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2. 1 ii rj sseugeu T 9M d ou i f LA 1 m 1 tes ji Md 1 1 1 PT eet ees RER res MEM CIE T E MIT puc ae ut INS ous gl SAL TM MA Annes 81239 19 Ty i gt v o o OL sduie 1 1 D 7 UU i 0004186 Series Operation Manual YANMAR 2008 Yanmar Marine International 16 Figure 134 3JH4E C Type Instrument Panel Color Description Coding R Red B Black Ww White L Blue RB Red Black LB Blue Black YW Yellow White YB Yellow Black YG Yellow Green WL White Blue WB White Black WG White Green GR Green Red WBr White Brown SYSTEM DIAGRAMS 1 Starter Switch 2 Stop Switch 3 Tachometer Hourmeter 4 Buzzer 5 Lubricating Oil Low Pressure Alarm 6 Coolant High Temperature Alarm 7 Water in Sail Drive Seal Alarm 8 Battery Low Charge Alarm 9 Relay for 2 station optional 10 11 Starter Switch 12
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4. 59 0004592 Figure 12 126 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 x t4 5 Rubber Hose 2 W CS D 3 Fuel Injection Pump 4 STS 5 Lubrication Oil Filter cartridge type 6 Lubrication Oil Cooler 7 4 76 x t0 7 Double Walled Steel Tube 8 10xt3 Rubber Hose 9 13 x t3 5 Rubber Hose 10 Oil Pressure Switch 11 Oil Pressure Sensor option 12 Fuel Injection Nozzle 13 Piston Cooling Oil Jet 14 Seawater Inlet 15 8 x t0 8 STKM 16 Clutch Lubrication Oil Cooler 17 Turbocharger 18 17 xt1 2 STKM 19 Mixing Elbow 20 25 4 x t4 3 Rubber Hose 21 8 5 x t3 5 Rubber Hose 22 25 4 x t4 3 Rubber Hose 23 17 xt3 Rubber Hose 24 Intercooler 25 Heat Exchanger 26 Main Bearing 27 Lubrication Oil Inlet Filter 28 25 x t2 C1201T 29 25 4 x 14 3 Rubber Hose 30 25 4 x 14 3 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 31 7 5 x t2 5 Rubber Hose 32 25 4 x t4 3 Rubber Hose 33 Cooling Water Pump seawater Fuel High Pressure Pipe 6 35 x t2 175 34 28 x t4 Rubber Hose 35 28 x t4 Rubber Hose 36 Hot Water Connection Outlet 37 Coolant Temperature Switch 38 Thermostat 39 Cooling Water Pump coolant 40 Hot Water Connection Return 41 Coolant Temperature Senso
5. az m n 1 ll 1 1 i i BENE e OAL i Aeyeg ut m 69 e e L L f 1 o Lr 4 8 12 19 19 Y LN l 48M oL sdwej e ze AGL jp erc eI cede Qr Ur EET UU XM IRI 1 uondO eee EH 1 0004185 JH4 Series Operation Manual 2008 Yanmar Marine International Figure 14 130 3JH4E B Type Instrument Panel Color Description Coding R Red B Black Ww White L Blue RB Red Black LB Blue Black YW Yellow White YB Yellow Black YG Yellow Green WL White Blue WB White Black WG White Green GR Green Red WBr White Brown SYSTEM DIAGRAMS 1 Starter Switch 2 Stop Switch 3 Tachometer Hourmeter 4 Buzzer 5 Lubricating Oil Low Pressure Alarm 6 Coolant High Temperature Alarm 7 Water in Sail Drive Seal Alarm 8 Battery Low Charge Alarm 9 Relay for 2 station optional 10 Fuse 3A 11 Starter Switch 12 Stop Switch 13 Tachometer Hourmeter 14 Buzzer 15 Lubricating Oil Low Pressure Alarm 16 Coolant Hig
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8. Engine Type Fuel Type Combustion cycle DECLARATION Z or sterndrive without integral r Engine model s or EC Type certificate exhaust Bd Diesel O 2stroke engine family name s number exhaust Inboard engine Petrol D 4stroke SNCH 94 25 2003 44 RCD 1GMIOXI 0009 00 RCD 2YMISXI 0004 00 Other 8 RCD 3YM30X1 0005 00 4 2 Essential requirements Standards Used normative 8 2 RCDAJHAXI 0014 00 document used 5 RCD 4JH3TXI 0011 01 SEED RCD 4LHAXI 0015 00 LB E s xnaustEmissions RCD 6LPADXI 0012 00 engine identification RCD 6LPASXI 0007 00 exhaust emission requirements EN ISO 8178 1 1996 X RCD 6CXMXI 0006 00 durability RC D 6LY2XI 0008 00 RCD 6LY3XI 0010 00 owner s manual RCD 4JH3TX2 0016 00 Annex I C Noise Emissions see craft manufacturer s Declaration of Conformity RCD 4JH4TX2 0017 00 I declare on behalf of the engine manufacturer that the engine s will meet the exhaust emission requirements of Directive 94 25 EC as amended by Directive 2003 44 EC when installed in a recreational craft in accordance with the engine manufacturer s supplied instructions and that this these engine s must not be put into service until the recreational craft into which it is they are to be installed has been declared in conformity with the relevant provisions of the above mentioned Directive G Je Elaa Signatur
9. 4 Before You Operate 4 During Operation and Maintenance 4 Location of Safety Decals 8 Product Overview 13 Yanmar Features and Applications 13 New Engine Break In 13 Component Identification 15 Service Side BJHME 15 Non Service Side 3UH4E 15 Service Side 4JH4AE 16 Non Service Side 4UH4AE 16 Service Side 4JH4 TE 17 Non Service Side 4UH4 TE 17 Service Side 18 Non Service Side 4UH4 HTE 18 eee eee 19 Function of Major Components 20 Control Equipment sss 21 Instrument Panel Optional 21 Single Lever Remote Control Handle 25 Before You Operate 27 Diesel Fuel eti cese tite de emi 27 Diesel Fuel Specifications 27 YANMAR JH4 Series Opera
10. aged jo 0 5295 55010 fuel _ _ 0004506 18 JH4 Series Operation Manual 2008 Yanmar Marine International 138 4JH4 TE 4JH4 HTE with B x B Type Panel SYSTEM DIAGRAMS Color Coding Engine 1 Option Harness 2 Alarm Lamps R Red 3 Buzzer B Black 4 Oil Pressure W White Ignition 5 Coolant Temperature L Blue Air Heater m Glow option 6 Sail Drive Seal RB Red Alternator 7 Battery Low Charge Alarm Black Exciter 8 Fuse 3A LB Blue Alternator Black Charge Alarm 9 Stop Switch YW Yellow Engine Oil 10 Diodes White Pressure Alarm 11 Key Switch YB Yellow Engine Oil 12 Tachometer Hourmeter Black Pressure YG Yellow Sail Drive Seal 13 Instrument Panel Sub Station option Green WL White Water 14 Instrument Panel Main Station option Blue Temperature Alarm 15 Wire Harness WB White Water 16 Relay Black Temperature 17 Wire Harness For Sub Panel WG White Seawater Flow Green Alarm 18 Amplifier Sail Drive only GR Green Fuel Filter Alarm 19 Procured by Customer Red 20 Battery Orange Pulse For 9 Tachometer 21 Battery Switch WBr White Electric Stop 22 Engine Stop Solenoid With VE Brown Pump 23 Air Heater 24 Opt
11. uondo Aq peunooJugd l 0004595 Series Operation Manual 17 2008 Yanmar Marine International Figure 136 4JH4AE C Type Instrument Panel Color Description Coding R Red B Black Ww White L Blue RB Red Black LB Blue Black YW Yellow White YB Yellow Black YG Yellow Green WL White Blue WB White Black WG White Green GR Green Red WBr White Brown SYSTEM DIAGRAMS 1 Starter Switch 2 Stop Switch 3 Tachometer Hourmeter 4 Buzzer 5 Lubricating Oil Low Pressure Alarm 6 Coolant High Temperature Alarm 7 Water in Sail Drive Seal Alarm 8 Battery Low Charge Alarm 9 Relay for 2 station optional 10 Fuse 3A 11 Starter Switch 12 Stop Switch 13 Tachometer Hourmeter 14 Buzzer 15 Seawater 16 Fuel Filter 17 Water in Sail Drive Seal Alarm 18 Battery Low Charge Alarm 19 Oil Pressure Meter Alarm 20 Coolant Temperature Meter Alarm 21 Air Heater 22 Engine Stop Solenoid 23 Stop Relay 24 Starter Relay 25 Starter 26 Coolant High Temperature Switch 27 Lubricating Oil Low Pressure Switch 28 Alternator optional 29 Alternator 30 Water In Sail Drive Seal Sensor on Sail Drive 31 Water in Sail Drive Seal Sensor Amplifie
12. Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 151 Declaration of Conformity for Recreational Craft Propulsion Engine with the Exhaust emission requirements of Directive 94 25 EC as amended by 2003 44 EC To be completed by manufacturer of inboard engines without integral exhaust Name of engine manufacturer Yanmar Co Ltd Street 1 32 Town Chayamachi Kitaku Osaka City Post Code 530 8311 Country Japan Name of Authorised Representative Yanmar Marine International B V Street Brugplein 11 Town Almere de Vaart Post Code 1332 BS Country The Netherlands Name of Notified Body for exhaust emission assessment Soci t Nationale de Certification et d Homologation Street 11 route de Luxembourg Town Sandweiler Post Code L 5230 Country Luxembourg ID Number 0499 Module used for exhaust emission assessment B C X B D B OB OGOH or engine type approved according to stage II of Directive 97 68 EC Directive 88 77 EC Other Community Directives applied 89 336 EEC DESCRIPTION OF ENGINE s AND ESSENTIAL REQUIERMENTS ENGINE S COVERED BY THIS
13. 4JH4AE Type API Class CH 4 only Be sure to perform inspections as outlined in Periodic Maintenance Procedures on page 67 and keep a record of the results Pay particular attention to these important points Replacing the engine oil Replacing the engine oil filter Replacing the fuel filter Cleaning the intake silencer air cleaner Note Inspections are divided into two sections in accordance with who is responsible for performing the inspection the user or the maker 55 2008 Yanmar Marine International PERIODIC MAINTENANCE Inspection and Maintenance See Inspection and Maintenance of EPA Emission Related Parts on page 60 for the EPA emission related parts Inspection and maintenance procedures not shown in Inspection and Maintenance of EPA Emission Related Parts on page 60 are covered in Periodic Maintenance Schedule on page 57 This maintenance must be performed to keep the emission values of your engine in the standard values during the warranty period The warranty period is determined by the age of the engine or the number of hours of operation 56 Series Operation Manual YANMAR 2008 Yanmar Marine International PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition The following is a summary of maintenance items by periodic maintenance intervals Periodic maintenance intervals vary depending on
14. 91 SPECIFICATIONS 4JH4AE Engine Specifications Engine Model 4JH4AE Marine Gear Model KM35P ZF30M KM35A2 KM4A1 Use Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders 4 Bore X Stroke 88 mm x 90 mm 3 46 in x 3 54 in Displacement 2 190 L 133 64 cu in Continuous Output Rating at Crankshaft 36 0 kW 48 9 hp metric 2907 rpm Maximum Output at crankshaft 39 6 kW 53 8 hp metric 3000 rpm Output Rating engine speed Output at propeller engine 38 0 kW 51 7 hp metric speed 3000 rpm Installation Flexible mounting Fuel Injection Timing FIR 5 1 BTDC at Fuel Stop Power FIT 18 1 BTDC at Plunger Lift 2 5 Fuel Injection Opening Pressure 19 6 20 6 MPa Main Power Take Off At flywheel end Direction Of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft ahead Clockwise viewed from stern Cooling System Freshwater cooling with heat exchanger Lubrication System Complete enclosed forced lubrication system Cooling Water Capacity fresh Engine 6 0 L 6 3 qt Coolant recovery tank 0 8 L 0 8 qt Lubricating Rake angle at rake angle 8 at rake angle 0 Total 5 0 0 3 L 5 3 0 3 qf 5 5 0 3 L 5
15. 28 N p 22 44 FR 24 47 25 0004175 Figure 1 104 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 8 x t4 5 Rubber Hose 2 Check Valve 3 7 8xt4 5 Rubber Hose 4 7 8xt4 5 Rubber Hose 5 Overflow 6 Diesel Fuel Inlet 7 7 8 x t4 5 Rubber Hose 8 5xt4 5 Rubber Hose 9 7 8 x t4 5 Rubber Hose 10 Fuel Feed Pump 11 Fuel Injection Pump 12 4 76 x 10 7 Steel Pipe 13 9 x t3 5 Rubber Hose 14 Lubricating Oil Filter cartridge type 15 Lubricating Oil Cooler 16 5 x t4 5 Rubber Hose 17 Fuel High Pressure Pipe 18 Fuel Injection Nozzle 19 9 x t3 5 Rubber Hose 20 Oil Pressure Switch 21 Mixing Elbow 22 25 4 x t4 3 Rubber Hose 23 Heat Exchanger 24 Lubricating Oil Inlet Filter YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 25 Main Bearing 26 Seawater Inlet 27 25 4 x t4 3 Rubber Hose 28 Cooling Water Pump seawater 29 28 x t4 Rubber Hose 30 28 x t4 Rubber Hose 31 Hot Water Connection Outlet R3 8 32 Thermostat 33 28 6 x 12 Copper Pipe 34 Cooling Water Pump coolant 35 Hot Water Connection Inlet R3 8 36 27 x t4 Rubber Hose 37 Coolant Temperature Switch 38 Lubricating Oil Pump 39 Pressure Control Valve 40 Diesel Fuel Filter cartridge type 41 To Cil Pan 42 From Cylinder Head 43 To Cam Shaft 44 Detail of Part A 45 Detail of Part B 46 Detail of Part C 47 Detail of Part
16. Engine Dry Mass 235 kg 237 kg 238kg 237 kg 249 kg 207 kg including marine gear 51816 52316 52516 engine engine 207 456 Ib 173 kg kg 549 Ib 523 Ib engine 456 Ib engine 381 Ib Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale Note Density of fuel 0 842g cm at 15 C Fuel temperature at the inlet of the fuel injection pump 1 hp metric 0 7355 kW YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 99 SPECIFICATIONS 4JH4 HTE Engine Specifications Engine Model 4JH4 HTE Marine Gear Model ZF30M KM4A2 KMH4A ZF25A Bobtail Use Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion System Direct injection Air Charging Turbocharged Number of Cylinders 4 Bore X Stroke 84 x 90 mm 3 31 x 3 54 in Displacement 1 995 L 121 74 cu in Continuous Output Rating at Crankshaft 73 6 kW 100 hp metric 3101 rpm Maximum Output at 80 9 110 hp metric 3200 rpm Output crankshaft Rating engine speed Output at 77 7 KW 106 hp metric 3200 rpm propeller engine speed Installation Flexible mounting Fuel Injection Timing Plunger lift at TDC 1 26 x 0 0
17. 1 3 8 0004184 Figure 10 122 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 x t4 5 Rubber Hose 2 W CS D 3 Fuel Injection Pump 4 STS 5 Lubrication Oil Filter cartridge type 6 Lubrication Oil Cooler 7 4 76 x t0 7 Double Walled Steel Tube 8 10xt3 Rubber Hose 9 13 x t3 5 Rubber Hose 10 Oil Pressure Switch 11 Oil Pressure Sensor option 12 Fuel Injection Nozzle 13 Piston Cooling Oil Jet 14 8 xt0 8 STKM 15 Seacock 16 Turbocharger 17 17 xt1 2 STKM 18 Mixing Elbow 19 8 5 x t3 5 Rubber Hose 20 17 x t3 Rubber Hose 21 Heat Exchanger 22 Main Bearing 23 Lubrication Oil Inlet Filter 24 25 4 x t4 3 Rubber Hose 25 25 4 x t4 3 Rubber Hose 26 7 5 x 12 5 Rubber Hose 27 25 4 t4 3 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 28 Cooling Water Pump seawater 29 28 x t4 Rubber Hose 30 28 x t4 Rubber Hose Fuel High Pressure Pipe 6 35 x t2 175 31 Hot Water Connection Outlet 32 Coolant Temperature Switch 33 Thermostat 34 Cooling Water Pump coolant 35 Hot Water Connection Return 36 Coolant Temperature Sensor option 37 Lubrication Oil Pump 38 Pressure Control Valve 39 13 x t3 5 Rubber Hose 40 10 x t3 Rubber Hose 41 Diesel Fuel
18. 1983 1360 1106 882 1253 rpm forward reverse 955 955 1993 1360 1106 882 rpm rpm rpm rpm rpm rpm Lubrication System Splash Oil bath Lubricating Oil Capacity 0 65 L 0 69 qt 2 3 L 2 4 qt SD50 2 1L total 2 2 qt Lubricating Oil Capacity 0 15 L 0 16 qt 0 20 L 0 21 qt SD50 0 5L effective 0 6 qt Cooling System Air cooling by Seawater cooling fan Weight 13 kg 28 Ib 29 0 kg 64 Ib 40 kg 88 Ib At continuous power engine sp 96 eed 2907 rpm JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International SPECIFICATIONS This Page Intentionally Left Blank YANMAR JH4 Series Operation Manual 97 2008 Yanmar Marine International SPECIFICATIONS 4JH4 TE Engine Specifications Engine Model 4JH4 TE Marine Gear Model ZF30M KM4A2 ZF25A SD50 4T Bobtail Use Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion System Direct injection Air Charging Turbocharged Number of Cylinders 4 Bore X Stroke 84 x 90 mm 3 31 x 3 54 in Displacement 1 995 L 121 74 cu in Continuous Output Rating at Crankshaft 50 2 kW 68 3 hp metric 3101 rpm Maximum Output at 55 2 75 1hp metric 3200 rpm Output crankshaft Rating engine speed Output at 53 0 kW 72 1hp metric 3200 rpm propeller engine speed Installation Flexible mounting Fuel Injection T
19. 9 80 9A PA 84 0 pa NTEN Ta UN EN a a30 PAPA CNE 9 Ly E z yoyms po _0 6 CE 1 1 1 SX 1 ju 1 I nds E ps 1 8 DA 9 1 BE 6 TM MA 1 1 1 1 SC ve t6 7 site i 1 44 T uz si s ssl xu M ws ORE 09 SAL ML u g guuuu os 1 1 e is u gz 5 6 d Wez gt ETS oz oz gt qui Oz 98 0 gt guuu st nS T u e z 121 1 uj amp ue jo uonoes 1 Aeyeq zo 6L Bale SSOJO 5 m ae __ Ag ejgemoly_ _ 140 4JH4 TE 4JH4 HTE with C x B Type Panel SYSTEM DIAGRAMS YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 14 Instrument panel main station Color Codin Engine 9 Harness option R Red gt 15 Wire Harness B Black E 16 Relay w White Ignition 17 Wire Harness for Sub Panel L Blue Air Heater 18 Amplifier Sail Drive only Glow option 19 Procured by Customer RB Red Alternator Black Exciter 20 Batte
20. Lubricating Oil 1 1L 1 2 qt 3 3 3 5 qt 2 3 L 2 4 qt 1 8 L 1 9 qt 2 21 2 3 qt Capacity total Lubricating Oil 0 2 L 0 2 qt 0 3 L 0 3 qt 0 2 L 0 2 qt 0 1 L 0 1 qt Capacity effective Cooling System Seawater cooling Weight 27 5 kg 30 kg 31 kg 30 kg 42 kg 61 Ib 66 Ib 68 Ib 66 Ib 93 Ib At continuous power engine speed 2907 min 102 Series Operation Manual YANMAR 2008 Yanmar Marine International SYSTEM DIAGRAMS PIPING DIAGRAMS Notation Description Screw Joint Union Flange Joint Eye Joint Insertion Joint nr os Drilled Hole gt Coolant Piping Cooling Seawater Piping nain Lubricating Oil Piping Diesel Fuel Piping YANMAR JH4 Series Operation Manual 103 2008 Yanmar Marine International SYSTEM DIAGRAMS 3JH4E with KM35P KM35A Marine Gear 9 G 10 11 Ty 69 12 42 VE fi ii 45 iE j 97 U RTS 4 uo n J 17 E 36 NN N Mm F Fi 18 CR N NS pep Ard A 4 AS 19 45 E AP 20 34 er 09 33 4 68 5 H 32 4 f J 1 __ 46 e E NN 2 29 21 ES
21. also describes the daily engine checkout Before performing any operations within this section review the Safety section on page 3 YANMAR JH4 Series Operation Manual Fire and Explosion Hazard NEVER jump start the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion ONLY use the key switch to start the engine Sudden Movement Hazard Be sure the boat is in open water away from other boats docks or other obstructions before increasing rpm Avoid unexpected equipment movement Shift the marine gear into the NEUTRAL position any time the engine is at idle To prevent accidental equipment movement NEVER start the engine in gear Sever Hazard i Keep children and pets away Qi while the engine is operating 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 41 2008 Yanmar Marine International ENGINE OPERATION e f the vessel is equipped with a water lift water lock muffler excessive cranking could cause seawater to enter the cylinders and damage the engine If the engine does not start after cranking for 10 seconds close the thru hull water intake valve to avoid filling the muffler with water Crank for 10 seconds at a time u
22. f seawater is left inside of the engine it may freeze and damage parts of the cooling system when the ambient temperature is below 0 C 32 F YANMAR JH4 Series Operation Manual PREPARE ENGINE FOR LONG TERM STORAGE Note If the engine is close to a periodic maintenance interval perform those maintenance procedures before putting the engine into long term storage 1 Wipe off any dust or oil from the outside of engine 2 Drain water from fuel filters 3 Drainfueltank completely or fill the tank to prevent condensation 4 Grease the exposed areas and joints of the remote control cables and the bearings of the remote control handle 5 Sealthe intake silencer exhaust pipe etc to prevent moisture or contamination from entering engine 6 Completely drain bilge in hull bottom 7 Waterproof the engine room to prevent rain or seawater from entering 8 Charge the battery once a month to compensate for battery s self discharge 9 Remove key from key switch and cover the key switch with moisture cap 85 2008 Yanmar Marine International LONG TERM STORAGE DRAIN SEAWATER 4JH4AE COOLING SYSTEM 0004569 Figure 3 1 Coolant Pump 00045562 2 Seawater Drain from Seawater Figure 1 Pump Cover 3 Coolant Tank Heat Exchanger 1 Coolant Tank Heat Exchanger 4 Coolant Drain Cock 2 Coolant Drain Cock 3JH4E only 5 Flywheel Housing 3 Coolant Pump 4 Seawater Drain from Seawater Pump Cover
23. A FRE 6 8 7 W 4 MR 8 242 0003628 5 Figure 28 1 Diaphragm Cover 2 Spring 3 Center Plate 4 Diaphragm 5 Rocker Arm Cover 6 Breather Baffle 7 Baffle Plate 8 Intake Silencer 9 Breather Pipe See your authorized Yanmar Marine dealer or distributor 78 Replacing the Alternator V Belt See Checking and Adjusting the Alternator V Belt Tension on page 64 Adjusting Intake Exhaust Valve Clearance See your authorized Yanmar Marine dealer or distributor Checking the Remote Control Cable Operation See your authorized Yanmar Marine dealer or distributor Adjusting the Propeller Shaft Alignment See your authorized Yanmar Marine dealer or distributor Series Operation Manual YANMAR 2008 Yanmar Marine International TROUBLESHOOTING Before performing any troubleshooting procedures within this section review the Safety section on 3 If a problem occurs stop the engine immediately Refer to the Symptom column in the Troubleshooting Chart to identify the problem YANMAR JH4 Series Operation Manual TROUBLESHOOTING AFTER STARTING Just after the engine has started check the following items at a low engine speed Is sufficient water being discharged from the seawater outlet pipe f the discharge is low stop the engine immediately Identify the cause and repair Is the exhaust color normal The continuous emission of black exhaust sm
