Yanmar 3JH5E User manual

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

Disclaimers:
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and / or specifications
to explain and / or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. Yanmar and are registered
trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic,
electronic, or mechanical, including photocopying, recording, taping, or information storage
and retrieval systems - without the written permission of Yanmar Marine International.
© 2009 Yanmar Marine International
0109
ii JH Series Operation Manual
© 2009 Yanmar Marine International

TABLE OF
CONTENTS
Page
Introduction......................................................................1
JH series Emission Control System Warranty-USA, the
Environmental Protection Agency (EPA) Only.......................2
Record of Ownership......................................................3
Safety...............................................................................5
Safety Precautions.........................................................6
General Information .................................................6
Before You Operate .................................................6
During Operation and Maintenance .............................6
Location of Safety Decals...............................................10
Product Overview.............................................................15
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.............. 19
Left Side (Viewed from Flywheel) - 4JH4-TE................ 19
Right Side (Viewed from Flywheel) - 4JH4-HTE............ 20
Left Side (Viewed from Flywheel) - 4JH4-HTE.............. 20
Nameplates................................................................21
Function of Major Components........................................22
Control Equipment........................................................23
Instrument Panel (Optional) ..................................... 23
Single-Lever Remote Control Handle ......................... 30
Before You Operate..........................................................31
Introduction.................................................................31
Safety Precautions.......................................................31
Diesel Fuel..................................................................32
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© 2009 Yanmar Marine International

Diesel Fuel Specifications ....................................... 32
Filling the Fuel Tank ............................................... 35
Bleeding the Fuel System........................................ 35
Engine Oil...................................................................37
Engine Oil Specifications ........................................ 37
Engine Oil Viscosity ............................................... 37
Checking the Engine Oil.......................................... 37
Adding Engine Oil.................................................. 38
Marine Gear or Sail Drive Oil...........................................38
Marine Gear Oil Specifications ................................. 38
Sail Drive Oil Specifications ..................................... 38
Checking Marine Gear Oil ....................................... 38
Adding Marine Gear Oil .......................................... 39
Checking and Adding Sail Drive Oil ........................... 39
Engine Coolant............................................................39
Engine Coolant Specifications .................................. 39
Coolant (Closed Cooling System) ............................. 39
Checking and Adding Coolant .................................. 40
Cranking the Engine......................................................43
Engine Operation.............................................................45
Introduction.................................................................45
Safety Precautions.......................................................45
Starting the Engine.......................................................47
Before Starting the Engine....................................... 47
To Start the Engine ................................................ 47
If the Engine Fails to Start........................................ 48
Starting at Low Temperatures .................................. 48
After the Engine has Started .................................... 49
Remote Control Handle Operation...................................49
Acceleration and Deceleration.................................. 49
Shifting the Engine................................................. 50
Switching to Trolling (KMH4A Only) ........................... 50
Cautions During Operation.............................................51
Shutting Down the Engine..............................................52
Normal Shutdown.................................................. 52
Emergency Shutdown ............................................ 52
Checking the Engine After Operation................................53
Periodic Maintenance.......................................................55
Introduction.................................................................55
Safety Precautions.......................................................55
Precautions.................................................................57
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
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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............................................................ 60
Inspection and Maintenance .................................... 61
Installation of Exhaust Sampling Port ......................... 61
Periodic Maintenance Schedule...................................... 62
Inspection and Maintenance of EPA Emission-Related
Parts................................................................... 65
Periodic Maintenance Procedures....................................66
Daily Checks ........................................................ 66
After Initial 50 Hours of Operation.............................. 67
Every 50 Hours of Operation .................................... 72
Every 250 Hours of Operation .................................. 74
Every 500 Hours of Operation .................................. 81
Every 1000 Hours of Operation................................. 81
Troubleshooting..............................................................83
Safety Precautions....................................................... 83
Troubleshooting After Starting.........................................83
Troubleshooting Information........................................... 84
Troubleshooting Chart...................................................85
Long-Term Storage..........................................................89
Prepare Engine for Long-Term Storage.............................89
Drain Seawater Cooling System...................................... 90
Returning the Engine to Service.......................................92
Specifications..................................................................93
Principal Engine Specifications........................................93
3JH5E Engine Specifications ................................... 93
3JH5E Marine Gear Specifications ............................ 94
4JH5E Engine Specifications ................................... 95
4JH5E Marine Gear or Sail Drive Specifications ........... 97
4JH4-TE Engine Specifications ................................ 98
4JH4-HTE Engine Specifications .............................100
4JH4-TE and 4JH4-HTE Marine Gear or Sail Drive
Specifications ......................................................102
System Diagrams...........................................................103
Piping Diagrams.........................................................103
Wiring Diagrams.........................................................133
EPA Warranty USA Only..................................................149
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© 2009 Yanmar Marine International

