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OPERATION MANUAL
3JH4E
4JH4AE
4JH4-TE
4JH4-HTE
P/N: 0AJH4G00102
MARINE
ENGINES
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 are
registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other
countries.
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.
1006
Introduction .............................................................. 1
Record of Ownership .............................................. 2
Safety ....................................................................... 3
Safety Precautions ................................................. 4
General Information ......................................... 4
Before You Operate ......................................... 4
During Operation and Maintenance ..................... 4
Location of Safety Decals ........................................ 8
Product Overview ..................................................... 13
Yanmar JH4 Features and Applications ..................... 13
New Engine Break-In ...................................... 13
Component Identification ........................................ 15
Service Side - 3JH4E ...................................... 15
Non-Service Side - 3JH4E ............................... 15
Service Side - 4JH4AE .................................... 16
Non-Service Side - 4JH4AE ............................. 16
Service Side - 4JH4-TE ................................... 17
Non-Service Side - 4JH4-TE ............................. 17
Service Side - 4JH4-HTE ................................. 18
Non-Service Side - 4JH4-HTE .......................... 18
Location of Nameplates .......................................... 19
Function of Major Components ................................ 20
Control Equipment ................................................ 21
Instrument Panel (Optional) .............................. 21
Single Lever Remote Control Handle .................. 26
Before You Operate .................................................. 27
Diesel Fuel .......................................................... 27
Diesel Fuel Specifications ................................ 27
Engine Model:
Date Purchased:
Dealer:
Dealer Phone:
! WARNING ! CAUTION
Piercing Hazard The safety messages that follow have
Avoid skin contact with high- CAUTION level hazards.
pressure diesel fuel spray Poor Lighting Hazard
caused by a fuel system leak
such as a broken fuel injection Avoid personal injury or equipment damage.
line. High-pressure fuel can Ensure that the work area is adequately
penetrate your skin and result in serious illuminated. ALWAYS install wire cages on
injury. If you are exposed to high-pressure portable safety lamps.
fuel spray, obtain prompt medical treatment.
Tool Hazard
NEVER check for a fuel leak with your Avoid personal injury or equipment damage.
hands. ALWAYS use a piece of wood or ALWAYS use tools appropriate for the task
cardboard. Have your authorized Yanmar at hand and use the correct size tool for
marine dealer or distributor repair the loosening or tightening machine parts.
damage.
Flying Object Hazard
Burn Hazard Avoid personal injury. ALWAYS wear eye
Avoid serious injury. Some of protection when servicing the engine or
the engine surfaces become when using compressed air or high-
very hot during operation and pressure water. Dust, flying debris,
shortly after shut-down. Keep compressed air, pressurized water or steam
hands and other body parts may injure your eyes.
away from hot engine
surfaces. Coolant Hazard
Wear eye protection and
Sudden Movement Hazard rubber gloves when you
Avoid personal injury. ALWAYS stop the handle Long Life engine
engine before beginning service. coolant. If contact with the
eyes or skin should occur,
Exhaust Hazard flush eyes and wash immediately with clean
Avoid serious injury or death. water.
NEVER block windows, vents
or other means of ventilation if
the engine is operating in an
enclosed area. All internal
combustion engines create carbon
monoxide gas during operation and special
precautions are required to avoid carbon
monoxide poisoning.
3JH4E Engines
(1) (2)
WARNING
(3)
196630-12980
0004550
Figure 1
1 Part Number: 12837707350
2 Part Number: 12837707260
3 Part Number: 19663012980
(3)
(4)
0004551
Figure 2
1 Part Number: 12837707350
2 Part Number: 12837707260
3 Part Number: 19663012980
4 Part Number: 12837707150
(3)
(4)
128296-07300
0003632
Figure 3
1 Part No.: 128377-07350
2 Part No.: 128377-07260
3 Part No.: 196630-12980
4 Part No.: 128296-07300
WARNING
128296-07300
(4)
0004552
Figure 4
1 Part No.: 128377-07350
2 Part No.: 128377-07260
3 Part No.: 128296-07300
4 Part No.: 196630-12980
During the break-in period, the engine Once past the initial 10 hours until 50 hours,
coolant temperature gauge should be the engine should be used over its full
monitored, temperature should be between operating range, with special emphasis on
71 - 87C (160 - 190F). running at relatively high power settings.
