yr (ea ATU MARINE ENGINES 3JHSE 4JHSE 4JH4-TE 4JH4-HTECalifornia Proposition 65 Warning Diesel engine exhaust and some of its California Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling. constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. This Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized Distributors and Yanmar authorized Dealers. Its written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and/or safely. Please contact an authorized Yanmar repair or service professional before working on your Yanmar product. 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 YANMIAR. 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 informa- tion storage and retrieval systems - without the written permission of Yanmar Co., Ltd © 2009 Yanmar Co. Ltd. Date of issue: Sep. 2008TABLE OF CONTENTS Introduction... Safety. a4 General Service Information... Periodic Maintenance 44 Engine . Fuel System Cooling System... Lubrication Turbocharger...... Starter Motor. Alternator oc Electrical Troubleshooting... Service Standards 144 YVANMAR. 11 series service Manual “© 2009 Yanmar Marine InternationalTABLE OF CONTENTS This Page Intentionally Left Blank it JH Series sevice Manual WARN VEAL FR. (© 2009 Vanmar Marine internationalSection 1 INTRODUCTION This manual gives specific instructions for the proper repair of Yanmar JH series marine engines. Please follow the procedures carefully to ensure quailty service, Yanmar recommends that you read this Service Manual completely before starting repairs. YVANMAR. 11 series sevice Manual Along with standard tools, Yanmar recommends the Use of special tools necessary to perform repairs correctly. Yanmar products are continuously undergoing improvement. This Service Manual has been checked carefully in order to avoid errors. However Yanmar is not liable for any misrepresentations, errors of description or omissions. Contact an. authorized Yanmar marine dealer or distributor for any questions you have regarding this Service Manual. “© 2009 Yanmar Marine InternationalINTRODUCTION Revision History REVISION HISTORY This manual is a living document. Periodic manual revisions are published to document product improvements and changes. This practice ensures the manual has the most current information. ‘As manual revisions become necessary, individual Pages are prepared and sent to those who need the information. if a page, or number of pages should be replaced, the replacement information is sent along with a revised Revision Control Table. Discard the older, obsolete information Revision Control Table At times, the revision involves inserting additional pages in one or more sections. Replace the Revision Control Table and insert the new pages. This method of revision control represents the most cost-effective solution to providing current, updated information as needed. Fovision Date] New Page Numbers Thitiating Revision Number Involved anne Dept. ‘war, 2009, Trat edition Folease JHE and HSE Marine operations department JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalSection 2 SAFETY SAFETY STATEMENTS Yanmar is concerned for your safety and the condition of your marine engine. Safety statements are one of the primary ways to call your attention to the potential hazards associated with Yanmar Marine engines. Follow the precautions listed throughout the manual before operation, during ‘operation and during periodic maintenance procedures for your safety, the safety of others and to protect the performance of your marine engine. Keep the decals 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 decal attached to it, make sure you order the new part and decal at the same time. This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol. 4H Satis Service Manual PNA elaias 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. AXCAUTION 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 engine, personal property and / or the environment, or cause the equipment to operate improperly. “© 2009 Yanmar Marine InternationalSAFETY Safety Precautions SAFETY PRECAUTIONS 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 safely. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance. PSS The safety messages that follow have DANGER level hazards. NEVER permit anyone to install or operate the engine without proper training + Read and understand this Service Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures. + Safety signs and decals are additional reminders for safe operating and maintenance techniques. + Contact your Yanmar RHQ for additional training, Crush Hazard When attaching an engine to a reps stand, be sure to use a stand of adequate capacity to safely support the engine to be repaired, and that it is securely attached to the engine. NEVER stand under a hoisted engine. If the hoist mechanism fails, the engine will fall on you ALWAYS secure the engine solidly to prevent the engine from falling during maintenance. 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 flame and any other form of ignition out of the area. ALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable before servicing the equipment. Fire and Explosion Hazard j,. Diesel uel 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. JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalSafety Precautions SAFETY Fire Hazard iz fj, Have appropriate safety equipment available. Have all fire extinguishers checked periodically for proper operation and / or readiness. ALWAYS read and follow safety-related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Undersized fire, ring systems can cause an electrical Coolant may be flammable under certain conditions. NEVER allow coolant to come into contact with hot surfaces or insulation material Piercing Hazard Avoid skin contact with high-pressure py 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. 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. Entanglement Hazard NEVER leave the key in the key switch when servicing the engine. Attach a “Do Not Operate” tag near the key switch while performing maintenance on the equipment. ALWAYS stop the engine before beginning service. If you must service the engine while itis operating, remove all jewelry, tie back long hair and keep your hands, other body parts and clothing away from moving / rotating parts. YVANMAR. 11 series sevice Manual Coolant Hazard Wear eye protection and rubber gloves e Ww when you handle Long Life Coolant (LLC). If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water. “© 2009 Yanmar Marine InternationalSAFETY Safety Precautions Sever Hazard NEVER wear jewelry, unbuttoned cuffs, ties or loose-fitting clothing and ALWAYS tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. The propeller may rotate during towing or if the engine is running at idle speed. NEVER service the engine while being towed or when the engine is running. If the vessel has more than one engine, NEVER service a engine if either of the engines are running. In multi-engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running. NEVER operate the engine without the guards in place. NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals. Electrical Hazard Make welding repairs safely. uly + ALWAYS turn off the battery switch (if Gy 24229) or disconnect the negative () battery cable and the leads to the alternator when welding on the equipment. + Remove the multi-pin connector to the engine control unit. 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 leads to the alternator and engine control unit prior to reconnecting the batteries. ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result. Exhaust Hazard All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning, + NEVER block windows, vents, or other means of ventilation if the engine is operating in an enclosed area. + ALWAYS ensure that all connections are tightened to specifications after repair is made to the exhaust system. Burn Hazard Some of the engine surfaces become very hot during operation and shortly @,_ after shut-down. te + Keep hands and other body parts away from hot engine surfaces. + Handle hot components with heat-resistant gloves. Sudden Movement Hazard To prevent accidental equipment movement, NEVER start the engine in gear. Shift the marine gear into the NEUTRAL position any time the engine is at idle. JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalSafety Precautions SAFETY ‘ing Hazard 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. Ifyou need to transport an engine for repair, have a helper assist you attach it to a hoist and load it on a truck. Alcohol and Drug Hazard NEVER operate the engine while you \) are under the influence of alcohol or tes drugs or are feeling ill Exposure Hazard ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, and eye and hearing protection as required by the task at hand. Tool Hazard ‘Always remove any tools or shop rags used during maintenance from the area before operation. YVANMAR. 11 series sevice Manual CAUTION The safety messages that follow have CAUTION level hazards. Poor Lighting Hazard Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps. Tool Hazard ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts. “© 2009 Yanmar Marine InternationalSAFETY lees The safety messages that follow have NOTICE, level hazards. 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. ALWAYS tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly Only use replacement parts specified. Other replacement parts may affect warranty coverage. NEVER attempt to modify the engine design or safety features such as defeating the engine speed limit control or the diese! fuel injection quantity control, 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. ALWAYS be environmentally responsible. 2 © roton the quideine othe EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. 26 Safety Precautions NEVER dispose of hazardous materials by dumping them into a sewer, on the ground, or into ground water or waterways. 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. Make sure the engine is installed on a level surface. Ifa Yanmar Marine engine is installed at an angle that exceeds the specifications stated in the. ‘Yanmar Marine Installation Manuals, engine oil may enter the combustion chamber causing excessive engine speed, white exhaust smoke and serious engine damage. This applies to engines that run continuously or those that run for short periods of time. JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalLocation of Safety Labels SAFETY LOCATION OF SAFETY LABELS To ensure safe work, safety labels are attached. The location of labels is shown below and they should always be visible. Replace if damaged or lost. 3JHSE Engine ay ‘eae WARNING a otatng carts. sts ease ier Figure 2-1 JH Series Service Manual 27 “© 2009 Yanmar Marine InternationalSAFETY Location of Safety Labels AJHSE Engine Figure 2-2 1 —Part No.: 128377-07350 2 —Part No.: 128990-07270 3 ~Part No.: 19660-12980 28 JH Series Service Manual WARN VEAL. (© 2009 Vanmar Marine internationalLocation of Safety Labels SAFETY 4JH4-TE Engine Figure 2-3 3 —Part Ni 4 ~Part No.: 128296-07300 YANMAR ses seis tanss oe “© 2009 Yanmar Marine InternationalSAFETY Location of Safety Labels 4JH4-HTE Engine Ad & WARNING. Figure 2-4 + 12837-07350 }28990-07270 28296-07300 4 —Part No: 196630-12980 240 JH Series sevice Marual_ WAN EVE AS (© 2009 Vanmar Marine internationalSection 3 GENERAL SERVICE INFORMATION Page Safety Precautions..... 