Yanmar 3JH5E User manual

MARINE ENGINES
3JH5E
4JH5E
4JH4-TE
4JH4-HTE1
4JH4-HTE
OPERATION MANUAL
en
English

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 CO., LTD.
MODEL
OPERATION MANUAL CODE
All Rights Reserved, Copyright
3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE1, 4JH4-HTE
0AJHM-G00202

JH Series Operation Manual i
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-HTE1 / 4JH4-HTE.................................. 20
Left Side (Viewed from Flywheel)
- 4JH4-HTE1 / 4JH4-HTE.................................. 20
NAMEPLATES ......................................................... 21
FUNCTION OF MAJOR COMPONENTS ................ 22
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TABLE OF CONTENTS
ii JH Series Operation Manual
CONTROL EQUIPMENT.......................................... 23
Instrument Panel (Optional) ............................... 23
Single-Lever Remote Control Handle ................ 31
BEFORE YOU OPERATE .............................................. 33
INTRODUCTION ...................................................... 33
SAFETY PRECAUTIONS......................................... 33
DIESEL FUEL........................................................... 34
Diesel Fuel Specifications .................................. 34
Filling the Fuel Tank........................................... 37
Bleeding the Fuel System .................................. 38
ENGINE OIL ............................................................. 39
Engine Oil Specifications .................................. 39
Engine Oil Viscosity ........................................... 40
Checking the Engine Oil..................................... 40
Adding Engine Oil .............................................. 40
MARINE GEAR OR SAIL DRIVE OIL ...................... 41
Marine Gear Oil Specifications........................... 41
Sail Drive Oil Specifications ............................... 41
Checking Marine Gear Oil.................................. 42
Adding Marine Gear Oil...................................... 42
Checking and Adding Sail Drive Oil ................... 42
ENGINE COOLANT ................................................. 43
Engine Coolant Specifications ........................... 43
Coolant (Closed Cooling System) ...................... 43
Checking and Adding Coolant............................ 44
CRANKING THE ENGINE........................................ 47
ENGINE OPERATION .................................................... 49
INTRODUCTION ...................................................... 49
SAFETY PRECAUTIONS......................................... 49
STARTING THE ENGINE ........................................ 51
If the Engine Fails to Start.................................. 52
Starting at Low Temperatures............................ 52
After the Engine has Started .............................. 53
REMOTE CONTROL HANDLE OPERATION.......... 54
Acceleration and Deceleration ........................... 54
Shifting the Engine ............................................. 54
Switching to Trolling (KMH4A Only)................... 54
CAUTIONS DURING OPERATION.......................... 55
SHUTTING DOWN THE ENGINE............................ 57
Normal Shutdown............................................... 57
Emergency Shutdown ........................................ 58
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TABLE OF CONTENTS
JH Series Operation Manual iii
12/05
CHECKING THE ENGINE AFTER OPERATION .... 58
PERIODIC MAINTENANCE........................................... 59
INTRODUCTION...................................................... 59
SAFETY PRECAUTIONS ........................................ 59
PRECAUTIONS ....................................................... 61
The Importance of Periodic Maintenance.......... 61
Performing Periodic Maintenance ..................... 61
The Importance of Daily Checks ....................... 61
Keep a Log of Engine Hours and Daily Checks 61
Yanmar Replacement Parts .............................. 61
Tools Required .................................................. 61
Ask Your Authorized Yanmar Marine Dealer or
Distributor for Help............................................. 61
EPA MAINTENANCE REQUIREMENTS................. 63
EPA Requirements for USA and Other
Applicable Countries.......................................... 63
EPA Requirements ............................................ 63
Installation of Exhaust Sampling Port ................ 65
PERIODIC MAINTENANCE SCHEDULE ................ 66
PERIODIC MAINTENANCE PROCEDURES .......... 70
Daily Checks...................................................... 70
After Initial 50 Hours of Operation ..................... 71
Every 50 Hours of Operation ............................. 76
Every 250 Hours of Operation ........................... 79
Every 500 Hours of Operation ........................... 87
Every 1000 Hours of Operation ......................... 87
TROUBLESHOOTING ................................................... 89
SAFETY PRECAUTIONS ........................................ 89
TROUBLESHOOTING AFTER STARTING ............. 89
TROUBLESHOOTING INFORMATION................... 90
TROUBLESHOOTING CHART................................ 91
LONG-TERM STORAGE ............................................... 93
PREPARE ENGINE FOR LONG-TERM STORAGE 93
DRAIN SEAWATER COOLING SYSTEM ............... 94
RETURNING THE ENGINE TO SERVICE .............. 96
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TABLE OF CONTENTS
iv JH Series Operation Manual