This is not the time for an extended cruise at
During the first 10 hours of operation, the idle or low speed. The boat should be run at
engine should be run at maximum rpm maximum speed minus 400 rpm most of the
minus 400 - 500 rpm (approximately time (approximately 70% load), with a 10
60 - 70% of load) most of the time. This will minute run at maximum minus 200 rpm
ensure the sliding parts break-in properly. (approximately 80% load) every 30 minutes
During this period, avoid operating at and a 4-5 minute period of operation at WOT
maximum engine speed and load to avoid (wide open throttle) once each 30 minutes.
damaging or scoring sliding parts. During this period, be sure not to operate
your engine at low speed and light load for
NOTICE: Do not operate at WOT (wide open more than 30 minutes. If operating engine at
throttle) for more than a minute at a time low speed and light load by necessity, just
during the first 10 hours of operation. after the low idle operation, be sure to race
Do not operate the engine at low idle or at the engine.
low speed and light load for more than
30 minutes at a time. Since unburned fuel To complete engine break-in, perform After
and engine oil will adhere to the piston rings Initial 50 Hours maintenance procedures.
when operating at low speeds for long See Periodic Maintenance Schedule on
periods, this will interfere with proper page 57.
movement of the rings and the lube oil
consumption may increase. Low idle speed
does not allow break-in of sliding parts.
(11)
(1) (5)
(10) (6)
(9) 0004544
(8) Figure 2
(5) (3)
(1) (6)
(7)
(2) (8)
(9) (8)
(4) (9)
0004546
(10) Figure 4
1 Engine Nameplate (on rocker arm
(3) (11) cover)
2 Fresh Water Pump
(4) (12)
3 Belt Cover
4 Seawater Pump
0004545
Figure 6
(7) 1 Engine Nameplate (on rocker arm
(3) (6) cover)
(5) 2 Coolant Filler Cap
(4) 0004516
3 Fresh Water Pump
Figure 5 4 Belt Cover
1 Intake Silencer (Air Cleaner) 5 Seawater Pump
2 Turbocharger 6 Alternator
3 Shift Lever 7 Starter Motor
4 Marine Gear (KMH4A shown) 8 Exhaust / Water Mixing Elbow
5 Engine Oil Cooler 9 Coolant Tank / Heat Exchanger
6 Engine Oil Filter
7 Fuel Injection Pump
8 Fuel Filter
9 Fuel Priming Pump
10 Engine Oil Dipstick
11 Intake Manifold
12 Engine Oil Filler Cap
(12) (11)
(1) (4)
(2) (10)
(9)
(8) (8)
(7)
(6)
(5)
0004549
Figure 8
(3) (7) 1 Engine Nameplate (on rocker arm
(5) (6) cover)
2 Coolant Filler Cap
(4) 0004548
3 Fresh Water Pump
Figure 7 4 Belt Cover
1 Intake Silencer 5 Seawater Pump
2 Turbocharger 6 Alternator
3 Shift Lever (KMH4A) 7 Intercooler
4 Marine Gear (KMH4A) 8 Starter Motor
5 Engine Oil Cooler 9 Exhaust Mixing Elbow
6 Engine Oil Filter 10 Coolant Tank / Heat Exchanger
7 Fuel Injection Pump
8 Fuel Filter
9 Fuel Priming Pump
10 Engine Oil Dipstick
11 Intake Manifold
12 Engine Oil Filler Cap
Model
Figure 11
Gear Model
Continuous power kW min -1
The sail drive nameplate (Figure 12) is
attached to the sail drive. Check the sail
Speed of prop shaft min -1
drive model and serial number.
Fuel stop power kW min -1
ENG.No.
MODEL
PASSED
MARK
MADE IN JAPAN
MFG.NO.
Figure 9
Model
MADE IN JAPAN
Gear Model
0004575
Continuous power kW // min-1
Figure 12
Speed of prop,shaf t min-1
Fuel stop power kW // min-1
ENG.No.