8 Engine Outline Drawings... 84 JHSE Models... 34 4JHBE Models... att 4JH4-TE Models... ae 820 4JH4-HTE Models 3:26 Piping Diagrars...... 3:31 JHSE Model se : 3-32 4JH5E Models 3-38 4JH4-TE Models. 3-46 4JH4-HTE Models 3-54 Exhaust Gas Emission Regulations 3-60 Engine Identification (EPA / CARB)..... 3-60 Emission Control Label (EPA / CARB) 3-60 Location of Nameplates. 361 Engine Nameplates (Typical)... 361 Diesel Fuel... . . 3-62 Diesel Fuel Specifications 3-62 Bleeding the Fuel SySteM.....cssnssnnueinnemnnenns 3-64 Engine Oi... a 3-65 Engine Oil Specifications... 3-65 Engine Coolant... 3-66 ations. 3-66 Principal Engine Specifications 3-67 JHBE Engine Specifications seonennnesenes 367 4JHSE Engine Specifications 3-68 4JH4-TE Engine Specifications... 3-70 Engine Coolant Spe 4H Series Service Manual a4 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION AJHA-HTE Engine Specifications ...conemsnnnnnnennnane TA Tightening Torques .. 372 Hexagon Bolts and Nuts..... 372 HoS€ ClaMpS..onenerens : Prepare Engine for Long-Term Storage 3-73 Abbreviations and Symbols. 374 SYMbOIS....0 374 Unit Conversions 3-75 Unit Prefixes... 3-75 Units of Length a, a 3-75 Units of Volume 375 Units of Mass 375 Units of Force... . . 375 Units of Torque. 3-75 Units of Pressure 375 . 375 3-75 Units of Power.. Units of Temperature. 22 JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalSafety Precautions GENERAL SERVICE INFORMATION SAFETY PRECAUTIONS Before you service the engine, review the Safety Section on page 2-1. 4H Series Service Manual 33 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Engine Outline Drawings ENGINE OUTLINE DRAWINGS. Note: All dimensions are metric (mm). 3JHS5E Models 3UJHS5E - Inboard Version (KM35P) at teu Figure 3-1 a scar soe tana WAIN IMEALER. ‘© 2009 Vanmar Maine IntemationalEngine Outline Drawings GENERAL SERVICE INFORMATION 3JHSE - Inboard Version (KM35P) with KMG65E Generator (Optional) Please refer to the manuals below for KMG65E: OAKMG-G00100 Operation Manual OBKMG-G00100 Service Manual OFKMG-G00100 /nstallation Manual Faron Figure 3-2 YANMAR ces sevice varus - “© 2009 Yanmar Maine IntemationalGENERAL SERVICE INFORMATION Engine Outline Drawings 3UHS5E - Inboard Version (KM35A) Figure 3-3 ae scar soe tana WAIN IMEALER. ‘© 2009 Vanmar Maine IntemationalEngine Outline Drawings GENERAL SERVICE INFORMATION 3JHSE - Inboard Version (KM35A) with KMG65E Generator (Optional) Please refer to the manuals below for KMG65E: 00 Operation Manual 00 Service Manual ki Fu i i® ‘eb cs Figure 3-4 YANMAR ces sevice varus = “© 2009 Yanmar Maine IntemationalGENERAL SERVICE INFORMATION Engine Outline Drawings 3JHSE - Sail Drive Version (SD50) Figure 3-5 as scar soe tana WAIN IMEALER. ‘© 2009 Vanmar Maine IntemationalPuoqewieu| euZeHY seuUeA 6962 Toners mw EAN A 9-€ enBiy ee Jenueyy 991AEg 001005-DIN4GO ‘s6uymeig euinno euibua renuey uone1ed 001009-WvO :S9QWM 10) mojaq sjenuew ey) 0} J8j@1 aseaIq (1euondo) s0ye12Ue5 3S9DW WWM (OGAS) UOISIeQ enti [IES - ASHE NOILWWHOSNI S9DIAWSS 1VHANAD Jenueyy UoHe/eISU} 001009-OWH40GENERAL SERVICE INFORMATION Engine Outline Drawings ‘3UJHS5E - without Marine Gear Figure 3-7 340 JH Series sevice Manual WARN IVEALES. ‘© 2009 Vanmar Maine IntemationalEngine Outline Drawings GENERAL SERVICE INFORMATION AJHSE Models 4JHSE - Inboard Version (ZF30M) YVANMAR. 110i soviohiut - “© 2009 Yanmar Maine IntemationalGENERAL SERVICE INFORMATION 4JHSE - Inboard Version (KM35A2) Engine Outline Drawings Figure 3-9 ‘© 2009 Vanmar Maine Intemational JH Series sevice Manual WARN IVEALES.Engine Outline Drawings GENERAL SERVICE INFORMATION 4JHSE - Inboard Version (KM35A2) with KMG6S5E Generator (Optional) Please refer to the manuals below for KMG65E: OAKMG-G00100 Operation Manual OBKMG-G00100 Service Manual OFKMG-G00100 /nstallation Manual Figure 3-10 YVANMAR. 110i soviohiut = “© 2009 Yanmar Maine IntemationalGENERAL SERVICE INFORMATION Engine Outline Drawings 4JH5E - Inboard Version (KM35P) Figure 3-11 244 JH Series sevice Manual WARN IVEALES. ‘© 2009 Vanmar Maine IntemationalEngine Outline Drawings GENERAL SERVICE INFORMATION 4JHSE - Inboard Version (KM35P) with KMG65E Generator (Optional) Please refer to the manuals below for KMG65E: OAKMG-G00100 Operation Manual OBKMG-G00100 S ‘Manual OFKMG-G00100 /nstallation Manual Figure 3-12 YVANMAR. 110i soviohiut 7 “© 2009 Yanmar Maine IntemationalGENERAL SERVICE INFORMATION Engine Outline Drawings 4JH5E - Inboard Version (KM4A1) Figure 3-13 2.46 JH Series sevice Manual WARN IVEALES. ‘© 2009 Vanmar Maine IntemationalEngine Outline Drawings GENERAL SERVICE INFORMATION 4JHSE - without Marine Gear Figure 3-14 YVANMAR. 110i soviohiut - “© 2009 Yanmar Maine IntemationalrPuoReuieul eurEW TEU, E002 o> ere HWAINGA Sremsmrser Sie anBiy (oSas) uorsseq onuia [eS - ASHPY NOILVWHOSNI SDIAYAS 1VHANSD ‘sBurmesg eulyno eulbuyEngine Outline Drawings GENERAL SERVICE INFORMATION 4JHSE - Sail Drive Version (SD50 with KMG6SE Generator (Optional)) Please refer to the manuals below for KMG65E: OAKMG-G00100 Operation Manual OBKMG-G00100 S ‘Manual OFKMG-G00100 /nstallation Manual Figure 3-16 YVANMAR. 110i soviohiut “© 2009 Yanmar Maine IntemationalrPuoReuieul eurEW TEU, E002 o> oe HWAINGA Sremsmrser Lb enbig 4. shows the centr of gravity. (woe4z) uorsie, preoquy - 31-rHrY SI@POW SL-vHEy NOILVWHOSNI SDIAYAS 1VHANSD ‘sBurmesg eulyno eulbuyPuoqewieu| euZeHY seuUeA 6962 Tenueyy sons 5609S HE BAL AD RA, ee at-e aunbig (@vbWy) UoIsien pseoquy - 31-pHry ‘s6uymeig euinno euibua NOILWWHOSNI S9DIAWSS 1VHANADrPuoReuieul eurEW TEU, E002 o> wee HWAINGA Sremsmrser 61-€ enBig marked wi) 3 show \Urming elbow ° optional upg. 4. thows be canto’ of gravy (WPHWy) UoIsieA pseoqu - 31-pHry NOILVWHOANI SDIAYAS TWHANAD ‘sBurmesg eulyno eulbuyPuoqewieu| euZeHY seuUeA 6962 Tenueyy sons 5609S HE BAL AD RA, wee oz-€ aunbiy Note ‘5 Drewing shows rubber mounts at ln! eight. “Engine welgh wil compress rubber mounds by 4 me (pp) 2. Rubber mounts are equipped for standard accessory. 5. The gues marad with show tne mensions wh counting. 4.2 shows he cata fara (ws24Z) uolsseq p1eoqu - 31-pHry ‘s6uymeig euinno euibua NOILWWHOSNI S9DIAWSS 1VHANADrPuoReuieul eurEW TEU, E002 o> vee HWAINGA Sremsmrser be-e aunBig — (p-0sa) uolsse, eauia Ie - 3L-arHry NOILVWHOSNI SDIAYAS 1VHANSD ‘sBurmesg eulyno eulbuyEngine Outline Drawings GENERAL SERVICE INFORMATION 4JH4E-TE - without Marine Gear Figure 3-22 YVANMAR. 110i soviohiut = “© 2009 Yanmar Maine IntemationalrPuoReuieul eurEW TEU, E002 o> wee €c-€ aby HWAINGA Sremsmrser iy Bue onto ein ee ZS (63) ees ee ara Note {;DWG, SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT. 7 ENGINE WEIGHT WL COMPRESS BLOCKS B¥ 4 HU APPROX ‘STANDARD ACCESSORY. ING BLOCKS ARE EQUIPPED FOR: SIME NGURES wage wh SHON THE OIMENSTONS TH UMxiNG ELBOW, OR OPTIONAL COUPLING. «4. @SHOWS THE CENTER OF GRAVITY. (Woe4z) uo!sse, PreOqUI - 3LH-pHPy ‘S|@POW SLH-PHEy NOILVWHOSNI SDIAYAS 1VHANSD ‘sBurmesg eulyno eulbuyPuoqewieu| euZeHY seuUeA 6962 Tenueyy sons 5609S HE BAL AD RA, Re pe-€ ainbiy my, ‘sevceron) veweorroms = ats, oe ete DETAIL OF COUPLING. ~ | peeaweru sence 18 BEDANDOLFLTER La BMOKIS, ag OT dag Tbe 0 6) DETAIL OF PULLEY VIEWED FROM A Note {DWG. SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT. ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4 MM APPROX). 2. MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY. 5: THE FIGURES MARKED WITH 3 SHOW THE OMENSIONS WITH {UixING ELBOW, OR OPTIONAL COUPLING. 4, SHOWS THE CENTER OF GRAVITY. ee (Zv PW) Uo!sieA preoqut - ALH-bHPy ‘s6uymeig euinno euibua NOILWWHOSNI S9DIAWSS 1VHANADwee HWAINGA Sremsmrser S2-¢ anbiy ETAL OF COUPLING: ag es) DEAL OF PULLEY ‘VIEWED: Note, *:OWG. SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT. ENGI WEIGHT WL COMPRESS BLOCKS BY 4 Nal A7ERON, “OR STANDARD: 2. MOUNTING BLOCKS ARE EQUIPPED FOR STF SINE FIGURES HacueD Wm SHOW THE OIENSIONS WT Une ELBOW, OR OPTIONAL COUPLING, 4, SHOWS THE CENTER OF GRAVITY. (wHINy) Uo!sieA preoquy - 3LH-PHEy NOILVWHOSNI SDIAYAS 1VHANSD ‘sBurmesg eulyno eulbuyPuoqewieu| euZeHY seuUeA 6962 Tenueyy sons 5609S HE BAL AD RA, 92-€ aunbiy . os 5 DETAL OF PULLEY ‘VIEWED FROM A (wSz4z) uoIsie, paeoquy - 3LH-bHEP ‘s6uymeig euinno euibua wee 4.\@ SHOWS THE CENTER OF GRAVITY. eae DETAIL OF COUPLING NOILWWHOSNI S9DIAWSS 1VHANADrPuoReuieul eurEW TEU, E002 o> Ore ze-¢ enbiy 4eeD euLieW NOyWM - 3LH-APHEP NOILVWHOSNI SDIAYAS 1VHANSD HWAINGA Sremsmrser \ Note ee "Dh howe owing nt hang Dota of putey -ltcuntng backs ae equipped x sander oct Viewed tom A aisSrows ne coer gay ‘sBurmesg eulyno eulbuyPiping Diagrams GENERAL SERVICE INFORMATION PIPING DIAGRAMS Notation Description “Serew Joint (Union) Flange Joint Eye Joint Insertion Joint Drilled Hole = Coolant Piping = [Cooling Seawater Piping <== [Lubricating Oi Piping ———_ [Diesel Fue! Piping Note: + Dimension of steel pipe: outer diameter x thickness * Dimension of rubber hose: inner diameter x thickness. + Fuel rubber hoses (marked *) satisfy EN/ 1S07840. 