Yanmar Marine Diesel Engine 4JH3-TE, 4JH3-TCE, 4JH3-HTE, 4JH3-DTE Operation Manual

GB California Proposition 65 Warning Diesel engine exhaust and some of its constituents are recognized by the State of California to cause cancer, birth defects, and other reproductive harm. MARINE DIESEL ENGINE MODELS: 4JH3-TE/-HTE/-DTE/-TCE Series OPERATION MANUAL JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 1 Downloaded from www.Manualslib.com manuals search engine

GB Warranty YANMAR CO., LTD. LIMITED EMISSIONS CONTROL SYSTEM WARRANTY Your Warranty Rights and Obligations: California: The California Air Resources Board and Yanmar Co., Ltd. ("Yanmar") is pleased to explain the emission control system warranty on your off-road compression-ignition model year 2000 or later engine. In California, new heavy-duty off-road engines must be designed, built and equipped to meet the State's stringent anti-smog standards. All States Yanmar warrants that the engine is: (1) designed, built and equipped so as to conform with all applicable emissions regulations, including in California, all applicable regulations adopted by the Air Resources Board; and (2) free from defects in materials and workmanship which cause such engine to fail to conform with applicable emissions regulations for its warranty period. Yanmar warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system may include parts such as the fuel injection system and the air induc- tion system. Also included may be hoses, belts, connectors and other emission-related as- semblies. Where a warrantable condition exists, Yanmar will repair your heavy-duty off-road engine at no expense to you for diagnosis, parts or labor. Warranty services or repairs wiII be provided at a Yanmar authorized Dealer. Manufacturer's Warranty Period: The model year 2000 or later heavy-duty off-road engines are warranted for the periods listed below. If any emission-related part on your engine is defective, the part will be replaced by Yanmar. Engine Type Warranty Period by Number of Years or Hours of 0peration Engines rated at or above 19 kW Warranty period is five (5) years or 3,000 hours of use, whichever occurs first. In the absence of a device to measure hours of use, the engine has a warranty period of five (5) years. Engines rated under 19 kW Warranty period is two (2) years or 1,500 hours of use, whichever occurs first. In the absence of a device to measure hours of use, the engine has a warranty period of two (2) years. Constant speed engines rated under 37 kW with rated speeds greater than or equal to 3,000 min-1 Warranty period is two (2) years or 1,500 hours of use, whichever occurs first. In the absence of a device to measure hours of use, the engine has a warranty period of five (5) years, Constant speed engines rated at or above 37 kW Warranty period is five (5) years or 3,000 hours of use, whichever occurs first. In the absence of a device to measure hours of use, the engine has a warranty period of five (5) years. Warranty-GB.fm Page 1 Tuesday, February 22, 2005 9:06 PM Downloaded from www.Manualslib.com manuals search engine

GB Warranty Coverage: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yan- mar dealer. Warranted parts not scheduled for replacement as required maintenance in the owner's manual shall be warranted for the warranty period. Any part repaired or replaced under warranty shall be warranted for the remaining warranty period. Warranted parts scheduled for replacement as required maintenance in the owner's manual are warranted for the period of time prior to the first scheduled replacement. Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period. Any replacement part which is functionally identical to the original equipment part in all re- spects may be used in the maintenance or repair of your engine, and shall not reduce Yan- mar's warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty. Warranted Systems/ Parts Covered by this Warranty: (1) Fuel Injection System (2) Cold start enrichment system (3) Intake manifold (4) Turbocharger Systems (5) Exhaust manifold Exclusions: Failures other than those arising from defects in material or workmanship are not covered by this warranty. The Warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, or use of non-recommended fuels or lubricating oils; accident- caused damage, or replacement of expendable items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment/engine or commercial loss. Owner's Warranty Responsibilities: As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your heavy-duty off-road engine, but Yanmar cannot deny warranty solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance. Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements. You are responsible for initiating the warranty process. You must present your off-road engine to a Yanmar Dealer as soon as a problem exists. The warranty repairs should be completed by the Dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, or would like information on the nearest Yanmar Dealer/authorized service center, you should contact Yanmar Marine U.S.A. Corp. at Adairsville, GA U.S.A. Warranty-GB.fm Page 2 Tuesday, February 22, 2005 9:06 PM Downloaded from www.Manualslib.com manuals search engine