0004574
Figure 10
(1)
(5)
(2)
(4)
(3)
0004486
Figure 13
1 Tachometer 6 Battery Low Charge Indicator
2 Hourmeter 7 Water in Sail Drive Seal Indicator
3 Moisture Cap for Key Switch 8 Engine Oil Low Pressure Indicator
4 Key Switch 9 Coolant High Temperature Indicator
5 Stop Button
(4) (8)
(7)
(5) (6) 0004503
Figure 14
1 Coolant High Temperature Indicator 8 Key Switch
2 Coolant Temperature Gauge 9 Stop Button
3 Engine Oil Low Pressure Indicator 10 Battery Low Charge Indicator
4 Engine Oil Pressure Gauge 11 Water in Sail Drive Seal Indicator
5 Tachometer 12 Water in Fuel Filter Indicator (if
6 Hourmeter equipped)
7 Moisture Cap for Key Switch 13 Insufficient Seawater Flow Indicator
Figure 16 Figure 19
Battery Low Charge Indicator Water in Sail Drive Seal Indicator and Alarm
(Figure 16) - When the alternator output is (Figure 19) - When water is detected
too low, the indicator will light. When between the seals of the sail drive, the
charging begins, the indicator will turn off. indicator will light and the alarm will sound.
No alarm will sound for low battery charge.
Figure 17
Figure 20
Coolant High Temperature Indicator and
Alarm (Figure 17) - When coolant Water in Fuel Filter Indicator and Alarm (C-
temperature reaches the maximum Type only) - 4JH4-TE and 4JH4HTE
allowable temperature (95C [203F] or engines only - (Figure 20) - When the water
higher), the indicator will light and the alarm level in the fuel filter / water separator
will sound. Continuing operation at becomes too high, the indicator will light and
temperatures exceeding the maximum limit the alarm will sound. Drain the water from
will result in damage and seizure. Check the the fuel filter / water separator. See Draining
load and troubleshoot the cooling system. Fuel Filter / Water Separator on page 65.
Figure 18
Engine Oil Low Pressure Indicator and
Figure 21
Alarm (Figure 18) - When the engine oil
pressure falls below normal, the oil pressure Insufficient Seawater Flow Indicator and
sensor will send a signal to the indicator Alarm (C-Type only) (Figure 21).
causing it to light and the alarm to sound.
Stop operation immediately to avoid
damage to the engine. Check the oil level
and troubleshoot the lubrication system.
(4) (1)
0004511
Figure 23
0004504 Note: Yanmar recommends the use of a
Figure 22 single-lever type for the remote control
Note: Direction of travel will vary depending system. If only a two-lever type is available
on installation location. in the market, reduce engine rpm to 1000
rpm or less before engaging and
1 Low Speed - FWD or REV disengaging the marine gear clutch.
2 Low Speed - FWD or REV
3 NEUTRAL - Power to the propeller
shaft is cut off and the engine idles
4 Maximum Engine Speed - FWD or
REV
5 Maximum Engine Speed - FWD or
REV
A single handle-type (Figure 22) should be
used to operate the marine gear clutch
(NEUTRAL, FORWARD, and REVERSE)
and to control the engine speed.
(3) (7)
(4)
(4)
(5)
(6)
(3)
(1) (2) 0004489
Figure 3
0004542
(1)
(4)
(5)
(5)
(6)
0004555
Figure 6
1 Fuel Injector
2 Fuel Filter
3 Priming Pump
(6)
4 Air Bleed Screw
0004554
Figure 8
0004490
Select the appropriate engine oil viscosity Figure 9
based on the ambient temperature shown in
the SAE Service Grade Viscosity Chart in Note: 4JH4-TE shown. Other models are
Figure 8. similar.
1. It is recommended that the engine be
SAE 10W30 or SAE15W40 are the
as level as possible before checking the
recommended oil viscosities.
oil.
If you operate your equipment at 2. Remove dipstick (Figure 9, (3)) and
temperatures outside the limits shown, wipe with clean cloth.
consult your authorized Yanmar dealer or 3. Fully reinsert dipstick.
distributor for special lubricants or starting 4. Remove dipstick. The oil level should
aids. be between upper (Figure 9, (4)) and
lower (Figure 9, (5)) lines on the
dipstick.
5. Add oil if necessary. See Adding
Engine Oil on page 33.
6. Fully reinsert dipstick.
Adding Engine Oil
1. NOTICE: Prevent dirt and debris from
contaminating engine oil. Carefully
clean the dipstick and the surrounding
area before you remove the cap.
Remove the yellow oil filler port cap
from filler port (Figure 9, (1)) and fill
with engine oil.
2. Fill with oil to the upper limit
(Figure 9, (4)) on the dipstick
(Figure 9, (3)). NOTICE: NEVER
overfill the engine with engine oil.
