Yanmar 4JH3-TE, Operation Manual

Page 1: ...OPERATION MANUAL Be sure to read this manual for safe and proper operation Store this manual carefully after use...

Page 2: ...ating 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...

Page 3: ...g Water 22 3 6 Cranking 23 3 7 Checking the Lube Oil and Cooling Water 23 4 HOW TO OPERATE 24 4 1 Inspection Before Starting 24 4 2 Checking the Illumination Lamps of the Panel Meters 26 4 2 1 Checkin...

Page 4: ...ction Every 1000 Hrs or 4 yrs 45 6 TROUBLE AND TROUBLESHOOTING 47 6 1 Simple problems and the appropriate countermeasures 47 6 2 Emergency Repairs for Marine Gear Trouble 49 6 3 Consulting Your Yanmar...

Page 5: ...manual and on the products Pay special attention to them DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Indicates a potentially...

Page 6: ...ke will result in ignition Be sure to stop the engine before refueling If you spill fuel wipe such spillage carefully Never place oils or other flammable material close to the engine as this could res...

Page 7: ...ect while the engine is operating never touch moving parts Keep your body and clothing well clear of all moving parts as this could result in injury Precautions for Removing Hot Oil and Water to Preve...

Page 8: ...in the diagram below Keep the labels from becoming dirty or torn and replace them if they are lost or damaged Also replace labels when parts are replaced ordering them in the same way as for the parts...

Page 9: ...engine It is equally important to use the correct driving device and a propeller of the appropriate size and specifications The engine must be installed correctly with safe cooling water and exhaust...

Page 10: ...2 04 2 45 2 45 2 63 2 63 3 30 3 30 Direction of rotation Crankshaft Counterclockwise Viewed from stern side Propeller shaft Clockwise Viewed from stern side Fuel injection pump Bosh distributor type...

Page 11: ...ller Refer to the operation manual for the sail drive Fuel injection pump Bosh distributor type Model VE ZEXEL Fuel injection valve Pinhole injection nozzle YDLLA P 5 0 22 150 Turbocharger RHB52 IHI W...

Page 12: ...45 2 63 2 63 3 30 3 30 Direction of rotation Crankshaft Counterclockwise Viewed from stern side Propeller shaft Clockwise Viewed from stern side Fuel injection pump Bosh distributor type Model VE ZEX...

Page 13: ...d from stern side Propeller shaft Clockwise Viewed from stern side Fuel injection pump Bosh distributor type Model VE ZEXEL Fuel injection valve Pinhole injection nozzle YDLLA P 5 0 26 150 Turbocharge...

Page 14: ...ample for the above drawings The 4JH3 TE is not equipped with an intercooler indicated by mark in the above Oil cooler engine Dipstick Marine gear Dipstick engine Fuel injection pump Lube oil filter T...

Page 15: ...ller cap closes the filler port It has two pressure regulating valves pressure valve and vacume valve Filler cap When the cooling water temperature rises the pressure inside the fresh water tank incre...

Page 16: ...el B C New B New C 7 Switch unit Key switch Starter switch O O O O 8 Engine stop switch O O O O 10 Alarm buzzer O O O O 9 Alarm buzzer stop switch O O O 11 Illumination switch for meters O O O O 11 La...

Page 17: ...blem arise the sensors will pick it up and cause the light behind the appropriate symbol to come on 1 BATTERY CHARGE When the charge is abnormal the lamp will come on When charging begins the lamp wil...

Page 18: ...rning on the air heater The air heater OPTION aids starting during cold con ditions by warming up the intake air before starting Note Neutral Safety Switch OPTION for KM4A KMH4A The engine can only be...

Page 19: ...manuals 1 Morse Remote Control Handle This is a single handle remote control device connected by a remote control cable It operates the clutch to neutral forward and reverse and controls the engine sp...

Page 20: ...ree throttle operation When the boat is stopped clutch is in neutral position the idling speed of the engine can be increased in the following manner 1 Leave the handle lever in NEUTRAL 2 Disengage th...

