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SERVICE MANUAL
JH4 Series Service Manual 3JH4E
4JH4AE
4JH4-TE
4JH4-HTE
P/N: 0BJH4-G00102
MARINE
ENGINES
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is 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.
Yanmar and 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 information storage and retrieval systems -
without the written permission of Yanmar Marine International.
2007 Yanmar Marine International
0707
Safety.................................................................................................... 2-1
Lubrication........................................................................................... 8-1
INTRODUCTION
This manual gives specific instructions for the Along with standard tools, Yanmar recommends the
proper repair of Yanmar JH4 series marine use of special tools necessary to perform repairs
engines. correctly.
Please follow the procedures carefully to ensure Yanmar products are continuously undergoing
quality service. improvement. This Service Manual has been
checked carefully in order to avoid errors. However
Yanmar recommends that you read this Service Yanmar is not liable for any misrepresentations,
Manual completely before starting repairs. errors of description or omissions. Contact an
authorized Yanmar marine dealer or distributor for
any questions you have regarding this Service
Manual.
REVISION HISTORY
This manual is a living document. Periodic manual At times, the revision involves inserting additional
revisions are published to document product pages in one or more sections. Replace the
improvements and changes. This practice ensures Revision Control Table and insert the new pages.
the manual has the most current information.
This method of revision control represents the most
As manual revisions become necessary, individual cost-effective solution to providing current, updated
pages are prepared and sent to those who need information as needed.
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.
SAFETY
SAFETY STATEMENTS
Yanmar is concerned for your safety and the Indicates a hazardous situation which, if not
condition of your marine engine. Safety statements avoided, will result in death or serious injury.
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 Indicates a hazardous situation which, if not
operation and during periodic maintenance avoided, could result in death or serious injury.
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 Indicates a hazardous situation which, if not
replace them if they are lost or damaged. Also, if avoided, could result in minor or moderate
you need to replace a part that has a decal injury.
attached to it, make sure you order the new part
and decal at the same time.
This safety alert symbol appears Indicates a situation which can cause damage to
the engine, personal property and / or the
A
with most safety statements. It
means attention, become alert, environment or cause the equipment to operate
your safety is involved! Please read improperly.
and abide by the message that
follows the safety alert symbol.
SAFETY PRECAUTIONS
There is no substitute for common sense and The safety messages that follow have
careful practices. Improper practices or WARNING level hazards. These safety
carelessness can cause burns, cuts, mutilation, messages describe a hazardous situation
asphyxiation, other bodily injury or death. This which, if not avoided, could result in death or
information contains general safety precautions serious injury.
and guidelines that must be followed to reduce risk
to personal safety. Special safety precautions are Explosion Hazard
listed in specific procedures. Read and understand While the engine is running or the
all of the safety precautions before operation or battery is charging, hydrogen gas is
performing repairs or maintenance. 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
The safety messages that follow have DANGER ignition out of the area.
level hazards. These safety messages describe
a hazardous situation which, if not avoided, will ALWAYS turn off the battery switch (if equipped) or
result in death or serious injury. disconnect the negative (-) battery cable before
servicing the equipment.
NEVER permit anyone to install or
operate the engine without proper
training. Fire and Explosion Hazard
Diesel fuel is flammable and explosive
Read and understand this Service Manual before under certain conditions.
you operate or service the engine to ensure that
you follow safe operating practices and
maintenance procedures.
NEVER use a shop rag to catch the fuel.
Safety signs and decals are additional reminders
for safe operating and maintenance techniques.
Wipe up all spills immediately.
See your authorized Yanmar Marine dealer or
distributor for additional training.
NEVER refuel with the engine running.
Piercing Hazard
Avoid skin contact with high-pressure
Fire Hazard diesel fuel spray caused by a fuel
Have appropriate safety equipment system leak such as a broken fuel
available. Have all fire extinguishers injection line. High-pressure fuel can
checked periodically for proper penetrate your skin and result in
operation and / or readiness. serious injury. If you are exposed to high-pressure
fuel spray, obtain prompt medical treatment.
ALWAYS read and follow safety-related precautions
found on containers of hazardous substances like NEVER check for a fuel leak with your hands.
parts cleaners, primers, sealants and sealant ALWAYS use a piece of wood or cardboard. Have
removers. your authorized Yanmar Marine dealer or distributor
repair the damage.
