keep the fluid away from your body. If you touch it,
wash it off immediately with a large quantity or fresh water and call your
doctor fortreatment.
Fire by Electric Short-Circuits
Always turn off the battery switch before inspecting the electrical
system.
Failure
to do so could cause short-circuiting and fires.
Stopthe engine before servicing
Stopthe engine before you service it.
Turn the battery switch off. If you must inspect while the engine is in
operation, never touch moving parts. Keep your body and clothing well
clear
of all moving parts.
Scalds
If extracting oil from the engine while it is still hot, don't let the oil splash
on you.
Wait until the temperature has dropped before extracting cooling water
from theengine. Don't let it splash on you.
Forbidden Modifications
Never release the limiting devices such as the engine speed limit, fuel
injection limit, etc.
Modification will impair the safety and performance
of the product and
shorten product life.
Also note that any troubles arising from modification are not covered by
ourwarranty.
Precautions for Treating Waste
Neverdispose of waste oil or otherfluid in a field, sewer, river, or the sea.
Treat waste matterssafely observing regulations
or laws.
Aska waste recovery company to collect it.

1. For your safety
SAFETYPRECAUTIONS FOR INSPECTION
1.3 WARNING LABELS
To insure safe operation, warning device
labels have been attached. Their location is
shown below and theyshould always
be
visible. Please replace if damaged or lost.
CD
3JH3(8)(C)E
CD
4JH3(8)(C)E
Warning Device Labels, Parts Numbers
No.
eD
®
Part Code No.
128296-07260
120324-07350
CD • &
AWARNING
A.
I!
Iii
ttil>hJlt: •
• Rolatlng parI •.
-Can Cau •• injury.
T282915-07350
@ .~ •• DANGER
~
•• ;a1l!1~J:~1',7'l1l11
.. t.I:~\t:"'Fl!~\. e.;aIJl~~
WI,.,~I1C~T~laft'H'o
e Naver ramov. th. cap while th. engine
il
11111 hoi. eHol wal.r ma, spurt out
end burn you. 1211296-07150
7

2. Productexplanation
2.1 USE, DRIVING SYSTEM, ETC.
The engine is equipped with a marine gear or a sail drive unit. The marine gear output shaft
connects with the propellorshaft.
In order to obtain full performance from your engine, it is imperative that you check the size
and structure ofthe hull and use a propeller ofthe appropriatesize.
The engine must be installed correctly with safe cooling water and exhaust piping and
electrical wiring. The PTO workshould be easy to useforonboard equipment.
To handle the drive equipment, driven systems (including the propeller) and other onboard
equipment,be sure
to observe the instructions and cautions given in the operation manuals
supplied bythe shipyard and equipment manufacturers.
The laws ofsome 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. Consult Yanmar's local subsidiary
in your region or your distributor or
dealer.
A WARNING
Never modify this product or release the limit devices (which limit engine
speed, fuel injection quantity, etc.). Modification will impair the safety and
performance
of the product and functions and shorten the product life. Please
note that any troubles arising from modification of the product will not be
covered byourwarranty.
DETAIL OF NAME PLATE
The name plate shown below is attached to
the engine. Check the engine's model,
output, rpm and serial number on the name
plate.
MODEL __________________ __
CONT.RATING __ --=:k:.:..W=-- __ ~r;.::;p.;.;.;m
MAX.OUT PUT __ ......;.;k;.;.W~ ___ r~p_m
8
The name plate shown below is described
in the marine gear. Checkthe marine gear's
model, gear ratio, oil used, oil quantity and
serial number.
0
MODEL
KM
0
GEAR RATIO
OIL SAE
2o
IJoHD
OIL QTY.
LTR.
NO.
1f6l1lZIIIC'
0
OSAKA JAPAN
0