24. ALWAYS use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair the damage Burn Hazard Some of the engine surfaces become very hot during operation and shortly after shut down Keep hands and other body parts away from hot engine surfaces s MD pr d Sudden Movement Hazard ALWAYS stop the engine before beginning service 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 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 If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Coolant Hazard Wear eye protection and rubber gloves when you handle Long Life engine JH4 Series Operation Manual YANMAR 2008
25. Disconnect the electrical connectors and remove the alarm switch with a spanner wrench Remove the filter housing Figure 14 1 with a filter wrench Figure 14 2 Clean the filter housing mounting surface Install new filter elementin filter housing Component Part No Fuel Filter 129574 55711 4JH4 TE 4JH4 HTE Install the alarm switch to the fuel filter Apply cleanfueltothe gasket of the new fuel filter Install filter housing into engine and tighten hand tight until the gasket comes into contact with the seat Use a filter wrench and tighten approximately 3 4 turn to 11 8 15 6 104 4 138 1 in Ib Install the fire resistant cover and tighten the hose clamp 71 2008 Yanmar Marine International PERIODIC MAINTENANCE 11 Bleed the fuel system See Bleeding the Fuel System on page 32 12 Dispose of waste properly Changing the Engine Oil and Replacing the Engine Oil Filter Element See Changing the Engine Oil and Replacing the Engine Oil Filter Element on page 63 Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter Element if equipped See Replace the Marine Gear Oil Filter if equipped and Change the Marine Gear Oil on page 63 Checking or Replacing Seawater Pump Impeller 1 Loosen side cover bolts and remove the side cover 2 Inspectthe inside ofthe seawater pump with a flashlight If any of the following are found disassembly and
26. Filter cartridge type 42 7 x t4 5 Rubber Hose 43 7 x t4 5 Rubber Hose 44 5 x t4 5 Rubber Hose 45 Diesel Fuel Inlet 46 Fuel Overflow 47 To Block 48 From Head 49 To Camshaft 50 To Oil Pan 51 Detail of Part A 52 Detail of Part B 53 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 123 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4 HTE with KM4A2 62 0 0004591 Figure 11 124 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7xt4 5 Rubber Hose 2 S D 3 Fuel Injection Pump SYSTEM DIAGRAMS 32 25 4 x t4 3 Rubber Hose 33 7 5 x 12 5 Rubber Hose 34 Seawater Inlet 4 Fuel High Pressure Pipe 6 35 x t2 175 35 25 4 x t4 3 Rubber Hose STS 36 Cooling Water Pump seawater 5 Lubrication Oil Filter cartridge type 37 28 x t4 Rubber Hose 6 Lubrication Oil Cooler 38 28 x t4 Rubber Hose 7 4 76 x t0 7 Double Walled Steel Tube 39 Hot Water Connection Outlet 8 10xt3 Rubber Hose 9 13 x t3 5 Rubber Hose 10 Oil Pressure Switch 11 Oil Pressure Sensor option 12 Fuel Injection Nozzle 13 Pis
27. No 1 D ASTM USA D975 EN590 96 European Union ISO 8217 DMX International BS 2869 A1 or A2 United Kingdom JIS K2204 Grade No 2 Japan 27 2008 Yanmar Marine International BEFORE YOU OPERATE Bio Diesel Fuels Yanmar approves the use of biodiesel fuels that do not exceed a blend of 5 non mineral oil based fuel with 9596 standard diesel fuel Such biodiesel fuels are known in the marketplace as B5 biodiesel fuels B5 biodiesel fuel can reduce particulate matter and the emission of greenhouse gases compared to standard diesel fuel CAUTION f the B5 biodiesel fuel used does not meet the approved specifications it will cause abnormal wear of injectors reduce the life of the engine and it may affect the warranty coverage of your engine B5 diesel fuels must meet certain specifications The biodiesel fuels must meet the minimum specifications for the country in which they are used n Europe biodiesel fuels must comply with the European Standard EN14214 e In the United States biodiesel fuels must comply with the American Standard ASTM D 6751 Biodiesel should be purchased only from recognized and authorized diesel fuel suppliers 28 Precautions and concerns regarding the use of bio fuels Biodiesel fuels have a higher content of methyl esters which may deteriorate certain metal rubber and plastic components of the fuel system The customer and or boat builder are responsible to verify the u
28. OR SAIL DRIVE OIL Marine Gear Oil Specifications Use marine gear oil that meets or exceeds the following guidelines and classifications KM35P KM35A KM35A2 KM4A1 KM4A2 KMH4A API Service Categories CD or higher SAE Viscosity 20 30 ZF30M ZF25A ATF Automatic Transmission Fluid Sail Drive Oil Specifications Refer to the operation manual of the sail drive for the procedure to fill or replace the sail drive oil 3JH4E 4JH4AE SD40 SD50 50 4T e SAE Viscosity 90 or 80W90 QuickSilver High Performance Gear Lube 4JH4 TE SD40 SD50 50 47 Only use QuickSilver High Performance Gear Lube QuickSilver is a registered trademark of Brunswick Corporation YANMAR JH4 Series Operation Manual 35 2008 Yanmar Marine International BEFORE YOU OPERATE Checking Marine Gear Oil 0004491 Figure 10 Note 4JH4 TE with KMH4A marine gear shown 1 Make sure engine is level 2 Remove the filler cap Figure 10 1 at the top of the housing 3 Remove dipstick Figure 10 2 and wipe with clean cloth 4 Fully reinsert dipstick 5 Remove dipstick The oil level should be between upper Figure 10 3 and lower Figure 10 4 lines on the dipstick 6 Fully reinsert dipstick Adding Marine Gear Oil 1 Make sure the engine is level 2 Remove the filler cap at the top of the housing Figure 10 1 3 Fill with oil to the upper limit on the
29. Pumps seawater from outside vessel to the engine The seawater pump is gear driven and has a replaceable rubber impeller Do not operate it without seawater as this will damage the impeller Coolant Filler Cap Whenthe coolanttemperature rises the pressure inside the coolanttank increases and opens the pressure valve in the filler cap When the pressure valve in the filler cap is opened hot water and steam pass through a rubber hose to the coolant recovery tank When the engine cools and the pressure inside the coolantrecovery tank drops the vacuum valve in the filler cap opens and the coolant in the coolant recovery tank returns to the water tank through the pipe and filler cap This minimizes coolant consumption Coolant Recovery Tank The pressure valve in the filler cap releases vapor and hot water overflow to the coolant recovery tank When the engine stops and the coolant cools the pressure in the coolant tank drops The filler cap vacuum valve then opens to send water back from the coolant recovery tank This minimizes coolant consumptions The closed cooling system coolant level can easily be checked and refilled inthis tank Oil Cooler Engine A heat exchanger that cools high temperature engine oil using coolant Oil Cooler Marine Gear Optional This heat exchanger that cools the marine gear KMH4A oil using seawater Turbocharger if equipped The turbocharger pressurizes the air coming into the en
30. Stop Switch 13 Tachometer Hourmeter 14 Buzzer 15 Seawater 16 FuelFilter 17 Water in Sail Drive Seal Alarm 18 Battery Low Charge Alarm 19 Oil Pressure Meter Alarm 20 Coolant Temperature Meter Alarm 21 Air Heater optional 22 Engine Stop Solenoid 23 Stop Relay 24 Starter Relay 25 Starter 26 Coolant High Temperature Switch 27 Lubricating Oil Low Pressure Switch 28 Alternator optional 29 Alternator 30 Water In Sail Drive Seal Sensor on Sail Drive 31 Water in Sail Drive Seal Sensor Amplifier Sail Drive only 32 Battery optional 33 Battery 34 Oil Pressure Sensor optional 35 Coolant Temperature Sensor optional YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 135 4JH4AE C Type Instrument Panel SYSTEM DIAGRAMS
31. Yanmar Marine dealer or distributor 4 Inspect the gasket and replace if necessary Cleaning the Turbocharger if equipped Contamination of the turbocharger causes revolutions to drop and engine output to fall If a significant drop in engine output is noted 1096 or more clean the turbocharger This should be done only by a trained and qualified technician See your authorized Yanmar Marine dealer or distributor Adjusting the Alternator V Belt Tension See Checking and Adjusting the Alternator V Belt Tension on page 64 Checking the Wiring Connectors See your authorized Yanmar Marine dealer or distributor Tightening Major Nuts and Bolts See Tightening Fasteners on page 54 or see your authorized Yanmar Marine dealer or distributor Series Operation Manual YANMAR 2008 Yanmar Marine International Every 500 Hours of Operation Perform the following maintenance every 500 hours or 2 years of operation whichever comes first Replacing Exhaust Water Mixing Elbow Replacing Rubber Hoses Replacing Exhaust Water Mixing Elbow Replace the mixing elbow with a new one every 500 hours or 2 years whichever comes first even if no damage is found See your authorized Yanmar Marine dealer or distributor Replacing Rubber Hoses Replace rubber hoses every 2000 hours or 2 years whichever comes first See your authorized Yanmar Marine dealer or distributor YANMAR JH4 Series Operati
32. anti smog standards In all states 1998 and later non road 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 engine forthe periods oftime listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system YANMAR JH4 Series Operation Manual Where a warrantable condition exists Yanmar will repair your non road compression ignition engine at no charge to you including diagnosis parts and labor Manufacturer s Warranty Period The model year 1998 or later certified and labeled non road compression ignition engines are warranted for the periods listed below If any emission related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar Engines rated at The warranty period is five or above 5 years or 3 000 hours of 19kW lt andless use whichever occurs first than 37 kW In the absence of a device to measure the hours of 25 5 hp lt and use the engine has less than 49 6 warranty period of five 5 hp years Engines rated The warranty period is two under 2 years or 1 500 hours of 19 gt use whichever occurs first In the absence of a device 25 5 hp gt to measure t
33. engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emission requirements 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 145 2008 Yanmar Marine International EPA WARRANTY USA ONLY Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor you should contact Yanmar Marine USA Corporation for assistance Yanmar Marine USA Corporation 101 International Parkway Adairsville GA 30103 USA Telephone 770 877 9894 Fax 770 877 7567 146 Series Operation Manual YANMAR 2008 Yanmar Marine International EMISSION SYSTEM NON ROAD EMISSION SYSTEM WARRANTY Yanmar Ltd Limited Emission Control System Warranty USA Only Your Warranty Rights and Obligations California The California Air Resources Board CARB the Environmental Protection Agency EPA and Yanmar Co Ltd hereafter referred to as Yanmar are pleased to explain the emission control system warranty on your compression ignition engine In California model year 2000 or later off road compression ignition engines must be designed built and equipped to meet the State s stringent
34. filling This prevents static electricity buildup which could cause sparks and ignite fuel vapors YANMAR JH4 Series Operation Manual BEFORE YOU OPERATE Stop fueling when the gauge shows the fuel tank is full NOTICE NEVER overfill the fuel tank Replace the fuel cap and hand tighten Over tightening the fuel cap will damage it 31 2008 Yanmar Marine International BEFORE YOU OPERATE Bleeding the Fuel System The fuel system has an automatic air bleeding device that purges air from the fuel system No manual air bleeding is required for normal operation Bleeding must be done if any fuel system maintenance has been performed replacement of fuel filter etc the engine does not start after several attempts Bleeding the Fuel System 3JH4E 6 0004554 Figure 5 1 Fuel Injector 2 Air Bleed Screw 3 To Fuel Tank 4 FuelFilter 5 Fuel Injection Pump 6 Fuel Feed Pump 32 1 Check the fuel level in the fuel tank Refill if necessary 2 Openthe fuel cock of the fuel tank 3 Loosen the air bleed screw Figure 5 2 2 3 turns 4 Push up and down on the priming pump Figure 5 1 to release air out of the air bleed screw 5 Continue pumping until a solid stream of fuel with no air bubbles begins to flow 6 Tightenthe air bleed screw Note After engine start up the automatic air bleeding device works to purge the air in the fuel system Bleeding the Fuel System 4JH4A
35. fuel filter water separator to protect the water alarm Switch 3 Attach a tube Figure 11 6 to the drain plug Figure 11 4 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 4 Loosen the drain plug Figure 11 4 at the bottom of the fuel filter water separator counterclockwise and drain off any water sediment Note If there is a large quantity of water and sediment in the fuel filter water separator also drain the fuel tank See Draining the Fuel Tank on page 62 NOTICE ALWAYS be environmentally responsible Dispose of the collected water and dirt properly 5 Tighten the drain plug Remove the drain tube 7 Install the fire resistant cover and tighten the hose clamp 8 Bleed air from the fuel system See Bleeding the Fuel System on page 32 Checking the Battery Electrolyte Level serviceable batteries only WARNING Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment D NOTICE NEVER turn off the battery switch if equipped or short the battery cables during operation Damage to the electric system will result NOTICE NEVER operate with insuffic
36. 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 itis 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 engine s life 2008 Yanmar Marine International SAFETY LOCATION OF SAFETY DECALS Figure 1 Figure 2 Figure 3 and Figure 4 show the location of safety decals on Yanmar JH4
37. maintenance are required Impeller blades are cracked nicked Edges or surfaces of the blades are marred or scratched Wear plate is damaged 3 damage is found when inspecting the inside ofthe pump install the O ring and side cover 4 Ifa large amount of water leaks continuously from the water drain line below the seawater pump during operation replace the mechanical seal See your authorized Yanmar Marine dealer or distributor 72 Replacing the Seawater Pump Impeller Note The impeller must be replace periodically every 1000 hours even if there is no damage 0004510 Figure 15 There are two types of special service tools for removing the impeller Puller A standard Part No 129671 92110 A B 0004501 Figure 16 Puller A Jack Screw B M18x1 5 M10x40 mm length 1 Remove the side cover of the seawater pump 2 Install puller Figure 16 A in the impeller Series Operation Manual YANMAR 2008 Yanmar Marine International 3 Turn the jack screw Figure 16 B clockwise to remove the impeller from the pump bogy 1 L an 0004567 Figure 17 0004568 Figure 18 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 YANMAR JH4 Series Operation Manual PERIODIC MAINTE
38. of the stop solenoid Figure 5 2 4JH4 TE 4JH4 HTE 0004488 Figure 6 If the engine cannot be shut down by the STOP button on the panel stop the engine by moving the stop lever Figure 6 2 by hand to the left Figure 6 1 The lever is attached to the fuel injection pump WARNING SEVER HAZARD ALWAYS keep hands body parts and loose fitting clothes away from moving rotating parts such as the flywheel or PTO shaft YANMAR JH4 Series Operation Manual ENGINE OPERATION CHECKING THE ENGINE AFTER OPERATION Check that the key switch is in the OFF position and battery master switch if equipped is turned to OFF Fill the fuel tank See Filling the Fuel Tank on page 31 Close seawater cock s If there is a risk of freezing check that the cooling system contains enough coolant See Engine Coolant Specifications on page 36 If there is a risk of freezing drain the seawater system See Drain Seawater Cooling System on page 86 At temperatures below 0 C 32 F drain seawater system and connect the engine heater if equipped 49 2008 Yanmar Marine International ENGINE OPERATION This Page Intentionally Left Blank 50 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International PERIODIC MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of the engine Before performing any maintenance procedures within this
39. on page 69 Cable terminal contact failure Remove corrosion from terminals Tighten battery cables Faulty safety switch device See your authorized Yanmar Marine dealer or distributor Faulty starter switch See your authorized Yanmar Marine dealer or distributor Power lacking due to accessory drive being engaged See your authorized Yanmar Marine dealer or distributor Engine cannot be turned manually Internal parts seized See your authorized Yanmar Marine dealer or distributor 82 Series Operation Manual YANMAR 2008 Yanmar Marine International TROUBLESHOOTING Symptom Probable Cause Measure Reference Abnormal Exhaust Color Black smoke Load increased See your authorized Yanmar Marine dealer or distributor Improper propeller matching See your authorized Yanmar Marine dealer or distributor Dirty intake silencer air Clean element See Cleaning the cleaner Intake Silencer Air Cleaner Element on page 76 Improper fuel Replace with See Diesel Fuel recommended fuel Specifications on page 27 Faulty spraying of fuel injector See your authorized Yanmar Marine dealer or distributor Incorrect See your authorized Yanmar intake exhaust valve Marine dealer or distributor clearance White smoke Improper fuel Replace with See Diesel Fuel recommended fuel S
40. section read the following safety information and review the Safety section on 3 YANMAR JH4 Series Operation Manual SAFETY PRECAUTIONS Crush Hazard NW 4 If the engine needs to be transported for repair have a helper assist you attach it to a hoist and load it on a truck The engine lifting eyes are engineered to lift the weight of the marine engine only 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 51 2008 Yanmar Marine International PERIODIC MAINTENANCE Welding Hazard ALWAYS turn off the battery switch if equipped or disconnect the negative battery cable and the leads to the alternator when welding on the equipment Remove the engine control unit multi pin connector Connect the weld clamp to the component to be welded and as close as possible to the welding point NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket When welding is completed reconnect the alternator and engine control unit prior to reconnecting the batteries Exhaust Hazard ALWAYS ensure that all connections are tightened to specifications after repair is made to the exhaust system All internal combustion engines create carbon monoxide gas during op
41. stop Figure 5 6 or Figure 6 6 position first and then the low speed stop Figure 5 4 or Figure 6 4 with the adjustment Screw on the remote control lever Figure 5 5 or Figure 6 5 Adjusting Clutch Remote Control Cable 3JH4E 4JH4AE 0004562 Figure 7 4JH4 TE 4JH4 HTE 0004563 Figure 8 1 Ensure that the remote control lever Figure 7 2 Figure 8 2 moves to the correct position when the remote control handle is in NEUTRAL FORWARD and REVERSE positions Use the NEUTRAL position as the standard for adjustment 2 To adjust loosen and retighten the cable fitting Figure 7 1 Figure 8 1 66 Adjusting Trolling Remote Control Handle If Equipped 1 2 3 4 5 6 7 8 0004498 Figure 9 Cable Fitting Trolling Lever Low Speed trolling High Speed Loosen Tighten Normal Operation high speed Trolling low speed Note KMH4A marine gear shown 1 Ensure that the trolling lever Figure 9 2 is in the high speed Figure 9 4 position when the trolling remote control handle is in high speed position Figure 9 7 Ensure that the trolling lever is inthe low speed Figure 9 3 position when the trolling remote control handle is in low speed position Figure 9 8 To adjust loosen the adjustment screw of the cable fitting Figure 9 1 and adjust the position of the cable JH4 Series Operation Manual YAN