KM4A2, KMH4A:
3JH4E, 4JH4AE:
SAE Viscosity #90 or 80W90
QuickSilver 1 High Performance Gear
Lube.
4JH4-TE:
Figure 10
Refer to the operation manual for SD50-T for
Note: 4JH4-TE with KMH4A marine gear the procedure to check and fill the sail drive
shown. oil.
1. Make sure engine is level.
2. Remove the filler cap (Figure 10, (1))
at the top of the housing.
3. Remove dipstick (Figure 10, (2)) and
wipe with clean cloth.
4. Fully reinsert dipstick.
5. Remove dipstick. The oil level should
be between upper (Figure 10, (3)) and
lower (Figure 10, (4)) lines on the
dipstick.
6. Fully reinsert dipstick.
(4)
(5)
(3)
0004514
(2) (6)
Figure 15
0004569
(1)
(3) 0004559
Figure 16
1 Coolant Drain Cock
(1) 0004558
2 Seawater Drain Cock
Figure 14 3 Marine Gear Cooler
1 Coolant Drain Cock
(1)
(2)
(6)
(5)
(3) 0004560
(3) (4)
Figure 17
0004492
Figure 18
1 Coolant Drain Cock
2 Seawater Drain Cock
3 Marine Gear Cooler
Visual Checks
1. Check for engine oil leaks.
(1) 2. Check for fuel leaks.
3. Check for engine coolant leaks.
4. Check for damaged or missing parts.
5. Check for loose, missing or damaged
0004488
Figure 22 fasteners.
a. Move and hold (Figure 22, (1)) 6. Check the electrical harnesses for
the stop lever (Figure 22, (2)) on cracks, abrasions, and damaged or
the governor to stop fuel flow while corroded connectors.
cranking. 7. Check hoses for cracks, abrasions and
Note: 4JH4-TE /4JH4-HTE models: Do damaged, loose or corroded clamps.
not use the STOP button on the control 8. Check the fuel filter / water separator for
panel for cranking procedure. presence of water and contaminants. If
b. Hold key in START position for you find any water or contaminants,
about 5 seconds and listen for drain the fuel filter / water separator.
abnormal noise during that time. See Draining Fuel Filter / Water
Note: If the governor lever is released Separator on page 65. If you have to
during the cranking procedure, the drain the fuel filter / water separator
engine will start. frequently, drain the fuel tank and check
for water in your fuel supply. See
Draining the Fuel Tank on page 67.
CAUTION! If any problem is noted
during the visual check, the necessary
corrective action should be taken before
you operate the engine.
Sever Hazard
Keep children and pets away
while the engine is operating.
Figure 5
Figure 6
! WARNING NOTICE
Welding Hazard Any part which is found defective as a result
Make welding repairs safely. of inspection, or any part whose measured
value does not satisfy the standard or limit,
ALWAYS turn off the battery switch (if must be replaced.
equipped) or disconnect the negative
battery cable and the leads to the Modifications may impair the engines
alternator when welding on the safety and performance characteristics and
equipment. shorten the engines life. Any alterations to
Remove the multi-pin connector to the this engine may void its warranty. Be sure to
engine control unit. Connect the weld use Yanmar genuine replacement parts.
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.
Exhaust Hazard
Avoid serious injury or death.
ALWAYS ensure that all
connections are tightened to
specifications after repair is
made to the exhaust system.
All internal combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning.
Shock Hazard
Avoid serious personal
injury or equipment
damage. ALWAYS turn
off the battery switch (if
equipped) or disconnect
the negative battery cable before servicing
the equipment.
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.
Bolt diameter x pitch M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 1.5 M16 x 1.5
(mm)
Nm 11.0 1.0 26.0 3.0 50.0 5.0 90.0 10.0 140.0 10.0 230.0 10.0
Tightening kgf-m 1.1 0.1 2.7 0.3 5.1 0.5 9.2 1.0 14.3 1.0 23.5 1.0
Torque lb-ft 19.0 2.1 37 3.6 66.0 7.2 103 7.2 170 7.2
lb-in. 96 9.0
See Conditions to Ensure Compliance with ASTM D975 No. 1-D or No. 2-D, or
EPA Emission Standards on page 55. equivalent (minimum of cetane No. 45)
Clean or replace the air cleaner element if The lubricating oil should be:
the air intake restriction exceeds the
referenced specifications. 3JH4E, 4JH4-TE and 4JH4-HTE: Type
API, Class CD or higher
EPA Requirements 4JH4AE: Type API, Class CH-4 only
The EPA emission regulation is applicable
Be sure to perform inspections as outlined
only in the USA and other countries that
in Periodic Maintenance Procedures on
have adapted the EPA requirements in part
page 61 and keep a record of the results.
or in whole. Determine and follow the
emission regulations in the country where Pay particular attention to these important
your engine will be operating to assist you in points:
specified compliance.