2. Productexplanation
2.2 Engine Specifications
2.2.1
Engine Model
Type
Combustion system
Numberof cylinders
Bore x stroke
Displacement
Output/crankshaft
Continuous speed
rating output Brake mean
effective pressure
Piston speed
Output/crankshaft
One hour speed
rating output Brake mean
effective pressure
Piston speed
Compression ratio
Fuel injection timing (b.T.D.C.)
Fuel injection pressure
Main powertake off
Front powertakeoff
Direction
of
Crankshaft
rotation Propellershaft(Ahead)
Cooling system
Lubrication system
Type
Starting Starting motor
system AC generator
Model
Type
Reduction Forward
ratio Reverse
Marine Gear Forward
or Sail Drive Propeller
speed Reverse
Lubricating oil capacity
Weight
Overall length
Dimensions Overall width
Overall height
Lubricating oil Total
capacity Effective
Engine weight
without marine gear/ sail drive
mm
e
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
kg/cm'
rpm
rpm
standard
unite
long-reach
unite
kg
mm
mm
mm
e
e
kg
(Note) 1. Rating condition: ISO 3046-1. 2.1 hp=0.7355 kW.
3JH3E 3JH3BE
Vertical 4-cyclewatercooled diesel engine
Direct injection
3
84x90
1.496
26.5/3650 (36/3650)
5.93
10.95
29.4/3800 (40/3800)
6.33
11.4
18.6
14±1
220±5
At Flywheel side
At CrankshaftV-pulley side
Counter-clockwiseviewed from stern
Clockwiseviewed from stem
Fresh water cooling with heatexchanger
Completeenclosed forced lubrication
Electric
DC 12V, 1.2 kW
12V,
55A (12V, 80A optional)
KM3P KM3A
Mechanical cone clutch with single stage forboth ahead and astern
2.36
2.61 3.20 2.33 2.64
3.16 3.16 3.16 3.04 3.04
1547 1399 1141 1564 1384
1155 1156 1156 1199 1199
0.35 0.45
-
13
755.6 752.8
520.6 520.6
624.9 624.9
5.0
(at rake angle 8') 5.5 (at rake angle 0')
1.1 (at rake angle 8') 1.2
(at rake angle 0')
173
9

2. Productexplanation
2.2 Engine Specifications
2.2.2
Engine Model
Type
Combustion system
Numberofcylinders
Bore x stroke
Displacement
Output/crankshaft
Continuous speed
rating output Brake mean
effective pressure
Piston speed
Output/crankshaft
One hour speed
rating output Brake mean
effective pressu
re
Piston speed
Compression ratio
Fuel injectiontiming (b.T.D.C.)
Fuel injection pressure
Main powertake off
Front powertake off
Direction
of
Crankshaft
rotation Propellershaft(Ahead)
Cooling system
Lubrication system
Type
Starting Starting
motor
system AC generator
Model
Type
Reduction Forward
ratio Reverse
Marine Gear Forward
orSail Drive Propeller
speed Reverse
Lubricating oil capacity
Weight
Overall length
Dimensions Overall width
Overall height
Lubricating oil Total
capacity Effective
Engine weight
without marine gear/ sail drive
mm
e
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
kg/cm'
rpm
rpm
standard
unite
long-reach
unite
kg
mm
mm
mm
e
e
kg
(Note) 1. Rating condition: ISO 3046-1.
2. 1 hp=O. 7355 kW.
10
3JH3CE
Vertical4-cyclewatercooled diesel engine
Directinjection
3
84x90
1.496
26.5/3650 (36/3650)
5.93
10.95
29.4/3800 (40/3800)
6.33
11.4
18.6
14±1
220±5
At Flywheel side
At CrankshaftV-pulley side
Counter-clockwiseviewed from stern
Clockwiseviewed from stern
Fresh watercooling with heat exchanger
Completeenclosed forced lubrication
Electric
DC 12V, 1.2 kW
12V, 55A (12V, 80Aoptional)
SD31
SD40
Sail drive unit- Dog typeclutch, spiral bevel gear
type
2.31 2.32
2.31 2.32
1580 1632
1580 1632
2.2 1.8
2.5 -
33 39
545.8 545.8
520.6 520.6
624.9 624.9
5.5 (at rake angle
0°)
1.2 (at rake angle 0°)
173