SPECIFICATIONS .......................................................... 97
PRINCIPAL ENGINE SPECIFICATIONS................. 97
3JH5E Engine .................................................... 98
3JH5E Marine Gears.......................................... 99
4JH5E Engine .................................................. 100
4JH5E Marine Gear or Sail Drive..................... 102
4JH4-TE Engine............................................... 103
4JH4-HTE1 Engine .......................................... 104
4JH4-HTE Engine ............................................ 105
4JH4-TE, 4JH4-HTE1 and 4JH4-HTE
Marine Gear or Sail Drive ................................ 106
SYSTEM DIAGRAMS................................................... 107
PIPING DIAGRAMS ............................................... 107
WIRING DIAGRAMS .............................................. 137
EPA WARRANTY USA ONLY ..................................... 143
YANMAR CO., LTD. LIMITED EMISSION
CONTROL SYSTEM WARRANTY - USA ONLY ... 143
Your Warranty Rights and Obligations:............ 144
Warranty Period: .............................................. 144
Warranty Coverage: ......................................... 145
Exclusions: ....................................................... 145
Owner’s Responsibility:.................................... 145
Customer Assistance: ...................................... 145
EMISSION SYSTEM WARRANTY............................... 147
NON-ROAD EMISSION SYSTEM WARRANTY .... 147
YANMAR CO., LTD. Limited Emission
Control System Warranty - USA Only .............. 147
Maintenance Log.............................................. 150
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JH Series Operation Manual 1
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.
•IfthisOperation 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.
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INTRODUCTION
2JH Series Operation Manual
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.
Note: Since 2012, the 4JH4-HTE does not comply with the EPA regulation.
Emission Control Certification
Model Year 2011 2012 2013
3JH5E EPA marine CI Tier 3 (Non-road Tier 2)
4JH5E / 4JH4-TE EPA marine CI Tier 3 intermediate
4JH4-HTE1 - EPA marine CI Tier 3 intermediate
4JH4-HTE EPA marine CI Tier 2 -
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INTRODUCTION
JH Series Operation Manual 3
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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: __________________________________________________________
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INTRODUCTION
4JH Series Operation Manual
This Page Intentionally Left Blank
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JH Series Operation Manual 5
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.
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.
A
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.
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SAFETY
6JH Series Operation Manual
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.
•Consult 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.
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SAFETY
JH Series Operation Manual 7
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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.
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SAFETY
8JH Series Operation Manual
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.
To o l H a z a rd
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.
Consult 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.
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SAFETY
JH Series Operation Manual 9
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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). Consult
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 speed,
you are overloading the engine that is
running. Immediately throttle back to
approximately 2/3 throttle or to a setting
where the engine performs normally.
Failure to do so may cause the running
engine to overheat or cause excess
carbon buildup which may shorten the
engine’s life.
Never turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electrical
system will result.
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SAFETY
10 JH Series Operation Manual
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
Figure 1
1–Part Number: 128377-07350
2–Part Number: 128990-07270
3–Part Number: 196630-12980
043811-00X00
WARNING
196630-12980
12
3
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SAFETY
JH Series Operation Manual 11
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4JH5E Engines
Figure 2
1–Part Number: 128377-07350
2–Part Number: 128990-07270
3–Part Number: 196630-12980
4–Part Number: 128377-07150
4
043812-00X00
WARNING
196630-12980
12
3
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SAFETY
12 JH Series Operation Manual
4JH4-TE Engines
Figure 3
1–Part Number: 128377-07350
2–Part Number: 128990-07270
3–Part Number: 196630-12980
4–Part Number: 128296-07300
WARNING
128296-07300
(1)
(3)
(4)
008830-03X
(2)
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SAFETY
JH Series Operation Manual 13
12/05
4JH4-HTE1 / 4JH4-HTE Engines
Figure 4
1–Part Number: 128377-07350
2–Part Number: 128990-07270
3–Part Number: 128296-07300
4–Part Number: 196630-12980
014387-01X
WARNING
128296-07300
(2)
(1)
(4)
(3)
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SAFETY
14 JH Series Operation Manual
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