42. the fuel filter hold the bottom of the fuel filter with a cloth to prevent the fuel from spilling Wipe up any spilled fuel immediately Apply a thin film of clean diesel fuel to the sealing surface of the new filter gasket Part No 129470 55703 119802 55801 Component Fuel Filter Fuel Filter 4JH4AE Install a new filter and tighten hand tight Use a filter wrench and tighten to 20 24 N m 14 75 17 7 ft Ib Bleed the fuel system See Bleeding the Fuel System on page 32 Dispose of waste properly Check for fuel leaks WARNING Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak suchasa broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair any damage YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE 4JH4 TE 4JH4 HTE 10 0004500 Figure 14 Close the fuel tank drain cock Loosen the hose clamp and remove the fire resistant cover which is installed to the lower part of the fuel filter water separator to protect the water alarm switch Attach a tube to the drain plug Loosen the drain plug and drain the fuel from the drain plug
43. underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintain engine performance and prolong the life of the engine 80 TROUBLESHOOTING INFORMATION Ifthe engine does not operate properly refer to the Troubleshooting Chart on page 81 or see your authorized Yanmar Marine dealer or distributor Supply the authorized Yanmar Marine dealer or distributor with the following information Model name and serial number of your engine Boat model hull material size tons Use type of boating number of hours run Total number of operation hours refer to hourmeter age of boat The operating conditions when the problem occurs Engine rpm Color of exhaust smoke Type of diesel fuel Type of engine oil Any abnormal noises or vibration Operating environment such as high altitude or extreme ambient temperatures etc Engine maintenance history and previous problems Other factors that contribute to the problem JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International TROUBLESHOOTING CHART TROUBLESHOOTING Symptom Probable Cause Measure Reference Indicators light on the instrument panel and alarm sounds during operation Shift to low speed operation immediately and check which indicator has come on Stop the engine and inspect If no abnormality is identified and there is no problem with operation return to port
44. water from the fuel filter water separator See Draining Fuel Filter Water Separator on page 67 Series Operation Manual YANMAR 2008 Yanmar Marine International PRODUCT OVERVIEW Alarms Check that indicators and alarms are working normally when the key is turned to ON Key Switch OFF ON START ON Engine Before start Running Alarm Sound Stop Indicators Battery Low Charge Indicator ON OFF Coolant High Temperature Indicator OFF OFF Engine Oil Low Pressure Indicator ON OFF Water in Sail Drive Seal Indicator ifequipped OFF OFF Single Lever Remote Control Handle 0004504 Figure 20 Note Direction of travel will vary depending on installation location 1 Low Speed FWD or REV 2 Low Speed FWD or REV 3 NEUTRAL Power to the propeller shaft is cut off and the engine idles 4 Maximum Engine Speed FWD or REV 5 Maximum Engine Speed FWD or REV A single handle type Figure 20 should be used to operate the marine gear clutch NEUTRAL FORWARD and REVERSE and to control the engine speed The handle controls the direction of the boat ahead or astern and also acts as an accelerator by increasing engine speed as the lever is pushed further in FORWARD or REVERSE directions YANMAR JH4 Series Operation Manual When the handle is pulled out Figure 21 1 the engine speed can be controlled without engaging the clutch The clutch remains in NE
45. 0 117 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4 TE with KM4A2 58 0004182 Figure 8 JH4 Series Operation Manual YANMAR 118 2008 Yanmar Marine International 1 7xt4 5 Rubber Hose 2 S D 3 Fuel Injection Pump SYSTEM DIAGRAMS 30 Seawater Inlet 31 25 4 x t4 3 Rubber Hose 32 Cooling Water Pump seawater 4 Fuel High Pressure Pipe 6 35 x 12 175 33 28 x 14 Rubber Hose STS 34 28 x t4 Rubber Hose 5 Lubrication Oil Filter cartridge type 35 Hot Water Connection Outlet 6 Lubrication Oil Cooler 36 Coolant Temperature Switch 7 4 76 x 10 7 Double Walled Steel Tube 37 Thermostat 8 10xt3 Rubber Hose 9 13xt4 5 Rubber Hose 10 Oil Pressure Switch 11 Oil Pressure Sensor option 12 Fuel Injection Nozzle 13 Piston Cooling Oil Jet 14 13 x t4 Rubber Hose 15 13 x 4 Rubber Hose 16 8 xt0 8 STKM 17 Clutch Lubrication Oil Cooler 18 Turbocharger 19 17 11 2 STKM 20 Mixing Elbow 21 8 5 x t3 5 Rubber Hose 22 25 4 x t4 3 Rubber Hose 23 17 xt3 Rubber Hose 24 Heat Exchanger 25 Main Bearing 26 Lubrication Oil Inlet Filter 27 25 4 t4 3 Rubber Hose 28 25 4 x 14 3 Rubber Hose 29 7 5 x 12 5 Rubber Hose YANMAR JH4 Series Operation Manual 38 Cooling W
46. 0 mm 3 46 x 3 54 in Displacement 2 190 L 133 6 cu in Continuous Output Rating at Crankshaft 36 0 kW 48 9 hp 2907 rpm Maximum Output Output at crankshaft engine 39 6 kW 53 8hp 3000 rpm Rating speed Output at propeller engine speed Installation Flexible mounting Fuel Injection Timing FIR 5 1 BTDC at Fuel Stop Power FIT 18 1 BTDC at Plunger Lift 2 5 Fuel Injection Opening Pressure 19 6 20 6 MPa Main Power Take Off At flywheel end Direction of Rotation Crankshaft Counterclockwise viewed from stern Propeller shaft Ahead Clockwise viewed from stern Cooling System Freshwater cooling with heat exchanger Lubrication System Closed forced lubrication system Cooling Water Capacity fresh Engine 6 0 L 6 3 qt Coolant recovery tank 0 8 L 0 8 qt Lubricating Oil Rake angle at rake angle 0 Capacity engine 5 5 0 3 L 5 8 0 3 qt Oil pan only 5 0 0 3 L 5 3 0 3 qt Effective 7 1 4 L 1 5 gt Starting System Type Electric Starting motor DC 12 V 1 4 kW AC generator 12V 80A Engine Dimension Overall length 795 mm 31 3 in Overall width 560 mm 22 0 in Overall height 625 mm 24 6 in Flywheel Major Dimension D300 x 66 mm 11 8 x 2 6 in Engine Dry Mass include marine gear 241 kg engine 201 kg 201 kg 443 Ib 531 Ib engine 443 Ib Rating Condi
47. 1 Intake Silencer Air Cleaner 2 Shift Lever 3 Marine Gear 4 Oil Cooler 5 Engine Oil Filter 6 Fuel Feed Pump 7 Engine Oil Filler Cap 8 Fuel Injection Pump 9 Fuel Filter 10 Engine Oil Dipstick 11 Intake Manifold YANMAR JH4 Series Operation Manual PRODUCT OVERVIEW Non Service Side 3JH4E 0004544 Figure 2 1 Coolant Filler Cap 2 Engine Nameplate on rocker arm cover 3 Coolant Pump 4 Belt Cover 5 Seawater Pump 6 Starter Motor 7 Mixing Elbow 8 Exhaust Manifold 9 Alternator 10 Coolant Tank Heat Exchanger 15 2008 Yanmar Marine International PRODUCT OVERVIEW Service Side 4JH4AE Figure 3 and Figure 4 illustrate a typical version of a 4JH4AE engine Your engine may have different equipment from that illustrated 4 12 0004545 Figure 3 1 Air Heater 2 Intake Silencer 3 Shift Lever 4 Marine Gear 5 Engine Oil Dipstick 6 Fuel Priming Pump 7 FuelFilter 8 Fuel Injection Pump 9 Engine Oil Filler Cap 10 Electric Fuel Feed Pump 11 Engine Oil Filter 12 Cil Cooler 16 Non Service Side 4JH4AE 4 0004546 Figure 4 1 Engine Nameplate on rocker arm cover 2 Coolant Pump 3 Belt Cover 4 Seawater Pump 5 CoolantFiller Cap 6 Coolant Tank Heat Exchanger 7 Exhaust Manifold 8 Starter Motor 9 Alternator Series Operation Manual YANMAR 2008 Yanmar Marine International Service Side 4JH4 TE Fi
48. 1 mm when W CSD is released Fuel Injection Opening Pressure 21 6 x 0 5 MPa Main Power Take Off At flywheel end Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise Clockwise or counterclockwise Ahead from stern Bi rotation Cooling System Freshwater cooling with heat exchanger Lubrication System Complete enclosed forced lubrication system Cooling Water Capacity Engine 7 2 L 7 6 qt Coolant recovery tank 0 8 L 0 8 fresh qt Lubricating Rake angle T 0 7 010 e 57203L 69 0 3L 7 3 0 3qt Referto apacity 6 0 0 3 left engine qt Oil pan only 5 2 0 3L 6 4 0 3 L 6 8 0 3 qt Refer to 5 5 0 3 left qt Effective 2 4 L 2 5 qt Starting Type Electric System Starting motor DC 12V 1 4 kW AC generator 12V 80A 12 V 60 A optional 100 Series Operation Manual YANMAR 2008 Yanmar Marine International SPECIFICATIONS Engine Model 4JH4 HTE Marine Gear Model ZF30M KM4A2 KMH4A ZF25A Bobtail Engine Overall length 923 903 933 mm 1017 782 mm Dimension 36 3 35 6in 36 7 in 40 0 in 30 8 in Overall width 616 mm 24 8 in Overall height 659 mm 25 9 in Flywheel Major Dimension D339 x 66 mm 13 3 x 2 6 in Engine Dry Mass 245 kg 247 kg 248 kg 247 kg 217 kg incl
49. 34 Thermostat 6 Lubrication Oil Cooler 35 Cooling Water Pump coolant 7 4 76 x t0 7 Double Walled Steel Tube 36 Hot Water Connection Return 8 10xt3 Rubber Hose 9 13 x t3 5 Rubber Hose 10 Oil Pressure Switch 11 Oil Pressure Sensor 12 Fuel Injection Nozzle 13 Piston Cooling Oil Jet 14 Seawater Inlet 15 8 x t0 8 STKM 16 Clutch Lubrication Oil Cooler 17 Turbocharger 18 17 x t1 2 STKM 19 Mixing Elbow 20 8 5 t3 5 Rubber Hose 21 17 xt3 Rubber Hose 22 Heat Exchanger 23 Main Bearing 24 Lubrication Oil Inlet Filter 25 25 4 x t4 3 Rubber Hose 26 25 4 x 14 3 Rubber Hose 27 7 5 x 12 5 Rubber Hose 28 25 4 x t4 3 Rubber Hose YANMAR JH4 Series Operation Manual 37 Coolant Temperature Sensor option 38 Lubrication Oil Pump 39 Pressure Control Valve 40 13 x t3 5 Rubber Hose 41 10 x t3 Rubber Hose 42 Diesel Fuel Filter cartridge type 43 7 x 14 5 Rubber Hose 44 7 x t4 5 Rubber Hose 45 5 x t4 5 Rubber Hose 46 Diesel Fuel Inlet 47 Fuel Overflow 48 To Block 49 From Head 50 To Camshaft 51 To Oil Pan 52 Detail of Part A 53 Detail of Part B 54 Detail of Part C 55 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 121 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4 TE with 5050 5040
50. 377 07260 Hot surface May cause burn 128296 07300 0003632 Figure 3 Series Operation Manual YANMAR 2008 Yanmar Marine International 4JH4 HTE Engines 5 DANGER e 9 y SERA Z BUCK EL p ELON EST GANG Never remove the cap while the engine is still hot eHot water may spurt out and burn you Rotating parts Can cause injury 128377 07350 C AC lam Figure 4 1 Part Number 128377 07350 2 Part Number 128377 07260 3 Part Number 128296 07300 4 Part Number 196630 12980 YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International SAFETY tz CAUTION 73 Du MR Am xata Hot surface May cause burn 128296 07300 0004552 11 SAFETY This Page Intentionally Left Blank 12 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International PRODUCT OVERVIEW YANMAR FEATURES AND APPLICATIONS The JH4 series are four stroke direct injection diesel engines equipped with liquid coolant systems The 3JH4E is 3 cylinder and naturally aspirated The 4JH4AE is 4 cylinder and naturally aspirated The 4JH4 TE is 4 cylinder and turbocharged The 4JH4 HTE is 4 cylinder and turbocharged with an intercooler The engines are equipped with a marine gear or sail drive unit These engines are designed for pleasure craft use It is recommende
51. 4 Marine Gear Cooler YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE 4JH4 HTE 0004560 Figure 26 1 Coolant Tank Heat Exchanger 2 Coolant Pump 3 Seawater Drain from Seawater Pump Cover 4 Coolant Drain Cock 5 Intercooler 6 Seawater Drain from Seawater Pump Cover 2 0004573 Figure 27 1 Coolant Drain Cock 2 Fuel Pump 3 Seawater Drain Cock 4 Marine Gear Cooler 75 2008 Yanmar Marine International PERIODIC MAINTENANCE Note The drain cocks are opened before Shipping from the factory Marine gear ZF25A does not have a drain cock on the clutch cooler 1 Open all coolant drain cocks 2 Allow to drain completely Dispose of waste properly 3 Close all the drain cocks 4 Fill coolant tank and coolant recovery tank with appropriate coolant See Engine Coolant Specifications on page 36 and Checking and Adding Coolant on page 37 Cleaning the Intake Silencer Air Cleaner Element 1 Disassemble the intake silencer air cleaner 2 Remove element Clean element and housing with a neutral detergent 3 Dry completely and reassemble 76 Cleaning Exhaust Water Mixing Elbow The mixing elbow is attached to the turbocharger The exhaust gas is mixed with seawater in the mixing elbow 1 Remove the mixing elbow 2 Clean dirt and scale out of the exhaust and seawater passages 3 mixing elbow is damaged repair or replace See your authorized
52. 4 WHICH APPLY TO MARINE ENGINES Figure 4 MODEL YEAR 2007 ENGINE MODEL 4JH4AE DISPLACEMENT PER CYLINDER 0 547 LITERS ENGINE FAMILY 7YDXM2 19D4N APPLICATION COMMERCIAL STANDARDS THC NOx 7 5g kWh CO 5 0g kWh PM 0 40g KWh REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS VANMAR YANMAR 0004577 Figure 2 YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 143 EPA WARRANTY USA ONLY THIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR 94 AND SOLD BY YANMAR THAT ARE INSTALLED IN VESSELS FLAGGED OR REGISTERED IN THE UNITED STATES Your Warranty Rights and Obligations Yanmar warrants to the first user and each subsequent purchaser the emission control system on your engine for periods of time listed below provided the engine has been installed according to Yanmar installation requirements and there has been no abuse neglect or improper maintenance of your Yanmar Marine engine Yanmar warrants that the engine is designed built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the U S Environmental Protection Agency and is free from defects in material and workmanship which would cause this engine to fail to conform to the applicable emission regulations over its limited emission control system warranty period Where a warrantable e
53. 5 Coolant Drain Cock 3JH4E 0004570 Figure 4 1 Coolant Drain Cock 2 Stop Solenoid 2 0004557 Figure 2 1 Coolant Drain Cock 2 Flywheel Housing 3 Stop Solenoid 86 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International x 5 WBS Gaz 3 Figure 5 0004571 1 Coolant Tank Heat Exchanger 2 Coolant Pump 3 Seawater Drain from Seawater Pump Cover 4 Coolant Drain Cock 2 used 0004559 3 Figure 6 1 Coolant Drain Cock 2 Seawater Drain Cock 3 Marine Gear Cooler YANMAR JH4 Series Operation Manual 1 2 4 5 6 LONG TERM STORAGE 4JH4 HTE 2 SN 3 0004560 Figure 7 Coolant Tank Heat Exchanger Coolant Pump Seawater Drain from Seawater Pump Cover Coolant Drain Cock Intercooler Seawater Drain from Heat Exchanger 1 2 3 0004561 Figure 8 Coolant Drain Cock Seawater Drain Cock Marine Gear Cooler 87 2008 Yanmar Marine International LONG TERM STORAGE Note The drain cocks are opened before Shipping from the factory Marine gear ZF25A does not have a drain cock on the clutch cooler NOTICE f seawater is left inside it may freeze and damage parts of the cooling system heat exchanger seawater pump etc when ambient temperature is below 32 F 0 C 1 Open the seawater drain cock on the clutch cooler if equipped Allow to drai
54. 7 xt1 2 STKM 19 Mixing Elbow 20 25 4 x t4 3 Rubber Hose 21 8 5 x t3 5 Rubber Hose 22 25 4 x t4 3 Rubber Hose 23 17 xt3 Rubber Hose 24 Intercooler 25 Heat Exchanger 26 Main Bearing 27 Lubrication Oil Inlet Filter 28 25 x t2 C1201T 29 25 4 x 14 3 Rubber Hose 30 25 4 x 14 3 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 31 7 5 x t2 5 Rubber Hose 32 25 4 x t4 3 Rubber Hose 33 Cooling Water Pump seawater Fuel High Pressure Pipe 6 35 x t2 175 34 28 x t4 Rubber Hose 35 28 x t4 Rubber Hose 36 Hot Water Connection Outlet 37 Coolant Temperature Switch 38 Thermostat 39 Cooling Water Pump coolant 40 Hot Water Connection Return 41 Coolant Temperature Sensor option 42 Lubrication Oil Pump 43 Pressure Control Valve 44 13 x t3 5 Rubber Hose 45 10 x t3 Rubber Hose 46 Diesel Fuel Filter 47 7 xt4 5 Rubber Hose 48 7 x t4 5 Rubber Hose 49 5xt4 5 Rubber Hose 50 Diesel Fuel Inlet 51 Fuel Overflow 52 To Block 53 From Head 54 To Camshaft 55 To Oil Pan 56 Detail of Part A 57 Detail of Part B 58 Detail of Part C 59 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 129 2008 Yanmar Marine International 3JH4E B Type Instrument Panel SYSTEM DIAGRAMS WIRING DIAGRAMS
55. 8 0 3 qf Oil pan only 4 5 0 3 L 4 8 0 3 qt 5 0 0 3 L 5 3 0 3 qt Effective 1 2 L 1 3 qt 1 4 L 1 5 qt Starting Type Electric System Starting motor DC 12V 1 4 kW AC generator 12V 80A Engine Overall length 871 mm 950 mm 864 mm 922 mm Dimension 34 3 in 37 4 in 34 0 in 36 3 in Overall width 560 mm 22 0 in Overall height 625 mm 24 6 in Flywheel Major Dimension D300 x 66 mm 11 8 x 2 6 in Engine Dry Mass include marine gear 213 kg 470 Ib 229 kg 214 kg 505 Ib 472 Ib 230 kg 507 Ib Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter 92 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 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 2 0 7355 kW YANMAR JH4 Series Operation Manual 93 2008 Yanmar Marine International SPECIFICATIONS 4JH4AE Specifications Continued Engine Model 4JH4AE Marine Gear Model SD50 Bobtail Use Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders 4 Bore X Stroke 88 x 9
56. AGRAMS 23 28 x t4 Rubber Hose 24 Hot Water Connection Outlet R3 8 25 Thermostat 26 28 6 x t2 Copper Pipe 27 Cooling Water Pump coolant 28 Hot Water Connection Inlet R3 8 29 27 x t4 Rubber Hose 30 Coolant Temperature Switch 31 Lubricating Oil Pump 32 Pressure Control Valve 33 Diesel Fuel Filter cartridge type 34 7 xt4 5 Rubber Hose 35 Fuel Feed Pump 36 Diesel Fuel Inlet 37 Fuel Overflow 38 To Oil Pan 39 From Cylinder Head 40 To Camshaft 41 Detail of Part B 42 Detail of Part C 43 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 115 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4 TE with ZF30M 1 2 53 32 rr E d T 54 i Y 32 f 278 30 Sins 28 55 0004181 Figure 7 116 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 x t4 5 Rubber Hose 2 W CS D 3 Fuel Injection Pump 4 STS 5 Lubrication Oil Filter cartridge type 6 Lubrication Oil Cooler 7 4 76 x t0 7 Double Walled Steel Tube 8 10xt4 3 Rubber Hose 9 13 x t3 5 Rubber Hose 10 Oi
57. After the Engine has Started 45 Remote Control Handle Operation 45 Acceleration and Deceleration 45 Shifting the Engine 45 Switching to Trolling only 46 Cautions During Operation 47 Shutting Down the Engine 48 Normal Shutdown sss 48 Emergency Shutdown 48 Checking the Engine After Operation 49 Periodic Maintenance 51 Safety Precautions 51 Precautions 53 The Importance of Periodic Maintenance 53 Performing Periodic Maintenance 53 The Importance of Daily Checks 53 Keep a Log of Engine Hours and Daily Checks 53 iv JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International TABLE OF CONTENTS Yanmar Replacement Parts 53 Tools Required 53 Ask Your Authorized Yanmar Marine Dealer or Distributor for Help 53 Tightening Fasteners 54 EPA Maintenance Requirements 55 EPA Requ
58. Color Description Coding R Red B Black Ww White L Blue RB Red Black LB Blue Black YW Yellow White YB Yellow Black YG Yellow Green WL White Blue WB White Black WG White Green GR Green Red WBr White Brown SYSTEM DIAGRAMS 1 Starter Switch 2 Stop Switch 3 Tachometer Hourmeter 4 Buzzer 5 Lubricating Oil Low Pressure Alarm 6 Coolant High Temperature Alarm 7 Water in Sail Drive Seal Alarm 8 Battery Low Charge Alarm 9 Relay for 2 station optional 10 Fuse 3A 11 Starter Switch 12 Stop Switch 13 Tachometer Hourmeter 14 Buzzer 15 Lubricating Oil Low Pressure Alarm 16 Coolant High Temperature Alarm 17 Water in Sail Drive Seal Alarm 18 Battery Low Charge Alarm 19 20 21 Air Heater 22 Engine Stop Solenoid 23 Stop Relay 24 Starter Relay 25 Starter 26 Coolant High Temperature Switch 27 Lubricating Oil Low Pressure Switch 28 Alternator optional 29 Alternator 30 Water In Sail Drive Seal Sensor on Sail Drive 31 Water in Sail Drive Seal Sensor Amplifier Sail Drive only 32 Battery optional 33 Battery 34 35 36 Fuel Feed Pump 4JH4AE only YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 133 3JH4E C Type Instrument Panel SYSTEM DIAGRAMS
59. D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 105 2008 Yanmar Marine International SYSTEM DIAGRAMS 3JH4E with 5050 5040 Sail Drive 9 7 d S rj 0763 m n d 46 27 2 22 5 23 28 0004176 Figure 2 106 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 8 x t4 5 Rubber Hose 2 Check Valve 3 7 8xt4 5 Rubber Hose 4 7 8xt4 5 Rubber Hose 5 Overflow 6 Diesel Fuel Inlet 7 7 8 x t4 5 Rubber Hose 8 5xt4 5 Rubber Hose 9 7 8xt4 5 Rubber Hose 10 Fuel Feed Pump 11 Fuel Injection Pump 12 4 76 x 10 7 Steel Pipe 13 9 x t3 5 Rubber Hose 14 Lubricating Oil Filter cartridge type 15 Lubricating Oil Cooler 16 5xt4 5 Rubber Hose 17 Fuel High Pressure Pipe 18 Fuel Injection Nozzle 19 9xt3 5 Rubber Hose 20 Oil Pressure Switch 21 Mixing Elbow 22 25 4 x t4 3 Rubber Hose 23 25 4 x t4 3 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 24 Heat Exchanger 25 Lubricating Oil Inlet Filter 26 Main Bearing 27 25 4 x 14 3 Rubber Hose 28 Cooling Water Pump seawater 29 28 x t4 Rubber Hose 30 28 x t4 Rubber Hose 31 Hot Water Connection Outlet 32 Thermostat 33 28 6 x 12 Copper Pipe 34 Coo