2. Productexplanation
2.2 Engine Specifications
2.2.3
Engine Model
Type
Combustion system
Number
of cylinders
Bore x stroke
Displacement
Output/crankshaft
Continuous speed
rating output Brake mean
effective pressure
Piston speed
Output/crankshaft
One hour speed
rating output Brake mean
effective pressure
Piston speed
Compression ratio
Fuel injection timing (b.T.D.C.)
Fuel injection pressure
Main powertake
off
Front powertake off
Direction
of
Crankshaft
rotation Propellershaft (Ahead)
Cooling system
Lubrication system
Type
Starting Starting motor
system AC generator
Model
Type
Reduction Forward
ratio Reverse
MarineGear Forward
or Sail Drive Propeller
speed Reverse
Lubricating oil capacity
Weight
Overall length
Dimensions Overall width
Overall height
Lubricating oil Total
capacity Effective
Engine weight
without marine gear/ sail drive
mm
e
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
°
kg/cm'
rpm
rpm
standard
unite
long-reach
unite
kg
mm
mm
mm
e
e
kg
4JH3E 4JH3BE 4JH3WE
Vertical4-cyclewatercooled diesel engine
Direct injection
4
84x90
1.995
36.8/3650
(50/3650)
6.18
10.95
41.2/3800
(56/3800)
6.65
11.4
17.7
12±1
220±5
At Flywheel side
At Crankshaft V-pulley side
Counter-clockwiseviewed from stern
Clockwiseviewed from stern
Fresh water
COOling with heatexchanger
Completeenclosed forced lubrication
Electric
DC 12V, 1.2 kW
12V,
55A (12V, 80A optional)
KM3P KM3A I KBW20-1
Mechanical coneclutch with single stagefor both ahead and astern
2.36
2.61
2.33
2.64 2.17 2.62
3.28
3.16
3.16 3.04 3.04 3.06 3.06 3.06
1547 1399 1564 1384
1685
1394 1114
1156 1156 1199 1199 1195 1195 1195
0.35 0.45 1.2
-
13 26
849.6 885.8 922.8
563.1 563.1 576.6
619.9 619.9 619.9
5.3* 5.8 (at rake angle
0°)
1.2* 1.4
(at rake angle 0°)
210 236
(Note) 1. Rating condition: ISO 3046-1. 2.1 hp=0.7355 kW. *At rake angle 8°
11

2. Productexplanation
2.2 Engine Specifications
2.2.4
Engine Model
Type
Combustion system
Number
of cylinders
Bore x stroke
Displacement
Output/crankshaft
Continuous speed
rating output Brake mean
effective pressure
Piston speed
Output/crankshaft
One hour speed
rating output Brake mean
effective pressure
Piston speed
Compression ratio
Fuel injectiontiming (b.T.D.C.)
Fuel injection pressure
Main powertake off
Front powertake off
Direction of Crankshaft
rotation Propeller shaft (Ahead)
Cooling system
Lubrication system
Type
Starting Starting
motor
system AC generator
Model
Type
Reduction Forward
ratio Reverse
MarineGear Forward
or Sail Drive Propeller
speed Reverse
Lubricating oil capacity
Weight
Overall length
Dimensions Overall width
Overall height
Lubricating oil Total
capacity Effective
Engine weight
without marinegear/ sail drive
mm
e
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
kW/rpm
(hp/rpm)
kg/cm'
m/sec.
°
kg/cm'
rpm
rpm
standard
unite
long-reach
unite
kg
mm
mm
mm
C
C
kg
(Note)
1. Rating condition: ISO 3046-1. 2. 1hp=0.7355 kW.
12
1.47
1.47
2485
2483
4JH3B4E 4JH3CE 4JH3CE1
Vertical4-cyclewatercooled diesel engine
Direct injection
4
84x90
1.995
36.8/3650 34.6/3650 36.8/3650
(50/3650)
(47.3/3650)
(50/3650)
6.18
5.81
6.18
10.95
41.2/3800 38.2/3800 41.2/3800
(56/3800) (52/3800) (56/3800)
6.65
6.17
6.65
11.4
17.7
12±1
220±5
At Flywheel side
At Crankshaft V-pulley side
Counter-clockwiseviewed from stern
Clockwiseviewed from stern
Fresh watercooling with heat exchanger
Completeenclosed forced lubrication
Electric
DC 12V, 1.2 kW
12V,
55A(12V, 80Aoptional)
KM4A1 SD31
SD40
Sail drive unit- Dog typeclutch, spiral bevel geartype
2.14 2.63 3.30
2.31
2.32
2.14 2.63 3.30
2.31
2.32
1708 1389 1107 1580 1632
1706 1388 1106 1580 1632
1.3 2.2 1.8
-2.5 -
27.5 33 39
905.8 639.8 639.8
580.6 563.1 563.1
619.9 623.6 623.6
5.8 (at rake angle
0°)
1.4(at rake angle 0°)
238 210