4H Series Service Manual 3a1 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> wee HUAINUGA "esses 8e-€ anBiy (ny (12) ® (13) (14) (wSewm ‘dSeWwy) aSHre SI@POW ASHE NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xt4.5 Rubber Hose 2 —Fuel Injection Pump 5 x 14.5 Rubber Hose * 4.76 x t0.7 Stool Pipe + 9xt3,5 Rubber Hose 6 —Lubricating Oil Filter (cartridge type) 7 -Lubricating Oil Cooler 5 x t4.5 Rubber Hose 9 —Fuel High-Pressure Pipe 6.35 x 12.975 Steel Pipe 10—Fuel Injection Nozzle 11-9 x 13.5 Rubber Hose 12-Oil Pressure Switch 13—Mixing Elbow 14-25.4 x t4.3 Rubber Hose 15—Heat Exchanger 16—Lubricating Oil Inlet Filter 17—Main Bearing 18—Seawater Inlet 19-25.4 x t4.3 Rubber Hose 20~Cooling Water Pump (seawater) 4H Series Service Manual 21-28 x t4 Rubber Hose 22-28 x t4 Rubber Hose 23-Hot Water Connection Outlet (R3/e) 24—Thermostat 25—Coolant Pump (freshwater) 26—Hot Water Connection inlet (R3/8) 27-Coolant Temperature Switch 28-Lubricating Oil Pump 29-Pressure Control Valve ‘30-Fuel Filter (cartridge type) 31-*7x t4.5 Rubber Hose 32-Fuel Feed Pump 33—-Fuel Inlet '34-Fuel Overflow 35—To Oil Pan 36~From Cylinder Head 37-To Camshaft 38—Detail of Part A '39-Detail of Part B ‘40 -Detail of Part C 41 Detail of Part D 3.33 “© 2009 Yanmar Marine InlomationalPee (Lwew) aSHre rPuoReuieul eurEW TEU, E002 o> HUAINUGA "esses 6z-€ enBiy A) (2) a 3) (38) Ta (34) (a) Taf (33) (8) 26 (32) P 6) (a1) (at) D 7) 45 (30) (37) ® + Lg —=4 5 (29) == = (gj 42) “\ : R @es tl ge5 < 1] ag sod A a tit - wey AH an 7 ty (40)) B I (43) 1 T 2 (15) NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xt4.5 Rubber Hose 2 —Fuel Injection Pump 3 -*5 xt4.5 Rubber Hose 4 -4.76 x 0.7 Stool Pipe 5 -9x 13.5 Rubber Hose 6 —Lubricating Oil Filter (cartridge type) 7 -Lubricating Oil Cooler 8 -*5 x t4.5 Rubber Hose 9 —Fuel High-Pressure Pipe 6.35 x 12.975 Steel Pipe 10—Fuel Injection Nozzle 11-9 x 13.5 Rubber Hose 12-Oil 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—Seawator Inlet 22-25.4 x t4.3 Rubber Hose 4H Series Service Manual 23—Cooling Water Pump (seawater) 24-28 x t4 Rubber Hose 25~28 x t4 Rubber Hose 26—Hot Water Connection Outlet (R3/8) 27—Thermostat 28-Coolant Pump (freshwater) 29-Hot Water Connection Inlet (R3/8) 30—Coolant Temperature Switch 31—Lubricating Oil Pump 32—Pressure Control Valve ‘33—Fuel Filter (cartridge type) 34—* 7 x t4.5 Rubber Hose 35~Fuel Feed Pump 36—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 3.35 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> oe HUAINUGA "esses o6-¢ aunBiy E (16) (eaug Wes osas) ASHP NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 -*7 xt4.5 Rubber Hose 2 —Fuel Injection Pump 5 xt4.5 Rubber Hose 76 x10.7 Steel Pipe ‘9x't3.5 Rubber Hose 6 Lubricating Oil Filter (cartridge type) 7 —Lubricating Oil Cooler '5 x t4.5 Rubber Hose 9 —Fuel High-Pressure Pipe 6.35 x 12.375 Steel Pipe 10-Fuel Injection Nozzle 11-9 x 3.5 Rubber Hose 12-Oil Pressure Switch 13-Cock (seawater inlet) 14-Mixing Elbow 15-25.4 xt4.3 Rubber Hose 16-25.4 x t4.3 Rubber Hose 17-Heat Exchanger 18-Lubricating Oil Inlet Filter 19-Main Bearing 2025.4 x t4.3 Rubber Hose 4H Series Service Manual 21—Cooling Water Pump (seawater) 22-28 x t4 Rubber Hose 23-28 x t4 Rubber Hose 24—Hot Water Connection Outlet (R3/8) 25~Thermostat 26—Coolant Pump (freshwater) 27—Hot Water Connection Inlet (R3/8) 28—Coolant Temperature Switch 29-Lubricating Oil Pump '30—Pressure Control Valve ‘91—Fuel Filter (cartridge type) 92-" 7x t4.5 Rubber Hose 33—Fuel Feed Pump 34—Fuel Inlet 35~Fuel Overflow 36~To Oil Pan 37-From Cylinder Head 38—To Camshaft '39—Detail of Part B ‘40— Detail of Part C ‘41—Detail of Part D 337 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> ee HUAINUGA "esses Lee enbiy (ay (ZvSewy ‘dSeW») aSHPy SI@POW ASHPP NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xt4.5 Rubber Hose 2 —Fuel Injection Pump 3 -*5 xt4.5 Rubber Hose 4 -4,76 x10.7 Steel Pipe 5 -9x 13.5 Rubber Hose 6 —Lubricating Oil Filter (cartridge type) 7 -Lubricating Oil Cooler 8 -*5 x t4.5 Rubber Hose 9 —Fuel High-Pressure Pipe 6.35 x 12.975 Steel Pipe 10—Fuel Injection Nozzle 11-9 x 13.5 Rubber Hose 12-Oil Pressure Switch 13—Mixing Elbow 14-25.4 x t4.3 Rubber Hose 15—Heat Exchanger 16—Lubricating Oil Inlet Filter 17—Main Bearing 18—Seawater Inlet 19-25.4 x t4.3 Rubber Hose 20~Cooling Water Pump (seawater) 4H Series Service Manual 21-28 x t4 Rubber Hose 22-28 x t4 Rubber Hose 23-Hot Water Connection Outlet (R3/e) 24—Thermostat 25—Coolant Pump (freshwater) 26—Hot Water Connection inlet (R3/8) 27-Coolant Temperature Switch 28-Lubricating Oil Pump 29-Pressure Control Valve ‘30-Fuel Filter (cartridge type) 31-*7x t4.5 Rubber Hose 32-Fuel Feed Pump 33—-Fuel Inlet '34-Fuel Overflow 35—To Oil Pan 36~From Cylinder Head 37-To Camshaft 38—Detail of Part A '39-Detail of Part B ‘40 -Detail of Part C 41 Detail of Part D 3.39 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> ore ze-e enbiy (1) HUAINUGA "esses Gq Got (15) (16) (17) (44) (Lye) aSHry NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xt4.5 Rubber Hose 2 —Fuel Injection Pump 3 -*5 xt4.5 Rubber Hose 4 -4.76 x 0.7 Stool Pipe 5 -9x 13.5 Rubber Hose 6 —Lubricating Oil Filter (cartridge type) 7 -Lubricating Oil Cooler 8 -*5 x t4.5 Rubber Hose 9 —Fuel High-Pressure Pipe 6.35 x 12.975 Steel Pipe 10—Fuel Injection Nozzle 11-9 x 13.5 Rubber Hose 12-Oil 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 4H Series Service Manual 22-25.4 x t4.3 Rubber Hose 23~Cooling Water Pump (seawater) 24-28 x t4 Rubber Hose 25-28 x t4 Rubber Ho: 26—Hot Water Connection Outlet (R3/8) 27-Thermostat 28—Coolant Pump (freshwater) 29—Hot Water Connection Inlet (R3/8) ‘30-Coolant Temperature Switch '31-Lubricating Oil Pump 32-Pressure Control Valve 33—Fuel Filter (cartridge type) ‘34-" 7 xt4.5 Rubber Hose ‘95-Fuel Feed Pump ‘36-Fuel Inlet 37—-Fuel Overflow 38—To Oil Pan ‘39-From Cylinder Head 40-To Camshaft 41—Detall of Part A 42—Detail of Part B 43—Detail of Part C 44-Detail of Part D 3a “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> we HUAINUGA "esses eee aunBiy (11) (42) iE ® ay a a) 19 . 28 (15) fH 2 6) | (42) (woe4z) aSHry NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 -*7 xt4.5 Rubber Hose 2 —Fuel Injection Pump 3 -"5 xt4.5 Rubber Hose 4 -4.76 x 10.7 Steel Pipe 5 -9x'3.5 Rubber Hose 6 Lubricating Oil Filter (cartridge type) 7 —Lubricating Oil Cooler 8 -"5 xt4.5 Rubber Hose 9 —Fuel High-Pressure Pipe 6.35 x 12.375 Steel Pipe 10-Fuel Injection Nozzle 11-9 x 3.5 Rubber Hose 12-Oil Pressure Switch 13-Seawater Inlet 14-Mixing Elbow 15-25.4 xt4.3 Rubber Hose 16-25.4 x t4.3 Rubber Hose 17-Heat Exchanger 18-Lubricating Oil Inlet Filter 19-Main Bearing 2025.4 x t4.3 Rubber Hose 4H Series Service Manual 21—Cooling Water Pump (seawater) 22-28 x t4 Rubber Hose 23-28 x t4 Rubber Hose 24—Hot Water Connection Outlet (R3/8) 25~Thermostat 26—Coolant Pump (freshwater) 27—Hot Water Connection Inlet (R3/8) 28—Coolant Temperature Switch 29-Lubricating Oil Pump '30—Pressure Control Valve ‘91—Fuel Filter (cartridge type) 92-" 7x t4.5 Rubber Hose 33—Fuel Feed Pump 34—Fuel Inlet 35~Fuel Overflow 36~To Oil Pan 37-From Cylinder Head 38—To Camshaft '39—Detail of Part A ‘40— Detail of Part B ‘41—Detail of Part C ‘42—Detail of Part D 343 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> Pre HWAINUA "orseesr ee anbly (16) (eau Wes osas) ASHry NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 -*7 xt4.5 Rubber Hose 2 —Fuel Injection Pump 3 -"5 xt4.5 Rubber Hose 4 ~4.76x t0.7 Steel Pipe 5 -9 x 3.5 Rubber Hose 6 Lubricating Oil Filter (cartridge type) 7 —Lubricating Oil Cooler 8 -"5 xt4.5 Rubber Hose 9 —Fuel High-Pressure Pipe 6.35 x 12.375 Steel Pipe 10-Fuel Injection Nozzle 11-9 x 3.5 Rubber Hose 12-Oil Pressure Switch 13-Seacock 14-Mixing Elbow 15-25.4 xt4.3 Rubber Hose 16-25.4 x t4.3 Rubber Hose 17-Heat Exchanger 18-Lubricating Oil Inlet Filter 19-Main Bearing 2025.4 x t4.3 Rubber Hose 4H Series Service Manual 21—Cooling Water Pump (seawater) 22-28 x t4 Rubber Hose 23-28 x t4 Rubber Hose 24—Hot Water Connection Outlet (R3/8) 25~Thermostat 26—Coolant Pump (freshwater) 27—Hot Water Connection Inlet (R3/8) 28—Coolant Temperature Switch 29-Lubricating Oil Pump '30—Pressure Control Valve ‘91—Fuel Filter (cartridge type) 92-" 7x t4.5 Rubber Hose 33—Fuel Feed Pump 34—Fuel Inlet 35~Fuel Overflow 36~To Oil Pan 37-From Cylinder Head 38—To Camshaft '39—Detail of Part B ‘40— Detail of Part C ‘41—Detail of Part D 345 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> oe HUAINUGA "esses se-€ anBig 762 (55) (Woe4z) 31-rHry SI@POW SL-vHEy NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 -*7 xt4.5 Rubber Hose 28-25.4 x 14.3 Rubber Hose 2-W-CS.D. 29-Cooling Water Pump (seawater) 3 -Fuel Injection Pump ‘30-28 x t4 Rubber Hose 4 -Fuel High-Pressure Pipe 31-28 x t4 Rubber Hose 6.35 x 12.175 STS 32—Hot Water Connection Outlet 5 —Lubrication Oil Filter (cartridge type) ‘33—Coolant Temperature Switch 6 Lubrication Oil Cooler ‘34-Thermostat 7 ~4.76 xt0.7 Double-Walled Steel Tube 35—Coolant Pump (freshwater) 8 -10x t4.3 Rubber Hose ‘36—Hot Water Connection Return 9-13 x 13.5 Rubber Hose 37—Coolant Temperature Sensor (option) 10-Oil Pressure Switch 38-Lubrication Oil Pump 11-Oil Pressure Sensor (option) 39-Pressure Control Valve 12—Fuel Injection Nozzle 40-13 x 13.5 Rubber Hose: 13-Piston Cooling Oil Jet 41-10 x t3 Rubber Hose 14-8 x t0.8 STKM 42~Diesel Fuel Filter (cartridge type) 15~Clutch Lubrication Oil Cooler 43-7 x14.5 Rubber Hose 16-Seawater Inlet 44-7 x14.5 Rubber Hose 17—Turbocharger 45-5 xt4.5 Rubber Hose 18-17 xt1.2 STKM 46-Diesel Fuel Inlet 19-Mixing Elbow 47~Fuel Overflow 20-8.5 x 3.5 Rubber Hose 48—To Block 21-17 x t3 Rubber Hose 49-From Head 22-Heat Exchanger 50-To Camshaft 23-Main Bearing 51-To Oil Pan 24- Lubrication Oil Inlet Filter 52-Detail of Part A 25-25.4 xt4.3 Rubber Hose 53 Detail of Part B 26-25.4 x t4.3 Rubber Hose 54—Detail of Part C 27-7.5 x12.5 Rubber Hose 55~ Detail of Part D JH Series Senvioe Manual 3.47 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> ore HUAINUGA "esses 96-¢ aunBiy (ZvoW) aL-vHey NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xtd.5 Rubber Hose 2-W-C SD. 3 -Fuel Injection Pump 4 -Fuel High-Pressure Pipe 6.35 x 12.175 STS 5 —Lubrication Oil Filter (cartridge type) 6 -Lubrication Oil Cooler 7 ~4.76 x 0.7 Double-Walled Steel Tube 8-10 x13 Rubber Hose 9-13 x t4.5 Rubber Hose 10-Oil Pressure Switch 11-Oil Pressure Sensor (option) 12—Fuel Injection Nozzle 13—Piston Cooling Oil Jet 14-13 x td Rubber Hose 15-13 x t4 Rubber Hose 16~8 x t0.8 STKM 17—Clutch Lubrication Oil Cooler 18— Turbocharger 19-17 xtt.2 STKM 20-Mixing Elbow 21-8. x t3.5 Rubber Hose 22-25.4 x t4.3 Rubber Hose 23-17 x13 Rubber Hose 24—Heat Exchanger 25~Main Bearing 26—Lubrication Oil Inlet Filter 27-25.4 x t4.3 Rubber Hose 28-25.4 x t4.3 Rubber Hose 4H Series Service Manual 29-7.5 x 12.5 Rubber Hose ‘30-Seawater Inlet 31-25.4 x t4.3 Rubber Hose 32-Cooling Water Pump (seawater) ‘33-28 x t4 Rubber Hose ‘34-28 x t4 Rubber Hose ‘95—Hot Water Connection Outlet 36-Coolant Temperature Switch 37—Thermostat '38—Coolant Pump (freshwater) '39-Hot Water Connection Return 40-Coolant Temperature Sensor (Option) 41—Lubrication Oil Pump 42-Pressure Control Valve 43-13 x 13.5 Rubber Hose 4410 x t3 Rubber Hose 48 —Diesel Fuel Filter (cartridge type) 46-* 7 x t4.5 Rubber Hose 47—* 7 x4.5 Rubber Ho: 48—* 5 x t4'5 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 349 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> ose HUAINUGA "esses Le-€ enBiy (wS@4z ‘WPHIN) aL-bHEy NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 -*7 xt4.5 Rubber Hose 2-W-CS.D. 3 -Fuel Injection Pump 4 -Fuel High-Pressure Pipe 6.35 x 12.175 STS 5 —Lubrication Oil Filter (cartridge type) 6 Lubrication Oil Cooler 7 ~4.76 xt0.7 Double-Walled Steel Tube 8-10 x t3 Rubber Hose 9-13 x 3.5 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 xt1.2 STKM 19-Mixing Elbow 20-8.5 x 3.5 Rubber Hose 21-17 x t3 Rubber Hose 22-Heat Exchanger 23-Main Bearing 24- Lubrication Oil Inlet Filter 25~-25.4 xt4.3 Rubber Hose 4H Series Service Manual 26-25.4 x 4.3 Rubber Hose 27-755 x'2.5 Rubber Hose 28-25.4 x 4.3 Rubber Hose 29-Cooling