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OPERATION MANUAL
3JH4E
4JH4AE
4JH4-TE
4JH4-HTE
P/N: 0AJH4–G00103
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.
0608
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
Nameplates ......................................................... 19
Function of Major Components ................................ 20
Control Equipment ................................................ 21
Instrument Panel (Optional) .............................. 21
Single Lever Remote Control Handle .................. 25
Before You Operate .................................................. 27
Diesel Fuel .......................................................... 27
Diesel Fuel Specifications ................................ 27
Engine Model:
Date Purchased:
Dealer:
Dealer Phone:
Store any containers containing fuel or other NEVER operate the engine while wearing a
flammable products in a well-ventilated headset to listen to music or radio because
area, away from any combustibles or source it will be difficult to hear the warning signals.
of ignition.
! 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 Ensure that the work area is adequately
line. High-pressure fuel can illuminated. ALWAYS install wire cages on
penetrate your skin and result in serious portable safety lamps.
injury. If you are exposed to high-pressure
fuel spray, obtain prompt medical treatment. Tool Hazard
ALWAYS use tools appropriate for the task
NEVER check for a fuel leak with your at hand and use the correct size tool for
hands. ALWAYS use a piece of wood or loosening or tightening machine parts.
cardboard. Have your authorized Yanmar
Marine dealer or distributor repair the Flying Object Hazard
damage. ALWAYS wear eye protection when
servicing the engine or when using
Burn Hazard compressed air or high-pressure water.
Some of the engine surfaces Dust, flying debris, compressed air,
become very hot during pressurized water or steam may injure your
operation and shortly after eyes.
shut-down. Keep hands and
other body parts away from Coolant Hazard
hot engine surfaces. Wear eye protection and
rubber gloves when you
Sudden Movement Hazard handle Long Life engine
ALWAYS stop the engine before beginning coolant. If contact with the
service. eyes or skin should occur,
flush eyes and wash immediately with clean
Exhaust Hazard 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: 128377–07350
2 – Part Number: 128377–07260
3 – Part Number: 196630–12980
(3)
(4)
0004551
Figure 2
1– Part Number: 128377–07350
2– Part Number: 128377–07260
3– Part Number: 196630–12980
4– Part Number: 128377–07150
(3)
(4)
128296-07300
0003632
Figure 3
1– Part Number: 128377-07350
2– Part Number: 128377-07260
3– Part Number: 196630-12980
4– Part Number: 128296-07300
WARNING
128296-07300
(4)
0004552
Figure 4
1– Part Number: 128377-07350
2– Part Number: 128377-07260
3– Part Number: 128296-07300
4– Part Number: 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˚ and 87˚C (160˚ - 190˚F). 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 more than 30 minutes. If operating engine at
open throttle) for more than a minute at low speed and light load by necessity, just
a time during the first 10 hours of after the low idle operation, be sure to race
operation. the engine.
Do not operate the engine at low idle or at To complete engine break-in, perform After
low speed and light load for more than Initial 50 Hours maintenance procedures.
30 minutes at a time. Since unburned fuel See Periodic Maintenance Schedule on
and engine oil will adhere to the piston rings page 57.
when operating at low speeds for long
periods, this will interfere with proper
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 – Coolant 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 – Coolant 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 – Coolant 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
0004529
Gear Model
Continuous power kW / min-1 Figure 10
Speed of prop,shaf t min-1 The sail drive nameplate (Figure 11) is
Fuel stop power kW / min -1 attached to the sail drive. Check the sail
ENG.No. drive model and serial number.
MODEL
PASSED
MARK
0004574
MFG.NO.
Figure 9
MADE IN JAPAN
0004575
Figure 11
(1)
(5)
(2)
(4)
(3)
0004486
Figure 12
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 13
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 – Not Used on This Engine
0003622
Figure 14
The GLOW position (Figure 14, (1)) is the
start aid position. Electric current to the glow
plug or air heater (if equipped) is turned on.
The air heaters is standard on the 4JH4AE
and optional on the 3JH4E, 4JH4–TE and
4JH4–HTE models. When the key is
released, the switch will automatically move
to the ON position.