2. Productexplanation
2.3 Names of Parts
Operation Side
3JH3(B)(C)E
Marine gear
Shift lever
Intake manifold Dipstick
Fuel filter
Fuel oil pump
Oil filler cap
Fuel feed pump
Lube oil filter
Note: This illustration shows Yanmar marine gear(Model: KM3A) after it has been attached.
Non Operation Side
3JH3(B)(C)E
Fresh water pump V-belt Fresh watertank
Alternator
Exhaust manifold
Starter motor
Seawater pump
13

2. Productexplanation
Operation Side
4JH3(8)(C)E
Marine
gear
Shift
lever
Oil FilterCap (Marine gear)
Intake manifold
Fuel filter
Fuel oil pump
Oil filler cap
Fuel feed pump
Lube oil filter
Note: This illustration showsYanmar marine gear (Model: KM3A) afterit has been attached.
Non Operation Side
4JH3(8)(C)E
Fresh water pump
14
V-belt Fresh watertank
Alternator
Exhaust
manifold
Startermotor
Seawaterpump

2. Productexplanation
2.4 Major Servicing Parts
Name of part Function
Fuel filter Removes dustand waterfrom fuel. Drain the filter periodically. The internal
element (filter) should be changed periodically.
Fuel feed pump Feed fuel to the fuel injection pump. Moving the priming
Priming lever lever up and down feeds the fuel. When there is no fuel, the priming lever
is used to bleed air from the fuel system.
Filler port (engine) Filler portforengine lube oil.
Fillerport (marine gear) Filler portfor marine gear lube oil.
Lube oil filter Filters fine metal fragments and carbon from the lube oil.
Filtered lube oil is distributed
to the engine's moving parts.
Cooling System Seawater passes through the heat exchanger cooling the fresh water,
which
in turn coolsthe engine.
Fresh water cooling
Fresh water pump
There are two cooling systems: fresh waterand seawater.
The fresh water pump is
run bythealternatorand the V-belt.
Fresh watercooling The fresh water in the fresh water cooler is fed to the engine by the fresh
water pump. The cooling fresh water returns to the engine after it is cooled
with seawater in thefresh water cooler.
Filler cap
The filler cap on the cooling water tank covers the water supply port. The
cap has a pressure regulating valve. When the cooling water temp. rises,
the pressure rises insidethe fresh water cooler.
Subtank The pressure regulating valve releases vaporand hot water overflow to the
subtank.
Rubber hose The hose connects the filler cap and subtank. Vapor and hot water
discharged to the subtank return there
to the cooling water. When the
engine stops and cooling water cools, the pressure
in the cooling water
tank also drops very low. The filler cap valve then opens to send water
backfrom the subtank. This minimizes cooling water consumption.
Fresh water pump The centrifugal water pump circulates fresh cooling water inside the
engine. The pump and alternator are driven bythe V-belt.
Intake airsilencer This is the air intake silencer. The silencer guards against dirt in the air and
reduces the noise ofair intake.
Nameplate Name plates are provided on the engine and the marine gear and have the
model, serial numberand otherdata.
Starter Startermotorfor the engine. Powered bythe battery.
Alternator Rotates by belt drive, generates electricityand charges the battery.
15