Page 21: ...ping against the clutch disk Do not operate at over 1000rpm engine speed 1 Loosen the handle grip by turning it to the left This frees the handle 2 Move the handle toward L low speed and position at t...

Page 22: ...l in a clean container Store the con tainer in a place away from rain and dirt as water and dust mixed in with the fuel cause engine failure Keep the fuel container stationery for several hours to all...

Page 23: ...brands Mixing may reduce the lubricating performance Different oils are used for the engine and the marine gear Be careful to use the correct oil for each one and store in separate clearly labeled co...

Page 24: ...ing operation 3 2 2 Bleeding the Fuel System Bleed the fuel system according to the following procedure When there is air in the fuel system the fuel injection pump will not be able to function 1 Chec...

Page 25: ...ith the specified amount of marine gear oil 1 Remove the oil inlet cap with dipstick on the top of the marine gear and fill with marine gear oil 2 Fill with oil to the upper mark on the dipstick attac...

Page 26: ...the water overflows from the filler port Fresh water tank capacity See 2 2 Engine Specification 4 After supplying cooling water replace filler cap and tighten it firmly To replace the cap align the n...

Page 27: ...utton turn the key to the START position and hold it there The engine will begin turning If you remove your hand from the stop button the engine will start Do not take your hand off the button 5 Conti...

Page 28: ...the area Bums from Contact with Hot Engine Parts The whole engine is hot during operation and immediately after stopping The turbocharger exhaust manifold exhaust pipe and engine are very hot Never to...

Page 29: ...operation while the engine is cold Checking the water level while the engine is hot is dangerous and the cooling water reading will be mis leading due to thermal expansion Check the cooling water dai...

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Page 31: ...ow steps 1 6 of the above procedure and then follow the steps below 7 Turn the key from the OFF position to GLOW Continue to hold the key in the GLOW position to heat up the air heater 8 Turn the key...

Page 32: ...und are normal 4 Check that sufficient cooling water is discharged from the seawater outlet pipe Operation with too little seawater discharge will burn the impeller of the seawater pump If seawater di...

Page 33: ...rd When the clutch is engaged in forward the speed will increase Move the handle to REV to go in reverse When the clutch is engaged in reverse the speed will increase 4 5 2 Switching to Trawling Avail...

Page 34: ...ely check the alarm lamps and stop the engine for repairs 5 Is there water oil or gas leakage or are there any loose bolts Check the engine room periodically for any problems 6 Is there sufficient oil...

Page 35: ...OFF remove the key and place it in a safe place 6 Cut off the battery switch 7 Close the fuel tank cock 8 Close the kingston cock In the rare instance where the engine does not stop when the stop butt...

Page 36: ...ion Alam Lamps Instrument Panel Speed Lever Govenor Remote Control Handle Speed Lever Govenor Remote Control Handle Speed Lever Govenor Remote Control Handle Low Speed Position 1000rpm or lower Trawli...

Page 37: ...s of the cooling water system Draining the water from the seawater system 1 Open the water drain cock on the marine gear oil cooler and drain off the cooling water The position of the drain cock varie...

Page 38: ...Safeguarding the Engine Against Water and Moisture Cover the intake silencer exhaust pipe etc with vinyl sheets and seal them to prevent moisture from enter ing Drain bilge in the hull bottom complete...

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Page 41: ...drain pump optional to the dipstick guide 2 Drain off the oil with the drain pump 2 Replace the lube oil filter 1 Turn the lube oil filter to the left with the filter wrench and remove 2 Clean the fi...

Page 42: ...is still warm after operation 1 Remove the filler port cap and insert the hose of the oil drain pump optional into the filler port until it reaches the bottom of the marine gear case 2 Drain off the...

Page 43: ...e fuel injection pump and the fuel injection valve to work Drain periodically to keep the filter from becoming clogged When there is a lot of drain collected in the oil water separator at the bottom o...

Page 44: ...the battery When the amount of fluid nears the lower limit fill with battery fluid available in the market to the upper limit If operation continues with insufficient battery fluid the battery life i...