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. Limited Emission Control System
Warranty - USA Only .............................................153
Maintenance Log..................................................156
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INTRODUCTION
Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and from
cruisers to mega yachts. In marine leisure
boating, the worldwide reputation of Yanmar
Marine is second to none. We design our
engines to respect nature. This means
quieter engines, with minimal vibrations,
cleaner than ever. All of our engines meet
applicable regulations, including emissions,
at the time of manufacture.
To help you enjoy your Yanmar JH series
engine for many years to come, please
follow these recommendations:
• Read and understand this Operation
Manual before you operate the machine to
ensure that you follow safe operating
practices and maintenance procedures.
• Keep this Operation Manual in a
convenient place for easy access.
• If this Operation Manual is lost or
damaged, order a new one from your
authorized Yanmar Marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
engine and remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in this
Operation Manual may differ slightly from
your engine. If you have any questions
about these differences, please contact
your authorized Yanmar Marine dealer or
distributor.
• The specifications and components
(instrument panel, fuel tank, etc.)
described in this manual may differ from
ones installed on your vessel. Please refer
to the manual provided by the
manufacturer of these components.
• Refer to the Yanmar Limited Warranty
Handbook for a complete warranty
description.
JH Series Operation Manual 1
© 2009 Yanmar Marine International

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.
Emission Control Certification
Model Year 2008 2009 2010 2011 2012
3JH5E Non-road Tier
2
EPA CI marine Tier 3 (Non-road Tier 2)
4JH5E
4JH4-TE
EPA CI marine Tier 3
4JH4-HTE EPA CI marine Tier 2
INTRODUCTION
2 JH Series Operation Manual
© 2009 Yanmar Marine International

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:
INTRODUCTION
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INTRODUCTION
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SAFETY
Yanmar considers safety of great
importance and recommends that anyone
that comes into close contact with its
products, such as those who install,
operate, maintain or service Yanmar
products, exercise care, common sense
and comply with the safety information in
this manual and on the machine’s safety
decals. Keep the labels from becoming dirty
or torn and replace them if they are lost or
damaged. Also, if you need to replace a part
that has a label attached to it, make sure you
order the new part and label at the same
time.
!
This safety alert symbol appears
with most safety statements. It
means attention, become alert,
your safety is involved! Please
read and abide by the message
that follows the safety alert
symbol.
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or
serious injury.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and / or the environment, or cause the
equipment to operate improperly.
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© 2009 Yanmar Marine International

SAFETY PRECAUTIONS
General Information
There is no substitute for common sense
and careful practices. Improper practices or
carelessness can cause burns, cuts,
mutilation, asphyxiation, other bodily injury
or death. This information contains general
safety precautions and guidelines that must
be followed to reduce risk to personal safety.
Special safety precautions are listed in
specific procedures. Read and understand
all of the safety precautions before operation
or performing repairs or maintenance.
Before You Operate
DANGER
The safety messages that follow have
DANGER level hazards.
NEVER permit anyone to install or
operate the engine without proper
training.
• Read and understand this Operation
Manual before you operate or service the
engine to ensure that you follow safe
operating practices and maintenance
procedures.
• Safety signs and labels are additional
reminders for safe operating and
maintenance techniques.
• See your authorized Yanmar Marine
dealer or distributor for additional training.
During Operation and
Maintenance
WARNING
The safety messages that follow have
WARNING level hazards.
Explosion Hazard
While the engine is running or
the battery is charging,
hydrogen gas is being
produced and can be easily
ignited. Keep the area around
the battery well-ventilated and keep sparks,
open flames and any other form of ignition
out of the area.
Fire and Explosion Hazard
Diesel fuel is flammable and explosive
under certain conditions.
NEVER use a shop rag to catch the fuel.
Wipe up all spills immediately.
NEVER refuel with the engine running.
Fire Hazard
Undersized wiring systems
can cause an electrical fire.
Store any containers containing fuel or other
flammable products in a well-ventilated
area, away from any combustibles or source
of ignition.
Store any equipment in a designated area
away from moving parts.
NEVER use the engine compartment for
storage.
SAFETY
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WARNING
Sever Hazard
Rotating parts can cause
severe injury or death.
NEVER wear jewelry,
unbuttoned cuffs, ties or
loose-fitting clothing and
ALWAYS tie long hair back when working
near moving / rotating parts such as the
flywheel or PTO shaft. Keep hands, feet and
tools away from all moving parts.
Alcohol and Drug Hazard
NEVER operate the engine
while under the influence of
alcohol or drugs, or when
feeling ill.
Exposure Hazard
ALWAYS wear personal
protective equipment
including appropriate
clothing, gloves, work shoes,
and eye and hearing
protection as required by the task at hand.
Sudden Movement Hazard
NEVER operate the engine while wearing a
headset to listen to music or radio because
it will be difficult to hear the warning signals.
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.
Exhaust Hazard
NEVER block windows, vents
or other means of ventilation if
the engine is operating in an
enclosed area. All internal
combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning.
SAFETY
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© 2009 Yanmar Marine International