2. Productexplanation
2.5 Control Equipment
The equipment
in the control room, making remote control possible, consists of: the
instrument panel, which is connected by wire harness; the remote control handle, which is
hooked up by remote control cable
to each of the engine control levers, and the stopping
equipment.
2.5.1 Control Panel
Electric Operation
There are two control panel options. The controls and alarm lamps included are shown
below.
8-2-type
CD Water Proof(sail drive)
@ High temp. cooling water
@ Low lubeoil pressure
@ Charge
® Key switch/start
16
® Buzzer
(J) Stop button
® Tachometre
® Illumination switch
®
@l Cooling watertemperature
® C-type
@ Lube oil pressure
@ Hour metre
® Fuse
@ Buzzer-off

2. Productexplanation
(1) Controls and Equipment
Controls and Equipment Mechanism
Key Switch
o~
Rotaryswitch with 2 positions.
In the OFF position, theswitch key can be inserted orremoved.
In OFF, all electric current is cutoff.
~M~
In ON (1 position to the right), the engine is tumed on.
In ON, electric current to the controls and equipment is turned on.
In the START position the enginewill start.
./' . The engine cannotbe stopped with the key switch.
/
Alarm Lamps
Lamps come on when there is a problem. See Section 2 forthe types of lamps and
thewaythey work.
Alarm Buzzer Buzzergoes offwhen there is a problem.
Illumination Switch
This switch turns on the control panel lamps.
Tachometre
The engine's rotation speed is indicated bythe needle.
Hour Metre
The number of hours of operation is indicated, and can beused as a guidefor periodic
(optional) maintenance checks. The hourmeteris atthe bottom
of thetachometre.
(2) Alarm Equipment (lamps and buzzer)
Mechanism
When the sensor detects a problem during
operation, the lamps come on and the
buzzer goes off.
Alarm monitors are located on the control
panel. Under normal conditions, the moni-
tors are off. When there is a problem, the
monitors light up.
(3) Alarm Devices
Check that the pilot lamps on the
instrument panel are as shown below when
thestarter key is turned on:
Low
L.O. pressure alarm lamp Lit
Pilot Charge lamp Lit
lamps Cooling watertemp. alarm lamp Off
NOTE:
All these signals will continue until the en-
ginestarts
up or the keyis turned off.
17

2. Product explanation
2.5.2 Single Lever Remote Control
Handle (MorseType) -Optional.
This remote control system uses a single
handle
to operate marinegear-clutch-
(neutral, forward, reverse) and to control the
enginespeed.
NEUTRAL: Power
to the propeller shaft is
cut off and the engine idles.
FWD (FORWARD)
REV (REVERSE)
~~·.,i-.i::
'-~ti~~//
<D FWD (forward)
o REv(reverse)
@ NEUTRAL (boat is stopped)
@ Clutch is disengaged
® Pull out handle
The handle controls the course of the boat
(ahead
or astern) and, at the same time,
acts as an accelerator increasing the engine
speed as it is pushed further
in the FWD or
REV direction. If the handle is pulled out,
engine speed can be controlled without
engaging
the clutch (clutch remains in the
NEUTRAL, noload position).
18
NOTICE
Yanmar recommends the use of a
single-lever type for the remote con-
trol lever. If only the two-lever type is
available in the market, operate the
engine at 1000 rpm or lower before
engaging and disengaging the marine
gear-clutch.
2.5.3 Stopping Equipment
Manual Operation
Engine stopping by engine stop cable
Engine stop cable
The engine is stopped by pulling out the
engine stop knob, which catches the fuel
injection pump stop lever thus cutting off
fuel injection.
Electric Operation
Stop button on the instrument panel
~
I-'
¢ "\, [
.....-J
'"
Engine stopping by stop button
Push the stop button on the instrument
panel.
A CAUTION
If the engine is stopped suddenly at a
high temperature, the temperature of
various parts will increase and engine
trouble mayoccur.