Undersized wiring systems can cause an electrical
fire. Flying Object Hazard
ALWAYS wear eye protection when servicing the
Entanglement Hazard engine or when using compressed air or
NEVER leave the key in the key switch high-pressure water. Dust, flying debris,
when servicing the engine. Attach a compressed air, pressurized water or steam may
Do Not Operate tag near the key injure your eyes.
switch while performing maintenance
on the equipment. Coolant Hazard
Wear eye protection and rubber gloves
ALWAYS stop the engine before beginning service. when you handle Long Life engine
coolant. If contact with the eyes or skin
If you must service the engine while it is operating, should occur, flush eyes and wash immediately with
remove all jewelry, tie back long hair and keep your clean water.
hands, other body parts and clothing away from
moving / rotating parts.
Sudden Movement Hazard The safety messages that follow have CAUTION
The engine lifting eyes are engineered to lift the level hazards. These safety messages describe
weight of the marine engine only. ALWAYS use the a hazardous situation which, if not avoided,
engine lifting eyes when lifting the engine. could result in minor or moderate injury.
ALWAYS wear eye protection when
servicing the engine or when using
Lifting Hazard compressed air or high-pressure water.
Additional equipment is necessary to lift the marine Dust, flying debris, compressed air,
engine and marine gear together. ALWAYS use pressurized water or steam may injure
lifting equipment with sufficient capacity to lift the your eyes.
marine engine.
Poor Lighting Hazard
If you need to transport an engine for repair, have a Ensure that the work area is adequately
helper assist you attach it to a hoist and load it on a illuminated. ALWAYS install wire cages on portable
truck. safety lamps.
Exposure Hazard
ALWAYS wear personal protective
equipment including appropriate
clothing, gloves, work shoes, 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.
ALWAYS be environmentally
responsible.
Follow the guidelines of the 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.
(1) (2)
WARNING
(3)
196630-12980
015863-01X
Figure 2-1
4JH4AE Engine
(1) (2)
WARNING
(3)
(4)
015514-00X
Figure 2-2
4JH4-TE Engine
(1) (2)
WARNING
(3)
(4)
128296-07300
008830-02X
Figure 2-3
4JH4-HTE Engine
128296-07300
(4)
014387-00X
Figure 2-4
GENERAL SERVICE
INFORMATION
Page
Safety Precautions .......................................................................... 3-3
Engine Outline Drawings................................................................. 3-4
3JH4E Models ........................................................................... 3-4
4JH4AE Models......................................................................... 3-8
4JH4-TE Models...................................................................... 3-14
4JH4-HTE Models ................................................................... 3-20
Engine Piping Diagrams................................................................ 3-25
3JH4E Models ......................................................................... 3-25
4JH4AE Models....................................................................... 3-27
4JH4-TE Models...................................................................... 3-31
4JH4-HTE Models ................................................................... 3-35
Location of Nameplates................................................................. 3-38
Engine Nameplates (Typical) .................................................. 3-38
Diesel Fuel .................................................................................... 3-39
Diesel Fuel Specifications ....................................................... 3-39
Bleeding the Fuel System........................................................ 3-40
Engine Oil...................................................................................... 3-43
Engine Oil Specifications......................................................... 3-43
Engine Coolant.............................................................................. 3-44
Engine Coolant Specifications................................................. 3-44
Principal Engine Specifications ..................................................... 3-45
3JH4E Engine Specifications .................................................. 3-45
4JH4AE Engine Specifications ................................................ 3-47
4JH4AE Specifications (Continued) ........................................ 3-48
4JH4AE Specifications (Continued) ........................................ 3-49
4JH4-TE Engine Specifications ............................................... 3-51
4JH4-HTE Engine Specifications ............................................ 3-53
SAFETY PRECAUTIONS
Before you service the engine, read the following
safety information and review the Safety Section on
page 2-1.
Fire Hazard
Avoid injury or equipment damage
from fire. Undersized wiring systems
can cause an electrical fire.
Electrical Hazard
Avoid personal injury or equipment
damage. ALWAYS keep the electrical
connectors and terminals clean. Check
the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors.