Yanmar 3JH5E Manuel utilisateur

http://www.yanmar.co.jp 0AJHM-M00201

PRINTED IN JAPAN

MARINE ENGINES

3JH5E

4JH5E

4JH4-TE

4JH4-HTE1

4JH4-HTE

OPERATION MANUAL

English

FR French

PT Portuguese

ES Spanish

DA Danish

DE German

EL Greek

FI Finnish

IT Italian

NL Dutch

NO Norwegian

SV Swedish

MARINE ENGINES 3JH5E 4JH5E 4JH4-TE 4JH4-HTE1 4JH4-HTE

OPERATION MANUAL

3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE1, 4JH4-HTE

Model

OPERATION MANUAL

0AJHM-M00201Code

عYanmar (Head office)

1-32, Chayamachi, Kita-ku, Osaka, Japan 530-8311

Marine Operations Division

Quality Assurance Dept.

Overseas Office

عYanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands

Phone: 31-36-5493200 Fax: 31-36-5493209

عYanmar Asia (Singapore) Corporation Pte Ltd. (YASC)

4 Tuas Lane, Singapore 638613

Phone: 65-6595-4200 Fax: 65-6862-5189

3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki,

Hyogo, Japan 661-0001

Phone: 81-6-6428-3251 Fax: 81-6-6421-5549

عYanmar Engine (Shanghai). Co., Ltd.

10F, E-Block POLY PLAZA, No.18 Dongfang Road,

Pudong Shanghai, CHINA P.R.C 200120

Phone: 21-6880-5090 Fax: 21-6880-8090

عYanmar America Corporation (YA)

101 International Parkway

Adairsville, GA 30103, U.S.A.

Phone: 1-770-877-9894 Fax: 1-770-877-9009

Issued by : YANMAR CO.,LTD. Marine Operations Division

Edited by : YANMAR TECHNICAL SERVICE CO.,LTD.

Aug2009: 1st edition

Dec

2011: 2nd edition

3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE1, 4JH4-HTE

OPERATION MANUAL

MARINE ENGINES

OPERATION MANUAL

English

3JH5E

4JH5E

4JH4-TE

4JH4-HTE1

4JH4-HTE

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest

information available at the time of publishing. The illustrations used in this manual

are intended as representative reference views only. Moreover, because of our

continuous product improvement policy, we may modify information, illustrations

and/or specifications to explain and/or exemplify a product, service or maintenance

improvement. We reserve the right to make any change at any time without notice.

Yanmar and are registered trademarks of YANMAR CO., LTD. in

Japan, the United States and/or other countries.

No part of this publication may be reproduced or used in any form by any means -

graphic, electronic, or mechanical, including photocopying, recording, taping, or

information storage and retrieval systems - without the written permission of

YANMAR CO., LTD.

JH Series Operation Manual i

TABLE OF

CONTENTS

Page

INTRODUCTION .............................................................. 1

JH SERIES EMISSION CONTROL SYSTEM

WARRANTY-USA, THE ENVIRONMENTAL

PROTECTION AGENCY (EPA) ONLY ...................... 2

RECORD OF OWNERSHIP ...................................... 3

SAFETY ........................................................................... 5

SAFETY PRECAUTIONS .......................................... 6

General Information ............................................. 6

Before You Operate............................................. 6

During Operation and Maintenance..................... 6

LOCATION OF SAFETY DECALS .......................... 10

PRODUCT OVERVIEW ................................................. 15

YANMAR JH SERIES FEATURES AND

APPLICATIONS ....................................................... 15

New Engine Break-In......................................... 16

COMPONENT IDENTIFICATION ............................ 17

Right Side (Viewed from Flywheel) - 3JH5E...... 17

Left Side (Viewed from Flywheel) - 3JH5E ........ 17

Right Side (Viewed from Flywheel) - 4JH5E...... 18

Left Side (Viewed from Flywheel) - 4JH5E ........ 18

Right Side (Viewed from Flywheel) - 4JH4-TE .. 19

Left Side (Viewed from Flywheel) - 4JH4-TE..... 19

Right Side (Viewed from Flywheel)

- 4JH4-HTE1 / 4JH4-HTE.................................. 20

Left Side (Viewed from Flywheel)

- 4JH4-HTE1 / 4JH4-HTE.................................. 20

NAMEPLATES ......................................................... 21

FUNCTION OF MAJOR COMPONENTS ................ 22

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TABLE OF CONTENTS

ii JH Series Operation Manual

CONTROL EQUIPMENT.......................................... 23

Instrument Panel (Optional) ............................... 23

Single-Lever Remote Control Handle ................ 31

BEFORE YOU OPERATE .............................................. 33

INTRODUCTION ...................................................... 33

SAFETY PRECAUTIONS......................................... 33

DIESEL FUEL........................................................... 34

Diesel Fuel Specifications .................................. 34

Filling the Fuel Tank........................................... 37

Bleeding the Fuel System .................................. 38

ENGINE OIL ............................................................. 39

Engine Oil Specifications .................................. 39

Engine Oil Viscosity ........................................... 40

Checking the Engine Oil..................................... 40

Adding Engine Oil .............................................. 40

MARINE GEAR OR SAIL DRIVE OIL ...................... 41

Marine Gear Oil Specifications........................... 41

Sail Drive Oil Specifications ............................... 41

Checking Marine Gear Oil.................................. 41

Adding Marine Gear Oil...................................... 42

Checking and Adding Sail Drive Oil ................... 42

ENGINE COOLANT ................................................. 42

Engine Coolant Specifications ........................... 42

Coolant (Closed Cooling System) ...................... 43

Checking and Adding Coolant............................ 43

CRANKING THE ENGINE........................................ 47

ENGINE OPERATION .................................................... 49

INTRODUCTION ...................................................... 49

SAFETY PRECAUTIONS......................................... 49

STARTING THE ENGINE ........................................ 51

If the Engine Fails to Start.................................. 52

Starting at Low Temperatures............................ 52

After the Engine has Started .............................. 53

REMOTE CONTROL HANDLE OPERATION.......... 54

Acceleration and Deceleration ........................... 54

Shifting the Engine ............................................. 54

Switching to Trolling (KMH4A Only)................... 54

CAUTIONS DURING OPERATION.......................... 55

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TABLE OF CONTENTS

JH Series Operation Manual iii

12/05

SHUTTING DOWN THE ENGINE ........................... 57

Normal Shutdown .............................................. 57

Emergency Shutdown ....................................... 58

CHECKING THE ENGINE AFTER OPERATION .... 58

PERIODIC MAINTENANCE........................................... 59

INTRODUCTION...................................................... 59

SAFETY PRECAUTIONS ........................................ 59

PRECAUTIONS ....................................................... 61

The Importance of Periodic Maintenance .......... 61

Performing Periodic Maintenance ..................... 61

The Importance of Daily Checks ....................... 61

Keep a Log of Engine Hours and Daily Checks 61

Yanmar Replacement Parts .............................. 61

Tools Required .................................................. 61

Ask Your Authorized Yanmar Marine Dealer

or Distributor for Help ........................................ 61

EPA MAINTENANCE REQUIREMENTS................. 63

EPA Requirements for USA and

Other Applicable Countries................................ 63

EPA Requirements ............................................ 63

Installation of Exhaust Sampling Port................ 65

PERIODIC MAINTENANCE SCHEDULE ................ 66

PERIODIC MAINTENANCE PROCEDURES .......... 70

Daily Checks...................................................... 70

After Initial 50 Hours of Operation ..................... 71

Every 50 Hours of Operation ............................. 76

Every 250 Hours of Operation ........................... 79

Every 500 Hours of Operation ........................... 87

Every 1000 Hours of Operation ......................... 87

TROUBLESHOOTING ................................................... 89

SAFETY PRECAUTIONS ........................................ 89

TROUBLESHOOTING AFTER STARTING ............. 89