CAUTION
The safety messages that follow have
CAUTION level hazards.
Poor Lighting Hazard
Ensure that the work area is adequately
illuminated. ALWAYS install wire cages on
portable safety lamps.
Tool Hazard
ALWAYS use tools appropriate for the task
at hand and use the correct size tool for
loosening or tightening machine parts.
Flying Object Hazard
ALWAYS wear eye protection when
servicing the engine or when using
compressed air or high-pressure water.
Dust, flying debris, compressed air,
pressurized water or steam may injure your
eyes.
Coolant Hazard
Wear eye protection and
rubber gloves when you
handle engine coolant. If
contact with the eyes or skin
should occur, flush eyes and
wash immediately with clean water.
NOTICE
The safety messages that follow have
NOTICE level hazards.
It is important to perform daily checks as
listed in the Operation Manual. Periodic
maintenance prevents unexpected
downtime, reduces the number of accidents
due to poor engine performance and helps
extend the life of the engine.
See your authorized Yanmar Marine dealer
or distributor if you need to operate the
engine at high altitudes. At high altitudes the
engine will lose power, run rough and
produce exhaust gases that exceed the
design specifications.
ALWAYS be environmentally
responsible.
Follow the guidelines of the
EPA or other governmental
agencies for the proper
disposal of hazardous materials such as
engine oil, diesel fuel and engine coolant.
Consult the local authorities or reclamation
facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground,
or into ground water or waterways.
If a Yanmar Marine Engine is installed at an
angle that exceeds the specifications stated
in the Yanmar Marine Installation Manuals,
engine oil may enter the combustion
chamber causing excessive engine speed,
white exhaust smoke and serious engine
damage. This applies to engines that run
continuously or those that run for short
periods of time.
SAFETY
8 JH Series Operation Manual
© 2009 Yanmar Marine International

NOTICE
If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the non-
running engine(s) should be closed. This will
prevent water from being forced past the
seawater pump and eventually finding its
way into the engine. The result of water
entering the engine could cause seizure or
other serious problems.
If you have an installation with two or three
engines, and only one engine is operating,
please note that if the propeller shaft thru-
hull (stuffing box) is lubricated by engine
water pressure and the engines are
interconnected, care must be taken that
water from the running engine does not
enter the exhaust of the non-running
engine(s). This water could cause seizure of
the non-running engine(s). See your
authorized Yanmar Marine dealer or
distributor for a complete explanation of this
condition.
If you have an installation with two or three
engines, and only one engine is operating,
it is important to limit the amount of throttle
applied to the running engine. If you observe
black smoke or movement of the throttle
does not increase engine rpm, you are
overloading the engine that is running.
Immediately throttle back to approximately
2/3 throttle or to a setting where the engine
performs normally. Failure to do so may
cause the running engine to overheat or
cause excess carbon buildup which may
shorten the engineʼs life.
NEVER turn off the battery switch (if
equipped) or short the battery cables during
operation. Damage to the electrical system
will result.
SAFETY
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© 2009 Yanmar Marine International

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
196630-12980
(1)
(3)
(2) (4)
Water Separator caution
Drain off water at every
100hr.
ISO10088
Diesel Fuel
0006956
Figure 1
1 – Part Number: 128377-07350
2 – Part Number: 128990-07270
3 – Part Number: 196630-12980
4 – Part Number: 120324-55751
(fuel / water separator attached
to the hull)
SAFETY
10 JH Series Operation Manual
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4JH5E Engines
WARNING
(1)
(3)
(4)
(2)
(5)
Water Separator caution
Drain off water at every
100hr.
ISO10088
Diesel Fuel
0006957
Figure 2
1 – Part Number: 128377-07350
2 – Part Number: 128990-07270
3 – Part Number: 196630-12980
4 – Part Number: 128377-07150
5 – Part Number: 120324-55751
(fuel / water separator attached
to the hull)
SAFETY
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© 2009 Yanmar Marine International

4JH4-TE Engines
WARNING
128296-07300
(1)
(3)
(4)
008830-03X
(2)
Figure 3
1 – Part Number: 128377-07350
2 – Part Number: 128990-07270
3 – Part Number: 196630-12980
4 – Part Number: 128296-07300
SAFETY
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4JH4-HTE Engines
014387-01X
WARNING
128296-07300
(2)
(1)
(4)
(3)
Figure 4
1 – Part Number: 128377-07350
2 – Part Number: 128990-07270
3 – Part Number: 128296-07300
4 – Part Number: 196630-12980
SAFETY
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SAFETY
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