Contents 2 GB CONTENTS INTRODUCTION .............................................. 3 1 FOR YOUR SAFETY ................................... 4 1.1 Warning symbols ................................ 4 1.2 Safety Precautions.............................. 4 1.3 Warning Labels ................................... 7 2 PRODUCT EXPLANATION ......................... 8 2.1 Use, Driving System etc ...................... 8 2.2 Engine Specifications ....................... 10 2.3 Names of Parts ..................................13 2.4 Major Servicing Parts.........................14 2.5 Control Equipment ............................15 2.5.1 Control Panel ...........................15 2.5.2 Remote Control Handle ...........18 2.5.3 Stopping Equipment ...............19 3 OPERATION ............................................. 20 3.1 Fuel Oil, Lube Oil & Cooling Water .... 20 3.1.1 Fuel Oil.................................... 20 3.1.2 Lube Oil .................................. 20 3.1.3 Cooling Water ......................... 21 3.2 Before Initial Operation ..................... 22 3.2.1 Supply Fuel Oil ........................ 22 3.2.2 Bleeding the fuel system......... 22 3.2.3 Supply Engine Lube Oil ........... 22 3.2.4 Supply Clutch Lube Oil .......... 23 3.2.5 Supply Cooling Water ............. 23 3.2.6 Cranking (Idling) ...................... 24 3.2.7 Check and Resupply Lube Oil and Cooling Water ............. 25 3.3 Operating your Engine ...................... 25 3.3.1 Inspection Before Starting ...... 25 3.3.2 How to Start the Engine .......... 27 3.3.3 Operation................................ 28 3.3.4 Cautions during Operation...... 29 3.3.5 Stopping the Engine ............... 30 3.3.6 Procedure ............................... 31 3.4 Long term Storage ............................ 32 4 MAINTENANCE & INSPECTION ............... 34 4.1 General Inspection Rules .................. 34 4.2 List of Periodic Inspection Items ....... 35 4.3 Periodic Inspection Items ................. 37 4.3.1 Inspection on Initial 50 Hrs. of Operation (or after 1 month) .... 37 4.3.2 Inspection Every 50 Hours (or monthly) ............................. 38 4.3.3 Inspection Every 250 Hrs ........ 39 4.3.4 Inspection Every 500 Hrs ........ 42 4.3.5 Inspection Every 1000 Hrs ...... 42 5 TROUBLE AND TROUBLESHOOTING ..... 43 5.1 Trouble and Troubleshooting ............ 43 5.2 Emergency Repairs for Clutch .......... 44 6 PIPING DIAGRAMS .................................. 47 7 WIRING DIAGRAMS ................................. 48 APPENDIX A (Piping diagrams)..................... A-1 (See the back of this Manual) APPENDIX B (Wiring diagrams) .................... B-1 (See the back of this Manual) JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 2 Downloaded from www.Manualslib.com manuals search engine

Introduction This Operation Manual describes the operation, maintenance and inspection of the 4JH3-TE/-HTE/-DTE/-TCE Series Yanmar Marine Diesel Engines. Read this Operation Manual carefully before operating the engine to ensure that it is used correctly and that it stays in the best possible condition. Keep this Operation Manual in a convenient place for easy access. If this Operation Manual is lost or damaged, order a new one from your dealer or distributor. Make sure this manual is transfered to subsequent owners. It should be considered as a permanent part of the engine and remain so. Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about this, please contact your Yanmar dealer or distributor. 3 GB Thank you for purchasing a YANMAR Marine Diesel Engine. Operation Manual (Marine Engine) Models Code. No. 4JH3-TE/-HTE/-DTE/-TCE 49961-202850 JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 3 Downloaded from www.Manualslib.com manuals search engine

4 GB 1. For your safety 1.1 WARNING SYMBOLS Most operation, maintenance and inspection problems arise due to users’ failure to comply with the rules and precautions for safe operation described in this operation manual. Often, users do not understand or recognize the signs of approaching problems. Improper handling can cause burns and other injuries and can result in death. Be sure to read this operation manual carefully before operating the engine and observe all of the instructions and precautions described in this manual. Below follow the warning signs used in this manual and on the products. Pay special attention to parts containing these words and signs. DANGER indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. This sign is also be used to alert against unsafe practices. The descriptions captioned by are particularly important cautions for handling. If you ignore them, the performance of your machine may deteriorate leading to problems. 1.2 SAFETY PRECAUTIONS (Observe these instructions for your own safety!) Precautions for Operation Filler Cap of Fresh Water Tank Never open the cap of the fresh water tank while the engine is still hot. Steam and hot water will spurt out and burn you seriously. Wait until the temperature of the fresh water tank has dropped, wrap a cloth around the filler cap and loosen the cap slowly. After inspection, refasten the cap firmly. NOTICE DANGER DANGER WARNING CAUTION JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 4 Downloaded from www.Manualslib.com manuals search engine