Figure 15
Battery Low Charge Indicator Figure 19
(Figure 15) - When the alternator output is Water in Fuel Filter Indicator and Alarm (C-
too low, the indicator will light. When Type only) - 4JH4-TE and 4JH4–HTE
charging begins, the indicator will turn off. engines only - (Figure 19) - When the water
No alarm will sound for low battery charge. level in the fuel filter / water separator
becomes too high, the indicator will light and
the alarm will sound. Drain the water from
the fuel filter / water separator. See Draining
Figure 16 Fuel Filter / Water Separator on page 67.
Coolant High Temperature Indicator and
Alarm (Figure 16) - When coolant
temperature reaches the maximum
allowable temperature (95˚C [203˚F] or
higher), the indicator will light and the alarm
will sound. Continuing operation at
temperatures exceeding the maximum limit
will result in damage and seizure. Check the
load and troubleshoot the cooling system.
Figure 17
Engine Oil Low Pressure Indicator and
Alarm (Figure 17) - When the engine oil
pressure falls below normal, the oil pressure
sensor will send a signal to the indicator
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.
0004504
Figure 20
Note: Direction of travel will vary depending (1)
on installation location.
1 – Low Speed - FWD or REV 0004511
2 – Low Speed - FWD or REV
Figure 21
3 – NEUTRAL - Power to the propeller
shaft is cut off and the engine idles Note: Yanmar recommends the use of a
4 – Maximum Engine Speed - FWD or single-lever type for the remote control
REV system. If only a two-lever type is available
5 – Maximum Engine Speed - FWD or in the market, reduce engine rpm to 1000
REV rpm or less before engaging and
disengaging the marine gear clutch.
A single handle-type (Figure 20) should be
used to operate the marine gear clutch
(NEUTRAL, FORWARD, and REVERSE)
and to control the engine speed.
(3) (7)
(3)
(4)
(5)
(6)
(1) (2) 0004489
Figure 3
0004542
(10)
(4) (9)
(2) (8)
(3) 0004553
Figure 4
1– Fuel Tank
2– Fuel Cock
3– Water Separator
4– Fuel Feed Pump
5– Fuel Filter
6– To 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.)
(1)
(4)
(5) (5)
(6)
0004555
Figure 6
1– Fuel Injector
2– Fuel Filter
3– Priming Pump
(6) 0004554 4– Air Bleed Screw
5– Fuel Feed Pump
Figure 5 6– Fuel Injection Pump
1– Fuel Injector 1. Check the fuel level in the fuel tank.
2– Air Bleed Screw Refill if necessary.
3– To Fuel Tank 2. Open the fuel cock of the fuel tank.
4– Fuel Filter 3. Loosen the air bleed screw
5– Fuel Injection Pump (Figure 6, (4)) 2 - 3 turns.
6– Fuel Feed Pump
(4)
Figure 8
Handling Engine Oil
0004490
1. When handling and storing engine oil, Figure 9
be careful not to allow dust and water to
contaminate the oil. Clean around the Note: 4JH4-TE shown. Other models are
filler port before filling. similar.
2. Do not mix lube oils of different types or 1. Make sure the engine is level.
brands. Mixing may cause the chemical 2. Remove dipstick (Figure 9, (3)) and
characteristics of the oil to change and wipe with clean cloth.
lubricating performance to decrease, 3. Fully reinsert dipstick.
reducing the engine’s life.
4. Remove dipstick. The oil level should
3. Engine oil should be replaced at the be between upper (Figure 9, (4)) and
specified intervals, regardless if the lower (Figure 9, (5)) lines on the
engine has been operated. dipstick.
Engine Oil Viscosity 5. Add oil if necessary. See Adding
SAE 10W30 or SAE15W40 are the Engine Oil on page 34.
recommended oil viscosities. 6. Fully reinsert dipstick.
