Yanmar 3JH4E, 4JH4AE, 4JH4-TE, 4JH4-HTE Operation Manual 0AJH4-G00103

Description

• Model List:
  • 3JH4E, 4JH4AE, 4JH4-TE, 4JH4-HTE

• 1. Table of Contents
• 2. Introduction
• 2.1. Record of Ownership
• 2.2. Safety Precautions
• 2.2.1. General Information
• 2.2.2. Before You Operate
• 2.2.3. During Operation and Maintenance
• 2.3. Location of Safety Decals
• 3. Product Overview
• 3.1. Yanmar JH4 Features and Applications
• 3.1.1. New Engine Break-In
• 3.2. Component Identification
• 3.2.1. Service Side – 3JH4E
• 3.2.2. Non-Service Side – 3JH4E
• 3.2.3. Service Side – 4JH4AE
• 3.2.4. Non-Service Side – 4JH4AE
• 3.2.5. Service Side – 4JH4-TE
• 3.2.6. Non-Service Side – 4JH4-TE
• 3.2.7. Service Side – 4JH4-HTE
• 3.2.8. Non-Service Side – 4JH4-HTE
• 3.3. Nameplates
• 3.4. Function of Major Components
• 3.5. Control Equipment
• 3.5.1. Instrument Panel (Optional)
• 3.5.1.1. Equipment and Functions
• 3.5.1.2. Key Switch
• 3.5.1.3. Indicators and Alarms (Optional)
• 3.5.2. Single Lever Remote Control Handle
• 4. Before You Operate
• 4.1. Diesel Fuel
• 4.1.1. Diesel Fuel Specifications
• 4.1.1.1. Bio-Diesel Fuels
• 4.1.1.1.1. B5 diesel fuels must meet certain specifications
• 4.1.1.1.2. Precautions and concerns regarding the use of bio-fuels
• 4.1.1.2. Additional Technical Fuel Requirements
• 4.1.1.3. Handling of Diesel Fuel
• 4.1.1.4. Fuel Tank (Optional)
• 4.1.1.5. Fuel System – 3JH4E, 4JH4-TE and 4JH4-HTE
• 4.1.1.6. Fuel System – 4JH4AE
• 4.1.2. Filling the Fuel Tank
• 4.1.2.1. Before filling fuel tank for the first time
• 4.1.2.2. To fill the fuel tank
• 4.1.3. Bleeding the Fuel System
• 4.1.3.1. Bleeding the Fuel System – 3JH4E
• 4.1.3.2. Bleeding the Fuel System – 4JH4AE
• 4.1.3.3. Bleeding the Fuel System – 4JH4-TE and 4JH4-HTE
• 4.2. Engine Oil
• 4.2.1. Engine Oil Specifications
• 4.2.1.1. Service Categories
• 4.2.1.2. Handling Engine Oil
• 4.2.2. Engine Oil Viscosity
• 4.2.3. Checking the Engine Oil
• 4.2.4. Adding Engine Oil
• 4.3. Marine Gear or Sail Drive Oil
• 4.3.1. Marine Gear Oil Specifications
• 4.3.2. Sail Drive Oil Specifications
• 4.3.3. Checking Marine Gear Oil
• 4.3.4. Adding Marine Gear Oil
• 4.3.5. Checking and Adding Sail Drive Oil
• 4.4. Engine Coolant
• 4.4.1. Engine Coolant Specifications
• 4.4.2. Coolant (Closed Cooling System)
• 4.4.3. Checking and Adding Coolant
• 4.4.3.1. H4-TE
• 4.4.3.2. H4-HTE
• 4.5. Cranking the Engine
• 5. Engine Operation
• 5.1. Starting the Engine
• 5.1.1. Before Starting the Engine
• 5.1.2. To Start the Engine
• 5.1.3. If the Engine Fails to Start
• 5.1.3.1. Air Bleeding the Fuel System After Starting Failure
• 5.1.4. Starting at Low Temperatures
• 5.1.4.1. Starting with Air Heater (if equipped)
• 5.1.5. After the Engine has Started
• 5.2. Remote Control Handle Operation
• 5.2.1. Acceleration and Deceleration
• 5.2.2. Shifting the Engine
• 5.2.3. Switching to Trolling (KMH4A only)
• 5.3. Cautions During Operation
• 5.4. Shutting Down the Engine
• 5.4.1. Normal Shutdown
• 5.4.2. Emergency Shutdown
• 5.5. Checking the Engine After Operation
• 6. Periodic Maintenance
• 6.1. Safety Precautions
• 6.2. Precautions
• 6.2.1. The Importance of Periodic Maintenance
• 6.2.2. Performing Periodic Maintenance
• 6.2.3. The Importance of Daily Checks
• 6.2.4. Keep a Log of Engine Hours and Daily Checks
• 6.2.5. Yanmar Replacement Parts
• 6.2.6. Tools Required
• 6.2.7. Ask Your Authorized Yanmar Marine Dealer or Distributor for Help
• 6.2.8. Tightening Fasteners
• 6.3. EPA Maintenance Requirements
• 6.3.1. EPA Requirements for USA and Other Applicable Countries
• 6.3.2. EPA Requirements
• 6.3.3. Conditions to Ensure Compliance with EPA Emission Standards
• 6.3.4. Inspection and Maintenance
• 6.4. Periodic Maintenance Schedule
• 6.4.1. Inspection and Maintenance of EPA Emission-Related Parts
• 6.4.1.1. Inspection and Maintenance of EPA Emission-Related Parts for Non-Road and CI Marine Engines
• 6.5. Periodic Maintenance Procedures
• 6.5.1. Daily Checks
• 6.5.1.1. Visual Checks
• 6.5.1.2. Check Diesel Fuel, Engine Oil and Engine Coolant Levels