1. For your safety Battery Never smoke or permit sparks near the battery, because it may emit explosive hydrogen gas. Place the battery in a well-ventilated place. Fuel Use only diesel oil. Never use other fuels, including gasoline, kerosene, etc., because they could cause a fire. The wrong fuel could also cause the fuel injection pump and injector to fail due to lack of proper lubrication. Be sure to check that you have selected the correct diesel fuel before filling the fuel tank. Fire Prevention Be sure to stop the engine and confirm that there are no open flames in the vicinity before supplying fuel. If you do spill fuel, wipe such spillage carefully and dispose of the wiping materials properly. Wash your hands thorougly with soap and water. Never place oil or other flammable material in the engine room. Install a fire extinguisher near the engine room, and familiarize yourself with its use. Exhaust Gas Exhaust gas contains poisonous carbon monoxide and should not be inhaled. Be sure to install ventilation ports or ventilators in the engine room and ensure good ventilation during engine operation. Moving Parts Do not touch or let your clothing get caught in the moving parts of the engine, such as the front drive shaft, V-belt or propeller shaft, during engine operation. You will be injured. Never operate the engine without the covers on the moving parts. Before starting the engine, check to see that any tools or cloths used in maintenance have been removed from the area. Burns The whole engine is hot during operation and immediately after stopping. The turbocharger, intercooler, exhaust manifold, exhaust pipe and high pressure fuel pipe are very hot. Never touch these parts with your body or clothing. 5 GB DANGER DANGER DANGER WARNING WARNING CAUTION JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 5 Downloaded from www.Manualslib.com manuals search engine

1. For your safety 6 GB Alcohol Never operate the engine while you are under the influence of alcohol. Never operate the engine when you are ill or feeling unwell. SAFETY PRECAUTIONS FOR INSPECTION Battery Fluid Battery fluid is dilute sulfuric acid. It can blind you if it gets in your eyes, or burn your skin. Keep the fluid away from your body. If you touch it, wash it off immediately with a large quantity or fresh water and call your doctor for treatment. Fire by Electric Short-Circuits Always turn off the battery switch before inspecting the electrical system. Failure to do so could cause short-circuiting and fires. Stop the engine before servicing Stop the engine before you service it. Turn the battery switch off. If you must inspect while the engine is in operation, never touch moving parts. Keep your body and clothing well clear of all moving parts. Scalds If extracting oil from the engine while it is still hot, don’t let the oil splash on you. Wait until the temperature has dropped before extracting cooling water from the engine. Don’t let it splash on you. Forbidden Modifications Never release the limiting devices such as the engine speed limit, fuel injection limit, etc. Modification will impair the safety and performance of the product and shorten product life. Also note that any troubles arising from modification are not covered by our warranty. Precautions for Treating Waste Never dispose of waste oil or other fluid in a field, sewer, river, or the sea. Treat waste matters safely observing regulations or laws. Ask a waste recovery company to collect it. DANGER WARNING CAUTION NOTICE NOTICE WARNING WARNING JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 6 Downloaded from www.Manualslib.com manuals search engine

SAFETY PRECAUTIONS FOR INSPECTION 1.3 WARNING LABELS To insure safe operation, warning device labels have been attached. Their location is shown below and they should always be visible. Please replace if damaged or lost. 1. For your safety 7 GB Product Safety Labels, Parts Code Numbers  128377-07350  128296-07260  128296-07300  196630-12980 JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 7 Downloaded from www.Manualslib.com manuals search engine

2.1 USE, DRIVING SYSTEM, ETC. This is a light, compact diesel engine for use in pleasure boats. The engine is equipped with a turbocharger and intercooler which insures maximum output while preserving lightness and compact size. (The 4JH3-TE series is equipped with the turbocharger only.) Power output for this group of engines increases progressively from 4JH3-TE, 4JH3-HTE to 4JH3-DTE. The inboard series is equipped with a marine gear connecting the output shaft with the propeller shaft for operation. The different types of marine gears used for each series are shown below. In order to obtain full performance from your engine, it is imperative that you check the size and structure of the hull and use a propeller of the appropriate size. The engine must be installed correctly with safe cooling water and exhaust piping and electrical wiring. The PTO work should be easy to use for onboard equipment. The laws of some countries may require hull and engine inspections, depending on the use, size and cruising area of the boat. The installation, fitting and surveying of this engine all require specialized knowledge and engineering skills. Consult Yanmar’s local subsidiary in your region or your distributor or dealer. Consult your Yanmar dealer or distributor when selecting optional parts. Optional parts selections should take into account operational and surrounding conditions. This Operation Manual explains the basic points for standard operation. Variations are explained under the specially marked sections. 2. Product explanation 8 GB 4JH3-TE 4JH3-HTE 4JH3-DTE Marine Gear Series Series Series KBW21 Clutch 4JH3-TE 4JH3-HTE N/A KM4A Clutch 4JH3-TBE 4JH3-HTBE N/A KMH4A Clutch 4JH3-THE 4JH3-HTHE 4JH3-DTHE Mechanical wet cone clutch Input/output special parallel drive Mechanical wet cone clutch 7° Down angle drive Hydraulic wet multiple disk clutch 8° Down angle drive JH-Turbo-Engels1a 30-06-2002 13:17 Pagina 8 Downloaded from www.Manualslib.com manuals search engine

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Yanmar Marine Diesel Engine 4JH3-TE, 4JH3-TCE, 4JH3-HTE, 4JH3-DTE Operation Manual

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