60. E O w 6 0004555 Figure 6 1 Fuel Injector 2 Fuel Filter 3 Priming Pump 4 Air Bleed Screw 5 Fuel Feed Pump 6 Fuel Injection Pump 1 Check the fuel level in the fuel tank Refill if necessary 2 Open the fuel cock of the fuel tank 3 Loosen the air bleed screw Figure 6 4 2 3 turns Series Operation Manual YANMAR 2008 Yanmar Marine International 4 Push up and down onthe priming pump Figure 6 3 to release air out of the air bleed screw 5 Continue pumping until a solid stream of fuel with no air bubbles begins to flow 6 Tighten the air bleed screw Bleeding the Fuel System 4JH4 TE and 4JH4 HTE 1 4 0004494 Figure 7 1 Priming Pump 2 Air Bleed Screw 3 From Fuel Tank 4 To Fuel Injection Pump 1 Checkthe fuel level in the fuel tank Refill if necessary 2 Open the fuel cock of the fuel tank 3 Loosen the air bleed screw Figure 7 2 2 3turns 4 Push up and down onthe priming pump Figure 7 1 to release air out of the air bleed screw 5 Continue pumping until a solid stream of fuel with no air bubbles begins to flow 6 Tighten the air bleed screw NOTICE NEVER use an engine starting aid such as ether Engine damage will result YANMAR JH4 Series Operation Manual BEFORE YOU OPERATE ENGINE OIL Engine Oil Specifications NOTICE Using engine oil that does not meet or exceed the following guidelines o
61. INES MODEL YEAR 2006 ENGINE MODEL 4JH4 TE DISPLACEMENT PER CYLINDER 0 499 LITERS ENGINE FAMILY 6YDXM2 00D4T APPLICATION COMMERCIAL 3JH4E EPA and ARB Nameplate STANDARDS THC NOx 7 5g kWh CO 5 0g kWh PM 0 40g kWh REFER TO OWNER S MANUAL FOR MAINTENANCE IMPORTANT ENGINE INFORMATION SPECIFICATIONS AND ADJUSTMENTS Sy THIS ENGINE CONFORMS TO 2006 M Y CALIFORNIAAND U S EPA YANMAR CO LTD REGULATIONS FOR OFF ROAD C I ENGINES T THIS ENGINE IS CERTIFIED TO OPERATE ON TYPE2 D FUEL ENGINE FAMILY 6YDXM1 64D3N_ DISPLACEMENT 1 642 LITERS Figure 3 ENGINE MODEL 3JH4E EMISSION CONTROL SYSTEM EM FUEL 33 8 29 4kW 3000RPM 4JH4 HTE EPA Nameplate REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS MARINE ENGINE EMISSION CONTROL INFORMATION AND ADJUSTMENTS YANMAR YANMARCO LTD THIS ENGINE COMPLIES TO U S EPA REGULATIONS 40 CFR PART 94 WHICH APPLY TO MARINE ENGINES 0004576 MODEL YEAR 2007 ENGINE MODEL 4JH4 HTE DISPLACEMENT PER CYLINDER 0 499 LITERS Figure 1 ENGINE FAMILY 7YDXM2 00D4H APPLICATION RECREATIONAL STANDARDS THC NOx 7 5g kWh CO 5 0g kWh PM 0 40g KWh 4JH4AE EPA Nameplate REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS MARINE ENGINE EMISSION CONTROL INFORMATION YANMAR arco THIS ENGINE COMPLIES TO U S EPA REGULATIONS 40 CFR PART 9
62. MAR 2008 Yanmar Marine International Adjusting Propeller Shaft Alignment The flexible engine mounts are compressed a little during initial engine operation and may cause misalignment between the engine and the propeller shaft After the first 50 hours of operation the alignment should be checked and readjusted if necessary 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 If there is unusual noise and or vibration this maintenance requires specialized knowledge and techniques See your authorized Yanmar Marine dealer or distributor to adjust the propeller shaft alignment YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE 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 Draining Fuel Filter Water Separator WARNING When removing any fuel system component to perform maintenance such as changing the fuel filter put an approved container under the opening to catch the fuel NEVER us a shop rage to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye prote
63. MAR JH4 Series Operation Manual BEFORE YOU OPERATE 0004493 Figure 20 Check the coolant level in the coolant recovery tank The level should be at the FULL mark Figure 20 2 Add coolant if necessary NOTICE NEVER pour cold coolant into a hot engine Remove coolant recovery tank cap Figure 20 4 to add coolant if necessary Do not add water 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 Check the rubber hose Figure 20 1 connecting the coolant recovery tank to the coolant tank heat exchanger Replace if damaged Note If the coolant runs low too often or only the coolant level in the coolant tank drops without any change in the level in the coolant recovery tank there may be water or air leaks in the cooling system See your authorized Yanmar dealer or distributor 39 2008 Yanmar Marine International BEFORE YOU OPERATE CRANKING THE ENGINE NOTICE When the engine has not been used for a long period of time engine oil will not be distributed to all of the operating parts Using the engine in this condition will lead to seizure After a long period of no use distribute engine oil to each part by cranking Perform in accordance with the following procedures before beginning operation 1 Open seacock 2 Open fuel cock 3 Putremote control shift lever in NEUTRAL See Starting the Engi
64. NANCE Puller B option Part No 129671 92100 0004502 Figure 19 A B 110 mm 140 mm Replacing Coolant CAUTION 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 Replace coolant every year NOTICE NEVER mix different types and or colors of coolants Discard old coolant in an approved manner according to environmental laws Note If Long Life coolant is used replace coolant every 2 years 73 2008 Yanmar Marine International PERIODIC MAINTENANCE 0004556 Figure 20 1 Coolant Tank Heat Exchanger 2 Coolant Pump 3 Seawater Drain from Seawater Pump Cover 4 Coolant Drain Cock 3JH4E 0004557 Figure 21 1 Stop Solenoid 2 Coolant Drain Cock 3 Flywheel Housing 74 4JH4AE 0004569 Figure 22 1 Coolant Pump 2 Seawater Drain from Seawater Pump Cover 3 Coolant Tank Heat Exchanger 4 Coolant Drain Cock 5 Flywheel Housing 4JHAAE e 2 0004570 Figure 23 1 Coolant Drain Cock 2 Stop Solenoid Series Operation Manual YANMAR 2008 Yanmar Marine International 0004571 Figure 24 1 Coolant Tank Heat Exchanger 2 Coolant Pump 3 Seawater Drain from Seawater Pump Cover 4 Coolant Drain Cock 2 used 0004572 Figure 25 1 Coolant Drain Cock 2 Fuel Pump 3 Seawater Drain Cock
65. Please read and abide by the message that follows the safety alert symbol YANMAR JH4 Series Operation Manual DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury 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 2008 Yanmar Marine International SAFETY 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 allofthe safety precautions before operation or performing repairs or maintenance Before You Operate A DANGER The safety messages that follow have WARNING 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 pr
66. Specifications 89 3JH4E Engine Specifications 89 3JH4E Marine Gear Specifications 91 4JH4AE Engine Specifications 92 4JH4AE Marine Gear or Sail Drive Specifications esee 96 4JH4 TE Engine Specifications 98 4JH4 HTE Engine Specifications 100 4JH4 TE and 4JH4 HTE Marine Gear or Sail Drive Specifications ovis ss sce ea 102 YANMAR Series Operation Manual V 2008 Yanmar Marine International TABLE OF CONTENTS System Diagrams 103 Piping Diagrams eterne erred 103 Wiring Diagrams sss 130 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 ees 145 gt me ete edat Wie 145 Owner s Responsibility 145 Customer Assistance 146 Emission System Warranty 147 Non Road Emission System Warranty 147 Yanmar Co Ltd Limited Emission Control System Warranty USA O
67. UTRAL no load position Turn the knob Figure 21 2 counterclockwise to move the handle or clockwise to lock the handle 0004511 Figure 21 Note Yanmar recommends the use of a single lever type for the remote control system If only a two lever type is available in the market reduce engine rpm to 1000 rpm or less before engaging and disengaging the marine gear clutch 25 2008 Yanmar Marine International PRODUCT OVERVIEW This Page Intentionally Left Blank 26 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International BEFORE YOU OPERATE This section of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them It also describes the daily engine checks Before performing any operations within this section review the Safety section on page 3 YANMAR JH4 Series Operation Manual DIESEL FUEL Diesel Fuel Specifications DANGER Diesel fuel is flammable and explosive under certain conditions Refer to Fire and Explosion Hazard on page 5 NOTICE Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA warranty requirements Only use clean diesel fuel Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels DIESEL FUEL LOCATION SPECIFICATION No 2 D
68. Y J J Hid series OPERATION MANUAL 3JH4E 4JHAAE 4JH4 TE 4JH4 HTE gt P N OAJH4 G00103 MARINE ENGINES 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 YANMAR 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 2008 Yanmar Marine International 0608 ii JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International TABLE OF CONTENTS Page Introduction aana E 1 Record of Ownership 2 Safety iad Da NG qt ee 3 Safety Precautions 4 General Information
69. Yanmar Marine International NOTICE The safety messages that follow have NOTICE level hazards Itis 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 4 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 the local authorities 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 YANMAR JH4 Series Operation Manual SAFETY continuously or those that run for short periods of time If you have an installation with two or three engines and only one engine is operating the water pickup thru
70. actices 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 DANGER The safety message that follows has DANGER level hazards NM Crush Hazard NEVER stand under hoisted engine If the hoist mechanism fails the engine will fall on you Series Operation Manual YANMAR 2008 Yanmar Marine International SAFETY 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 Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Fire Hazard Undersized wiring systems cause an electrical fire PAN 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 a
71. ain from Seawater Pump Cover 4 Coolant Drain Cock 5 Intercooler 6 Seawater Drain Cock 4JH4 HTE 0004561 Figure 18 1 Coolant Drain Cock 2 Seawater Drain Cock 3 Marine Gear Cooler Series Operation Manual YANMAR 2008 Yanmar Marine International Ensure all drain cocks are closed Note The drain cocks are opened before shipping from the factory Marine gear ZF25A does not have a drain cock on clutch cooler Loosen the filler cap of the coolant tank to relieve the pressure then remove the filler cap WARNING NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will spray out and seriously burn you Allow the engine to cool down before you attempt to remove the cap 3 4 0004492 Figure 19 NOTICE NEVER pour cold coolant into a hot engine Pour coolant slowly into the coolanttank Figure 19 4 to avoid air bubbles Fill until coolant overflows from the filler port Align filler cap tabs Figure 19 2 with filler port notches Figure 19 3 and tighten filler cap firmly Figure 19 1 WARNING ALWAYS tighten the coolant tank cap securely after checking the coolant tank Steam can spray out during engine operation if the cap is loose Note The coolant level rises in the coolant recovery tank during operation After stopping the engine the coolant will cool down and the extra coolant will return to the coolant tank YAN
72. als regardless if the engine has been operated Engine Oil Viscosity SAE 10W30 or SAE15W40 the recommended oil viscosities If you operate your equipment at temperatures outside the limits shown consult your authorized Yanmar dealer or distributor for special lubricants or starting aids 34 Checking the Engine Oil Figure 9 Note 4JH4 TE shown Other models are similar 1 Make sure the engine is level 2 Remove dipstick Figure 9 3 and wipe with clean cloth 3 Fully reinsert dipstick 4 Remove dipstick The oil level should be between upper Figure 9 4 and lower Figure 9 5 lines on the dipstick 5 Addoilif necessary See Adding Engine Oil on page 34 6 Fully reinsert dipstick Adding Engine Oil 1 NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick and the surrounding area before you remove the cap Remove the yellow oil filler port cap from filler port Figure 9 1 and fill with engine oil 2 Fill with oil to the upper limit Figure 9 4 on the dipstick Figure 9 3 NOTICE NEVER overfill the engine with engine oil 3 Insert the dipstick fully to check the level NOTICE ALWAYS keep the oil level between upper and lower lines on the oil cap dipstick Series Operation Manual YANMAR 2008 Yanmar Marine International 4 1 Hand tighten the filler port securely BEFORE YOU OPERATE MARINE GEAR
73. as delivered by Yanmar to the original retail purchaser Such components may include the following Fuel Injection System Cold Start Enrichment System Positive Crankcase Ventilation System Since emissions related parts may vary slightly between models certain models may not contain all of these parts and other models may contain the functional equivalents 148 Exclusions Failures other than those arising from defects in material and or workmanship are not covered by this warranty The warranty does not extend to the following malfunctions caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance or use of non recommended fuels and lubricating oils accident caused damage and replacement of expendable items made in connection with scheduled maintenance Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of equipment engine or commercial loss Owner s Warranty Responsibilities As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your non road compression ignition engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all sched
74. at lowest speed and request repairs Engine oil low Engine oil level is low Check engine oil level See Checking pressure alarm Add or replace the Engine Oil on indicator comes on page 34 Engine oil filter clogged Replace engine oil filter See Changing Replace engine oil the Engine Oil and Replacing the Engine Oil Filter Element on page 63 e Water in sail drive seal Rubber sail drive seal broken See your authorized indicator comes on Yanmar Marine dealer or distributor Coolant high Coolant freshwater in coolant Check coolant level and See Checking temperature alarm tank is low refill and Adding comes on Coolant on page 37 Insufficient seawater causing temperature to rise Check seawater system Contamination inside cooling system See your authorized Yanmar Marine dealer or distributor Faulty Warning Devices Do not operate the engine if alarm devices are not repaired Serious accidents may result if abnormalities are not identified due to faulty indicators or alarm Indicators Do Not Go On When key is turned ON When any trouble occurs oil pressure etc No electrical current available Circuit broken or lamp burned out See your authorized Yanmar Marine dealer or distributor One of the indicators does not go out Sensor switch is faulty See your authorized Yanmar Marine dealer or distributor Battery low charge indicator
75. ater Pump coolant 39 Hot Water Connection Return 40 Coolant Temperature Sensor option 41 Lubrication Oil Pump 42 Pressure Control Valve 43 13 x t3 5 Rubber Hose 44 10 x t3 Rubber Hose 45 Diesel Fuel Filter cartridge type 46 7 x t4 5 Rubber Hose 47 7 x t4 5 Rubber Hose 48 5xt4 5 Rubber Hose 49 Diesel Fuel Inlet 50 Fuel Overflow 51 To Block 52 From Head 53 To Camshaft 54 To Oil Pan 55 Detail of Part A 56 Detail of Part B 57 Detail of Part C 58 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 119 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4 TE with ZF25A 28 55 0004183 Figure 9 120 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7xt4 5 Rubber Hose 2 W C S D 3 Fuel Injection Pump SYSTEM DIAGRAMS 29 Cooling Water Pump seawater 30 28 x t4 Rubber Hose 31 28 x t4 Rubber Hose 4 Fuel High Pressure Pipe 6 35 x 12 175 32 Hot Water Connection Outlet STS 33 Coolant Temperature Switch 5 Lubrication Oil Filter cartridge type
76. bustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury The Importance of Daily Checks The Periodic Maintenance Schedule assumes that the daily checks are performed on a regular basis Make it a habit of performing daily checks before the start of each operating day See Daily Checks on page 61 YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE Keep a Log of Engine Hours and Daily Checks Keep alog of the number of hours the engine is run each day and a log of the daily checks performed Also note the date type of repair e g replaced alternator and parts used for any service needed between the periodic maintenance intervals Periodic maintenance intervals are every 50 250 500 and 1000 engine hours Failure to perform periodic maintenance will shorten the life of the engine NOTICE Failure to perform periodic maintenance will shorten the life of the engine and may void the warranty Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Tools Required Before you start any periodic maintenance procedure make sure you have the tools you need to
77. c Maintenance Schedule on page 57 and the Periodic Maintenance Procedures on page 61 EPA Requirements for USA and Other Applicable Countries The following are the requirements for the EPA Unless these requirements are met the exhaust gas emissions will not be within the limits specified by the EPA See Conditions to Ensure Compliance with EPA Emission Standards on page 55 Clean or replace the air cleaner element if the air intake restriction exceeds the referenced specifications EPA Requirements The EPA emission regulation is applicable only in the USA and other countries that have adapted the 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 Conditions to Ensure Compliance with EPA Emission Standards The 3JH4E 4JH4AE 4JH TE and 4JH4 HTE are EPA certified engines The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards The operating conditions should be as follows Ambient temperature 20 to 40 C 4 to 104 F Relative humidity 80 or lower YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE The diesel fuel should be ASTM D975 No 1 0 or No 2 D or equivalent minimum of cetane No 45 The lubricating oil should be 3JH4E 4JH4 TE and 4JH4 HTE Type API Class CD or higher
78. catch fuel 2 Openthe drain cock and drain water and sediment Close the drain cock when the fuel is clean and free of air bubbles JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International PERIODIC MAINTENANCE Changing the Engine Oil and Replacing the Engine Oil Filter Element The engine oil on a new engine becomes contaminated from the initial break in of internal parts It is very important that the initial oil replacement is performed as scheduled Itis easiest and most effective to drain the engine oil after operation while the engine is still warm WARNING f you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection 1 Turnthe engine OFF 2 NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick and the surrounding area before removing the dipstick Remove the engine oil dipstick Attach the oil drain pump if equipped and pump out the oil For easier draining remove the engine oil fill cap Dispose of used oil properly NOTICE ALWAYS be environmentally responsible 3 Remove the engine oil filter Figure 2 with a filter wrench turn counterclockwise 0004508 Figure 2 Note 4JH4 TE shown 4 Install a new filter element and tighten by hand until the seal touches the housing YANMAR JH4 Series Operation Manual 5 Turn filter an additional 3 4 turn clockwise
79. changer 17 Lubricating Oil Inlet Filter 18 Main Bearing 19 Seawater Inlet 20 25 4 x 14 3 Rubber Hose 21 Cooling Water Pump seawater 22 28 x t4 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 23 28 x t4 Rubber Hose 24 Hot Water Connection Outlet R3 8 25 Thermostat 26 28 6 x t2 Copper Pipe 27 Cooling Water Pump coolant 28 Hot Water Connection Inlet R3 8 29 27 x t4 Rubber Hose 30 Coolant Temperature Switch 31 Lubricating Oil Pump 32 Pressure Control Valve 33 Diesel Fuel Filter 34 7 x t4 5 Rubber Hose 35 Fuel Feed Pump 36 Diesel Fuel Inlet 37 Fuel Overflow 38 To Oil Pan 39 From Cylinder Head 40 To Camshaft 41 Detail of Part A 42 Detail of Part B 43 Detail of Part C 44 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 109 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4AE with KM4A1 Marine Gear 1 BE Lo 3 4 5 6 22 18 16 H A i 21 19 17 n 47 20 0004588 Figure 4 110 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 x t4 5 Rubber Hose 2 Fue