Replacing the engine oil
Conditions to Ensure Replacing the engine oil filter
Compliance with EPA Emission
Replacing the fuel filter
Standards
Cleaning the intake silencer (air cleaner)
The 3JH4E, 4JH4AE, 4JH-TE and
4JH4-HTE are EPA-certified engines. Note: Inspections are divided into two
sections in accordance with who is
The following are the conditions that must be responsible for performing the inspection:
met in order to ensure that the emissions the user or the maker.
during operation meet the EPA standards.
: Check or Clean : Replace : Contact your authorized Yanmar marine dealer or distributor
System Item Periodic Maintenance Interval
Daily Every 50 Every Every Every
hours or 250 500 1000
monthly hours or hours or hours or
which- one year 2 years 4 years
ever which- which- which-
comes ever ever ever
first comes comes comes
first first first
Whole Visual inspection of engine
exterior
Fuel Check the fuel level and refill
System if necessary
Drain water and sediment
from fuel tank Initial 50
Drain the fuel / water
separator
Replace the fuel filter
element
Check the fuel injection
timing
Check the fuel injector spray *
pattern*
Lubricating Check the Engine
System lube oil level
Marine
Gear
Replace the Engine
lube oil Initial 50
Marine
Gear Initial 50
Replace the Engine
oil filter Initial 50
element
Marine
Gear Initial 50
(if
equipped)
Cooling Seawater outlet
System During
Oper-
ation
Check coolant level
Check or replace the
seawater pump impeller
Replace coolant Every year. When Long Life Coolant is used, replace every two
years. See Engine Coolant Specifications on page 36.
Clean and check the
seawater passages
* For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 60.
Note: These procedures are considered normal maintenance and are performed at the
owners expense.
Note: The inspection and maintenance items shown above to be performed at your Yanmar
dealer or distributor.
(4)
(3)
(1) (2)
0004542
Figure 1
(1)
(1)
(2)
(5)
(3)
(4)
0004495
Figure 3
Note: 4JH4-TE / 4JH4-HTE engines with 0004509
0004496
(1) (2)
Figure 6
1 Cable
2 Fuel Injection Pump
3 Cable Fitting
4 Low Speed Stop
5 Control Lever
6 High Speed Stop
1. To adjust, loosen the adjustment screw
or cable fitting (Figure 5, (3)) or
(Figure 6, (3)) for the remote control
cable on the engine side and adjust.
(2)
(3) (1)
(3)
0004562
(4) 0004498
Figure 7
Figure 9
4JH4-TE / 4JH4-HTE
1 Cable Fitting
2 Trolling Lever
3 Low Speed (Trolling)
4 High Speed
5 Loosen
6 Tighten
(3) 7 Normal Operation (High Speed)
8 Trolling (Low Speed)
(1) 0004564
Figure 10
1. Close the fuel cock of the fuel tank.
2. Loosen the drain plug (Figure 10, (1))
of water separator and drain off any
water or dirt collected inside.
3. After draining, tighten the air bleed
screw (Figure 10, (2)).
Note: 4JH4-TE shown. If no water or fuel Note: Battery fluid tends to evaporate in high
drains from the fuel filter / water separator, temperatures, especially in summer. In such
loosen the air bleed screw on the fuel filter conditions, inspect the battery earlier than
2 - 3 times. This can occur when the fuel specified.
level is lower than the position of the 1. Turn the battery master switch to OFF
fuel / water separator. (if equipped) or disconnect the negative
1. Make sure the fuel cock of the fuel tank (-) battery cable.
is closed. 2. Do not operate with insufficient battery
2. Loosen the hose clamp and remove the electrolyte as the battery will be
fire-resistant cover, which is installed to destroyed.
the lower part of the fuel filter / water 3. Remove the plugs and check the
separator to protect the water alarm electrolyte level in all cells. NOTICE:
switch. NEVER attempt to remove the covers
3. Attach a tube (Figure 11, (6)) to the or fill a maintenance-free battery.
drain plug (Figure 11, (4)).