3. Operation
3.1 Fuel Oil, Lube Oil, and Cooling Water
3.1.1 Fuel Oil
NOTICE
When other than the specified fuel
oil is used, the engine will not
perform to full capacity and parts
may be damaged.
(1) Selection of Fuel Oil
Use diesel fuels for best engine perfor-
mance.
Cetane fuel number should be 45 or
greater.
(2) Handling of Fuel Oil
1) Water and dust in the fuel cause engine
failure. When fuel is stored, be sure that
the inside
of the storage container is
clean, and that the fuel is stored away
from dirt or rain water.
2) Keep the fuel container stationery for
several hours to allow any dirt or water
to settle to the bottom. Use a pump to
extract the clear, filtered fuel from the
top of the container for use.
Use the clear filtered fuel from the upper
middle section of the container only, leaving any
contaminated fuel at the bottom.
(3) Fuel Tank (optional)
Be sure to attach a drain cock to the fuel
tank to enable dirt and water to settle at
the bottom of the tank
to be drained off.
The fuel outlet should be positioned 20-
30mm above the bottom
of the tank so
that only clean fuel is used.
-+---CD
@
CD Sediment @G) Drain cock
@)Toengine
(4) Fuel System
Install the fuel pipe from the fuel tank to
the fuel pump in accordance with the
diagram. The oil/water separator (optional)
is placed at the centre section of the line.
CD
CD Fuel filter
@ Fuel feed pump
(priming lever)
®OillWater separator
@) Approx. 20-30 mm
®Within 500 mm
Fuel system
®
=-- !-::::::
® Drain cock
(j) Fuel cock
® Fuel return
®To fuel injection
pump
@)Fueltank
19

3. Operation
3.1.2 Lube Oil
NOTICE
Using other than the specified
lube oil will lead to seizure of
parts, abnormal wear, and shorten
engine life.
(1) Selection of Engine Lube Oil
Use the following lube oil:
• API Classification.............................CD
(2) Selection of Oil for Marine Gear
• API Classification.............................CD
(3) Selection of Oil for Sail Drive Unit
SAE Viscosity ...................90 or 80W90
(4) Handling the Lube Oil
1) When handling and storing lube oil, be
careful not to allow dust and water to
enter the lube oil. Clean around the
filter port before refilling.
2) Do not mix lube oils of different types
or brands. Mixing may cause the
chemical characteristics of the lube oil
to change and lubricating performance
to drop, reducing the engine's life.
Before supplying lube oil to the engine
and marine gear for the first time,
extract all the lube oil already
in the
tank. Use new lube oil.
3) Lube oil supplied to the engine will
undergo natural degeneration with time
even when the engine is not used.
Lube oil should be replaced at the
specified intervals, regardless of
whether the engine is being used or
not.
20
Air temperature
Single grade Multi grade
"C "F
L11::
$: -~.
~10'
i-
15
'
_ -10'
-25'
-30'
-35' -31'
-41i" -40
-55'llJy67'
If you operate your equipment at temperatures
below the limits shown, consult your dealer for
special lubricants and starting aids,
3.1.3 Cooling Water
It is important to check the cooling water
daily. Be sure to use clean soft water (tap
water) for cooling fresh water.
NOTICE
Be sure to add antirust or anti-
freeze to cooling fresh water.
In cold seasons, the antifreeze is
especially important.
Without antirust, cooling perfor-
mance will drop due to scale and
rust in the cooling water system.
Without antifreeze, cooling water
will freeze and expand, breaking
various parts.
For your reference, antifreeze
mixed with antirust is now avail-
able in
the market.