80. ction The fuel system is under pressure and fuel could spray out when removing any fuel system component 67 2008 Yanmar Marine International PERIODIC MAINTENANCE 3JH4E and 4JHAAE attach to hull s e m t 1 0004564 Figure 10 1 Close the fuel tank cock 2 Loosen the drain plug Figure 10 1 of water separator and drain off any water or dirt collected inside Dispose ofthe collected water and dirt properly NOTICE ALWAYS be environmentally responsible 3 After draining tighten the air bleed screw Figure 10 2 4 Be sure to bleed air from the fuel system See Bleeding the Fuel System on page 32 68 4JH4 TE and 4JH4 HTE 0004565 Figure 11 Note 4JH4 TE shown CAUTION f the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 1 Close the fuel tank cock 2 Loosenthe hose clamp and remove the fire resistant cover which is installed to the lower part of the
81. d that new vessels be propped so the engines can operate at 100 200 rpm above the fuel stop power rpm to allow for some added weight and hull resistance Failure to do so can lead to reduced vessel performance lead to increased smoke levels and cause permanent damage to your engine YANMAR JH4 Series Operation Manual The engine must be installed correctly with coolant lines exhaust gas lines and electrical wiring Any auxiliary equipment attachedtothe engine should be easy to use and accessible for service To handle the drive equipment propulsion systems including the propeller and other onboard equipment always observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers The JH4 series engines are designed to be operated at maximum throttle 8000 3200 rpm for less than 5 of total engine time 30 minutes out of every 10 hours and cruising speed 2800 rpm or less for less than 9096 of total engine time 9 hours out of every 10 hours The laws of some 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 See Yanmar s local subsidiary in your region or your authorized Yanmar Marine dealer or distributor New Engine Break In As with all reciprocating engines the way your engine is ope
82. dipstick Figure 10 3 See Marine Gear Oil Specifications on page 35 NOTICE NEVER overfill the marine gear with oil 4 Fully reinsert dipstick 5 Tighten the filler port cap by hand car een and Adding Sail Drive Refer to the operation manual for SD50 T for the procedure to check and fill the sail drive oil 36 ENGINE COOLANT Engine Coolant Specifications Note In the U S LLC is required for the warranty to be valid Texaco Long Life Coolant LLC both standard and premixed product code 7997 and 7998 Havoline Extended Life Antifreeze Coolant product code 7994 NOTICE Following the manufacturer s recommendations use a proper LLC which will not have any adverse effects on the materials cast iron aluminum copper etc of the engine s cooling system See Engine Coolant Specifications on page 33 ALWAYS use the mixing ratios specified by the antifreeze manufacturer for the temperature range Coolant Closed Cooling System NOTICE ALWAYS add LLC to soft water especially when operating in cold weather NEVER use hard water Water should be clean and free from sludge or particles Without LLC cooling performance will decrease due to scale and rust in the coolant system Water alone may freeze and form ice it expands approximately 9 6 in volume Use the proper amount of coolant concentrate for the ambient temperature as specified by the LLC manufacturer LLC concentration should b
83. does not go out during operation V belt is loose or broken Replace V belt or adjust See Checking tension and Adjusting the Alternator V Belt Tension on page 64 Battery is defective Check battery fluid level See Checking specific gravity or the Battery replace battery Electrolyte Level serviceable batteries only on page 69 Alternator power generation failure See your authorized Yanmar Marine dealer or distributor YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 81 TROUBLESHOOTING Symptom Probable Cause Measure Reference Starting Failures Starter turns but No fuel Add fuel Bleed fuel See Filling the engine does not start System Fuel Tank on page 31 and Bleeding the Fuel System on page 32 Fuel filter is clogged Replace filter element See Replacing the Fuel Filter Element on page 70 Improper fuel Replace with See Diesel Fuel recommended fuel Specifications on page 27 Problem with fuel injection See your authorized Yanmar Marine dealer or distributor Compression leakage See your authorized Yanmar from intake exhaust Marine dealer or distributor valve Starterdoesnotturnor Faulty clutch position Shift to NEUTRAL and turns slowly engine start can be turned T manually Insufficient battery charge Check fluid level See Checking Recharge Replace the Battery Electrolyte Level serviceable batteries only
84. e a minimum of 30 to a maximum of 60 Too much LLC will decrease the cooling efficiency Excessive use of antifreeze also lowers the cooling efficiency of the engine NEVER mix different types or brands of 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 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International Checking and Adding Coolant 3JH4E 0004556 Figure 11 1 Coolant Tank Heat Exchanger 2 Coolant Pump 3 Seawater Drain from Seawater Pump Cover 4 Coolant Drain Cock 2 0004664 Figure 12 1 Coolant Drain Cock 2 Flywheel Housing 3 Stop Solenoid YANMAR JH4 Series Operation Manual BEFORE YOU OPERATE 4JH4AE 0004569 Figure 13 1 Coolant Pump 2 Seawater Drain from Seawater Pump Cover 3 Coolant Tank Heat Exchanger 4 Coolant Drain Cock 5 Flywheel Housing 1 0004558 Figure 14 1 Coolant Drain Cock 37 2008 Yanmar Marine International BEFORE YOU OPERATE 4JH4 TE 0004514 Figure 15 1 Coolant Tank Heat Exchanger 2 Coolant Pump 3 Seawater Drain from Seawater Pump Cover 4 Coolant Drain Cock 2 used 0004559 3 Figure 16 1 Coolant Drain Cock 2 Seawater Drain Cock 3 Marine Gear Cooler 38 4JH4 HTE 0004560 Figure 17 1 Coolant Tank Heat Exchanger 2 Coolant Pump 3 Seawater Dr
85. e and title E identification of the person empowered to sign on or an equivalent marking Presiden behalf of the engine manufacturer or his authorised representative ma LAS FT Date yr month day 2005 10 21 Series Operation Manual YANMAR 2008 Yanmar Marine International
86. e at low speed for long periods of time race the engine once every 2 hours Note Racing the engine With the gear in NEUTRAL accelerate from the low speed position to the high speed position and repeat this process about 5 times This is done to clean out carbon from the cylinders and the fuel injection valve Neglecting to race the engine will result in poor exhaust color and reduce engine performance If possible periodically operate the engine at near maximum rpm while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintaining engine performance and prolonging the life of the engine NOTICE NEVER turn off the battery switch if equipped or short the battery cables during operation Damage to the electric system will result 47 2008 Yanmar Marine International ENGINE OPERATION SHUTTING DOWN THE ENGINE Normal Shutdown 1 48 Reduce engine speed to low idle and put remote control handle in NEUTRAL Accelerate from low speed to high speed and repeat five times This will clean out the carbon from the cylinders and the fuel injection nozzles Allow engine to run at low speed approximately 1000 rpm without load for 5 minutes CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for 5 minutes This will allow the engine components that operate at high temperatures
87. e engine as delivered by Yanmar to the original retail purchaser Such components may include the following Fuel Injection System Turbocharger System Aftercooler Electronic Engine Control Units and its associated Sensor and Actuators gt m Exclusions Failures other than those arising from defects in material and or workmanship are not covered by this limited emissions warranty This warranty does not extend to the following malfunction caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance improper storage or use of non recommended fuels and lubricating oils accident caused damage and replacement of expendable and or consumable items made in connection with scheduled maintenance Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of marine vessel engine or commercial loss YANMAR JH4 Series Operation Manual EPA WARRANTY USA ONLY Owner s Responsibility As the Yanmar Marine engine owner you are responsible for the performance of the required maintenance listed in your Operation Manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your marine engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Your
88. engine application loads diesel fuel and engine oil used and are hard to establish definitively The following should be treated only as a general guideline YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE CAUTION Establish a periodic maintenance plan according to the engine application and make sure to perform the required periodic maintenance at the intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a e 57 2008 Yanmar Marine International PERIODIC MAINTENANCE O Check or Clean 9 Replace Contact your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval Daily Every 50 Every Every Every See hours or 250 500 1000 Daily monthly hours or hours or hours or Check which one year two four son ever which years years page comes ever which which 61 first comes ever ever first comes comes first first Whole Visual inspection of engine O exterior Fuel Check the fuel level and refill System ifnecessary Drain water and sediment O from fuel tank Initial 50 Drain the fuel water separator Replace the fuel filter 9 element Check t
89. erating conditions the indicators are off 9 5 Figure 15 Battery Low Charge Indicator Figure 15 When the alternator output is too low the indicator will light When charging begins the indicator will turn off No alarm will sound for low battery charge is EI Figure 16 Coolant High Temperature Indicator and Alarm Figure 16 When coolant temperature reaches the maximum allowable temperature 95 C 203 F or higher the indicator will light and the alarm will sound Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure Check the load and troubleshoot the cooling system Figure 17 Engine Oil Low Pressure Indicator and Alarm Figure 17 When the engine oil pressure falls below normal the oil pressure sensor will send a signal to the indicator causing it to light and the alarm to sound Stop operation immediately to avoid damage to the engine Check the oil level and troubleshoot the lubrication system 24 L SSS Figure 18 Water in Sail Drive Seal Indicator and Alarm Figure 18 When water is detected between the seals of the sail drive the indicator will light and the alarm will sound Figure 19 Water in Fuel Filter Indicator and Alarm C Type only 4JH4 TE and 4JH4 HTE engines only Figure 19 Whenthe water level in the fuel filter water separator becomes too high the indicator will light and the alarm will sound Drain the
90. eration and special precautions are required to avoid carbon monoxide poisoning W equipment Shock Hazard ALWAYS turn off the battery switch if equipped or disconnect the negative battery cable before servicing the ALWAYS keep the electrical connectors and terminals clean Check the electrical harnesses for cracks abrasions and damaged or corroded connectors NEVER use undersized wiring for the electrical system 52 NOTICE Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use Yanmar genuine replacement parts Series Operation Manual YANMAR 2008 Yanmar Marine International PRECAUTIONS The Importance of Periodic Maintenance Engine deterioration and wear occur in proportion to the length of time the engine has been in service and the conditions the engine is subjected to during operation Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine Performing Periodic Maintenance WARNING NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal com
91. ght load you must race the engine to clean the carbon from the cylinders and fuel injection valve 14 Perform this procedure in open waters With the clutch in NEUTRAL accelerate from the low speed position to the high Speed position briefly Repeat this process five times Once past the initial 10 hours until 50 hours the engine should be used over its full operating range with special emphasis on running at relatively high power settings This is notthe time for an extended cruise at idle or low speed The boat should be run at maximum speed minus 400 rpm most of the time approximately 70 load with a 10 minute run at maximum minus 200 rpm approximately 8096 load every 30 minutes and a 4 5 minute period of operation at WOT wide open throttle once each 30 minutes During this period be sure not to operate your engine at low speed and light load for more than 30 minutes If operating engine at low speed and light load by necessity just after the low idle operation be sure to race the engine To complete engine break in perform After Initial 50 Hours maintenance procedures See Periodic Maintenance Schedule on page 57 Series Operation Manual YANMAR 2008 Yanmar Marine International COMPONENT IDENTIFICATION Service Side 3JH4E Figure 1 and Figure 2 illustrate a typical version of a 3JH4E engine Your engine may have different equipment from that illustrated 0004543 Figure 1
92. gine It is driven by aturbine that is energized by exhaust gases Intercooler if equipped This heat exchanger cools the pressurized charging air from the turbocharger with seawater to increase the charging air quantity Intake Silencer Air Cleaner The intake silencer guards against dirt in the air and reduces the noise of air intake Nameplates Nameplates are provided on the engine and the marine gear and have the model serial number and other data Starter 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 20 Series Operation Manual YANMAR 2008 Yanmar Marine International PRODUCT OVERVIEW CONTROL EQUIPMENT The equipment in the control room makes remote control operation possible consists of the instrument panel which is connected to the engine by a wire harness and the remote control handle which is connected by control cables to the engine control lever and marine gear Instrument Panel Optional Equipment and Functions The instrument panel is located in the cockpit The following instruments enable you to start or stop the engine and to monitor its condition during operation B Type 9 8 7 6 5 7 7 04 0004486 Figure 12 1 Tachometer 6 Battery Low Charge I
93. gure 5 and Figure 6 illustrate a typical version of a 4JH4 TE engine Your engine may have different equipment from that illustrated 0004516 Figure 5 1 Intake Silencer Air Cleaner 2 Turbocharger 3 Shift Lever 4 Marine Gear shown 5 Engine Oil Cooler 6 Engine Oil Filter 7 Fuel Injection Pump 8 FuelFilter 9 Fuel Priming Pump 10 Engine Oil Dipstick 11 Intake Manifold 12 Engine Oil Filler Cap YANMAR JH4 Series Operation Manual PRODUCT OVERVIEW Non Service Side 4JH4 TE 2 3 4 5 6 7 8 9 1 9 5 6 0004547 Figure 6 Engine Nameplate on rocker arm cover Coolant Filler Cap Coolant Pump Belt Cover Seawater Pump Alternator Starter Motor Exhaust Water Mixing Elbow Coolant Tank Heat Exchanger 17 2008 Yanmar Marine International PRODUCT OVERVIEW Service Side 4JH4 HTE Non Service Side 4JH4 HTE Figure 7 and Figure 8 illustrate a typical version of a 4JH4 HTE engine Your engine may have different equipment from that illustrated 12 11 0004549 Figure 8 1 Engine Nameplate on rocker arm cover 4 2 CoolantFiller Cap 3 Coolant Pump Figure 7 4 Belt Cover 1 Intake Silencer Seawater Pump 2 Turbocharger 6 Alternator 3 Shift Lever KMH4A 7 Intercooler 4 Marine Gear 8 Starter Motor 5 Engine Oil Cooler 9 Exhaust Mixing Elbow 6 Engine Oil Filter 10 Coolant Tank Heat Excha
94. h Temperature Alarm 17 Water in Sail Drive Seal Alarm 18 Battery Low Charge Alarm 19 20 21 Air Heater optional 22 Engine Stop Solenoid 23 Stop Relay 24 Starter Relay 25 Starter 26 Coolant High Temperature Switch 27 Lubricating Oil Low Pressure Switch 28 Alternator optional 29 Alternator 30 Water In Sail Drive Seal Sensor on Sail Drive 31 Water in Sail Drive Seal Sensor Amplifier Sail Drive only 32 Battery optional 33 Battery 34 35 YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 131 SYSTEM DIAGRAMS 4JH4AE B Type Instrument Panel youms Kane ce ACL Act
95. he fuel injection e timing Check the fuel injector spray pattern Lubricating Check the Engine lube oil level O Gear Replace the Engine lube oil Initial 50 Marine Gear Initial 50 Replace the Engine oil filter Initial 50 element Marine Gear Initial 50 if equipped Cooling Seawater outlet System During Oper ation Check coolant level Check or replace the 9 seawater pump impeller Replace coolant Every year When Long Life Coolant is used replace every two years See Engine Coolant Specifications on page 36 Clean and check the e seawater passages 58 Series Operation Manual YANMAR 2008 Yanmar Marine International PERIODIC MAINTENANCE O Check or Clean 9 Replace Contact your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval Daily Every 50 Every Every Every See hours or 250 500 1000 Daily monthly hours or hours or hours or Check which one year two four son ever which years years page comes ever which which 61 first comes ever ever first comes comes first first Air Intake Clean intake silencer air and cleaner element Exhaust System Clean or replace the exhaust water mixing elbow Clean the turbocharger 4JH4 TE or 4JH4 HTE only Check diaphragm assembly e 4JHAAE only Electrical Check the alarm a
96. he hours of use the engine has a warranty period of two 2 years Warranty Coverage This warranty is transferable to each subsequent purchaser for the duration of the warranty period Repair or replacement of any warranted part will be performed at an authorized Yanmar Marine engine dealer or distributor 147 2008 Yanmar Marine International EMISSION SYSTEM WARRANTY Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement Any part repaired or replaced under warranty shall be warranted for the remaining warranty period During the warranty period Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine and shall not reduce Yanmar s warranty obligations Add on or modified parts that are not exempted may not be used The use of any non exempted add on or modified parts shall be grounds for disallowing a warranty Warranted Parts This warranty covers engine components that are a part of the emission control system of the engine
97. heck turbocharger adjustment if equipped Check electronic engine control unit and its associated sensors and actuators if equipped Note The inspection and maintenance items shown above to be performed at your Yanmar Marine dealer or distributor 60 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International PERIODIC MAINTENANCE PROCEDURES WARNING ALWAYS wear personal protective equipment Refer to Exposure Hazard on page 6 Daily Checks Before you head out for the day make sure the Yanmar engine is in good operating condition CAUTION is important to perform the daily checks as listed in this 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 Make sure you check the following items Visual Checks 1 Check for engine oil leaks 2 Check for fuel leaks WARNING Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair any damage 3 Checkforengine coolant leaks Check for damaged or mis
98. htly 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 onesinstalled 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 2008 Yanmar Marine International 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 2 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 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
99. ient battery electrolyte Operating with insufficient electrolyte will destroy the battery NOTICE Battery fluid tends to evaporate in high temperatures especially in summer In such conditions inspect the battery earlier than specified YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE 1 Turn the battery master switch to OFF if equipped or disconnectthe negative battery cable 2 Do not operate with insufficient battery electrolyte as the battery will be destroyed 3 Remove the plugs and check the electrolyte level in all cells NOTICE NEVER attempt to remove the covers or fill a maintenance free battery 4 Ifthe level is lower than the minimum fill level Figure 12 1 fill with distilled water Figure 12 2 available in the grocery store up to the upper limit Figure 12 3 of the battery Th Ti Ex 0004566 Figure 12 Note The maximum fill level is approximately 10 15 mm 3 8 9 16 in above the plates 69 2008 Yanmar Marine International PERIODIC MAINTENANCE Every 250 Hours of Operation Perform the following maintenance every 250 hours or one year of operation whichever comes first Draining the Fuel Tank Replacing the Fuel Filter Element Changing the Engine Oil and Replacing the Engine Oil Filter Element Changing the Marine Gear Oil and Replacing Marine Gear Oil Filter Element if equipped Checking or Replacing the Seawater Impel