Water Pump (seawater) ‘30-28 x t4 Rubber Hose ‘31-28 x t4 Rubber Hose ‘32—Hot Water Connection Outlet 33—Coolant Temperature Switch ‘34—Thermostat ‘35 -Coolant Pump (freshwater) ‘36-Hot Water Connection Return 37—Coolant Temperature Sensor (option) 38-Lubrication Oil Pump 39-Pressure Control Valve 40-13 x 13.5 Rubber Hose 41-10 x t3 Rubber Hose 42—Diesel Fuel Filter (cartridge type) 43—* 7 x t4.5 Rubber Hose 44—* 7x t4.5 Rubber Ho: 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 351 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> se HUAINUGA "esses ge-€ eunBig (51) (eau Wes Ops / OSaS) 3L-bHry NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xtd.5 Rubber Hose 2-W-C SD. 3 -Fuel Injection Pump 4 -Fuel High-Pressure Pipe 6.35 x 12.175 STS 5 —Lubrication Oil Filter (cartridge type) 6 -Lubrication Oil Cooler 7 ~4.76 x 0.7 Double-Walled Steel Tube 8-10 x13 Rubber Hose 9-13 x 13.5 Rubber Hose 10-Oil Pressure Switch 11-Oil Pressure Sensor (option) 12—Fuel Injection Nozzle 13—Piston Cooling Oil Jet 14-8 x 10.8 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 4H Series Service Manual 26-7.5 x 12.5 Rubber Hose 2725.4 xt4,3 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—Coolant Temperature Switch 33—Thermostat ‘34—Coolant Pump (freshwater) '35—Hot Water Connection Return '96-Coolant Temperature Sensor (option) 37-Lubrication Oil Pump 38—Pressure Control Valve 39-13 x 13.5 Rubber Hose 40-10 x t3 Rubber Hose ‘41—Diesel Fuel Filter (cartridge type) 42—"7 x t4.5 Rubber Hose 43—* 7 x ta.5 Rubber Hose 44—* § 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 353 “© 2009 Yanmar Marine InlomationalrPuoReuieul eurEW TEU, E002 o> re HUAINUGA "esses 6E-€ anBiy (62) 9 (ZvPW) ALH-PHEe S|@POW [Link]-PHEP NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 -*7 xt4.5 Rubber Hose 2-W-CS.D. 3 -Fuel Injection Pump 4 -Fuel High-Pressure Pipe 6.35 x 12.175 STS 5 —Lubrication Oil Filter (cartridge type) 6 Lubrication Oil Cooler 7 ~4.76 xt0.7 Double-Walled Steel Tube 8-10 x t3 Rubber Hose 9-13 x 3.5 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 xt4 Rubber Hose 16-8 x t0.8 STKM 17~Clutch Lubrication Oil Cooler 18~Turbocharger 19-17 «1.2 STKM 20-Mixing Elbow 2125.4 x t4.3 Rubber Hose 22-25.4 xt4.3 Rubber Hose 23-8.5 x13.5 Rubber Hose 2425.4 xt4.3 Rubber Hose 25-17 x t3 Rubber Hose 26- Intercooler 27-Heat Exchanger 28-Main Bearing 29-Lubrication Oil Inlet Filter 4H Series Service Manual 30-25 x 12 C1201T 31-25.4 x t4.3 Rubber Hose 92~28.4 x t4.3 Rubber Hose 33-7.5 x t2.5 Rubber Hose 34—Seawater Inlet 35~25.4 x 4.3 Rubber Hose '36-Cooling Water Pump (seawater) 37-28 x t4 Rubber Hose ‘38-28 x t4 Rubber Hose 39—Hot Water Connection Outlet 40-Coolant Temperature Switch 41—-Thermostat 42—Coolant Pump (freshwater) 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 355 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Piping Diagrams 4JH4-HTE (KMH4A, ZF25A) < o ° oe feted cds | (56) (58) (59) (s7) (a) (9) (10) (11) (12) (13) (15) (16) (17) (18) (19) Figure 3-40 256 JH Series sevice Manual WARN IVEALES. ‘© 2009 Vanmar Maine IntemationalPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xtd.5 Rubber Hose 2-W-C SD. 3 -Fuel Injection Pump 4 -Fuel High-Pressure Pipe 6.35 x 12.175 STS 5 —Lubrication Oil Filter (cartridge type) 6 -Lubrication Oil Cooler 7 ~4.76 x 0.7 Double-Walled Steel Tube 8-10 x13 Rubber Hose 9-13 x 13.5 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 0.8 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. x t3.5 Rubber Hose 22-25.4 x t4.3 Rubber Hose 23-17 x3 Rubber Hose 24-Intercooler 25~Heat Exchanger 26—Main Bearing 27-Lubrication Oil Inlet Filter 28-25 x12C1201T 29~25.4 x t4.3 Rubber Hose 4H Series Service Manual 90-25.4 x 14.3 Rubber Hose 31-7.5 x t2.5 Rubber Hose 32-25.4 x t4.3 Rubber Hose 33—Cooling Water Pump (seawater) ‘34-28 x t4 Rubber Hose ‘35-28 x t4 Rubber Hose ‘36-Hot Water Connection Outlet 37—Coolant Temperature Switch ‘38-Thermostat '39—Coolant Pump (freshwater) 40-Hot Water Connection Return 41—Coolant Temperature Sensor (option) 42—Lubrication Oil Pump 43-Pressure Control Valve 44-13 x 13.5 Rubber Hose 45-10 x t3 Rubber Hose 46 —Diesel Fuel Filter 47—* 7 x14.5 Rubber Hose 48-* 7 x t4.5 Rubber Ho: 49~* 5 x t4.5 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 387 “© 2009 Yanmar Marine Inlomationalese GWIANNWA "rows evs tr bee eng (59) (Woe4Z) SLH-PHTy NOILWWHOGSNI SOIAHAS TVWHSN3aD sues6eiq 6uidigPiping Diagrams GENERAL SERVICE INFORMATION 1 —"7 xtd.5 Rubber Hose 2-W-C SD. 3 -Fuel Injection Pump 4 -Fuel High-Pressure Pipe 6.35 x 12.175 STS 5 —Lubrication Oil Filter (cartridge type) 6 -Lubrication Oil Cooler 7 ~4.76 x 0.7 Double-Walled Steel Tube 8-10 x13 Rubber Hose 9-13 x 13.5 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 0.8 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. x t3.5 Rubber Hose 22-25.4 x t4.3 Rubber Hose 23-17 x3 Rubber Hose 24-Intercooler 25~Heat Exchanger 26—Main Bearing 27-Lubrication Oil Inlet Filter 28-25 x12C1201T 29~25.4 x t4.3 Rubber Hose 30~26.4 x t4.3 Rubber Hose 4H Series Service Manual 31-7.5 x12. Rubber Hose 92~25.4 x t4.3 Rubber Hose '33-Cooling Water Pump (seawater) 34-28 x t4 Rubber Hose ‘35~28 x t4 Rubber Hose '36—Hot Water Connection Outlet 37-Coolant Temperature Switch 38—Thermostat '39—Coolant Pump (freshwater) 40—Hot Water Connection Return 41—Coolant Temperature Sensor (option) 42—Lubrication Oil Pump 43—Pressure Control Valve 44—13 x 13.5 Rubber Hose 45-10 x t3 Rubber Hose 46— Diesel Fuel Filter 47-"7 xt4.5 Rubber Hose 48—* 7 x ta.5 Rubber Hose 49-5 x t4.5 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 359 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Exhaust Gas Emission Regulations EXHAUST GAS EMISSION REGULATIONS JHSE, 4JH5E, 4JH4-TE and 4JH4-HTE series engines are applicable with Non-road Compression Ignition engines regulations and Compression Ignition Marine engines regulations of the EPA (Environmental Protection Agency) and CARB (California Air Resources Board) in USA and RCD. and BSO (Borehole Sites and Operations) regulations in Europe. Engine Identification (EPA / CARB) With the regulations on exhaust gas emission worldwide, it has become necessary to identify engines in a manner to determine with which regulations they comply. Emission Control Label (EPA / CARB) 3JH5E EPA and CARB Label ENISSION CONTROL NFORWATION ELAM: PST GPa HOUSM YANMAR. Figure 3-42 4JHSE / 4JH4-TE EPA Label For Example (4JH4-TE) EMISSION CONTROL NFORWATION THS)BNE ENG COUPLES THUS EM Sie bY sD HOA KGHEUOEL CAE RDS Nr TAQ CO. 0XM mo nes Figure 3-43 360 4JH4-HTE EPA Label ARINE ENGIVE EMISSION CONTROL INFORMATION THS ENGNE CONPUES WT US. EN 40 CER PART St VC APPLY TO ODE. DSPLACEN NGRE Bl sia mi PUM LNTEMNCE Figure 3-44 NOTICE: Emission Control is accomplished through Engine Modification (EM-Design). A tamper-resistant device is installed on EPA/ CARB-certified 3JH5E, 4JH5E, 4JH4-TE and 4JH4-HTE series engines to prevent illegal modification of the fuel injection volume and high idling speed, + Fuel injection volume: cap type + High idling speed: cap type JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalLocation of Nameplates GENERAL SERVICE INFORMATION LOCATION OF NAMEPLATES The following figures show the location of informational nameplates on Yanmar JH series marine engines. Engine Nameplates (Typical) Engine Data and Drive Information Nameplates ‘The nameplate shown (Figure 3-45) is attached to the engine. Check the engine's model, output, rpm and serial numbers on the nameplate. Model Gear Mode! Coit i! Seed pop. sh si! Fu sep poner in! ENON, MFG, DATE Figure 3-45 4H Series Service Manual The nameplate shown (Figure 3-46) is attached to the marine gear. Check the marine gear’s model, gear ration, oil used, oil quantity and serial number. KM GEAR RATIO Ol SAE?/s0HD OIL QTY. LTR No. KANZAKI OSAKA JAPAN Figure 3-46 The nameplate shown (Figure 3-47) is attached to the sail drive (except 4JH4-HTE). Check the sail drive model and serial number. MODEL, PASSED MARK [Link]. Figure 3-47 361 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Diesel Fuel DIESEL FUEL Diesel Fuel Specifications Diesel fuel should comply with the following specifications. The table lists several specifications for diesel fuels. DIESEL FUEL SPECIFICATION LOCATION No. 2D, No. -D, ASTM DOTS Usa EN590:96 European Union 180 6217 DUK International BS 2869-A1 or A2 United Kingdom “IS K7204 Grade No.2 “pan Bio-Diesel Fuels Yanmar approves the use of bio-diesel fuels that do not exceed a blend of 5% non-mineral oil based fuel with 95% standard diesel fuel. Such bio-diesel fuels are known in the marketplace as BS bio-diesel fuels. BS bio-diesel fuel can reduce particulate matter and the emission of “greenhouse” gases compared to standard diesel fuel. NOTICE: If the BS bio-diesel 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 bio-diesel fuels must meet the minimum specifications for the country in which they are used: + In Europe, bio-diesel fuels must comply with the European Standard EN14214. + In the United States, bio-diesel fuels must comply with the American Standard ASTM D-6751 io-diesel should be purchased only from recognized and authorized diesel fuel supplier. 362 Precautions and concerns regarding the use of bio-fuels: + Bio-diesel fuels have a higher content of methylesters, which may deteriorate certain metal, rubber and plastic components of the fuel system. The customer and / or boat builder are responsible to verify the usage of bio-diesel compatible components on the vessel fuel supply and return systems. + Free water in bio-diesel 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. * Bio-diesel may have adverse effects on some: elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil, + Even bio-diesel 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. Itis 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 bio-diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine. JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalDiesel Fuel GENERAL SERVICE INFORMATION 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. Water and sediment in the fuel should not exceed 0.05% by volume. Keep the fuel tank and fuel-handling equipment clean at all times. Ash content not to exceed 0.01% by volume. Carbon residue content not to exceed 0.35% by volume. Less than 0.1% 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 or mix winter and summer fuels. Keep the fuel tank and fuel-handling equipment clean at all times. Poor quality fuel can reduce engine performance and / or cause engine damage. Fuel additives are not recommended. Some fuel additives may cause poor engine performance. 