• 6.5.1.3. Checking and Refilling Marine Gear Oil
• 6.5.1.4. Checking the Battery Electrolyte Level
• 6.5.1.5. Checking the Alternator Belt
• 6.5.1.6. Checking the Remote Control Handle
• 6.5.1.7. Checking the Alarm Indicators
• 6.5.1.8. Preparing Fuel, Oil, and Coolant in Reserve
• 6.5.2. After Initial 50 Hours of Operation
• 6.5.2.1. Draining the Fuel Tank
• 6.5.2.2. Changing the Engine Oil and Replacing the Engine Oil Filter Element
• 6.5.2.3. Replace the Marine Gear Oil Filter (if equipped) and Change the Marine Gear Oil
• 6.5.2.4. Checking and Adjusting the Alternator V-Belt Tension
• 6.5.2.5. Inspecting and Adjusting Intake / Exhaust Valve Clearance
• 6.5.2.6. Checking and Adjusting Remote Control Cables
• 6.5.2.6.1. Adjusting Engine Speed Remote Control Cable
• 6.5.2.6.2. Adjusting Clutch Remote Control Cable
• 6.5.2.6.3. Adjusting Trolling Remote Control Handle – If Equipped
• 6.5.2.7. Adjusting Propeller Shaft Alignment
• 6.5.3. Every 50 Hours of Operation
• 6.5.3.1. Draining Fuel Filter / Water Separator
• 6.5.3.1.1. H4E and 4JH4AE (attach to hull)
• 6.5.3.1.2. H4-TE and 4JH4-HTE
• 6.5.3.2. Checking the Battery Electrolyte Level (serviceable batteries only)
• 6.5.4. Every 250 Hours of Operation
• 6.5.4.1. Draining the Fuel Tank
• 6.5.4.2. Replacing the Fuel Filter Element
• 6.5.4.2.1. H4E / 4JH4AE
• 6.5.4.2.2. H4-TE / 4JH4-HTE
• 6.5.4.3. Changing the Engine Oil and Replacing the Engine Oil Filter Element
• 6.5.4.4. Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter Element (if equipped)
• 6.5.4.5. Checking or Replacing Seawater Pump Impeller
• 6.5.4.5.1. Replacing the Seawater Pump Impeller
• 6.5.4.6. Replacing Coolant
• 6.5.4.7. Cleaning the Intake Silencer (Air Cleaner) Element
• 6.5.4.8. Cleaning Exhaust / Water Mixing Elbow
• 6.5.4.9. Cleaning the Turbocharger (if equipped)
• 6.5.4.10. Adjusting the Alternator V-Belt Tension
• 6.5.4.11. Checking the Wiring Connectors
• 6.5.4.12. Tightening All Major Nuts and Bolts
• 6.5.5. Every 500 Hours of Operation
• 6.5.5.1. Replacing Exhaust / Water Mixing Elbow
• 6.5.5.2. Replacing Rubber Hoses
• 6.5.6. Every 1000 Hours of Operation
• 6.5.6.1. Checking the Fuel Injection Timing
• 6.5.6.2. Checking the Fuel Injector Spray Pattern
• 6.5.6.3. Replacing the Seawater Pump Impeller
• 6.5.6.4. Clean and Check the Seawater Passages
• 6.5.6.5. Check Diaphragm Assembly (3JH4E / 4JH4AE only)
• 6.5.6.6. Replacing the Alternator V-Belt
• 6.5.6.7. Adjusting Intake / Exhaust Valve Clearance
• 6.5.6.8. Checking the Remote Control Cable Operation
• 6.5.6.9. Adjusting the Propeller Shaft Alignment
• 7. Troubleshooting
• 7.1. Troubleshooting After Starting
• 7.2. Troubleshooting Information
• 7.3. Troubleshooting Chart
• 8. Long-Term Storage
• 8.1. Prepare Engine for Long-Term Storage
• 8.2. Drain Seawater Cooling System
• 8.3. Returning the Engine to Service
• 9. Specifications
• 9.1. Principal Engine Specifications
• 9.1.1. H4E Engine Specifications
• 9.1.2. H4E Marine Gear Specifications
• 9.1.3. H4AE Engine Specifications
• 9.1.3.1. H4AE Specifications (Continued)
• 9.1.4. H4AE Marine Gear or Sail Drive Specifications
• 9.1.5. H4-TE Engine Specifications
• 9.1.6. H4-HTE Engine Specifications
• 9.1.7. H4-TE and 4JH4-HTE Marine Gear or Sail Drive Specifications
• 10. System Diagrams
• 10.1. Piping Diagrams
• 10.2. Wiring Diagrams
• 11. EPA Warranty USA Only
• 11.1. Yanmar Co., Ltd. Limited Emission Control System Warranty – USA Only
• 11.1.1. Your Warranty Rights and Obligations
• 11.1.2. Warranty Period
• 11.1.3. Warranty Coverage
• 11.1.4. Exclusions
• 11.1.5. Owners Responsibility
• 11.1.6. Customer Assistance
• 12. Emission System Warranty
• 12.1. Non-Road Emission System Warranty
• 12.1.1. Yanmar Co., Ltd. Limited Emission Control System Warranty – USA Only
• 12.1.1.1. Your Warranty Rights and Obligations
• 12.1.1.2. California
• 12.1.1.3. Manufacturerʼs Warranty Period
• 12.1.1.4. Warranty Coverage
• 12.1.1.5. Warranted Parts
• 12.1.1.6. Exclusions
• 12.1.1.7. Ownerʼs Warranty Responsibilities
• 12.1.1.8. Customer Assistance
• 12.1.2. Maintenance Log