100. iming Plunger lift at TDC 1 26 0 01 mm when W CSD is released Fuel Injection Opening Pressure 21 6 x 0 5 MPa Main Power Take Off At flywheel end Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise Clockwise or Ahead from stern counterclockwise Bi rotation Cooling System Freshwater cooling with heat exchanger Lubrication System Complete enclosed forced lubrication system Cooling Water Capacity fresh Engine 7 2 L 7 6 qt Coolant recovery tank 0 8 L 0 8 qt Lubricating Rake angle 7 0 7 010 e _ _ Total 5 7 0 3L 6 9 0 3 L 7 3 0 3 qt Refer to apacity 6 0 0 3 left engine qi Oil pan only 5 2x0 3L 6 4 0 3 L 6 8 0 3 qt Refer to 5 5 x 0 3 left qt Effective 2 4 L 2 5 qt Starting Type Electric System Starting motor DC 12V 1 4 kW AC generator 12V 80 A 12 V 60 A optional 98 Series Operation Manual YANMAR 2008 Yanmar Marine International SPECIFICATIONS Engine Model 4JH4 TE Marine Gear Model ZF30M KM4A2 KMH4A ZF25A SD50 4T Bobtail Engine Overall length 923mm 903 mm 933 mm 1017 mm 782 mm 782 mm Dimension 36 3 85 6in 36 7 40 0in 30 8 in 30 8 in 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
101. ion Pay particular attention to the following 1 Is sufficient seawater being discharged from the exhaust and seawater outlet pipe Ifthe discharge is small stop the engine immediately identify the cause and repair 2 Is the exhaust color normal The continuous emission of black exhaust smoke indicates engine overloading This shortens the engine s life and should be avoided 3 Arethere abnormal vibrations or noise CAUTION Excessive vibration may cause damage to the engine marine gear hull and onboard equipment In addition it causes noticeable passenger and crew discomfort Depending on the hull structure engine and hull resonance may suddenly become great at a certain engine speed range causing heavy vibrations Avoid operation in this speed range If you hear any abnormal sounds stop the engine and inspect YANMAR JH4 Series Operation Manual ENGINE OPERATION Alarm buzzer sounds during operation NOTICE f any alarm indicator with audible alarm sound appears on the display during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine Isthere water oil orfuel leakage or are there any loose bolts Check the engine room periodically for any problems Is there sufficient diesel fuel in the diesel fuel tank Replenish diesel fuel before leaving the dock to avoid running out of fuel during operation When operating the engin
102. ion 25 Stop Relay 26 Starter Relay 27 Starter 28 Coolant Temperature Switch 29 Engine Oil Pressure Switch 30 Alternator 31 Earth Bolt ground 32 Sail Drive Only 33 Details Of Coupler view from A A YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 139 4JH4 TE 4JH4 HTE with C x B Type Panel SYSTEM DIAGRAMS 0004507 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International Figure 19 100 800 9 mors YD
103. irements for USA and Other Applicable MAN 55 EPA Requirements 55 Conditions to Ensure Compliance with EPA Emission Standards 55 Inspection and Maintenance 56 Periodic Maintenance Schedule 57 Inspection and Maintenance of EPA Emission Related Parts 60 Periodic Maintenance Procedures 61 Daily Checks anaa anae anana eaaa neste anane 61 After Initial 50 Hours of Operation 62 Every 50 Hours of Operation 67 Every 250 Hours of Operation 70 Every 500 Hours of Operation 77 Every 1000 Hours of Operation 77 Troubleshooting 79 Troubleshooting After Starting 79 Troubleshooting Information tenes 80 Troubleshooting Chart 81 Long Term Storage 85 Prepare Engine for Long Term Storage 85 Drain Seawater Cooling System 86 Returning the Engine to Service 88 Specifications eerte eA YA 89 Principal Engine
104. l Injection Pump 3 5 x t4 5 Rubber Hose 4 7 xt4 5 Rubber Hose 5 9xt3 5 Rubber Hose 6 Lubricating Oil Filter cartridge type 7 Lubricating Oil Cooler 8 5xt4 5 Rubber Hose 9 6 35 x 12 375 Steel Pipe Fuel High Pressure Pipe 10 Fuel Injection Nozzle 11 9xt3 5 Rubber Hose 12 Cil Pressure Switch 13 13 x t4 Rubber Hose 14 Clutch Lubricating Oil Cooler 15 Mixing Elbow 16 25 4 x t4 3 Rubber Hose 17 25 4 x t4 3 Rubber Hose 18 Heat Exchanger 19 Lubricating Oil Inlet Filter 20 Main Bearing 21 Seawater Inlet 22 25 4 x t4 3 Rubber Hose 23 Cooling Water Pump seawater 24 28 x t4 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 25 28 x t4 Rubber Hose 26 Hot Water Connection Outlet R3 8 27 Thermostat 28 28 6 x 12 Copper Pipe 29 Cooling Water Pump coolant 30 Hot Water Connection Inlet R3 8 31 27 x t4 Rubber Hose 32 Coolant Temperature Switch 33 Lubricating Oil Pump 34 Pressure Control Valve 35 Diesel Fuel Filter cartridge type 36 7xt4 5 Rubber Hose 37 Fuel Feed Pump 38 Diesel Fuel Inlet 39 Fuel Overflow 40 To Cil Pan 41 From Cylinder Head 42 To Camshaft 43 Clutch Lubricating Oil Cooler 44 Detail of Part A 45 Detail of Part B 46 Detail of Part C 47 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked sa
105. l Pressure Switch 11 Oil Pressure Sensor option 12 Fuel Injection Nozzle 13 Piston Cooling Oil Jet 14 8 xt0 8 STKM 15 Clutch Lubrication Oil Cooler 16 Seawater Inlet 17 Turbocharger 18 17 xt1 2 STKM 19 Mixing Elbow 20 8 5 x t3 5 Rubber Hose 21 17 xt3 Rubber Hose 22 Heat Exchanger 23 Main Bearing 24 Lubrication Oil Inlet Filter 25 25 4 x t4 3 Rubber Hose 26 25 4 x 14 3 Rubber Hose 27 7 5 x 12 5 Rubber Hose 28 25 4 x t4 3 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 29 Cooling Water Pump seawater 30 28 x t4 Rubber Hose 31 28 x t4 Rubber Hose Fuel High Pressure Pipe 6 35 x 12 175 32 Hot Water Connection Outlet 33 Coolant Temperature Switch 34 Thermostat 35 Cooling Water Pump coolant 36 Hot Water Connection Return 37 Coolant Temperature Sensor option 38 Lubrication Oil Pump 39 Pressure Control Valve 40 13 x t3 5 Rubber Hose 41 10 x t3 Rubber Hose 42 Diesel Fuel Filter cartridge type 43 7 x 14 5 Rubber Hose 44 7 x t4 5 Rubber Hose 45 5 x t4 5 Rubber Hose 46 Diesel Fuel Inlet 47 Fuel Overflow 48 To Block 49 From Head 50 To Camshaft 51 To Oil Pan 52 Detail of Part A 53 Detail of Part B 54 Detail of Part C 55 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO784
106. ler Changing the Coolant Cleaning Intake Silencer Air Cleaner Element Cleaning the Exhaust Water Mixing Elbow Cleaning the Turbocharger if equipped Adjusting the Tension of the Alternator V Belt Checking the Wiring Connectors Tightening All Major Nuts and Bolts Draining the Fuel Tank See Draining the Fuel Tank on page 62 70 Replacing the Fuel Filter Element WARNING When removing any fuel system component to perform maintenance such as changing the fuel filter put an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors form the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when removing any fuel system component 4JH4AE When there is not enough tension in the belt it will slip and the freshwater pump will fail to supply coolant Engine overheating and seizure will result When there is too much tension in the V belt the belt will become damaged more quickly and the freshwater pump bearing may be damaged WARNING Perform this check with engine OFF and key removed to avoid contact with moving parts 0003627 Figure 13 1 Close the fuel tank drain cock JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International Remove the cartridge filter Figure 13 1 with a filter wrench Note When removing
107. ling Water Pump coolant 35 Hot Water Connection Inlet R3 8 36 27 x t4 Rubber Hose 37 Coolant Temperature Switch 38 Lubricating Oil Pump 39 Pressure Control Valve 40 Diesel Fuel Filter cartridge type 41 To Oil Pan 42 From Cylinder Head 43 To Cam Shaft 44 Detail of Part B 45 Detail of Part C 46 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 107 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4AE with KM35P KM35A2 Marine Gear 1 B c 14 20 16 15 17 18 a4 D 0004587 Figure 3 108 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 x t4 5 Rubber Hose 2 Fuel Injection Pump 3 5 x t4 5 Rubber Hose 4 4 76 x t0 7 Steel Pipe 5 9xt3 5 Rubber Hose 6 Lubricating Oil Filter cartridge type 7 Lubricating Oil Cooler 8 5xt4 5 Rubber Hose 9 6 35 x 12 375 Steel Pipe 10 Fuel High Pressure Pipe 11 Fuel Injection Nozzle 12 9 x t3 5 Rubber Hose 13 Oil Pressure Switch 14 Mixing Elbow 15 25 4 x t4 3 Rubber Hose 16 Heat Ex
108. missions condition exists Yanmar will repair your engine at no charge to youfor diagnosis parts and labor Warranty service or repair will be provided at authorized Yanmar Marine dealers or distributors 144 It is recommended that any replacement parts used for maintenance repair or replacement of emission control systems are Yanmar parts The owner may elect to have maintenance replacement or repair of the emission control components and systems performed by any repair establishment or individual and may elect to use parts other than Yanmar parts for such maintenance replacement or repair However the cost of such service or parts and subsequent failures from such service or parts will not be covered under this emission control system warranty Warranty Period The warranty starts on either the date of delivery to the first end user or the date the unit is first leased rented or loaned For Pleasure Use The warranty period is five 5 years or 2000 hours of use whichever occurs first In the absence of a device to measure hours of use the engine has a warranty period of five 5 years Series Operation Manual YANMAR 2008 Yanmar Marine International Warranty Coverage Repair or replacement of any warranted parts will be performed at an authorized Yanmar dealer or distributor This limited emission control system warranty covers engine components that are a part of the emission control system of th
109. n Open the seawater drain cock on the intercooler 4JH4 HTE only and drain If no water drains use a stiff brush to remove any debris 2 Remove four bolts attaching the side cover of the seawater pump Remove the cover and drain the seawater 3 Install cover and tighten bolts 4 Close all the drain cocks 88 RETURNING THE ENGINE TO SERVICE 1 Replace the oil and the oil filter before running the engine 2 Supply fuel if the fuel in the fuel tank was removed and prime the fuel system 3 Confirm that there is engine coolant in the engine 4 Operate the engine at idle speed for 1 minute 5 Check fluid levels and check engine for leaks JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS 3JH4E Engine Specifications Specification 3JH4E Marine Gear Model KM35P KM35A SD40 SD50 Bobtail Use Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders 3 Bore x Stroke 88 mm x 90 mm 3 46 in x 3 54 in Displacement 1 642 L 100 20 cu in Continuous Output Rating at 26 7 kW 36 3 hp metric 2907 rpm Crankshaft Maximum Output at 29 4 kW 40 0 hp metric 3000 rpm Output Rating crankshaft engine 28 7 kW 39 0 hp metric 3000 rpm speed Output at
110. n the filter periodically The filter element should be replaced periodically The water separator if equipped should be drained periodically See Draining Fuel Filter Water Separator on page 67 Fuel Feed Pump Pumps fuel from the tank to the fuel injection system Fuel Priming Pump if equipped This is a manual fuel pump Pushing the knob on the top of the fuel filter feeds the fuel The pump is also used to bleed air from the fuel system Engine Oil Filler Port Filler port for engine oil Engine Oil Filter Filters fine metal fragments and carbon from the engine oil Filtered engine oil is distributed to the engine s moving parts The filter is a cartridge type and the element should be replaced periodically See Changing the Engine Oil and Replacing the Engine Oil Filter Element on page 72 Marine Gear Filler Port Filler port for marine gear lube oil Located on top of the marine gear case Cooling System There are two cooling systems closed cooling with coolant freshwater and seawater The engine is cooled by the closed cooling circuit The closed circuit is cooled by seawater using a heat exchanger The seawater also cools the engine marine gear oil and intake air depending on model through the cooler s in an open circuit Closed Cooling Circulation Pump The centrifugal water pump circulates coolant inside the engine The circulating pump is driven by a V belt Seawater Pump
111. nd O System indicators Check the electrolyte level in the battery Adjust the tension of the 9 alternator V belt or replace Initial 50 V belt Checkthe wiring connectors Engine Check for leakage of fuel Cylinder engine oil and engine After Head and coolant starting Block Tighten all major nuts and e bolts Adjust intake exhaust valve e e clearance Initial 50 Miscellane Checkthe remote control ous Items cable operation Initial 50 Adjust the propeller shaft e e alignment Initial 50 Replace rubberized hoses Replace every 2 years or every 2000 hours whichever comes fuel and water first For EPA requirements see Inspection and Maintenance of EPA Emission Related Parts on page 60 Note These procedures are considered normal maintenance and are performed at the owner s expense YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 59 PERIODIC MAINTENANCE Inspection and Maintenance of EPA Emission Related Parts Marine diesel engines less than 37 kW 3JH4E is certified as EPA non road engine e Marine diesel engines greater than 37 kW 4JHAAE 4JH4 TE and 4JH4 HTE are certified as EPA CI marine engines Inspection and Maintenance of EPA Emission Related Parts for Non Road and CI Marine Engines Parts Interval Clean fuel injection nozzle 1500 hours Check fuel injection nozzle pressure and spray pattern 3000 hours Check fuel injection pump adjustment C
112. ndicator 2 Hourmeter 7 Water in Sail Drive Seal Indicator 3 Moisture Cap for Key Switch 8 Engine Oil Low Pressure Indicator 4 Key Switch 9 Coolant High Temperature Indicator 5 Stop Button YANMAR JH4 Series Operation Manual 21 2008 Yanmar Marine International PRODUCT OVERVIEW C Type 13 12 57 5 12 1 11 TAN o axon 10 2 LA D 4o 9 3 v sa GLOW on 4 amp START 4 8 ZAC AUG D 6 7 5 6 0004503 Figure 13 1 Coolant High Temperature Indicator 8 Key Switch 2 Coolant Temperature Gauge 9 Stop Button 3 Engine Oil Low Pressure Indicator 10 Battery Low Charge Indicator 4 Engine Oil Pressure Gauge 11 Water in Sail Drive Seal Indicator 5 Tachometer 12 Water in Fuel Filter Indicator if 6 Hourmeter equipped 7 Moisture Cap for Key Switch 13 Not Used on This Engine 22 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International PRODUCT OVERVIEW Meters B Type and C Type panels use analog electric gauges with needle indicators Instrument Function Tachometer Shows engine rotation speed Hourmeter Shows number of operating hours Can be used as a guide for periodic maintenance checks The hourmeter is located at the bottom of the tachometer Coolant Temperature Gauge C Type only Shows the coolant temperature Engine Oil Pressure Gauge C Type only Shows the engine oil pressu
113. ne on page 43 4 battery switch to ON if equipped TS a AN cQ T a 7 0003622 Figure 21 5 Turn key to ON Figure 21 3 6 S3JH4E 4JH4AE models a While pushing the STOP button on the control panel turn the key to the START position Figure 21 4 NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 40 b Whenthe key is in the START position the engine will begin cranking Continue cranking for about 5 seconds and listen for abnormal noise during that time WARNING the STOP button is released during the cranking procedure the engine will start NEVER start the engine in this mode 7 4JH4 TE 4JH4 HTE models LE S 2 0004488 Figure 22 a Move and hold Figure 22 1 the stop lever Figure 22 2 on the governor to stop fuel flow while cranking CAUTION 4JH4 TE 4JH4 HTE models NEVER use the STOP button on the control panel for cranking procedure b Hold key in START position for about 5 seconds and listen for abnormal noise during that time WARNING f the governor lever is released during the cranking procedure the engine will start JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International ENGINE OPERATION This section of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them
114. nger 7 Fuel Injection Pump 8 FuelFilter 9 Fuel Priming Pump 10 Engine Oil Dipstick 11 Intake Manifold 12 Engine Oil Filler Cap 18 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International NAMEPLATES The nameplates of Yanmar series engines are shown in Figure 9 Check the engine s model output rpm and serial number on the nameplate Please replace if damaged or lost The engine nameplate is attached to the engine rocker arm cover O Model Gear Model Continuous power KW Speed of prop shaft Fuel stop power kW ENG No YANMAR CO LTD MADE IN JAPAN 0004574 Figure 9 YANMAR JH4 Series Operation Manual PRODUCT OVERVIEW The marine gear nameplate Figure 10 is attached to the marine gear Check the marine gear s model gear ratio oil used oil quantity and serial number O MODEL KM O GEAR RATIO OIL SAE OIL QTY NO KANZAKI OSAKA JAPAN 0004529 20 30HD LTR Figure 10 The sail drive nameplate Figure 11 is attached to the sail drive Check the sail drive model and serial number MODEL PASSED MARK MFG NO YANMAR SAIL DRIVE YANMAR CO LTD MADE IN JAPAN 0004575 Figure 11 19 2008 Yanmar Marine International PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of Component Function Fuel Filter Removes dirt and water from the fuel Drai
115. nly 147 Maintenance Log 150 vi JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 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 JH4 series engine for many years to come please follow these recommendations YANMAR JH4 Series Operation Manual 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 slig
116. ntil the engine starts When the engine does start stop the engine immediately and turn the switch to the OFF position Be sure to re open the seacock and restart the engine Operate the engine normally 42 NOTICE If any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine If the alarm window with audible alarm fails to display and go out about 3 seconds later when the ignition switch is in the ON position see your authorized Yanmar Marine dealer or distributor for service before operating the engine Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes NEVER run the engine if the ambient temperature is above 40 C 104 F or below 16 C 5 If the ambient temperature exceeds 40 C 104 F the engine may overheat and cause the engine oil to break down If the ambient temperature is below 16 C 5 F rubber components such as gaskets and seals will harden causing premature engine wear and damage Contact your authorized Yanmar Marine engine dealer or distributor if the engine will be operated outside of this standard temperature range NEVER engage the starter motor while the engine is running Damage to the starter mo
117. oke indicates engine overloading This shortens the engine s life and should be avoided Are there abnormal vibrations or noise Depending on the hull structure engine and hull resonance may suddenly increase at certain engine speed ranges causing heavy vibrations Avoid operation in this speed range If any abnormal sounds are heard stop the engine and inspect for cause Alarm sounds during operation f the alarm sounds during operation lower the engine speed immediately check the warning lamps and stop the engine for repairs 79 2008 Yanmar Marine International TROUBLESHOOTING Is there water oil or fuel leakage Are there any loose bolts or connections Checkthe engine room daily for any leaks or loose connections Is there sufficient fuel in the fuel tank Refill fuel in advance to avoid running out of fuel If the tank runs out of fuel bleed the fuel system See Bleeding the Fuel System on page 32 When operating the engine at low speed for long periods of time race the engine once every 2 hours Racing the engine with the clutch in NEUTRAL accelerate from the low speed position to the high speed position and repeat this process about five times This is done to clean out carbon from the cylinders and the fuel injection valves NOTICE Neglecting to race the engine will result in poor exhaust color and reduce engine performance Periodically operate the engine near maximum speed while