(4) (4)
(2) (5)
(3) 0004569
Figure 13
0004556
(1)
(1) 0004558
(6)
(5)
(3) (3)
0004514 0004560
Figure 15 Figure 17
1 – Coolant Tank (Heat Exchanger) 1 – Coolant Tank (Heat Exchanger)
2 – Coolant Pump 2 – Coolant Pump
3 – Seawater Drain from Seawater 3 – Seawater Drain from Seawater
Pump Cover Pump Cover
4 – Coolant Drain Cock (2 used) 4 – Coolant Drain Cock
5 – Intercooler
4JH4-TE
6 – Seawater Drain Cock
4JH4-HTE
(2)
(2)
(1)
(3) 0004559
Figure 16
(1)
1 – Coolant Drain Cock (3)
2 – Seawater Drain Cock 0004561
0004488
(2)
(1) (3) Figure 22
a. Move and hold (Figure 22, (1))
(4)
the stop lever (Figure 22, (2)) on
the governor to stop fuel flow while
cranking.
CAUTION! 4JH4-TE /4JH4-HTE
models: NEVER use the STOP
0003622
button on the control panel for
Figure 21 cranking procedure.
5. Turn key to ON (Figure 21, (3)). b. Hold key in START position for
6. 3JH4E / 4JH4AE models: about 5 seconds and listen for
a. While pushing the STOP button on abnormal noise during that time.
the control panel, turn the key to WARNING! If the governor
the START position lever is released during the
(Figure 21, (4)). NOTICE: cranking procedure, the
NEVER hold the key in the engine will start.
START position for longer than
15 seconds or the starter motor
will overheat.
Sever Hazard
Keep children and pets away
while the engine is operating.
Exhaust Hazard
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.
! CAUTION NOTICE
• If the vessel is equipped with a water lift If any indicator illuminates during engine
(water lock) muffler, excessive cranking operation, stop the engine immediately.
could cause seawater to enter the Determine the cause and repair the problem
cylinders and damage the engine. If the before you continue to operate the engine.
engine does not start after cranking for 10 If the alarm window with audible alarm fails
seconds, close the thru-hull water intake to display and go out about 3 seconds later
valve to avoid filling the muffler with water. when the ignition switch is in the ON
Crank for 10 seconds at a time until the position, see your authorized Yanmar
engine starts. When the engine does Marine dealer or distributor for service
start, stop the engine immediately and before operating the engine.
turn the switch to the OFF position.
• Be sure to re-open the seacock and Observe the following environmental
restart the engine. Operate the engine operating conditions to maintain engine
normally. performance and avoid premature engine
wear:
0004487
Figure 4
(1)
0004488
Figure 6
If the engine cannot be shut down by the
STOP button on the panel, stop the engine
by moving the stop lever (Figure 6, (2)) by
hand to the left (Figure 6, (1)). The lever is
attached to the fuel injection pump.
! WARNING NOTICE
Welding Hazard Any part which is found defective as a result
• ALWAYS turn off the battery switch (if of inspection, or any part whose measured
equipped) or disconnect the negative value does not satisfy the standard or limit,
battery cable and the leads to the must be replaced.
alternator when welding on the
equipment. Modifications may impair the engine’s
• Remove the engine control unit multi-pin safety and performance characteristics and
connector. Connect the weld clamp to the shorten the engine’s life. Any alterations to
component to be welded and as close as this engine may void its warranty. Be sure to
possible to the welding point. use Yanmar genuine replacement parts.
• 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 alternator and engine control unit prior
to reconnecting the batteries.
Exhaust Hazard
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
ALWAYS turn off the
battery switch (if
equipped) or disconnect
the negative battery cable
before servicing the
equipment.
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 — — — — —
Conditions to Ensure
Compliance with EPA Emission
Standards
The 3JH4E, 4JH4AE, 4JH-TE and
4JH4-HTE are EPA-certified engines.
The following are the conditions that must be
met in order to ensure that the emissions
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
See hours or 250 500 1000
Daily monthly hours or hours or hours or
Check which- one year two four
s on ever which- years years
page comes ever which- which-
61. first comes ever ever
first comes comes
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
owner’s expense.
Note: The inspection and maintenance items shown above to be performed at your Yanmar
Marine dealer or distributor.