4H Series Service Manual Diesel Fuel Lines NOTICE: The fuel supply line between the fuel tank and engine must have minimum diameter of 8 mm (0.315 in.) ‘Shown is a typical installation of a boat fuel system. Fuel supply (Figure 3-48, (2)) and return (Figure 3-48, (8)) lines connect to fittings at the engine, Figure 3-48 4 Fuel Filter 2 ~To Fuel Injection Pump 3 —Less than 500 mm (20.0 in.) 4 —Fuel Cock 5 —20-30 mm (0.75-1.126 in.) Approximate 6 -Drain Cock 7 ~Fuel Tank 8 —Fuel Return Line Install a drain cock (Figure 3-48, (6)) at the bottom of the fuel tank to remove water and contaminants. Boat fuel return system restriction must not exceed 200 mmAg (7.87 [Link]).. Note: Yanmar does not recommend installing additional fuel filtration before the engine. The engine is equipped with a fuel / water separation filter, plus a fine filter 363 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Diesel Fuel Diesel Fuel Lines for 3JH5E and 4JH5E only Ms Figure 3-49 4 —Fuel Tank 2 -Fuel Cock 3 —Water Separator 4 —Fuel Feed Pump 6 —Fuel Filter 6 —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.) 11-Orifice for Air Bleeding 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. The fuel system needs to be bled under the following conditions: + Starting the engine for the first time. + After running out of fuel and fuel has been added to the fuel tank + After fuel system maintenance such as changing fuel filters, draining the fuel filter / water separator, or replacing a fuel system component, NOTICE: NEVER crank the engine using the starter motor to prime the fuel system. This may cause the starter motor to overheat and damage the starter. 364 3JHSE and 4JHSE Engine 1. Check the fuel level in the fuel tank. Replenish if insufficient. 2. Open the fuel cock of the fuel tank. 3. Tum the electric fuel feed pump (Figure 3-50, (4)) on to release air out of the fuel return line, Figure 3-50 1 Fuel Injector 2 -Fuel Filter 3 —Header (fuel filter) 4 -Electric Fuel Feed Pump 5 Fuel Injection Pump 4. Continue pumping until a solid stream of fuel with no air bubbles begins to flow. Tighten the air bleed screw. After the engine start-up, the automatic air-bleeding device works to purge the air in the fuel system. JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalEngine Oil GENERAL SERVICE INFORMATION 4JH4-TE and 4JH4-HTE Engine ENGINE OIL 1. Check the fuel level in the fuel tank. Replenish if . | : insufficient : Engine Oil Specifications 2. Open the fuel cock of the fuel tank. Use an engine oil that meets or exceeds the 3. Loosen the air bleeding bolt (Figure 3-51, (2)) ‘wing guidelines and classifications of the fuel filter by turning it two or three turns. Service Categories + SAE Viscosity: 10W30 or 15W40 (2) The 10W30 and 15W40 can be used throughout the year. See Figure 3-52. Selection of Viscosity (SAE Service Grade) Figure 3-51 1 -Priming Pump SEF seF WF ceF oof OF 2 ~Air Bleeding Bolt reycne) 0) Ge (APE) 9) 3 —From Fuel Tank om 4 ~To Fuel Injection Pump Figure 3-52 5 —Fuol Filter 4, Feed fuel with the fuel feed pump by movingthe __* API Classification: lever on the feed pump (Figure 3-51, (1)) up RATE and down, kare 5. Allow the fuel containing air bubbles to flow out SUHBET POF, Oba from the air bleeding bolt hole. When the fuel no ‘HSE longer contains bubbles, tighten the air bleeding bolt. This completes the air bleeding of the fuel system CD or higher 6. After the engine start-up, the automatic air-bleeding device works to purge the air in the fuel system. 4H Series Service Manual 365 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Engine Coolant Definitions + SAE (Society of Automotive Engineer, API (American Petroleum Institute) Notice: * Be sure the engine oil, engine oil storage containers and engine oil filing equipment are free of sediment and water. + Change the engine oil after the first 50 hours of operation and then at every 250 hours (or annually) thereafter. + Select the oil viscosity based on the ambient temperature where the engine is operated. See Figure 3-52. + Yanmar does not recommend the use of engine oil adaitives. Note: Yanmar recommends using genuine Yanmar marine oil, specifically formulated for the JH engine. 366 ENGINE COOLANT WARNING! Fire Hazard. Coolant may be flammable under certain conditions. NEVER allow coolant to come into contact with hot surfaces or insulation material. WARNING! Coolant Hazard. Wear protective rubber gloves and eye protection when handling Long Life Coolant Antifreeze. Flush eyes and exposed skin with water immediately after contact. Engine Coolant Specifications Note: In the U.S., LLC is required for the warranty to be valid NOTICE: Follow the manufacturer's recommendations. Use the proper LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.) of the engine's freshwater cooling system. Engine Coolant Mixture (NOTICE: ALWAYS add LLC to deionized soft water, especially when operating in cold weather. Without LLC, cooling performance will decrease due to scale and rust in the cooling system. Water alone may freeze and form ice; it expands approximately 9% in volume. Use the proper amount of coolant concentrate for the ambient temperature as specified by the LLC ‘manufacturer. LLC concentration should be a minimum of 30% to a maximum of 60%. Too much LLC will decrease the cooling efficiency. NEVER mix different types or brands of LLC or a harmful sludge may form. NEVER use hard water. Use deionized water. Recommended Engine Coolant + Texaco Long Life Coolant, both standard and premixed, Product code 7997 and 7998, + Havoline Extended Life Antifreeze / Coolant. Product code 7994. Remove scale from the cooling system periodically by flushing the system. Note: Yanmar recommends using genuine Yanmar antifreeze / coolant. JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalPrincipal Engine Specifications GENERAL SERVICE INFORMATION PRINCIPAL ENGINE SPECIFICATIONS 3JHSE Engine Specifications Specification SUREE Marine Gear Model KMa5P [| _KMS5A_[___SD50___| __ Bobtail Use Pleasure use Type Vertical waler cooled 4-cycle diesel engine Combustion system Direct injection ‘Aspiration Natural aspiration Number of oyinders Trine 3 Bore x stroke BETMNSO TM BAH KSSH] Displacement T8421 (100.20 cu in} Output at Continuous power | crankshaft Engine * 26.1 KW (35.5 hp metticy2907 rpm speed Output at crankshatt / Engine : metric) pm Maxirum Rated | 7nkGheh Eo 28.7 KW (39.0 hp metric) / 3000 rp Output Power Ouiputatpropalier” area * 27.4 kW (37.3 hp metric) / 2000 rpm : : Tnataliation Flexible mounting Fuel injection trang FIRS2 1 degb.T D.C (FIT 16.0 1 deg [Link] [at Plunger LASS mm) Fuel injection opening pressure 216 — 20.6 MPa (8132-3277 psi) iain power take off ‘Atflywheal end Direction of ee Counterclockwise viewed from stem Rotation area Clockwise viewed from stern Coaing system Freshwater cooling wih heat exchanger Lubricating system Complete enclosed forced lubrication system Coolant capacity (rash) Engine 45 L (4.8 ql), Coolant recovery tank: 0.8 L (0.8 ai) Rake angle at rake angie 8 ‘atrake angie O° es S0r03L : n Lubricating oil oe (63+03 ah) ea enraeman capacity (engine) 454037 i i Oil pan only as eosa 5.04031 (53403 q1) = Effective TAL (2 at) T2L03 a) Type Electic Starting system —_[ Starting motor DoTaV-14 KW, ‘AC generator T2V- 80A (12V- 60A optional) TI mm 776 mm 700 mm cage Overall length (306 in) (30.6 in.) (27.6 in.) naine dimension” Overall width 560 mm (22.01) ‘Overall height 623 mm (24.5in.) Flywheel major dimension D300 x 66 mm (11.8x 26 in) B13 kg ngine dry mass (include marine gear) eer fee hal cones) de) BA Male oo (408 tb) (410 Ib) (470 Ib) (467 ib) (engine: 281 lb) * Rating Condition: Temperature of fuel; 40°C at FO pump inlet; ISO 8665 Note 1 hp metric=0.7355 kW VANMAR. 11 sores sovice Manual The ‘total oll quantity includes oi in ol pan, channels, coolers and fier The effective amount of ail shows the difference in maximum scale ofthe dipstick and minimum scale, : Density of fuel: 0.842g/em3 at 15°C 367 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Principal Engine Specifications 4JH5E Engine Specifications Engine Model SE Marine Gear Wedel NEP ZEON KNEE Maa Use Pleasure use Type Varical water cooled 4-cycle diesel engine Combustion system Direct injection Aireharsing Tatura’ aspiration Number of eyindars 4 Bore x stoke Bemmxeo mm B.A x354IN) Displacement 2.180 (18864 cuIn) ee Output at crankshait7 * 36.0 KW (48.9 hp metric) 2907 rpm Engine speed Output at erankshat7 : hp metic) 000 Maximum Rated Output | Engine speed eels ene Power Output at propeller? * SB ORW G17 hp ete) 7 Engine speed 1/3000 rpm Trstalation Fexble mounting Fuel injection timing FIR@ = BTDC (at Maximum Rated Output Power) (FIT 20.0 + 1° BTDC (at Plunger Litt 2.5)) Fuel injection opening pressure 21.6-22.6 MPa (3192-3227 psi) Main power take off Ai flywheel end Direction of Rotation coe Caunterclackwise viewed from ster Propeller shaft (Ahead) Clockwise viewed from stern Coaling system Frashwater cooling with heat exchanger Lubricating system Complete enclosed forced lubrication system Coolant capacity (reshh Engine 6.0 L (6.3 al), Coolant recovery tank: 0.8L (08 al) Fake angie atrake angie atrake angie O° Lubricating ol capacity [Total 50x08 63203 55203168103) (engine) Oitpan only 52031 (48=03q) 50=03L (63203) = Effective Tata Tal isa Type Cletio Staring system Starting motor Dove V- 1a RW AG generator T2V-B0A aim 30mm 364 ram Samm & di Overall length (34.3 in.) (37.4 in.) (34.0 in) (36.3 in.) ngine cimension ‘Overall width 560 mm (22.0 in.) Overall height G25 mmm (24.6) Fiywheel major dimension D80OK 66 mm (11.8x20im) ere ase 228 kg 2iakg Boke Engine dry mass (include marine gear) aaa) eae aa ey 371 mm 250 mm 364 mm 322 mm a a Overall length {34.3 in} (37.4 in.) {34.0 in.) (36.3 in.) naine dimension Overall width ‘560 mm (22.0 in.) Overall height 25 rm 246i) Fiywheel major dimension DOK EE mm (118x207) Soearacescnareaaeas ashe 28 kg 2iakg BO Ke Engine dry mass (include marine gear) ae) ae aa eal Rating Condition: Temperature of fuel, 40°C at FO pump inet; ISO 8665 “The “otal” oil quantity includes oil in oll pan, channels, coolers and iter. "* The effective amount of ol shows the difference in maximum scale of the alpstick and minimum scale. Note: Density of fuel: 0.842g/ems at 15°C. 1 hp metric = 0.7355 kW 368 JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalPrincipal Engine Specifications GENERAL SERVICE INFORMATION 4JHSE Specifications (Continued) Engine Model THBE Sail Drive Model ‘5050 Bobtail Use Pleasure use. Type Verlical water cooled 4-cycle diesel engine Combustion system Direct injection ‘ir charging Natural aspiration ‘Number of cylinders 4 Bore x stroke x80 mm (S4ExSS4IN) Displacement 2490L ‘Ouiput at orankshant7 Engine speed * 26.0 KW (48.9 hp metticy2907 rpm Continuous power ‘Output at orankshant7 ~ 99.6 KW (59.8 hp}9000 rpm Maximum Rated Output | Engine speed Power ‘Output at propeller Engine speed Installation Flexible mounting FRG BTOC (at Maximum Rated Output Power) Fuel injection timing (iT 20.0 41" BTOG (at Plunger Lit 25) Fuel injection opening pressure 21.6-22,6 MPa (3152-5227 psi) ain power take off ‘At fiywheel end Crankshaft ‘Counterclockwise viewed from stern Direction of Rotation Propeller shat (Ahead) Clockwise viewed from stern Cooling system Freshwater cooling with heat exchanger Lubricating system Closed forced lubrication system Engine 6.0L (62 qi), Coolant capacity (resh) Coolant recovery tank: 0.8 L (0.8 qt) Fake angle at rake angle O° Lubricating oil capacty [Total 55203156203 a) (engine) Oilpan only 502031 (632034) Effective TALS ah Type Electic Starting system Starting motor Doi V-1aKW ‘AC generator T2V-80A ‘Overall length 75 mm (B12 in) Engine dimension ‘Overall wicth ‘560 mim (22.0 in ‘Overall height 625 mm (24.6 in) Flywheel major dimension Da00x 66 mm (11.8x 261m) Dat kg engine: 201 ki 201 K¢ Engine dry mass (include marine gear) sori fase) (engine: 443 to) * Rating Condition: Temperature of fuel: 40°C at fuel pump inlet, SO 8665 “The “otal oil quantity includes olin oll pan, channels, coolers and fier The effective amount of ail shows the difference in maximum scale ofthe dipstick and minimum scale, Density of fuel: 0.842g/cm3 at 15°C. 1 hp metric = 0.7355 kW Note VANMAR. 