118. on Manual PERIODIC MAINTENANCE Every 1000 Hours of Operation Perform the following maintenance every 1000 hours or 4 years of operation whichever comes first Checking the Fuel Injection Timing Checking the Fuel Injector Spray Pattern Replacing the Seawater Pump Impeller Cleaning and Checking the Seawater Passages Checking Diaphragm Assembly 3JH4E 4JH4AE only Replacing the Alternator V Belt Adjusting Intake Exhaust Valve Clearance Checking the Remote Control Cable Operation Adjusting the Propeller Shaft Alignment Checking the Fuel Injection Timing See your authorized Yanmar Marine dealer or distributor Checking the Fuel Injector Spray Pattern See your authorized Yanmar Marine dealer or distributor Replacing the Seawater Pump Impeller The seawater impeller must be replaced every 1000 hours even if it is not damaged See Checking or Replacing Seawater Pump Impeller on page 72 77 2008 Yanmar Marine International PERIODIC MAINTENANCE Clean and Check the Seawater Passages After prolonged use clean the seawater passages to remove trash scale rust and other contaminants that collect in the cooling water passages This can cause declining cooling performance The following items need to be inspected Heat Exchanger Pressure Cap See your authorized Yanmar Marine dealer or distributor Check Diaphragm Assembly SJHAE 4JH4AE only 2 3 a 4 77 gt
119. out of the system See Bleeding the Fuel System on page 32 Starting at Low Temperatures Comply with local environmental requirements Use engine heaters to avoid starting problems and white smoke Do not use starting aids NOTICE NEVER use an engine starting aid such as ether Engine damage will result To limit white smoke run the engine at low speed and under moderate load until the engine reaches normal operating temperature A light load on a cold engine provides better combustion and faster engine warm up than no load Avoid running the engine at idling speed any longer than necessary Starting with Air Heater if equipped 1 Open the seacock if equipped 2 Openthe fuel tank cock 3 Putremote control handle in NEUTRAL 4 the battery master switch if equipped ON 5 key switch to GLOW for 15 seconds 6 Turn key switch to ON Ensure that the instrument panel indicators light and the alarm sounds This shows that indicators and alarm are working correctly Note The coolant high temperature alarm indicator does not come on during start up 44 7 Turnkey switch to START Release the key switch when the engine has started The alarm should stop and the indicators should go out NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International After the Engine ha
120. p 35 Diesel Fuel Inlet 36 Fuel Overflow 37 To Cil Pan 38 From Cylinder Head 39 To Camshaft 40 Detail of Part A 41 Detail of Part B 42 Detail of Part C 43 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 113 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4AE with 5050 Sail Drive 1 2 9 l s g ak 43 20 17 15 18 16 19 0004590 Figure 6 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 114 1 3 x 14 5 Rubber Hose 2 Fuel Injection Pump 3 5 x t4 5 Rubber Hose 4 4 76x t0 7 Steel Pipe 5 9xt3 5 Rubber Hose 6 Lubricating Oil Filter cartridge type 7 Lubricating Oil Cooler 8 5xt4 5 Rubber Hose 9 6 35 x 12 375 Steel Pipe Fuel High Pressure Pipe 10 Fuel Injection Nozzle 11 9xt3 5 Rubber Hose 12 Cil Pressure Switch 13 Seacock 14 Mixing Elbow 15 25 4 x t4 3 Rubber Hose 16 25 4 x t4 3 Rubber Hose 17 Heat Exchanger 18 Lubricating Oil Inlet Filter 19 Main Bearing 20 25 4 x t4 3 Rubber Hose 21 Cooling Water Pump 22 28 x t4 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DI
121. pecifications on page 27 e Faulty spraying of fuel injector See your authorized 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 YANMAR JH4 Series Operation Manual 83 2008 Yanmar Marine International TROUBLESHOOTING This Page Intentionally Left Blank 84 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International LONG TERM STORAGE If the engine will not be used for an extended period of time special measures should be taken to protect the cooling system fuel system and combustion chamber from corrosion and the exterior from rusting The engine can normally stand idle for up to 6 months If it remains unused for longer than this please contact your authorized Yanmar Marine dealer or distributor Before performing any storage procedures within this section review the Safety section on page 3 In cold temperatures or before long term storage be sure to drain the seawater from the cooling system WARNING NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will spray out and seriously burn you Allow the engine to cool down before you attempt to remove the cap CAUTION DO NOT drain the coolant system A full coolant system will prevent corrosion and frost damage CAUTION
122. perform all of the required tasks Ask Your Authorized Yanmar Marine Dealer or Distributor for Help Our professional service technicians have the expertise and skills to help you with any maintenance or service related procedures you need help with 53 2008 Yanmar Marine International PERIODIC MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the machine Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure NOTICE The tightening torque in the Q Standard Torque Chart should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy ri XPpitch M x1 0 8 1 25 10 1 5 M12x1 75 14 1 5 M16x1 5 11 0 1 0 260 3 0 50 0 5 0 90 0 10 0 140 0 10 0 230 0 10 0 Tightening Kgf m 1 1 0 1 2 7 0 3 5 13 0 5 9 2 1 0 14 3 1 0 23 5 1 0 Torque Ib ft 19 0 2 1 37 3 6 66 0 7 2 103 7 2 170 7 2 Ib in 96 9 0 54 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International EPA MAINTENANCE REQUIREMENTS To maintain optimum engine performance and compliance with the Environmental Protection Agency EPA Regulations for Engines it is essential that you follow the Periodi
123. propeller 28 0 kW 38 1 hp metric 3000 engine speed 27 4 kW 37 3 hp 3000 rpm Installation Flexible mounting Fuel Injection Timing FIC 13 1 BTDC FID 12 1 BTDC Fuel Injection Opening Pressure 21 6 x 0 5 MPa Main Power Take Off At flywheel end Direction Of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise viewed from stern ahead Cooling System Freshwater cooling with heat exchanger Lubrication System Complete enclosed forced lubrication system Cooling Water Capacity fresh Engine 4 5 L 4 8 qt Coolant recovery tank 0 8 L 0 8 qt YANMAR JH4 Series Operation Manual 89 2008 Yanmar Marine International SPECIFICATIONS Specification 3JH4E Marine Gear Model KM35P KM35A SD40 SD50 Bobtail Lubricating angle at rake angle 8 at rake angle 0 For Total 5 0 0 3L 5 5 0 3L 5 3 0 3 qt 5 8 0 3 qt Oil pan only 4 5 0 3L 4 8 5 0 0 3 L 5 3 0 3 qt 0 3 qt Effective 1 1L 1 2 qt 1 2 L 1 3 qt Starting Type Electric System Starting motor DC 12V 1 4 kW AC generator 12 V 80 A 12 V 60 A optional Engine Overall length 777 mm 776 mm 30 6 in 700 mm Dimension 30 6 in 27 6 in Overall width 539 mm 21 2 in Overall height 623 mm 24 5 in Flywheel Major Dimension D300 x 66 mm 11 8 x 2 6 in Engine Dry Mass including marine 185 kg 186 kg 213 kg engine 173 kg gea
124. r 408 Ib 4101b 173 4706 467 Ib engine 381 Ib Rating Condition Temperature of fuel 25 C at fuel pump inlet ISO 3046 1 Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale Note Density of fuel 0 842g cm at 15 C Fuel temperature at the inlet of the fuel injection pump 1 hp metric 2 0 7355 kW 90 Series Operation Manual YANMAR 2008 Yanmar Marine International 3JH4E Marine Gear Specifications SPECIFICATIONS Model KM35P KM35A SD40 SD50 coupled at boat builder Type Mechanical cone clutch Reduction Ratio forward 2 33 3 16 2 33 3 06 2 32 reverse Propeller Speed forward 1231 1114 1246 1103 1253 rpm reverse rpm rpm Lubrication System Splash Oil bath Lubricating Oil Capacity total 0 5 L 0 5 qt 10 65 1 0 69 qt SD40 Old type 1 8 L 1 9 qt 5050 2 2 2 3 qt Long Reach 58 2 35 L 2 48 qt Long Reach 100 2 45 L 2 59 qt Lubricating Oil Capacity 0 05 L 0 05 qt 0 15 L 0 16 qt effective Cooling System Air cooling by fan on flywheel Weight 12 kg 26 5 Ib 13 kg 28 7 Ib 39 kg 86 0 Ib At continuous power engine speed 2907 rpm YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International
125. r option 42 Lubrication Oil Pump 43 Pressure Control Valve 44 13 x t3 5 Rubber Hose 45 10 x t3 Rubber Hose 46 Diesel Fuel Filter 47 7 xt4 5 Rubber Hose 48 7 x t4 5 Rubber Hose 49 5xt4 5 Rubber Hose 50 Diesel Fuel Inlet 51 Fuel Overflow 52 To Block 53 From Head 54 To Camshaft 55 To Oil Pan 56 Detail of Part A 57 Detail of Part B 58 Detail of Part C 59 Detail of Part D Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 127 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4 HTE with ZF30 0004593 Figure 13 128 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 x t4 5 Rubber Hose 2 W CS D 3 Fuel Injection Pump 4 STS 5 Lubrication Oil Filter cartridge type 6 Lubrication Oil Cooler 7 4 76 x t0 7 Double Walled Steel Tube 8 10xt3 Rubber Hose 9 13 x t3 5 Rubber Hose 10 Oil Pressure Switch 11 Oil Pressure Sensor option 12 Fuel Injection Nozzle 13 Piston Cooling Oil Jet 14 Seawater Inlet 15 8 x t0 8 STKM 16 Clutch Lubrication Oil Cooler 17 Turbocharger 18 1
126. r Sail Drive only 32 Battery optional 33 Battery 34 Oil Pressure Sensor optional 35 Coolant Temperature Sensor optional 36 Fuel Feed Pump 4JH4AE only YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International 137 SYSTEM DIAGRAMS 4JH4 TE 4JH4 HTE with B x B Type Panel 300 22 7800 0 yoyms HO IM A 99 EM gigs Ae 9990 zww 09 ww og I4 0 zww og zww oz 98 0 gt zWUNG 2 1 7 UBue ejqewollv jo
127. r Forward 4 Throttle Handle Clutch Handle Note Direction of travel will vary depending on installation location Use the throttle handle Figure 2 4 to control acceleration and deceleration Move the handle slowly Shifting the Engine WARNING SUDDEN MOVEMENT HAZARD The boat will start to move when the marine gear is engaged Ensure the boat is clear of all obstacles forward and aft Quickly shift to the FORWARD position then back to the NEUTRAL position Observe whether the boat moves in the direction you expect NOTICE Shifting the marine gear while operating at high speed or not pushing the handle fully into position partial engagement will result in damage to marine gear parts and abnormal wear 45 ENGINE OPERATION 1 Before using the marine gear be sure to move the throttle handle to a low idle position less than 1000 rpm Move the throttle handle slowly to a higher speed position after completing clutch engagement 2 NOTICE NEVER shift the marine gear at high engine speed During normal operation the marine gear should only be shifted with the engine at idle When moving the handle between FORWARD Figure 2 1 and REVERSE Figure 2 3 bring the clutch to NEUTRAL Figure 2 2 and pause before slowly shifting to the desired position NEVER shift abruptly from FORWARD to REVERSE or vice versa NOTICE When sailing set the remote control lever in neutral Not doing so WILL int
128. r and sediment in the fuel should not exceed 0 0596 by volume Keep the fuel tank and fuel handling equipment clean at all times Ash content not to exceed 0 0196 by volume Carbon residue content not to exceed 0 35 by volume Less than 0 196 is preferred Total aromatics content should not exceed 35 by volume Less than 30 is preferred PAH polycyclic aromatic hydrocarbons content should be below 10 by volume Do not use Biocide Do not use kerosene or residual fuels YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International BEFORE YOU OPERATE Handling of Diesel Fuel 1 Water and dust in the fuel may cause engine failure When fuel is stored be sure that the inside of the storage container is clean and dry and that the fuel is stored away from dirt or rain 17 0004512 Figure 1 Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container Use a pump to extract the clear filtered fuel from the top of the container 29 BEFORE YOU OPERATE Fuel Tank Optional 0004542 Figure 2 1 Sediment Bowl 2 Drain Cock 3 Fuel Line To Engine Install a drain cock Figure 2 2 at the bottom of the fuel tank to remove water and contaminants from the sediment bowl Figure 2 1 The fuel outlet should be positioned 20 30 mm 0 75 1 125 in above the bottom of the tank so
129. r specifications may cause seizure of parts abnormal wear and shorten engine life Service Categories Use an engine oil that meets or exceeds the following guidelines and classifications 3JH4E 4JH4 TE and 4JH4 HTE API Service Categories CD or higher 4JH4AE API Service Category CH 4 or higher SAE Viscosity 10W30 15W40 Engine oil 10W30 and 15W40 can be used throughout the year NOTICE Be sure the engine oil engine oil storage containers and engine oil filling equipment are free of sediment or water Change the engine oil after the first 50 hours of operation and then at every 250 hours thereafter Select the oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart Figure 8 Yanmar does not recommend the use of engine oil additives 33 2008 Yanmar Marine International BEFORE YOU OPERATE 4F 14 329 50 68 F 86 F 1049 20 C 10 C 0 C 10 C 20 C 30 C 40 C 0000005 Figure 8 Handling Engine Oil 1 When handling and storing engine oil be careful not to allow dust and water to contaminate the oil Clean around the filler port before filling 2 Do not mix lube oils of different types or brands Mixing may cause the chemical characteristics of the oil to change and lubricating performance to decrease reducing the engine s life 3 Engine oil should be replaced at the specified interv
130. rated during its first 50 hours of operation plays a very significant role in determining how long it will last and how well the engine will perform over its lifetime 13 2008 Yanmar Marine International PRODUCT OVERVIEW A new Yanmar diesel engine must be operated at suitable speeds and power settings during the break in period to make the sliding parts such as piston rings break in properly and to stabilize engine combustion During the break in period the engine coolant temperature gauge should be monitored temperature should be between 71 and 87 C 160 190 F During the first 10 hours of operation the engine should be run at maximum rpm minus 400 500 rpm approximately 60 70 of load most of the time This will ensure the sliding parts break in properly During this period avoid operating at maximum engine speed and load to avoid damaging or scoring sliding parts NOTICE Do not operate at WOT wide open throttle for more than a minute at a time during the first 10 hours of operation Do not operate the engine at low idle or at low speed and light load for more than 30 minutes at a time Since unburned fuel and engine oil will adhere to the piston rings when operating at low speeds for long periods this will interfere with proper movement of the rings and the lube oil consumption may increase Low idle speed does not allow break in of sliding parts If operating engine at low speed and li
131. re Panel Lights When turning the key switch to ON the gauges will illuminate for easier viewing Key Switch The ON position Figure 14 3 allows je 20 0003622 Figure 14 The GLOW position Figure 14 1 is the start aid position Electric currentto the glow plug or air heater if equipped is turned on The air heaters is standard on the 4JH4AE and optional on the 3JH4E 4JH4 TE and 4JH4 HTE models When the key is released the switch will automatically move to the ON position The START position Figure 14 4 allows current to the starting motor When starting the engine move the key to the START position and release The key will automatically move to the ON position When the key is in the OFF position Figure 14 2 the electric current is off The key can be inserted or removed in this position YANMAR JH4 Series Operation Manual electrical current to the controls and equipment and allows the engine to keep running To stop the engine keep the key Switch in the ON position and push the stop button After stopping the engine turn key to OFF position 23 2008 Yanmar Marine International PRODUCT OVERVIEW Indicators and Alarms Optional When a sensor detects a problem during operation the indicator on the instrument panel will light and an alarm will sound Indicators are located on the instrument panel the alarm is located on the back of the panel Under normal op
132. rea away from moving parts NEVER use the engine compartment for storage YANMAR JH4 Series Operation Manual Sever Hazard Rotating parts can cause severe injury or death NEVER wear jewelry unbuttoned cuffs ties or loose fitting Fe 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 NO while under the influence of alcohol or drugs or feeling ill Exposure Hazard 7 ALWAYS wear personal d Pa clothing gloves work shoes eye and hearing protection as protective equipment required by the task at hand including appropriate Entanglement Hazard NEVER leave the key in the key switch when you are ay A servicing the engine Someone may accidentally start the engine and not realize you are servicing it NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals 2008 Yanmar Marine International SAFETY Piercing Hazard Avoid skin contact with high pressure diesel fuel spray D caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands
133. roduce slippage and void your warranty Figure 2 2 Switching to Trolling KMH4A only Use the trolling handle to begin trolling When changing from FORWARD or REVERSE to trolling the speed of the propeller revolution will be reduced to a minimum 46 1 2 3 4 5 6 7 8 0004498 Figure 3 Cable Fitting Trolling Lever Low Speed trolling High Speed Loosen Tighten Normal Operation high speed Trolling low speed Operation continues at low engine speed of 1000 rpm or less Reduce the speed by moving the trolling handle from high speed H Figure 3 4 to low speed L Figure 3 3 Adjust the speed to the desired rate and secure the trolling handle in place Before returning to normal operation be sure to put the trolling handle in high speed H position Increase engine speed and continue normal operation JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International CAUTIONS DURING OPERATION Note Engine trouble can arise if the engine is operated for a long time under overloaded conditions with the control lever in the full throttle position maximum engine speed position exceeding the continuous rated output engine speed Operate the engine at about 100 rpm lower than the full throttle engine speed Note If the engine is in the first 50 hours of operation see New Engine Break In on page 13 Always be on the lookout for problems during engine operat
134. rol Handle Check the operation of the remote control handle and ensure it moves smoothly If it is hard to operate grease the joints of the remote control cable and lever bearings If the lever is too loose adjust the remote control cable See Checking and Adjusting Remote Control Cables on page 64 61 2008 Yanmar Marine International PERIODIC MAINTENANCE Checking the Alarm Indicators When operating the start switch on the rocker switch panel check that there is no alarm message on the display and the alarm indicators work normally See Control Equipment on page 21 Preparing Fuel Oil and Coolant in Reserve Prepare sufficient fuel for the day s operation Always store engine oil and coolant in reserve for at least one refill onboard to be ready for emergencies 62 After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation Draining the Fuel Tank Changing the Engine Oil and Replacing the Engine Oil Filter Element Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter if equipped Adjusting the Alternator V Belt Tension Adjusting Intake Exhaust Valve Clearance Checking and Adjusting the Remote Control Cable Adjusting Propeller Shaft Alignment Draining the Fuel Tank 0004542 Figure 1 Note Optional fuel tank shown Actual equipment may differ 1 Puta pan under the drain cock Figure 1 2 to
135. ry LB Blue Alternator 21 Battery Switch Black Charge Alarm 22 Engine Stop Solenoid with VE yw Yellow Engine Oil Pump White Pressure 23 Air Heater Alarm 24 Option YB Yellow Engine Oil Black Pressure 25 Stop Relay YG Yellow Sail Drive Seal 26 Starter Relay Green 27 Starter WL White Water Blue Temperature 28 Coolant Temperature Switch Alam 29 Engine Oil Pressure Switch WB White Water Black Temperature 30 Alternator WG White Seawater Flow 31 Earth bolt ground Green Alarm 32 Sail Drive Only GR Green Fuel Filter 33 Details of Coupler view from A Red Alarm A O Orange Pulse For 34 Seawater Tachometer WBr White Electric Stop Sor J PILE Brown 36 Oil Pressure Meter Alarm 37 Water Temperature Meter 1 Option Alarm 2 Alarm Lamps 38 Fuel Filter Switch 3 Buzzer 39 Oil Pressure Sender 4 Oil Pressure 40 Coolant Temperature Sender 5 Coolant Temperature 6 Sail Drive Seal 7 Battery Low Charge Alarm 8 Fuse 3A 9 Stop Switch 10 Diodes 11 Key Switch 12 Tachometer Hourmeter 13 Instrument panel sub station option 141 SYSTEM DIAGRAMS This Page Intentionally Left Blank 142 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International EPA WARRANTY USA ONLY YANMAR CO LTD LIMITED 4JH4 TE EPA Nameplate EMISSION CONTROL MARINE ENGINE EMISSION CONTROL INFORMATION SYSTEM WARRANTY USA THIS ENGINE COMPLIES TO U S EPA REGULATIONS ONLY 40 CFR PART 94 WHICH APPLY TO MARINE ENG