(3)
(1) (2)
0004542
Figure 1
Note: Optional fuel tank shown. Actual
equipment may differ.
1. Put a pan under the drain cock
(Figure 1, (2)) to catch fuel.
2. Open the drain cock and drain water
and sediment. Close the drain cock
when the fuel is clean and free of air
bubbles.
(5)
(3)
(4)
0004495
Figure 3
Note: 4JH4-TE / 4JH4-HTE engines with
KMH4A marine gear shown. Refer to the
Operation Manual for the marine gear or sail
0004508 drive for procedure.
Figure 2 1. Remove cap from the filler port and
attach an oil drain pump. Drain marine
Note: 4JH4-TE shown.
gear oil. NOTICE: ALWAYS be
4. Install a new filter element and tighten environmentally responsible.
by hand until the seal touches the
housing.
(3) 0003625
Figure 5
1– Cable
2– Fuel Injection Pump
3– Adjustment Screw
4– Low Speed Stop
5– Control Lever
6– High Speed Stop
4JH4-TE / 4JH4-HTE
(6) (5) (4) (3)
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)
After the first 50 hours of operation, the • Draining Fuel Filter / Water Separator
alignment should be checked and • Checking Battery Electrolyte Level
readjusted if necessary. This is considered Draining Fuel Filter / Water
normal maintenance and the adjustment Separator
requires specialized knowledge and
WARNING! When removing any fuel
techniques. Consult your authorized
system component to perform
Yanmar Marine dealer or distributor.
maintenance (such as changing the fuel
Check for any unusual noise and vibration in filter), put an approved container under
the engine / boat hull, while increasing and the opening to catch the fuel. NEVER us
decreasing the engine speed gradually. a shop rage to catch the fuel. Vapors
from the rag are flammable and
If there is unusual noise and / or vibration, explosive. Wipe up any spills
this maintenance requires specialized immediately. Wear eye protection. The
knowledge and techniques. See your fuel system is under pressure and fuel
authorized Yanmar Marine dealer or could spray out when removing any fuel
distributor to adjust the propeller shaft system component.
alignment.
(1)
(2) (3)
(4)
(6)
0004565
Figure 11
Note: 4JH4-TE shown.
(1)
0003627
Figure 13
1. Close the fuel tank drain cock.
Checking or Replacing Seawater There are two types of special service tools
Pump Impeller for removing the impeller:
1. Loosen side cover bolts and remove Puller A (standard) Part No.
the side cover. 129671-92110
2. Inspect the inside of the seawater pump (A)
with a flashlight. If any of the following
are found, disassembly and (B)
maintenance are required:
• Impeller blades are cracked or
nicked. Edges or surfaces of the
blades are marred or scratched.
• Wear plate is damaged.
3. If no damage is found when inspecting 0004501
(1)
(A)
0004502
Figure 19
A B
110 mm 140 mm
A B
Replacing Coolant
0004567 CAUTION! Wear eye protection and
Figure 17 rubber gloves when you handle engine
coolant. If contact with the eyes or skin
should occur, flush eyes and wash
immediately with clean water.
0004568
Figure 18
Note: When replacing a used
impeller with a new one, the
impeller must have an M18x1.5
thread (Figure 17, (1)). Turn the
M18 screw-side of the impeller to
the cover side and install
(Figure 18).
Figure 20 Figure 22
(1)
(2)
(1)
(2) 0004557
0004570
Figure 21 Figure 23
1 – Stop Solenoid 1 – Coolant Drain Cock
2 – Coolant Drain Cock 2 – Stop Solenoid
3 – Flywheel Housing
(6)
(5)
(3) 0004560
(3) Figure 26
0004571
(3)
(3)
(2)
(4) (1) (2)
0004572 (4) (1)
Figure 25 0004573
Figure 27
1– Coolant Drain Cock
2– Fuel Pump 1– Coolant Drain Cock
3– Seawater Drain Cock 2– Fuel Pump
4– Marine Gear Cooler 3– Seawater Drain Cock
4– Marine Gear Cooler
(9)
(6)
(8)
(7)
0003628
Figure 28
1– Diaphragm Cover
2– Spring
3– Center Plate
4– Diaphragm
5– Rocker Arm Cover
6– Breather Baffle
7– Baffle Plate
8– Intake Silencer
9– Breather Pipe
See your authorized Yanmar Marine dealer
or distributor.