4. Loosen the drain plug (Figure 11, (4))
at the bottom of the fuel filter / water
separator counterclockwise and drain
off any water or sediment.
Note: If there is a large quantity of water and
sediment in the fuel filter / water separator,
also drain the fuel tank. See Draining the
Fuel Tank on page 61.
5. Tighten the drain plug.
6. Remove the drain tube.
7. Install the fire-resistant cover and
tighten the hose clamp.
(1)
0003627
Figure 13
1. Close the fuel cock of the fuel tank.
(1)
(A)
0004502
Figure 19
A B
110 mm 140 mm
A B
Replacing Coolant
0004567 Replace coolant every year.
Figure 17
Note: If Long Life coolant is used, replace
coolant every 2 years.
3JH4E
(4) (1)
(6)
(3)
(5)
(2)
0004556
0004568 Figure 20
Figure 18
1 Coolant Tank (Heat Exchanger)
Note: When replacing a used impeller with 2 Seawater Drain Cock
a new one, the impeller must have an M18 x 3 Coolant Drain Cock (3JH4E Only) -
1.5 thread (Figure 17, (1)). Turn the M18 Located behind the V-belt cover
screw-side of the impeller to the cover side 4 Coolant Pump (Fresh Water)
and install (Figure 18). 5 Seawater Drain from Seawater
Pump Cover
6 Coolant Drain Cock
(1) (2)
(1)
(2) 0004570
0004557
Figure 23
Figure 21
1 Coolant Drain Cock
1 Stop Solenoid
2 Stop Solenoid
2 Coolant Drain Cock
3 Flywheel Housing 4JH4-TE
(1)
4JH4AE
(3) (2) (4)
(1)
(4)
(5)
(3)
(2) (6) 0004571
Figure 24
0004569
(3)
(3)
(2) (2)
(4) (1) (4) (1)
0004573
0004572
Figure 25 Figure 27
1 Coolant Drain Cock 1 Coolant Drain Cock
2 Fuel Pump 2 Fuel Pump
3 Seawater Drain Cock 3 Seawater Drain Cock
4 Marine Gear Cooler 4 Marine Gear Cooler
4JH4-HTE
(1) Note: The drain cocks are opened before
(4) shipping from the factory. Marine gear
(2) ZF25A does not have a drain cock on the
clutch cooler.
1. Open all coolant drain cocks.
2. Allow to drain completely. Dispose of
waste properly.
3. Close all the drain cocks.
4. Fill coolant tank and coolant recovery
(6) tank with appropriate coolant. See
(5)
(3) 0004560
Engine Coolant Specifications on page
36 and See Checking and Adding
Figure 26
Coolant on page 36.
1 Coolant Tank (Heat Exchanger)
Cleaning the Intake Silencer (Air
2 Coolant Pump (Fresh Water) Cleaner) Element
3 Seawater Drain from Seawater
Pump Cover 1. Disassemble the intake silencer (air
cleaner).
4 Coolant Drain Cock
5 Intercooler 2. Remove element. Clean element and
housing with a neutral detergent.
6 Seawater Drain from Seawater
Pump Cover 3. Dry completely and reassemble.
3JH4E
(4) (1)
(6)
(1)
(3)
(2) 0004557
Figure 2
(5)
(2) 1 Coolant Drain Cock
0004556 2 Flywheel Housing
Figure 1 3 Stop Solenoid
1 Coolant Tank (Heat Exchanger)
2 Seawater Drain Cock
3 Coolant Drain Cock (3JH4E only)
4 Coolant Pump (Fresh Water)
5 Seawater Drain from Seawater
Pump Cover
6 Coolant Drain Cock
(5)
(2) (6)
0004569
(3)
0004571
Figure 3 Figure 5
1 Coolant Pump (Fresh Water) 1 Coolant Tank (Heat Exchanger)
2 Seawater Pump 2 Coolant Pump (Fresh Water)
3 Coolant Tank (Heat Exchanger) 3 Seawater Drain from Seawater
4 Coolant Drain Cock Pump Cover
5 Seawater Drain from Seawater 4 Coolant Drain Cock (2 used)
Pump Cover
4JH4-TE
6 Flywheel Housing
4JH4AE
(2)
(1)
(3) 0004559
(2) Figure 6
(1) 1 Coolant Drain Cock
0004570
2 Seawater Drain Cock
Figure 4 3 Marine Gear Cooler
1 Coolant Drain Cock
2 Stop Solenoid
(2)
(1)
(3)