136. s Started After the engine has started check the following items at a low engine speed 1 Check that the gauges indicators and alarm are normal Normal coolant operating temperature is approximately 76 to 90 C 169 to 194 F Normal oil pressure at 3000 rpm is 0 28 to 0 54 MPa 41 to 78 psi Check water fuel or oil leakage from the engine Check that the exhaust color engine vibration and sound are normal When there are no problems keep the engine at low speed with the boat still stopped to distribute engine oil to all parts of the engine Check that sufficient cooling water is discharged from the seawater outlet pipe Operation with inadequate seawater discharge will damage the impeller of the seawater pump If seawater discharge is too low stop the engine immediately Identify the cause andrepair CAUTION The engine will seize if itis operated when seawater discharge is too small or if load is applied without any warming up operation For troubleshooting assistance see Troubleshooting After Starting on page 79 or Troubleshooting Chart on page 81 If necessary see your authorized Yanmar dealer or distributor YANMAR JH4 Series Operation Manual 2008 Yanmar Marine International ENGINE OPERATION REMOTE CONTROL HANDLE OPERATION Acceleration and Deceleration 2 3 e 1 4 p 0004513 Figure 2 1 Forward or Reverse 2 Neutral 3 Reverse o
137. s made while the engine is running the pinion gear of the starter motor will be damaged NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat NOTICE NEVER attempt to restart the engine if the engine has not stopped completely Pinion gear and starter motor damage will occur Note Hold the key switch for a maximum of 15 seconds in the Start position If the engine does not start the first time turn the key switch OFF and wait for about 15 seconds before trying again After the engine has started do not turn the key switch OFF It should remain on NOTICE f the vessel is equipped with a water lift water lock muffler excessive cranking could cause seawater to enter the cylinders and damage the engine If the engine does not start after cranking for 15 seconds close the thru hull water intake valve to avoid filling the muffler with water Crank for 10 seconds at a time until the engine starts When the engine does start stop the engine immediately and turn the key switch to the OFF position Be sure to re open the seacock and restart the engine Operate the engine normally 43 2008 Yanmar Marine International ENGINE OPERATION Air Bleeding the Fuel System After Starting Failure If the engine does not start after several attempts there may be air inthe fuel system If air is in the fuel system fuel cannot reach the fuel injection pump Bleed the air
138. sage of biodiesel compatible components on the vessel fuel supply and return systems Free water in biodiesel may result in plugging of fuel filters and increased bacterial growth High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomization Biodiesel may have adverse effects on some elastomers seal materials and may result in fuel leakage and dilution of the engine lubricating oil Even biodiesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks It is important to maintain a supply of clean fresh fuel Regular flushing of the fuel system and or fuel storage containers may be necessary The use of biodiesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers or biodiesel fuels that have degraded as per the precautions and concerns above may affect the warranty coverage of your engine Series Operation Manual YANMAR 2008 Yanmar Marine International Additional Technical Fuel Requirements The fuel cetane number should be equal to 45 or higher The sulfur content must not exceed 0 5 by volume Less than 0 05 is preferred NEVER mix kerosene used engine oil or residual fuels with the diesel fuel Wate
139. series marine engines 3JH4E Engines A ER DANGER A Z DANGER vy TER WARNING Sy CR LOH EST e Never remove the cap while the engine is still hot Hot water may spurt out and burn you 128377 07260 SAAR Rotating parts Can cause injury 28377 07350 3 196630 12980 0004550 Figure 1 1 Part Number 128377 07350 2 Part Number 128377 07260 3 Part Number 196630 12980 8 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International SAFETY 4JH4AE Engines HLPITEST SBnHY e Never remove the cap while the engine is still hot Hot water may spurt out and burn you 27 87 9 BOTTO ORAE AA ER Rotating parts cause injury 128377 07350 CAUTION Overcranking engine with water lift muffler can cause damage 0004551 1 Part Number 128377 07350 2 Part Number 128377 07260 3 Part Number 196630 12980 4 Part Number 128377 07150 YANMAR JH4 Series Operation Manual 9 2008 Yanmar Marine International SAFETY 4JH4 TE Engines 75 DANGER eSI v y ZEB Rotating parts Can cause injury 1 Part Number 128377 07350 2 Part Number 128377 07260 3 Part Number 196630 12980 4 Part Number 128296 07300 10 HLPITEETS e Never remove the while the engine is still hot Hot water may spurt out and burn you 128
140. sing parts 5 Checkforloose missing or damaged fasteners 6 Checkthe electrical harnesses for cracks abrasions and damaged or corroded connectors 7 Checkhoses for cracks abrasions and damaged loose or corroded clamps gt YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE 8 Check the fuel filter water separator for presence of water and contaminants If you find any water or contaminants drain the fuel filter water separator See Draining Fuel Filter Water Separator on page 67 f you have to drain the fuel filter water separator frequently drain the fuel tank and check for the presence of water in your fuel supply See Draining the Fuel Tank on page 62 CAUTION f any problem is noted during the visual check the necessary corrective action should be taken before operating the engine Check Diesel Fuel Engine Oil and Engine Coolant Levels Follow the procedures in Diesel Fuel on page 27 Engine Oil on page 33 and Engine Coolant on page 36 to check these levels Checking and Refilling Marine Gear Cil Refer to the Operation Manual for the marine gear Checking the Battery Electrolyte Level Check the battery electrolyte level before use See Checking the Battery Electrolyte Level serviceable batteries only on page 69 Checking the Alternator Belt Check the belt tension before use See Checking and Adjusting the Alternator V Belt Tension on page 64 Checking the Remote Cont
141. such as the turbocharger if equipped and exhaust system to cool slightly before the engine itself is shut down 1 gt 0004487 Figure 4 4 With the key in the ON position push and hold the stop button Figure 4 1 After the engine has stopped turn the key switch to OFF WARNING Continue to hold the STOP button Figure 5 1 in until the engine is completely stopped If the button is released before the engine has completely stopped it may restart If the engine does not shut down see Emergency Shutdown on page 48 5 Remove the key and cover the key Switch with the moisture cap 6 Turn off the battery master switch if equipped Close the fuel cock 8 Close the seacock if equipped CAUTION Be sure to close the seacock Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink CAUTION f seawater is left inside the engine it may freeze and damage parts of the cooling system when the ambient temperature is below 0 C 32 F Emergency Shutdown CAUTION NEVER use the emergency stop switch for a normal engine shutdown Use this switch only when stopping the engine suddenly in an emergency N JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 3JH4E 4JH4AE 1 2 0003624 Figure 5 If the engine cannot be shut down by the STOP button on the panel stop the engine by pushing the button Figure 5 1 atthe back
142. that only clean fuel is distributed to the engine 30 Fuel System 3JH4E 4JH4 TE and 4JH4 HTE 1 8 7 UA MC 0004489 Figure 3 1 FuelFilter 2 To Fuel Injection Pump 3 Less than 500 mm 20 0 in 4 Fuel Cock 5 20 30 mm 0 75 1 125 in approximate 6 Drain Cock 7 Fuel Tank 8 Fuel Return Line Install the fuel line from the fuel tank to the fuel injection pump as shown in Figure 3 The recommended fuel water separator optional is installed at the center section of that line JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International Fuel System 4JH4AE 4 5 5 mon 4 3 D T 0004553 Figure 4 1 Fuel Tank 2 Fuel Cock 3 Water Separator 4 Fuel Feed Pump 5 Fuel Filter 6 To Fuel Injection Pump 7 Fuel Return Line 8 Drain Cock 9 20 30 mm 0 75 1 25 in approximate 10 Less than 400 mm 16 38 in Filling the Fuel Tank Before filling fuel tank for the first time DANGER NEVER refuel with the engine running Refer to Fire and Explosion Hazard on page 5 1 Rinse fuel tank with kerosene or diesel fuel Dispose of waste properly To fill the fuel tank 1 Cleanthe area around the fuel cap 2 Remove the fuel cap from the fuel tank 3 Fillthetank with clean fuel free of oil and dirt NOTICE Hold the hose nozzle firmly against the filler port while
143. ting Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage See your authorized Yanmar Marine dealer or distributor to adjust the intake exhaust valve clearance Checking and Adjusting Remote Control Cables CAUTION Never adjust the high speed stop bolt on the governor This will void the engine warranty JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International Adjusting Engine Speed Remote Control Cable Ensure the control lever on the engine side moves to the high speed stop position and low speed stop position when the remote control lever is moved to HIGH and then to LOW YANMAR JH4 Series Operation Manual PERIODIC MAINTENANCE 3JH4E 4JH4AE 2 4 3 0003625 Figure 5 1 Cable 2 Fuel Injection Pump 3 Adjustment Screw 4 Low Speed Stop 5 Control Lever 6 High Speed Stop 4JH4 TE 4JH4 HTE 6 5 4 3 0004496 Figure 6 1 Cable 2 Fuel Injection Pump 3 Cable Fitting 4 Low Speed Stop 5 Control Lever 6 High Speed Stop 1 To adjust loosen the adjustment screw or cable fitting Figure 5 3 or Figure 6 3 for the remote control cable on the engine side and adjust 65 2008 Yanmar Marine International PERIODIC MAINTENANCE 2 Adjustthe high speed
144. tion Temperature of fuel 40 C at fuel pump inlet ISO 8665 94 Series Operation Manual YANMAR 2008 Yanmar Marine International 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 Note Density of fuel 0 842g cm at 15 C Fuel temperature at the inlet of the fuel injection pump 1 hp metric 2 0 7355 kW YANMAR JH4 Series Operation Manual 95 2008 Yanmar Marine International SPECIFICATIONS 4JH4AE Marine Gear or Sail Drive Specifications Model KM35P ZF30M Type Mechanical cone clutch Reduction Ratio 2 36 3 16 2 61 3 16 2 15 2 64 2 70 2 64 forward reverse Propeller Speed 1232 921rpm 1114 921 rpm 1353 1103 1078 1103 forward reverse rpm rpm Lubrication System Splash Lubricating Oil Capacity total 0 5 L 0 5 qt 1 1 L 1 2 qt Lubricating Oil Capacity 0 05 L 0 05 qt 0 2 L 0 2 qt effective Cooling System Air cooling by fan Seawater cooling Weight 12 kg 26 Ib 27 5 kg 61 Ib At continuous power engine speed 2907 rpm ZF30M Lubricating oil ATF Model KM35A2 KM4A1 SD50 coupled at boat builder Type Mechanical cone clutch Reduction Ratio 2 33 2 64 1 47 2 14 2 63 3 30 2 32 forward reverse 3 06 3 06 1 47 2 14 2 63 3 30 Propeller Speed 1246 1103
145. tion Manual 2008 Yanmar Marine International TABLE OF CONTENTS Filling the Fuel Tank erecta eee 31 Bleeding the Fuel System 32 Engine Qil nr rt em HR t ERE tents 33 Engine Oil Specifications 33 Engine Oil Viscosity 34 Checking the Engine Oil 34 Adding Engine Oil eter irte and 34 Marine Gear or Sail Drive Oil 35 Marine Gear Oil Specifications 35 Sail Drive Oil Specifications 35 Checking Marine Gear Oil 36 Adding Marine Gear Oil 36 Checking and Adding Sail Drive Oil 36 Engine Coolant 36 Engine Coolant Specifications 36 Coolant Closed Cooling System 36 Checking and Adding Coolant 37 Cranking the Engine 2 40 Engine Operation 41 Starting the Engine 43 Before Starting the Engine 43 To Start the Engine 43 If the Engine Fails to Start 43 Starting at Low Temperatures 44
146. tisfy EN ISO7840 111 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JHAAE with ZF30M Marine Gear D a h o A lis 17 18 0004589 Figure 5 112 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International 1 7 x t4 5 Rubber Hose 2 Fuel Injection Pump 3 5 x t4 5 Rubber Hose 4 4 76 x t0 7 Steel Pipe 5 9xt3 5 Rubber Hose 6 Lubricating Oil Filter cartridge type 7 Lubricating Oil Cooler 8 5xt4 5 Rubber Hose 9 6 35 x 12 375 Steel Pipe Fuel High Pressure Pipe 10 Fuel Injection Nozzle 11 9xt3 5 Rubber Hose 12 Cil Pressure Switch 13 Seawater Inlet 14 Mixing Elbow 15 25 4 x t4 3 Rubber Hose 16 Heat Exchanger 17 Lubricating Oil Inlet Filter 18 Main Bearing 19 25 4 x t4 3 Rubber Hose 20 Cooling Water Pump seawater 21 28 x t4 Rubber Hose 22 28 x t4 Rubber Hose YANMAR JH4 Series Operation Manual SYSTEM DIAGRAMS 23 Hot Water Connection Outlet R3 8 24 Thermostat 25 28 6 x t2 Copper Pipe 26 Cooling Water Pump coolant 27 Hot Water Connection Inlet R3 8 28 27 x t4 Rubber Hose 29 Coolant Temperature Switch 30 Lubricating Oil Pump 31 Pressure Control Valve 32 Diesel Fuel Filter cartridge type 33 7 xt4 5 Rubber Hose 34 Fuel Feed Pum
147. ton Cooling Oil Jet 14 13 x t4 Rubber Hose 15 13 x 4 Rubber Hose 16 8 xt0 8 STKM 17 Clutch Lubrication Oil Cooler 18 Turbocharger 19 17 11 2 STKM 20 Mixing Elbow 21 25 4 x t4 3 Rubber Hose 22 25 4 x t4 3 Rubber Hose 23 8 5 13 5 Rubber Hose 24 25 4 x t4 3 Rubber Hose 25 17 xt3 Rubber Hose 26 Intercooler 27 Heat Exchanger 28 Main Bearing 29 Lubrication Oil Inlet Filter 30 25 x t2 C1201T 31 25 4 x 14 3 Rubber Hose YANMAR JH4 Series Operation Manual 40 Coolant Temperature Switch 41 Thermostat 42 Cooling Water Pump coolant 43 Hot Water Connection Return 44 Coolant Temperature Sensor option 45 Lubrication Oil Pump 46 Pressure Control Valve 47 13 x t3 5 Rubber Hose 48 10 x t3 Rubber Hose 49 Diesel Fuel Filter cartridge type 50 7 x t4 5 Rubber Hose 51 7x t4 5 Rubber Hose 52 5 x t4 5 Rubber Hose 53 Diesel Fuel Inlet 54 Diesel Fuel Overflow 55 To Block 56 From Head 57 To Camshaft 58 To Oil Pan 59 Detail of Part A 60 Detail of Part B 61 Detail of Part C 62 Detail of Part B Note Dimension of steel pipe outer diameter x thickness Dimension of rubber pipe inner diamter x thickness Fuel rubber pipes marked satisfy EN ISO7840 125 2008 Yanmar Marine International SYSTEM DIAGRAMS 4JH4 HTE with ZF25A
148. tor pinion and or ring gear will result JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International STARTING THE ENGINE Before Starting the Engine 1 Open the seacock if equipped 2 Openthe fuel tank cock 3 Putremote control handle in NEUTRAL Note Safety equipment should make it impossible to start the engine in any other position than NEUTRAL PN UL 9 4 4 Cd 0003622 Figure 1 4 Turn the battery master switch if equipped to ON 5 Turn key switch to ON Figure 1 3 Ensure that the instrument panel indicators light and the alarm sounds This indicates that indicators and alarm are working correctly Note The coolant high temperature alarm indicator does not come on during start up To Start the Engine 1 Turn key switch to START Figure 1 4 Release the key switch when the engine has started NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat YANMAR JH4 Series Operation Manual ENGINE OPERATION 2 The alarm should stop and the indicators should go out NOTICE f any indicator fails to illuminate when the key switch is in the ON position see your authorized Yanmar Marine dealer or distributor for service before operating the engine If the Engine Fails to Start Before turning the key switch again be sure to confirm that the engine has stopped completely If an attempt to restart i
149. uding marine gear 540 Ib 54516 54716 54516 478 Ib Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale Note Density of fuel 0 842g cm at 15 C Fuel temperature at the inlet of the fuel injection pump 1 hp metric 2 0 7355 kW YANMAR JH4 Series Operation Manual 101 2008 Yanmar Marine International SPECIFICATIONS 4JH4 TE and 4JH4 HTE Marine Gear or Sail Drive Specifications Model ZF30M KM4A2 KMH4A ZF25A SD50 4T coupled at boat builder Down Angle 0 T 8 8 Mechanical Mechanical cone Hydraulic Hydraulic Mechanical wet multiple clutch multiple disk wet multiple cone clutch disk clutch clutch disk clutch Reduction Ratio 2 15 2 70 1 47 2 14 2 63 2 04 2 45 1 93 2 48 2 32 forward reverse 2 64 2 64 1 47 2 14 2 63 2 04 2 45 1 93 2 48 Propeller Speed 1444 1150 2115 1451 1180 1520 1263 1607 1250 1337 forward reverse 1176 1176 2113 1450 1179 1520 1263 1607 1250 rpm Lubrication System Splash Centrifugal pump Trochoid Trochoid Oil bath pump pump Lubrication Oil ATF API CD or higher SAE 20 30 ATF Quick Silver only
150. uled maintenance Yanmar may deny your warranty coverage of your non road compression ignition engine if a part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements You are responsible for initiating the warranty process You must present your engine to a Yanmar dealer as soon as a problem exists The warranty repairs should be completed by the dealer as expeditiously as possible JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor you should contact Yanmar Marine USA Corporation for assistance Yanmar Marine USA Corporation 101 International Parkway Adairsville GA 30103 USA Telephone 770 877 9894 Fax 770 877 7567 YANMAR JH4 Series Operation Manual EMISSION SYSTEM WARRANTY 149 2008 Yanmar Marine International Maintenance Log Date Operating Maintenance Performed Dealer Name Stamp or Hours Signature 150 JH4 Series Operation Manual YANMAR 2008 Yanmar Marine International
151. ure 3 4 in the side cover d Install side cover Figure 3 5 and tighten side cover bolts 3 Fill marine gear with clean marine gear oil See Marine Gear Oil Specifications on page 35 4 Perform atrial run and check for oil leaks 5 Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low Checking and Adjusting the Alternator V Belt Tension WARNING Perform this check with engine OFF and key removed to avoid contact with moving parts NOTICE When there is not enough tension in the V belt it will slip and the freshwater pump will fail to supply coolant Engine overheating and seizure will result NOTICE When there is too much tension in the V belt the belt will become damaged more quickly and the freshwater pump bearing may be damaged NOTICE NEVER get any oil on the belt s Oil on the belt causes slipping and stretching Replace the belt if it is damaged 64 0004509 Figure 4 Note 4JH4 TE shown 1 Remove the belt cover 2 Checkthebeltby pushing onthe middle of the belt Figure 4 1 with your finger With proper tension the belt should deflect 8 10 mm approximately 3 8 in 3 Loosenthealternator boltand movethe alternator to adjust the V belt tension 4 Install the belt cover Note If replacing the V belt loosen the V pulley of the coolant pump to remove V belt Inspecting and Adjus
152. with a box wrench Tighten to 20 24 N m 177 212 in Ib 6 Fill with new engine oil See Adding Engine Oil on page 34 NOTICE NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 7 Performatrial run and check for oil leaks 8 Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low CAUTION Be careful not to get any oil on the V belt Oil on the belt causes slipping and stretching Replace the belt if it is damaged Replace the Marine Gear Oil Filter if equipped and Change the Marine Gear Oil 0004495 Figure 3 Note 4JHA TE 4JH4 HTE engines with KMHAA marine gear shown Refer to the Operation Manual for the marine gear or sail drive for procedure 1 Remove cap from the filler port and attach an oil drain pump Drain marine gear oil NOTICE ALWAYS be environmentally responsible 63 2008 Yanmar Marine International PERIODIC MAINTENANCE 2 Marine Gear Wash the marine gear oil filter a Remove side cover Figure 3 5 and remove the filter Figure 3 2 b Cleanthe filter thoroughly with kerosene or clean diesel fuel c Holdthe filter in place with the coil spring Figure 3 3 and insert into the case Install a new O ring Fig

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