Yanmar JH4 Series Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the 3JH4E/4JH4E/4JH4-TE/4JH4-HTE Yanmar Marine Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar 3JH4E
Yanmar 4JH4E
Yanmar 4JH4-TE
Yanmar 4JH4-HTE


TABLE OF CONTENTS :

1. General
2. Inspection and adjustment
3. Troubleshooting
4. Disassembly and reassembly
5. Inspection and servicing of basic engine parts
6. Fuel Injection equipment
7. Intake and exhaust system
8. Lubrication system
9. Coolant system
10. Reduction and reversing gear
11. Remote control system (Optional)
12. Electrical system
13. Service standards
14. Tightening torque for bolts and nuts


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Code No. : OBJH4-G00101
Total Pages : 346


This service manual has been compiled for engineers engaged in sales, service, inspection and maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized in this manual, while items, which should already be common knowledge, are omitted.

Model 3JH4E and 4JH4-TE have been used for the illustrations in this service manual, but they apply to other models in the JH4 series engines.

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
History of Revision
FOREWORD
CONTENTS
FOR SAFETY
1. General
1.1 Exterior views
1.2 Specifications
1.3 Fuel oil, lubricating oil and coolant
1.3.1 Fuel oil
1.3.2 Lubricating oil
1.3.3 Coolant
1.4 Engine outline
1.5 Piping diagrams
1.6 Exhaust Gas Emission Regulation in U.S.A. only
1.6.1 Engines under 37kw: 3JH4E
1.6.2 Engines of 37kW or more: 4JH4-TE and 4JH4-HTE
2. Inspection and adjustment
2.1 Periodic maintenance schedule
2.2 Periodic inspection and maintenance procedure
2.2.1 Check before starting
2.2.2 Inspection after initial 50 hours or one month operation
2.2.3 Inspection every 50 hours or monthly
2.2.4 Inspection every 250 hours or one year
2.2.5 Inspection every two years
2.2.6 Inspection every 1,000 hours or four years
2.3 Adjusting the no-load maximum or minimum speed
2.4 Sensor inspection
2.4.1 Oil pressure switch
2.4.2 Thermo switch
2.5 Thermostat inspection
2.6 Adjusting operation
2.6.1 Preliminary precautions
2.6.2 Adjusting operation procedure
2.6.3 Check points and precautions during running
2.7 Long storage
3. Troubleshooting
3.1 Preparation before troubleshooting
3.2 Quick reference chart for troubleshooting
3.3 Troubleshooting (Concerning engine and fuel injection equipment)
3.4 Troubleshooting by measuring compression pressure
4. Disassembly and reassembly
4.1 Disassembly and reassembly precautions
4.2 Disassembly and reassembly tools
4.2.1 General hand tools
4.2.2 Special hand tools
4.2.3 Measuring instruments
4.2.4 Other material
4.3 Disassembly and reassembly
4.3.1 Disassembly
4.3.2 Reassembly
5. Inspection and servicing of basic engine parts
5.1 Cylinder block
5.1.1 Inspection of parts
5.1.2 Cleaning of oil holes
5.1.3 Color check procedure
5.1.4 Replacement of cup plugs
5.1.5 Cylinder bore measurement
5.2 Cylinder head
5.2.1 Inspecting the cylinder head
5.2.2 Valve seat correction procedure
5.2.3 Intake/exhaust valves, valve guides
5.2.4 Valve springs
5.2.5 Assembling the cylinder head
5.2.6 Measuring top clearance
5.2.7 Intake and exhaust rocker arms
5.2.8 Adjustment of valve clearance
5.3 Piston and piston pins
5.3.1 Piston
5.3.2 Piston pin
5.3.3 Piston rings
5.4 Connecting rod
5.4.1 Inspecting the connection rod
5.4.2 Crank pin metal
5.4.3 Piston pin bushing
5.5 Crankshaft and main bearing
5.5.1 Crankshaft
5.5.2 Main bearing
5.6 Camshaft and tappets
5.6.1 Camshaft
5.6.2 Tappets
5.7 Timing gear
5.7.1 Inspecting the gears
5.7.2 Gear timing marks
5.8 Flywheel and housing
5.8.1 Position of top dead center and fuel injection timing
5.8.2 Damper disc
6. Fuel Injection equipment
6.1 Fuel Injection pump/governor for 3JH4E and 4JH4E
6.1.1 Fuel system diagram
6.1.2 Fuel injection pump service data
6.1.3 Fuel injection pump structure
6.1.4 Removing a fuel injection pump
6.1.5 Installing a fuel injection pump
6.1.6 Adjusting fuel injection timing
6.1.7 Troubleshooting of fuel injection pump
6.1.8 Tools
6.2 Fuel feed pump
6.2.1 Construction of fuel feed pump