TROUBLESHOOTING INFORMATION................... 90

TROUBLESHOOTING CHART................................ 91

LONG-TERM STORAGE ............................................... 93

PREPARE ENGINE FOR LONG-TERM STORAGE 93

DRAIN SEAWATER COOLING SYSTEM ............... 94

RETURNING THE ENGINE TO SERVICE .............. 96

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TABLE OF CONTENTS

iv JH Series Operation Manual

SPECIFICATIONS .......................................................... 97

PRINCIPAL ENGINE SPECIFICATIONS................. 97

3JH5E Engine .................................................... 98

3JH5E Marine Gears.......................................... 99

4JH5E Engine .................................................. 100

4JH5E Marine Gear or Sail Drive..................... 102

4JH4-TE Engine............................................... 103

4JH4-HTE1 Engine .......................................... 104

4JH4-HTE Engine ............................................ 105

4JH4-TE, 4JH4-HTE1 and 4JH4-HTE

Marine Gear or Sail Drive ................................ 106

SYSTEM DIAGRAMS................................................... 107

PIPING DIAGRAMS ............................................... 107

WIRING DIAGRAMS .............................................. 137

EPA WARRANTY USA ONLY ..................................... 149

YANMAR CO., LTD. LIMITED EMISSION CONTROL

SYSTEM WARRANTY - USA ONLY...................... 149

Your Warranty Rights and Obligations:............ 150

Warranty Period: .............................................. 150

Warranty Coverage: ......................................... 151

Exclusions: ....................................................... 151

Owner’s Responsibility:.................................... 151

Customer Assistance: ...................................... 151

EMISSION SYSTEM WARRANTY............................... 153

NON-ROAD EMISSION SYSTEM WARRANTY .... 153

Yanmar Co., Ltd. Limited Emission Control

System Warranty - USA Only........................... 153

Maintenance Log.............................................. 156

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JH Series Operation Manual 1

INTRODUCTION

Welcome to the world of Yanmar Marine!

Yanmar Marine offers engines, drive

systems and accessories for all types of

boats, from runabouts to sailboats, and

from cruisers to mega yachts. In marine

leisure boating, the worldwide reputation of

Yanmar Marine is second to none. We

design our engines to respect nature. This

means quieter engines, with minimal

vibrations, cleaner than ever. All of our

engines meet applicable regulations,

including emissions, at the time of

manufacture.

To help you enjoy your Yanmar JH series

engine for many years to come, please

follow these recommendations:

• Read and understand this Operation

Manual before you operate the machine

to ensure that you follow safe operating

practices and maintenance procedures.

• Keep this Operation Manual in a

convenient place for easy access.

•IfthisOperation Manual is lost or

damaged, order a new one from your

authorized Yanmar Marine dealer or

distributor.

• Make sure this manual is transferred to

subsequent owners. This manual should

be considered a permanent part of the

engine and remain with it.

• Constant efforts are made to improve the

quality and performance of Yanmar

products, so some details included in

this Operation Manual may differ slightly

from your engine. If you have any

questions about these differences,

please contact your authorized Yanmar

Marine dealer or distributor.

• The specifications and components

(instrument panel, fuel tank, etc.)

described in this manual may differ from

ones installed on your vessel. Please

refer to the manual provided by the

manufacturer of these components.

• Refer to the Yanmar Limited Warranty

Handbook for a complete warranty

description.

INTRODUCTION

2JH Series Operation Manual

JH SERIES EMISSION CONTROL SYSTEM

WARRANTY-USA, THE ENVIRONMENTAL PROTECTION

AGENCY (EPA) ONLY

JH series engines come with an emission control system warranty. In all states, 2009 and

later compression-ignition engines must be designed, built and equipped to meet the

United States EPA emissions standards. Yanmar warrants the emission control system on

your JH series engine for the periods of time listed below.

Note: Since 2012, the 4JH4-HTE does not comply with the EPA regulation.

Emission Control Certification

Model Year 2011 2012 2013

3JH5E EPA marine CI Tier 3 (Non-road Tier 2)

4JH5E / 4JH4-TE EPA marine CI Tier 3 intermediate

4JH4-HTE1 - EPA marine CI Tier 3 intermediate

4JH4-HTE EPA marine CI Tier 2 -

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