If a problem occurs, stop the engine Just after the engine has started, check the
immediately. Refer to the Symptom column following items at a low engine speed:
in the Troubleshooting Chart to identify the
Is sufficient water being discharged
problem.
from the seawater outlet pipe?
Figure 3
(4)
1 – Coolant Pump
0004556a 2 – Seawater Drain from Seawater
Figure 1 Pump Cover
3 – Coolant Tank (Heat Exchanger)
1– Coolant Tank (Heat Exchanger) 4 – Coolant Drain Cock
2– Coolant Drain Cock (3JH4E only) 5 – Flywheel Housing
3– Coolant Pump
4– Seawater Drain from Seawater 4JH4AE
Pump Cover
5 – Coolant Drain Cock
3JH4E
(3)
(2)
(1)
0004570
Figure 4
(1)
1 – Coolant Drain Cock
(2) 2 – Stop Solenoid
0004557
Figure 2
1 – Coolant Drain Cock
2 – Flywheel Housing
3 – Stop Solenoid
(6)
(5)
(3) 0004560
(3) Figure 7
0004571
(2)
(2)
(1)
(3) 0004559
Figure 6 (1)
(3)
1 – Coolant Drain Cock 0004561
* Rating Condition: Temperature of fuel; 25˚C at fuel pump inlet; ISO 3046-1
** Rating Condition: Temperature of fuel; 40˚C 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 15˚C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
* Rating Condition: Temperature of fuel; 40˚C at fuel pump inlet; ISO 8665
** The “total” oil quantity includes oil in oil pan, channels, coolers and filter.
* Rating Condition: Temperature of fuel; 40˚C at fuel pump inlet; ISO 8665
* Rating Condition: Temperature of fuel; 40˚C 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 15˚C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
* Rating Condition: Temperature of fuel; 40˚C 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 15˚C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
Notation Description
Screw Joint (Union)
Flange Joint
Eye Joint
Insertion Joint
Drilled Hole
Coolant Piping
Cooling Seawater Piping
Lubricating Oil Piping
Diesel Fuel Piping
Figure 1
Figure 2
(31) (7)
(30) (8)
(9)
(10)
(29) (11)
(37)
(28) (12)
(38)
(13)
(27) (42)
(26)
(39)
(25)
(40)
(24)
(23) (43)
(22) (14)
(21)
(18) (44)
0004587
Figure 3
(32) (8)
(9)
(31) (10)
(39)
(30) (11)
(40)
(12)
(29) (13)
(14) (45)
(43)
(28) (41)
(27) (42)
(26)
(25)
(46)
(24) (15)
(23)
(47)
(20)
0004588
Figure 4
(30) (7)
(29) (8)
(9) (10)
(28)
(36)
(27) (11) (41)
(37)
(12)
(26)
(25) (38)
(24) (39)
(13) (42)
(23)
(22)
(21) (14)
(20)
(18) 0004589
Figure 5
(30) (8)
(9)
(29) (10)
(37)
(28) (38) (11)
(12)
(27)
(42)
(26) (39) (13)
(25) (40)
(24)
(23)
(22) (14)
(43)
(21)
Figure 6
(1) (3)
(45) (2)
(44) (4)
(47)
(5)
(8) (52)
(43) (6) (9)
(42) (46) (10)
(7)
(41) (11)
(40)
(39) (12)
(38) (13) (53)
(37)
(36) (14)
(15)
(35) (48)
(49) (16)
(34)
(50) (51) (17)
(33) (54)
(18)
(32)
(31) (19)
(30)
(29)
(28)
(22)
(23)
(24)
(25) (20) (55)
(26)
(27) (21) 0004181
Figure 7
(1) (3)
(48) (2)
(47) (4)
(50) (5)
(8) (55)