0004561
Figure 8
1 Coolant Drain Cock
2 Seawater Drain Cock
3 Marine Gear Cooler
* Rating Condition: Temperature of fuel; 25C at fuel pump inlet; ISO 3046-1
** Rating Condition: Temperature of fuel; 40C at fuel pump inlet; ISO 8665
*** The total oil quantity includes oil in oil pan, channels, coolers and filter.
**** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
Note: Density of fuel: 0.842g/cm3 at 15C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
* Rating Condition: Temperature of fuel; 25C at fuel pump inlet; ISO 3046-1
* Rating Condition: Temperature of fuel; 40C at fuel pump inlet; ISO 8665
** The total oil quantity includes oil in oil pan, channels, coolers and filter.
*** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
Note: Density of fuel: 0.842g/cm3 at 15C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
* Rating Condition: Temperature of fuel; 40C at fuel pump inlet; ISO 8665
** The total oil quantity includes oil in oil pan, channels, coolers and filter.
*** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
Note: Density of fuel: 0.842g/cm3 at 15C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
Notation
Screw Joint (Union)
Flange Joint
Eye Joint
Insertion Joint
Drilled Hole
Coolant Piping
Cooling Seawater Piping
Lubricating Oil Piping
Fuel Oil Piping
*
*
* * *
*
0004175
Figure 1
*
*
* *
*
0004176
Figure 2
* *
cylinder
* * *
*
0004177
Figure 3
*
*
*
0004587
Figure 4
*
*
*
0004588
Figure 5
*
*
*
0004589
Figure 6
*
*
*
0004590
Figure 7
0004181
Figure 8
0004182
Figure 9
0004183
Figure 10
0004184
Figure 11
0004591
Figure 12
0004592
Figure 13
0004593
Figure 14
1
1
4 5 6 7 8 W
3R
Battery
3
3
YW WL YG LB 17 AC
2
2
switch
R
30 2R
G2 G1
2B
diodes L L 22
SYSTEM DIAGRAMS
1
WIRING DIAGRAMS
5R 5R
2B B 2W
B S
3L 2R
Relay WBr B
21Option 23 W/Y
O 24
P Wire 25
harness 3R
3
10B
Instrument panel (sub station) (Option) Option
YW
WL E E
B 10R B
L LB LB L Earth bolt
RB RB
Figure 15
R R
Y
Alarm lamps Fuse (3A) 12
R WBr 29
LB
RB
27 28
14 15 16 17 18 W 26
17 AC YG B
YW WL YG LB O
R A
30
G2 G1
3JH4E - B-Type Instrument Panel
diodes 11 L L
30 only for
sail drive
0004185
SYSTEM DIAGRAMS
3JH4E - B-Type Instrument Panel
1
1
4 5 6 7 8 W 3R
3
3
YW WL YG LB 17 AC
Battery switch
2
2
R
30
2R
+
G2 G1 -
2B
SYSTEM DIAGRAMS
diodes L L 22
1
5R 5R
2B 2W
B B S
3L 2R
B
Relay 21 WBr W/Y
O 23
+ - P
24
Wire 25
harness 3R
3
10B
Option
Instrument panel (sub station) (Option) YW
WL E E
B 10R B Earth bolt
Alarm lamps L LB LB
L
RB RB R
R
Figure 16
12 Y
Fuse(3A) R WBr 28
27 29
LB
RB
14 15 16 17 18 W
26
17 AC YG B
YW WL YG LB O
R A
30
G2 G1
R B
4JH4AE - B-Type Instrument Panel
diodes L L
11 30
P
only for sail drive
B
36
(4JH4AE only)
0004594
3R 3W WB YR Y WR OFF
31 YW WL WG B