11 sores sovice Manual “© 2009 Yanmar Marine Inlomational 369GENERAL SERVICE INFORMATION Principal Engine Specifications 4JH4-TE Engine Speci Engine Model SHETE Marine Gear Model Fao | KWaR2 | KMHGA | ZF26A_| SD50-aT | Bobt Use Pleasure use Type Varical waler cooled 4cycle diesel engine ‘Combustion system Direct injection ‘Ar charging Turbocharged Number of inde 4 Bore x-troke Bx DO mM BSIXSEAA) Displacement 7995 L (121 Tecu In) Continuous | Output at crankshaft? on ae 50.2 KW (68:3 hp metic) /3101 rpm ‘Output at crankshalt? ; areata Maximum Rated | Engine speed ee ee ee Output Power Output at propaler7 7 ey 59,0 kW (72.1hp metic) 3200 rpm installation Flexble mounting Plunger lift at TOC Fuel injection timing 1.26 £0.01 mm (when W-CSD is released) Fuel injection opening pressure 27.6205 MPa Main power take off ‘Al iywheel end Grankahatt Courterclockwise viewed fom stem Direction of Rotation Propeller shaft (Ahead) ae eee cea Cooling system: Freshwater cooling wil Real exchanger Lubricating system Complete enclosed forced lubrication system Coolant capacty resh) Engine: 72 (7.6 qi), Coolant recovery tank: 08 L (08 a) Fake angle = e Foe = 72037 a Fifer to Lubicatngot [Tt eoeasal 69203L (73034) et ; 52203. y Fifer to (engine) Oilpan only fescusal 6.42031 (6803) et = etective 2aL eB a Type Electie Starting system [Staring moor DoieV- 1a KW ‘AG generator T2V-80 A (12 V- 60 A optional ee mm] Sm | aImm | 107mm | 72mm | 72mm Engine 7 (363in) | (35.6in) | (367in) | (40.0in.) | (0.8in) | (80.8 in) dimension [Overall wath 616 mm @43in} ‘Overall height 659 mm @59in}) Fiywheel major dimension 830% 65 mm (13.5x26 in) Zarkg | 25k (52316) | (540 fb) SR pe 205kg | 2a7kg | 2aekg | engine: | engine: | 207kg Engine dry mass (includ gear) (rep) | G23) | 251) | 173kg | 207kg | (4561b) (engine: | (engine get) | 456 1b) Rating Condition: Temperature of fuel; 40°C at fuel pump inlet ISO 8665 "The "total oil quantity includes oil in oll pan, channels, coolers and filter. “+ The effective amount of ol shows the difference in maximum scale of the apstick and minimum scale. Note: Density of fuel: 0.842g/em? at 15°C. 1 hp metric = 0.7355 kW 370 JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalPrincipal Engine Specifications GENERAL SERVICE INFORMATION 4JH4-HTE Engine Speci Engine Model GeATE Warine Gear Model ‘ZFSOM KMGA2 | _KMHAA | _ZF25A_| Bobi Use Pleasure use’ Type Vertical water cooled 4-cycle diesel engine Combustion system Direct injection ‘Aspiration Turbocharged Number of eyinders 4 Bore x stroke 4x80 mm (831 xS54in) Displacement 7.995 ‘Output at crankshatt7 Continuous power Se * 78.6 KW (100 hp metric) /3101 rpm ‘Output at crankshalt7 Maximum Rated Output | Engine speed * 80.9 KW (110 hp metric) / 3200 rpm Power ‘Output at propeller Engine speed * 77.7 KW (108 hp metric) / 8200 rpm : installation Flexible mounting Fuel injection timing Plunger lit at TOC 1.26 + 0.01 mm (when W-CSD is released) Fuel injection opening pressure 21.6205MPa ain power take off Ai iywhesl end Grankshat Counterclackwise viewed trom stem Droste Ratton aia | Cinco ves Pople eaten) | ORR en tnt ci a) hg: TSU Teal Cok ova nk 98U OIA aa 7 e Fae ™* Total pa eeae 9: + iefer to Lubricating oil capacity Tol {6.0+0.3qt) einem Refer'o left trae Orpen ony 52205t | __easosuiearoag) [raion ae ZLBSal Tie cee taangenem [Sgt sevav-1a0 AS EV-ROATEV-BOA & é Overall length {36.3 in.) (35.6in) | (36.7in) | (40.0in) | (30.8 in.) ingine dimension ‘Overall width 816 mm (24.3 in.) Sr seammesn} Fyneatrapraaaen sex nm ioaxzS) lating Condition: Temperature of fuel 40°C at fuel pump inlet; ISO 8665 The ‘total oil quantity includes oi in ol pan, channels, coolers and fier “The effective amount of oil shows the diference in maximum scale of the dipstick and minimum scale Note: Density of fuel: 0.842g/em? at 15°C. 1 hp metric = 0.7355 kW. VANMAR. 11 sores sovice Manual 371 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Tightening Torques TIGHTENING TORQUES Use the correct amount of torque when tightening fasteners. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. Hexagon Bolts and Nuts Tightening Torque Name Bolt Diameter x pitch (mm) ay Remarks Hexagon bolt with a "7" head Mex 88-118 (7287) __| Apply 80% torque when and hexagon nut Max. 22.5285 (16.8-21.4) | tahtening to aluminum alloy. (-7" mark means JIS strength Mion S 4454834406) | Apply 60% torque to 4T bolts classification 77") MI2K1-75 782982 (688-732) | and locknuts (4T bolt has no mark onthe head.) PT plug (Taper plug) ve 28 (73) va 1286196) a 254 (216) ° 1 588 (3.4) Line joint bok a 127-167 (4-123) Mio 795255 (144-188) iz 244-344 (180-25.4) a Mia 39.1-491 (289-362) Mie [Link] (86.1-43.5) Hose Clamps Note: Reuse and retightening is prohibited for all hose clamps. Always install new hose lamps. 372 JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalPrepare Engine for Long-Term Storage GENERAL SERVICE INFORMATION PREPARE ENGINE FOR LONG-TERM STORAGE NOTICE: Do not drain engine coolant for long-term storage. Antifreeze must be used to avoid freezing and damage to components. Antifreeze will prevent rusting during long-term storage. 1. Change engine oil and filter. See Changing Engine Oil, Replacing Engine Oil Filter Element and Cleaning Engine Oil Cooler on page 8-8. 2. Drain seawater cooling system. See Draining / Refiling Seawater Cooling System on page 7-8. 3. Wipe off any dust of oil from the outside of the engine, 4. Drain fuel tank or fill the tank to prevent condensation. 5. Grease the exposed areas and joints of the remote control cables and the bearings of the remote control handle. 6. Seal the intake silencer, exhaust pipe, etc. to prevent moisture or contamination from entering engine. 7. Completely drain bilge in hull bottom. 8. Waterproof the engine room to prevent rain or seawater from entering, 9. Charge the battery once a month to compensate for battery's self-discharge. 10. Remove key from key switch and cover key switch with moisture cap (if equipped) 4H Series Service Manual 373 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Abbreviations and Symbols ABBREVIATIONS AND SYMBOLS A AC ACEA Ah API ARB ato BDC BTDC °c CARB CCA cfm cm cm? cem/minimum cu D De oD DVA EPA EsG F floz fl oz/minimum ft ftelb ft-lbt/minimum g gal gaV/hr gal/minimum GL 374 ampere alternating current Association des Constructeurs Européens d Automobilies ampere-hour American Petroleum Institute Air Resources Board after top dead center bottom dead center before top dead center degree Celsius California Air Resources Board cold cranking amp cubic feet per min. centimeter cubic centimeter cubic centimeter per min. cubie inch diameter direct current direct injection direct volt adapter Environmental Protection Agency electronic speed governor degree Fahrenheit fluid ounce (US.) fluid ounce (US.) per min, foot foot pound? {foot pound force per min. gram gallon (US.) gallon (U.S, per hour gallon (US,) per min. gear lubricant horsepower (metric) hour inside diameter identification indirect injection inch inches Aqueous (water) inches Mercury inch pound” joule Japanese Automobile Standards Organization kelvin kilogram kgtfem? kgtim kPa kw Une ib lot Ib Ib-in mmAq Psi kilogram force per square centimeter kilogram force per meter kilometers kilopascal kilowatt liter liter per hour pound pound-force pound foot (Tightening Torque) pound inch (Tightening Torque) meter milter millimeter millimeter Aqueous (water) megapascal millivolt newton newton meter number outside diameter ounce pascal horsepower (metic) pound per square inch quart (US.) radius revolutions per min, Society of Automotive Engineers second short ton 2000 Ib total base number top dead center volt volt alternating current volt direct current watt degree plus minus plus or minus ‘ohm micro percent * Work torque such as engine torque * Work torque such as starter motor torque JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalUnit Conversions GENERAL SERVICE INFORMATION UNIT CONVERSIONS Units of Torque i i Ib-tt x 1.3558 =Nm Unit Prefixes Ib-tt x 0.1383 =kgtim Prefix Symbol Power I-in x 0.1130 =Nm mega M x 1,000,000 [Link] x 0.0115, kgt/m kilo k x 1,000 kafim x 7.2330 Ib-ft c x0.01 kati x 86.8000 =Ibin m x 0.001 kafim x 9.8070 Nm " x 0.000001 Nm x 0.7376 lb-ft Nm x 8.8510 tb-in Units of Length Nem x 0.1020 =kgf/im Hed x ree Units of Pressure in x 2.5400 psi x 0.0689 = bar in x 25.4000 psi x 6.8950 =kPa km x 06210 psi x 0.0703 =kgt/om? m x 3.2810 bar x 14.5030 = psi om x 0.3940 bar x 100.0000 =kPa mm x 0.0394 bar x 29.5300 = inHg (60°F) kPa x 0.1450 =psi Units of Volume kPa x 0.0100 = bar kPa x 0.0102 =kgt/em= US) ee kgficm? = x _—-98.0700 = psi ee ae kgflom? =x (0.9807 = bar eri Rie rea7oe kgflom? == x 14.2200 =kPa floz(Us) x o0bse7 inHg (60°) x 0.0333 = bar flctus) 2 2987000 inHg (60°) x 3.3770 =kPa 3 Rte erocco0 inHg (60°) x 0.0344 = kgf/cm? a ae mmAq x 0.0394 = [Link] Units of Mass Units of Power 5 eo hp(metric x — 0.9868201 =hp SAE or PS) ig x eeeee. hp(metric x 0.7354988 = kW ; or PS) 9 eee hpSAE =x —_1.0138697 = hp (metric or PS) i hpSAE x 0.745699 = kW Ce te otce kw x 1.3596216 = hp (metric or PS) tof x 4.4480 kw x 1.341021 = hp SAE tof x 0.4536 5 N x 0.2248 Units of Temperature N 102 C iol x ooo = (1.8x °C) +32 kgf fa 9.8070 °C = 0.556 x (°F - 32) VAINMAAB. 11 series service Manual 3-75 “© 2009 Yanmar Marine InlomationalGENERAL SERVICE INFORMATION Unit Conversions This Page Intentionally Left Blank 276 JH Series sevice Manual WARN IVEALES. (© 2009 Vanmar Matine inemationalSection 4 PERIODIC MAINTENANCE Introduction The Importance of Periodic Maintenance. Performing Periodic Maintenance Yanmar Replacement Parts..... Reauired EPA Maintenance EPA Requirements, Conditions to Ensure Compliance with EPA Emission Standards....soenenas . Inspection and Maintenance. Periodic Maintenance Schedule. Inspection and Maintenance of EPA Emission-Related Parts... Inspection and Maintenance of EPA Emission-Related Parts for Non-Road and Cl Matine Engines Periodic Maintenance Procedures Alter Initial 50 Hours of Operation Every 50 Hours of Operation Every 250 Hours of Operation Every 500 Hours of Operation Every 1000 Hours of Operation YVANMAR. 11 series sevice Manual at “© 2009 Yanmar Marine InternationalPERIODIC MAINTENANCE This Page Intentionally Left Blank a2 JH Series sevice Manual WARN VEAL FR. (© 2009 Vanmar Marine internationalSafety Precautions PERIODIC MAINTENANCE SAFETY PRECAUTIONS Before you perform maintenance, review the Safety Section on page 2-1 INTRODUCTION This section of the Service Manual describes the procedures for proper care and maintenance of the engine. The Importance of Periodic Maintenance Engine deterioration and wear ocouts in proportion to length of time the engine has been in service and the conditions the engine is subject 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 Perform periodic maintenance procedures in an open, level area free from traffic. If possible, perform the procedures indoors to prevent environmental conditions such as rain, wind or snow from damaging the engine. WARNING! Exhaust Hazard. NEVER block windows, vents or other means of ventilation if the engine is operating in an enclosed area. Alll internal combustion engines create carbon monoxide gas during operation. Accumulation of this gas within an enclosure will cause illness or even death. Yanmar Replacement Parts ‘Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed. Genuine replacement parts help ensure long engine life, Required EPA Maintenance ‘To maintain optimum engine performance and compliance with the Environmental Protection ‘Agency (EPA) Regulation Engines, it is essential that you follow the Periodic Maintenance Schedule on page 4-4 and Periodic Maintenance Procedures on page 4-6. YVANMAR. 11 series sevice Manual EPA REQUIREMENTS The EPA emission regulation is applicable only in USA. Conditions to Ensure Compliance with EPA Emission Standards This product is an EPA-approved engine. The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards: + Ambient temperature: -16° to +40°C (3° to 104°F) * Relative humidity: 80% or lower The fuel and lubricating oil used should be as follows: * Diesel fuel: ASTM D975 No. 1-D or No. 2-D, or equivalent (minimum cetane No. 45) * Lubricating oil: Type API, Class CD for Model 4JH4-TE and 4JH4-HTE engines ‘Type API, Class CF-4, Cl-4 or higher for Model SJH5E and 4JHSE engine Be sure to perform inspections as outlined in Periodic Maintenance Schedule on page 4-4 and keep a record of the result. Pay particular attention to these important points: + Replacing the engine oil * Replacing the lubricating oil filter + Replacing the fuel + Replacing the air filter Note: Inspections are divided into two sections in accordance with who is responsible for performing the inspection: the user or the maker. Inspection and Maintenance ‘See EPA Requirements on page 4-3. Inspection and maintenance procedures not shown in this section are covered in Periodic Maintenance ‘Schedule on page 4-4. This maintenance must be performed to keep the emission values of your engine within standard values during the warranty period. The warranty period is determined by the age of the engine or the ‘number of hours of operation. 43 “© 2009 Yanmar Marine InternationalPERIODIC MAINTENANCE Periodic Maintenance Schedule 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 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. heck. leplace Perioa Walnenance THETA Everys0 | Every 250 | Every soo Brey Se lL Cr system tom monthly | one year years whichever | whichever | whichever | 2S first frst frst ome fore Vicar napecTon oFengie Fie Sata Check i ol vel and TF ecessay Dia waerandsoarenTam| ——o 5 ful an ia 50 Dran te et warrsoparrer| — 0 apace The hel Wer ele [eck he Tet ecto tring 3 [Sneckme Tutjctr Spray or pater ubreatag ones Engine Sytem fubreating it arin Goar lever Repiace he [Enghe ubresing oi nt 50 aie Gear > > na 50 apse he ot |Enghe titer element a 50 Marine Gear (if o oS eaipne) na 50 tng Sytem Seawater ot ck oon val Check or replace Te Saar 3 pump pele Replace coolant aye When long if coolants used replace every Wo years, See Engine Coolant Specticatons on page 3-6, Cie ane Seas eR 3 passages I aa Clean ake Sen 0 Exhaust System leaner element Clea the exhaust Water 9 > xing sbow Crean te wrbochaTgaT o farete) rie only Check daptragrrasserby 9 UNE eae ony os JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalPeriodic Maintenance Schedule PERIODIC MAINTENANCE Q: Check : Replace Periodic Maintenance Interval Eves | Every250 | Every500 oe roureor | noursor | oursor2 | 100° system tem monthly | one year years vibichever | whichever | whichever | 00 comes comes comes first first first ee first ec aT Spa | ORS TaN TTS Check he seco ever 9 he oatary Check tension TSE o 3 tensor Vet ta 90 hock the witng connectors 5 Engine Cynder [Check or esage oe Headland Bleck [engine a and engine coolant Toten al jr nts and bof o ust ake exhaust valve o tearence ta 0 isaTareais [Check he arate coRTaTeRET ——O em eration ita 90 Rojak opera o algnment lta 9 Replace obbe7=6a Roses (al Tepe every 2 years or very 2000 FOU and water) whenever comes st * For EPA requirements see Inspection and Maintenance of EPA Emission-Related Parts on page 4-5Periodlec Maintenance Procedures. Note: These procedures are considered normal maintenance and are performed at the owner's expense. Inspection and Maintenance of EPA Emission-Related Parts + Marine diesel engines less than 37 kW: 3JH5E is certified as Non-Road and EPA Cl marine engine + Marine diesel engines greater than 37 kW: 4JHSE, 4JH4-TE and 4JH4-HTE are certified as EPA Cl marine engines Inspection and Maintenance of EPA Emission-Related Parts for Non-Road and Cl Marine Engines Parts Tatewal Clean ful njoction nozzle 500 hours ‘Ghack fuel injection nozzle pressure and spray pattern (Check fuel injection pump adjustment (Check turbocharger adjustment (il quipped) ‘Ghack eleatroni engine control unit and is assoslated sensors and actuators (T equipped) 3000 hours Note: The inspection and maintenance items shown above to be performed at your Yanmar dealer or distributor. YANMAR ses seis tanss = “© 2009 Yanmar Marine InternationalPERIODIC MAINTENANCE Periodic Maintenance Procedures PERIODIC MAINTENANCE PROCEDURES iia jal 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation. + Draining Water and Sediment from the Fuel Tank See Cleaning Fuel Injection Nozzle Cavities on page 6-13. + Changing the Engine Oil and Replacing the Engine Oil Filter See Changing Engine Oil, Replacing Engine Oil Filter Element and Cleaning Engine Oil Cooler on page 8-8, * Adjusting / Replacing the Alternator V-belt See Replace V-Belt on page 11-8 + Adjusting Intake / Exhaust Valve Clearance See Inspecting Intake / Exhaust Valves and Valve Guides on page 5-47. * Checking Remote Control Cable Operation See Checking and Adjusting Remote Control Operation on page 5-100. + Adjusting Propeller Shaft Alignment (If Equipped with Marine Gear) See Principal Engine Specifications on page 3-67. 46 Beker cal ‘After you complete the initial 50 hour maintenance procedures, perform the following procedures every 50 hours or monthly thereafter, whichever comes first. * Draining the Fuel Filter / Water Separator ‘See Replacing the Fuel / Water Separator on page 6-49. + Checking Battery Electrolyte Level (Serviceable Batteries Only) See Tests and Adjustments on page 5-22. JH Series sevice Manual WARN VEAL FR. (© 2009 Vanmar Marine internationalPeriodic Maintenance Procedures PERIODIC MAINTENANCE Renken OOO eke oro Perform the following maintenance every 250 hours of operation or one year, whichever comes first. “Dr Tank See Cleaning Fuel Injection Nozzle Cavities on page 6-13. 1g Water and Sediment from the Fuel * Replacing the Fuel Filter Element ‘See Servicing the Fuel System on page 6-12. * Changing Engine Oil and Replacing the Engine Oil Filter Element ‘See Changing Engine Oil, Replacing Engine Oil Filter Element and Cleaning Engine Oil Cooler on page 8-8. * Checking or Replacing the Seawater Pump Impeller ‘See Seawater Pump on page 7-17. + Cleaning the Intake Silencer (Air Cleaner) Element ‘See Cleaning the Air Cleaner on page 9-6. + Replacing Coolant (LLC) ‘See Removing and Installing Coolant Pump on page 7-15. + Replacing the Anodes (4JH4-TE and 4JH4-HTE Only) See Draining and Filling Closed Cooling System on page 7-10. * Cleaning the Exhaust / Water Mixing Elbow * Cleaning the Turbocharger (4JH4-TE and AJH4-HTE only) See Turbocharger Service on page 9-6. * Adjusting / Replacing the Alternator V-belt See Replace V-Belt on page 11-8. * Tightening All Major Nuts and Bolts ‘See Main Bolt and Nut on page 14-15. YVANMAR. 11 series sevice Manual Perform the following maintenance every 500 hours of operation or 2 years, whichever comes first. * Cleaning the Engine Oil Cooler See Changing Engine Oil, Replacing Engine Oil Filter Element and Cleaning Engine Oil Cooler on page 8-8. * Replacing Coolant (LLC) ‘See Removing and Installing Coolant Pump on page 7-15. * Replacing the Anodes (4JH4-TE and 4JH4-HTE Only) See Draining and Filling Closed Cooling System on page 7-10. * Replacing Rubberized Hoses (Fuel and Water) See Servicing the Fuel System on page 6-12 and Inspecting the Cylinder Block on page 5-40. a7 “© 2009 Yanmar Marine InternationalPERIODIC MAINTENANCE Periodic Maintenance Procedures * Replacing Rubberized Hoses (Fuel and Water) Ts A cesta ie seiko See Servicing the Fuel System on page 6-12 and Inspecting the Cylinder Block on page 5-40. Perform the following maintenance every 1000 hours of operation or 4 years, whichever comes first * Checking the Fuel Injection Timing See Flywheel and Housing on page 5-70. + Checking the Fuel Injector Spray Pattern See Fuel Injectors on page 6-52. * Checking or Replacing the Seawater Pump Impeller See Seawater Pump on page 7-17. ‘+ Replacing Coolant (LLC) ‘See Removing and Installing Coolant Pump on page 7-15. + Cleaning the Seawater Passages See Draining and Filling Closed Cooling System ‘on page 7-10. + Replacing the Anodes (4JH4-TE and 4JH4-HTE Only) See Draining and Filling Closed Cooling System on page 7-10. + Checking the Diaphragm Assembly (4JH4-TE and 4JH4-HTE only) See 4JH4-TE and 4JH4-HTE Engines on page 5-30. + Replacing the Alternator V-belt See Replace V-Belt on page 11-8. + Adjusting Intake / Exhaust Valve Clearance See Inspecting Intake / Exhaust Valves and Valve Guides on page 5-47. * Checking Remote Control Cable Operation See Checking and Adjusting Remote Control Operation on page 5-100. + Adjusting Propeller Shaft Alignment (If Equipped with Marine Gear) See Principal Engine Specifications on page 3-67. 1 sete sancettoust WAUNIVIAL (© 2009 Vanmar Marine internationalENGINE Safety Precautions. Introduction... Specifications General Information. Section 5 Test and Adjustment Specifications Repair Specifications. Special Torque Chart... Standard Torque Chart (w/o Lubricating Oil Special Service Tools... Measuring Instruments. Sealants and Compounds Tests and Adjustments Test Compression Disassembly... Inspection .... Cylinder Block. Cylinder Head. Piston and Piston Rings Connecting Rod, Crankshaft and Camshaft and Tappets Timing Gear. Flywheel and Housing Assembly Checking and Adit YVANMAR. 11 series sevice Manual Main Bearings lusting Remote Control Operation 54 “© 2009 Yanmar Marine InternationalENGINE This Page Intentionally Left Blank 52 JH Series sevice Marual_ WAN EVE AS (© 2009 Vanmar Marine internationalSafety Precautions SAFETY PRECAUTIONS Before you service the engine, read the following safety information and review the Safety Section on page 2-1. NOTICE NEVER attempt to adjust the low or high idle speed limit screw. This may impair the safety and performance of the engine and shorten its life. If adjustment is ever required, see your authorized Yanmar Marine dealer or distributor. YVANMAR. 11 series sevice Manual ENGINE INTRODUCTION This section of the Service Manual describes the disassembly, inspection, and reassembly of the JH Series engines. 53 “© 2009 Yanmar Marine InternationalENGINE Specifications SPECIFICATIONS General Information Engine Model ‘SHEE “HSE HATE SHGTE Number of Gylinders| Tndine S In-Line @ Bore 88 mm (8.465 in) 84mm @.S07 in) Stroke 20 mm (3.543 in) Displacement 1642 c6 (100.20 eu in) | 2180 co (198.64 cum) 1805 66 (121,74 Guin) ‘Compression Ratio 19.01 ‘Compression Pressure 3450.1 MPa 32201 MPa (at 250 rpm) (493 2 145 psi) (4642145 psi) Valve Clearance 0.24005 mm Intake / exhaust (0.0078 +: 0,029 in) Fuel Injection Pressure | 21.6 +1.0MPa 206+1.0 MPa 21.62 05 MPa (2133 4217 psi) (2987 +145 psi) (193 « 72 psi Test and Adjustment Specifications Testitem | Remarks | Specification | SJHSE “HSE a Oylinder Compression | Al Gylinders a nee Gomproesion | Fresure | approxima lesen ease Repair Specifications ‘Component Remarks ‘SUSE aE HEE HHEHTE Coolant Geoolant Gapacty sstaeqy | sol@sa 7aL (76a) Coolant Recovery Tank st oasa 54 JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalSpecifications ENGINE Component Temarks SHE TBE TRETE [RTE Tabcaing 7 | ibicatna a Engine Wh 502037 capacty [Link] | feowe 1.1L : trilo® deyees) | (e908! eftecive 12 Engi (ah 35203) feissa/Sbe0 a | eflectve 1.2L : take angie on cages eftectve 3. Engine wih 302037 ‘ease 2FooM eflecwe 12 trrake ange® (eas03/ degrees) effective 1.3 qt) Engino (wh 502087 Fea ata eflecbe 4 : (300 tro (e303! ane depres) efterive 15 40 Engine (ath 57 203 /eflecive 241 Ba alae? icdasimeassaeg Engine (oh rattan she £9203 /ofecio 244 [arasa soso, au (zrzeh Se (73303 /eteave 264) case) Tare gearal PUREE oso capacity. (0.53 qt) BR OSL aoa TIRE ome (eaoqn zm TIL (tg) am Ta Tate OT (12 /etcive 02 a9 vanaaT 73 aan raira 200/ecive 02L reas Givetecive 02 ah Warne pera 2F2SA 78 capaci (3a soueaT a7 etlecive 0.1L : es! eflecive 0.1 a) Tabialag a pete OE BIET-OA8 Pa wr dove (10 22-87 por above) TaE-DITT OROTPa rave (65-251 87 paior above) Themosat | Vahe opening onperanre 73C (eres) Fal opening Wa peaed Tia or bove fC reports (Gm orabove at 94°) Thermo swich [ON o7 8° eng eorsin) tomporature [OFF ‘@°Cormore (raeFormere) Refer to section 14, Service Standards, for other part repair specifications. YANMA! }_sH Seties Service Manual “© 2009 Yanmar Marine InternationalENGINE Special Torque Chart SPECIAL TORQUE CHART System (Component Model Thread Comments | Specification Engine Block Metal Cap Bok ‘HSE MiaxtS | Coat with 98 2Nm HSE lubricating oil (721.5 bt) ‘Connecting Rod and | Connecting Rod Boks ‘RIHSE Moxi.0 | Coat with 44.12 50Nm Bearing AJHSE lubricating ol | (92.523.7 bt) Oylinder Head Cylinder Head Bots SUHSE | MI0x1.25 | Coat with 882230NM HSE lubricating ot | (65.1 + 2.2 bt) Grankshaft Flywheel Bok SE | Miox125 | Coat with 033250Nm HSE lubricating ol | (61.423.7 bt) Pulley Bolt (F300 Pulley) | SJH5E MiaxtS | Coat with 8822 50Nm HSE lubricating oll (65237 bh) Lubricating Systam | Plate machine bolt HSE Mexi.0 [No lubricating oi | 69215Nm (Lubricating Oil Cover) (4821.1 bot) Fusl System Nozzle Retainer Bot ‘SUHSE Maxt.25 |Nolubricating ol | 284220Nm HSE (1957.5) lott Fuel injection Purp Drive | _4JH5E Maxi.0 | Nolubricating ot | 242220Nm Gear Nut (253215 bit) 4HETE | MT4xi5 | Goat with 592 10Nm 4JH4-HTE lubricating oll (442 7.4 ot Fuel Injection Line Joint Nut | SJH5E MiaxtS [Nolubricating ol | 28.4250Nm HSE (215237 bt) Fuel Return Line Bolts RSE Méxi.0_ [Nolubricating ol | 78=40Nm (682 18 bot) Fuel Injection Pump HSE Mext.25 |Nolubricating of | 2825Nm Mounting Nuts (724 1b) Fuel injection Nozzle Gase | JHE 0605-40 [Nolubricatingoll | 302249Nm Nuts UNS-28 (903 bt) Fuel Injection Pump Plunger | _4JH5E Miaxto |Nolubrieating ol | 3025Nm Plug (2224 1o-t) Electrical System | Starter Relay Terminal Nut | SJHSE Méxi.0_[Nolubricaiing oi | 36=06Nm (Magnetic Relay) HSE (2.7 £0.45 bt) 56 JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalStandard Torque Chart (w/o Lubricating Oil) ENGINE STANDARD TORQUE CHART (W/O LUBRICATING OIL) Name Thread Specification ‘Comments Hexagon bot wih a7" mark Mext 98220Nm Apply 80% torque when head and hexagon nut (7 (72215 b+) tightening to aluminum alloy, Shssicaion 71) Ment 2s Gees eaten | Apply 60% torque to 4T bolts (1662.44 bt) and locknuts (4T bot has no MiOxS 442 60Nm mark onthe head) ([Link]) Mia 7 7822 10Nm (57.7 + 7.4 lb-ft) PT Plug taper plug) ve 2aNm When lock adhesive is (2b) applied, decide separately 7 196Nm (1454) 38 234Nm (2174) 1 58.8Nm (43.44) Tine Joint Bok we T27240Nm (9.44 3.0 lb-ft) m0 1954 60Nm (1432 440-8) mie 2442 10Nm (18.0 7.41o-1) ua 3012 10Nm (20.82 7.4-") me 4892 10Nm (36.1.2 7.4 o-f) YVANMAR. 11 series sevice Manual “© 2009 Yanmar Marine InternationalENGINE Special Service Tools SPECIAL SERVICE TOOLS The following tools are required when disassembling and reassembling the engine. Please use them as instructed. Tool Name Applicable Model ‘Applicable Model and Tool Size IMlustration 1 | Piston pininsertion/ Extraction of piston pin extraction tool 8. c vo) a 8 © D__] | Insertion of piston pin mom 2 20 80 25 in cara | over | 3180 | 0984 4 Extraction 2 | Connecting rod ‘small end bushing insertion/extraction tool for S3UHGE / AJHATE x Bo D mm | 254257 | 20 | 80 | 284287 in, [1000-1012 [o7a7 [9.160 | 1.118-1.130 58 JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalSpecial Service Tools ENGINE Too! Name Wo. | appticebie Model Applicable Model and Tool Size Mustration 3 | Connecting rod Extraction small end bushing F. insertion extraction tool for 4JH4-TE/ AJHEHTE Al D E| AT® Te > ,TE]F mm | 284 | 80 | 20 [ara] e |e 28.7 207 in | tate | ais | ove |1.07e | oats | & 1.130 1.091 4 | Intake exhaust valve guide B. c insertion extraction tool a 8 € D mam 75 20 5 1 in 20s | o7a7 | 2053 | 0433 1~Tool 5 | Lubricating of fiter VANMAARL seis sonconanst 7 “© 2009 Yanmar Marine InternationalENGINE Special Service Tools Tool Name oil aeeue mead ‘Applicable Model and Tool Size IMustration @ | Puller A (standard) | Puller A: 120671-82170 (standard) for seawater pump impeller ry : B a 3 Miexts TO-langth 40 mm (157in) 1-M16x1.5 Threaded 7 | PulerB (option) Tor | Puller 129677-82100 (option) seawater pump impeller a 3 ‘round 170 mm ‘ound 140 min (4.93 in) (51in) 5.10 JH Series sevice Marual_ WAN EVE AS (© 2009 Vanmar Marine internationalSpecial Service Tools ENGINE Too! Name gjustment of fuel injection timing No. | ppplicable Model Applicable Model and Tool Size Illustration @ |[Link] ‘Spacer: 128671-51860 spacer for the A x 8 c 750 mm 20mm | 7540.1 mm ot in) (o79in) | (0.30 +0.004 in) 1- Wax Pellet 2- Screwdriver 3-C.S.D. Lever (for removal / insertion of piston ring) 47 Spacer + | Pion ing compressor C4 10 | Piston ring replacer 4H Satis Service Manual “© 2009 Yanmar Marine International BatENGINE Special Service Tools Tool Name iia | aes ae ‘Applicable Model and Tool Size IMustration 77_| Vale lapping tool (Rubber cap type) 72 | Vawe lapping powder eS 7 | Foster gauge 1 Feeler Gauge 2 Locknut 3 Adjusting Bolt 74 | Pulley puller Tocal supply Removing the coupling 5.12 JH Series sevice Marual_ WAN EVE AS (© 2009 Vanmar Marine internationalSpecial Service Tools ENGINE ToolNane 80. | ape ae ‘Applicable Model and Tool Sizo Mustation TE | Press oot forfiler | Toot rock = STeT® TEL FLSA wom [esse [oars | os [ee [o> [1 | 2 [oe 56 | Press vote tortor | Toor rock copper tube Chanter xa/aoe cae mene a XC VANMIABL. s series senice va 513 “© 2009 Yanmar Marine InternationalENGINE Special Service Tools Tool Name Applicable Model 17 | Stem seal insertion (for inserting stem seal) No. ‘Applicable Model and Tool Size Mlustration al e@lapl ujlel,e mm | 162) 22 | 198 | 18a] 68 | 4 in, [0.638 | 0.866 | 0.831 | 0.740 | 2559 | 0.757 a | Fuel nozzle extraction tool Part No. 729470-82300 514 JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalMeasuring Instruments ENGINE MEASURING INSTRUMENTS No. Name of tool Use lustration 1 | Vernier calipers 0.05 mm 0-150 mm ———- 2 | Micrometer 0.01 mm 025 mm 25-50 mm 50-75 mm 75-100 mem 100-125 mm 125-150 mm Measures the outer diameter ofthe crankshaft, piston, piston pin, etc. 3 [Cylinder gauge 01 mm 18-35 mm 35-60 mm 50-100 mm Measures the inner diameter of the eylinder liner and rod metal 4 _| Thickness gauge 0.05-2 mm 5 | Torque wrench 728 Nm (0-13 kgf) 6 [Nozzle tester 0-49 Mpa (0-500 katiomr2) YVANMAR. 11 series sevice Manual “© 2009 Yanmar Marine InternationalENGINE Measuring Instruments Wo, Name of oot Use. Tiustration 7 [Baloauge Measures shalt banding distortions oflevelness, and 2p @ | Testindeator Measures narrow and deep places, which cannot be _ measured with cial gauge. Zs | Magnetic stand iKeaps the dal gauge fim in postion, thereby permiting t to be used at various angles. 70 | Vernier capers Measures various outer diameter, thickness and with — 11 | Depth micrometer Measures sinking of valves. 5.16 JH Series Sevice Manual WARN AVE ALE. (© 2009 Vanmar Marine internationalMeasuring Instruments ENGINE No. Name of tool Use) Tlustration 12 | Square Measures distortion in position cof springs and perpendicularity of pars. 13 [Viblock Measures shaft distortion 14 [Torque wrench Used to tighten bolts and nuts to standard torque. es 18 _ | Thickness gauge Measures the distance between the ring and ring groove, and between the shat and shaft joint at time of assembling. 16 | Captester Checks for leakage in the freshwater system, 17 _ | Battery current tester ‘Checks density of antifreeze and charging condition of battery fluid YVANMAR. 11 series sevice Manual 517 “© 2009 Yanmar Marine International