(46) (49) (6) (9)
(45) (7) (10)
(44) (11)
(43)
(42) (12)
(41) (13)
(56)
(40) (14)
(15)
(39) (16)
(17)
(38) (51)
(52)
(37) (54) (18)
(53)
(36)
(19) (57)
(35)
(34) (20)
(33)
(32)
(31)
(24)
(30) (25)
(26)
(27) (21) (58)
(28) (22)
(29) (23) 0004182
Figure 8
(1) (3)
(45) (2)
(44) (4)
(47)
(5) (52)
(43) (8)
(46) (6) (9)
(42) (10)
(7)
(41) (11)
(40)
(39) (12)
(38) (13) (53)
(37)
(14)
(36) (15)
(16)
(35) (48)
(49)
(34)
(50) (51) (17)
(33) (54)
(18)
(32)
(31) (19)
(30)
(29)
(28)
(22)
(23)
(24)
(55)
(25) (20)
(26)
(27) (21) 0004183
Figure 9
(1) (3)
(43) (2)
(44) (4)
(46)
(5)
(8)
(42) (6) (9)
(41) (45) (7) (10) (51)
(40) (11)
(39)
(38) (12)
(37) (13)
(36)
(35) (14) (52)
(15)
(34) (47)
(48)
(33)
(49) (50) (16)
(32)
(17)
(31)
(30) (18)
(53)
(29)
(28)
(27)
(21)
(22)
(23)
(24) (19)
(25)
(26) (20) 0004184
Figure 10
(52) (3)
(51) (1) (4)
(54) (2)
(5)
(8) (59)
(50) (53) (6) (9)
(49) (7) (10)
(48) (11)
(47)
(46) (12)
(45) (13)
(44) (14) (60)
(15)
(43) (16)
(55) (17)
(42)
(56)
(41) (18)
(57) (58)
(40)
(19) (61)
(39)
(38) (20)
(37)
(36)
(35) (26)
(34) (27)
(21)
(30) (28) (22)
(31) (23) (62)
(32) (29) (24)
(33) (25) 0004591
Figure 11
(49) (3)
(48) (1) (4)
(51) (2)
(5)
(8) (56)
(47) (6) (9)
(50)
(46) (7) (10)
(45) (11)
(44)
(43) (12)
(42) (13)
(57)
(41)
(14)
(40) (15)
(16)
(39) (52)
(53)
(38) (17)
(54) (55)
(37) (58)
(18)
(36)
(35) (19)
(34)
(33)
(32) (24)
(25)
(59)
(28) (26) (20)
(29) (21)
(30) (27) (22)
(31) (23) 0004592
Figure 12
(49) (3)
(48) (1) (4)
(51) (2)
(5)
(56)
(8)
(47) (6) (9)
(50)
(46) (7)
(10)
(45) (11)
(44)
(43) (12)
(42) (13)
(57)
(41)
(40) (14)
(52) (15)
(39)
(16)
(38) (53) (17)
(54) (55)
(37) (58)
(18)
(36)
(35) (19)
(34)
(33)
(32) (24)
(25)
(28) (26) (20)
(29) (21) (59)
(30) (27) (22)
(31) (23)
0004593
Figure 13
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 14
R R
Y
Alarm lamps Fuse (3A) 12
R WBr 29
LB
RB
27 28
14 15 16 17 18 W 26
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 15
12 Y
Fuse(3A) R WBr 28
27 29
LB
RB
14 15 16 17 18 W
26
AC YG B
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 16
R R
Y
Alarm lamps Fuse (3A)
R 12 WBr 28 29
LB
RB
26 27
14 15 16 17 18 W
YG B
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 17
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
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
138
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 18
2 R R
9 Y P
3 4 5 6 7 8 R 30 30
WBr 29
LB
RB
28
W
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 19
2 R R
9 Y P
3 34 35 6 7 8 R 30 30
WBr 29
LB
RB
28
W
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
5 Coolant Temperature
6 Sail Drive Seal
7 Battery Low Charge Alarm
8 Fuse (3A)
9 Stop Switch
10 Diodes
11 Key Switch
12 Tachometer / Hourmeter
13 Instrument panel (sub station)
(option)
0004577
Figure 2