Page 45: ...hten it by hand until the gasket comes into contact with the seat After tightening by hand use the filter wrench to tighten it about 3 4 of a turn Tightening torgue 11 8 15 6N m 1 2 1 6kgf m 7 Bleed t...

Page 46: ...setting screws on the fittings for the accelerator cable and adjust the position of the cable NOTICE Never remove the limiting bolt for the fuel injec tion pump or the restraint bolt on the amount of...

Page 47: ...h water and a small pitcher Blower Wash 4L Parts Code 974500 00400 2 Put the clutch in neutral and run the engine at high speed 2500 3000rpm 3 Slowly pour approximately 50cc of blower wash into the tu...

Page 48: ...E If the V belt tension is too tight the belt and the bearings of the alternator will be dam aged Be careful not to spill any oil on the V belt as this will lead to stretching and slippage 5 2 4 Inspe...

Page 49: ...CE When the impeller has been disassembled be careful to replace it so that it moves in the correct direction The seawater pump turns clockwise but the impeller blades must be installed in the counter...

Page 50: ...contact with exhaust gas and seawater deteriorates with use and must be replaced If operation is continued without replacing faulty elbow water will leak into the boat and gas leakage may result in fi...

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Page 52: ...ection Excessive intake exhaust valve clearance Reduce load Replace with recommended fuel Wash turbocharger blower Ask for repairs Ask for repairs 3 1 1 5 2 3 5 White smoke emitted Improper fuel Fault...

Page 53: ...orm the following after turning off the engine 1 Remove the hexagonal red bolts at the back of the marine gear with a spanner 2 Check to see if the emergency bolt is visible at the back of the bolt ho...

Page 54: ...us Normally any problems concerning the product will be handled by our dealer s service department If you have a warranty problem that has not been handled to your satisfaction we suggest you take th...

Page 55: ...MEMO...

Page 56: ...ing diagram 7 1 1 B type Instrument Panel Optional 1 2 Panel side Detail of coupler AA Starter SW Tachometer Buzzer Eng Oil Press C W Temp Charge Engine stop switch Illumi lamp check switch Extension...

Page 57: ...r C W temp sender Not available for B type C W temp SW Eng oil press SW Alternator Earth bolt Tacho sensor Optional Cross sectional area of wire Customer Battery Battery SW Neutral SW Starter relay St...

Page 58: ...tation Eng stop SW Buzzer Starter SW Illumi switch Buzzer Switch Fuse 3A C W Temp Charge Eng Oil Press Optional Hour M Relay B type No 2 station C type Eng Oil Press M C W Temp M Tacho M Starter SW Ta...

Page 59: ...Air heater Cross sectional area of wire Customer Battery SW Starter motor Alternator Tacho sensor Eng Oil Press sendor Eng Oil Press SW C W temp SW C W temp sendor Optional Detail of coupler AA Earth...

Page 60: ...side Color coding Starter switch Detail of coupler CC Detail of coupler AA Buzzer Charge C W Temp Eng OilPress Sail Drive Leak Fuel Emp Buzzer stop Illumi Eng stop switch Starter switch Local supplied...

Page 61: ...ag valvee Air heater Cross sectional area of wire Customer Battery SW Starter motor Alternator Tacho sensor Fuel filter Eng Oil Press SW C W Temp SW Optional Local supplied sail drive leak sensor Eart...

Page 62: ...Fuel Emp Fuel Filter Buzzer stop New B typen No 2 station Illumi Eng stop SW Starter SW Local supplied fuel empty sensor Extension harness Optional Harness No 2 Tachometer with hour M C W temp M Eng...

Page 63: ...f wire Customer Battery SW Starter motor Alternator Tacho sensor Fuel filter Eng Oil Press SW Eng Oil Press sendor C W Temp SW C W temp sendor Optional Local supplied sail drive leak sensor Earth bolt...

Page 64: ...4JH3 TE TCE HTE DTE 49961 202851 Operation Manual Models Marine Engine Code No...

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