only for sail drive ON
Instrument panel (main station) (Option) 3L RB LB O YG YB GB G GR
START
SYSTEM DIAGRAMS
4JH4AE - B-Type Instrument Panel
1
1
4 W
5 6 7 8 3R
Battery
3
3
YW WL YG LB 17 AC switch
2
2
R
30 2R
22
G2 G1
2B
SYSTEM DIAGRAMS
1 L L
diodes
5R 5R
2B B 2W
B S
3L 2R
Relay 21 B
Option WBr W/Y
O 23
P
24
Wire 25
harness 3R
3
10B
Instrument panel (sub station) (Option) Option
YW
WL E E
B 10R B
L LB LB L Earth bolt
RB RB
Figure 17
R R
Y
Alarm lamps Fuse (3A)
R 12 WBr 28 29
LB
RB
26 27
14 15 16 17 18 W
17 AC YG B
YG G YG LB O
R A
30
G2 G1 WB
3JH4E - C-Type Instrument Panel
11 L L YB
diodes 30
only for
B sail drive
34 35
0004186
SYSTEM DIAGRAMS
3JH4E - C-Type Instrument Panel
1
1
4 W
5 6 7 8 3R
3
3
YW WL YG LB 17 AC
Battery switch
2
2
R
30
2R
+
G2 G1 -
2B
L L
SYSTEM DIAGRAMS
diodes 22
1
5R 5R
2B 2W
B B S
3L 2R
Relay B
21 WBr W/Y
O
23 24
+ - P
Wire 25
harness 3R
3
10B
Instrument panel (sub station) (Option) YW
WL E E
B 10R B
Earth bolt
Alarm lamps L LB LB L
RB RB
R R
Figure 18
12 Y
Fuse(3A)
R WBr 28 29
RB
LB
26 27
14 15 16 17 18 W
17 AC YG B
WG G YG LB O
R A
30
G2 G1 WB R B
L L YB
diodes
4JH4AE - C-Type Instrument Panel
11 30
P only for sail drive
B
36
(4JH4AE Only)
34 35
0004595
only for sail drive 3L YB GB G GR
Instrument panel (main station) (Option) RB LB O YG
START
SYSTEM DIAGRAMS
4JH4AE - C-Type Instrument Panel
124
cross sectional area 19
of battery cable
1 section of cable Allowable length
L=1+2+3(m) 12V 12V
(mm2)
2 16 15(mm2) < 0.86(m)
9 2 20 20
20(mm ) < 1.3(m)
3 4 5 6 7 8 R + - + -
WBr 30(mm2) < 2.3(m)
1
1
W 40(mm2) < 2.8(m)
3R 50(mm ) 2
< 3.5(m)
3
3
2
YW WL YG LB 17 AC 60(mm ) < 4.1(m) 21
2
2
R
30
2R
G2 G1
L L 22
10
SYSTEM DIAGRAMS
11
5R 5R
2B 2W
B B
S
3L 23 2R
16 WBr B
25 W/Y 26
O 24
+ - P 27
15 3R
12
10B
13 YW 24
WL E E
B 10R B
L LB LB L 31
RB RB
Figure 19
2 R R
9 Y P
3 4 5 6 7 8 R 30 30
WBr 29
LB
RB
28
W
YW WL YG LB 17 AC O YG B
R
30
G2 G1
L L
10
4JH4-TE / 4JH4-HTE with B x B Type Panel
11 32
O
+ - P B
L - Key switch
15 17
12 YG 33 30 AC G1 G2 17
RB
+ GLOW
OFF
0004506
3R 3W YW WL WG B WB YR Y WR
18 ON
14 3L RB LB O YG YB GB G GR
START
008433-00E
SYSTEM DIAGRAMS
4JH4-TE / 4JH4-HTE with B x B Type Panel
1
1
W 40(mm2) < 2.8(m)
3R 50(mm2) < 3.5(m)
3
3
60(mm ) 2
YW WL YG LB 17 AC < 4.1(m) 21
2
2
R
30
2R
G2 G1
L L 22
10
SYSTEM DIAGRAMS
11
5R 5R
2B 2W
B B
S
3L 23 2R
16 WBr B
25 W/Y 26
O 24
+ - P 27
15 3R
12
10B
13 YW 24
WL E E
B 10R B
L LB LB L 31
RB RB
Figure 20
2 R R
9 Y P
3 34 35 6 7 8 R 30 30
WBr 29
LB
RB
28
W
WG G YG LB 17 AC O YG B
R
30
G2 G1 WB
L L YB
10
11
4JH4-TE / 4JH4-HTE with C x B Type Panel
32
B
0004507
18 YW WL WG B
ON
14 3L RB LB O YG YB GB G GR
START
008434-00E
SYSTEM DIAGRAMS
4JH4-TE / 4JH4-HTE with C x B Type Panel
B Black - 16 Relay
0004577
Figure 2