6.2.2 Fuel feed pump specifications
6.2.3 Disassembly and reassembly of fuel feed pump
6.2.4 Fuel feed pump inspection
6.3 Fuel injection pump/ governor for 4JH4-TE and 4JH4-HTE
6.3.1 Fuel system diagram
6.3.2 Fuel injection pump structure
6.3.3 Fuel injection pump service data
6.3.4 Removing a fuel injection pump
6.3.5 Installing a fuel injection pump
6.3.6 Adjusting fuel injection timing
6.3.7 Troubleshooting of fuel injection pump
6.4 Fuel injection nozzle
6.5 Fuel Filter
6.5.1 Fuel filter for 3JH4E and 4JH4E
6.5.2 Fuel filter for 4JH4-TE and 4JH4- HTE
6.6 Fuel tank
7. Intake and exhaust system
7.1 Intake system
7.1.1 3JH4E and 4JH4E
7.1.2 4JH4-TE
7.1.3 4JH4-HTE
7.1.4 Breather system (A reductor to intake air system of blowby gas)
7.1.5 Diaphragm assy inspection (only for 3JH4E and 4JH4E)
7.2 Exhaust system
7.2.1 Exhaust system for 3JH4E and 4JH4E
7.2.2 Exhaust system for 4JH4-TE and 4JH4-HTE
7.2.3 Mixing elbow inspection
7.3 Turbocharger
8. Lubrication system
8.1 Lubrication system
8.2 Lube oil pump
8.2.1 Lube oil pump construction
8.2.2 Specifications of lube oil pump
8.2.3 Lube oil pump disassembly and reassembly
8.2.4 Lube oil pump inspection
8.2.5 Oil pressure control valve construction
8.3 Lube oil filter
8.3.1 Lube oil filter construction
8.3.2 Lube oil filter replacement
8.4 Lube oil cooler
8.4.1 Lube oil cooler construction
8.4.2 Inspecting the lube oil cooler
8.5 Piston cooling oil nozzle
8.6 Rotary waste oil pump (Optional)
9. Coolant system
9.1 Coolant system
9.2 Seawater pump
9.2.1 Specifications of seawater pump
9.2.2 Seawater pump disassembly
9.2.3 Seawater pump Inspection
9.2.4 Seawater pump reassembly
9.3 Fresh water pump
9.3.1 Fresh water pump construction
9.3.2 Specifications of fresh water pump
9.3.3 Fresh water pump disassembly
9.3.4 Fresh water pump inspection
9.4 Heat exchanger
9.4.1 Heat exchanger construction
9.4.2 Specifications of heat exchanger
9.4.3 Disassembly and reassembly of the heat exchanger
9.4.4 Heat exchanger inspection
9.5 Pressure cap and coolant recovery tank
9.5.1 Pressure cap construction
9.5.2 Pressure cap pressure control
9.5.3 Pressure cap inspection
9.5.4 Replacing filler neck
9.5.5 Function of the coolant recovery tank
9.5.6 Specifications of coolant recovery tank
9.5.7 Mounting the coolant recovery tank
9.5.8 Precautions on usage of the coolant recovery tank
9.6 Thermostat
9.6.1 Functioning of thermostat
9.6.2 Thermostat construction
9.6.3 Characteristics of thermostat
9.6.4 Thermostat inspection
9.6.5 Testing the thermostat
9.7 Bilge pump and bilge strainer (Optional)
9.7.1 Introduction
9.7.2 Description
9.7.3 Cautions
9.7.4 Assembly procedure
9.7.5 Cautions for assembling
9.7.6 Troubleshooting
10. Reduction and reversing gear
10.1 Specifications of 3JH4E marine gears
10.2 Specifications of 4JH4E and marine gears
10.3 Specifications of 4JH4-TE and 4JH4-HTE marine gears
11. Remote control system (Optional)
11.1 Remote control system
11.1.1 Construction of remote control system
11.1.2 Remote control device components
11.2 Remote control installation
11.3 Remote control inspection
11.4 Remote control adjustment
12. Electrical system
12.1 Electrical system
12.1.1 Wiring diagram
12.2 Battery
12.3 Starting motor
12.3.1 Specifications
12.3.2 Characteristics
12.3.3 Structure
12.3.4 Wiring diameter of a starting motor
12.4 Alternator 12V/60A (Optional)
12.4.1 Specifications
12.4.2 Structure
12.4.3 Wiring diagram
12.4.4 Standard output characteristics
12.4.5 Inspection
12.5 Alternator 12V/80A (Standard)
12.5.1 Specifications
12.5.2 Structure
12.5.3 Wiring diagram
12.5.4 Standard output characteristics
12.6 Instrument panel
12.6.1 B-type instrument panel (Selectable optional)
12.6.2 C-type instrument panel (Selectable optional)
12.7 Warning devices
12.7.1 Oil pressure alarm

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12.7.2 Sender unit for lube oil pressure gauge
12.7.3 Coolant temperature alarm
12.7.4 Sender unit for the coolant temperature gauge
12.8 Air heater (Optional)
12.9 Electric engine stopping device
13. Service standards
13.1 Engine tuning
13.2 Engine body
13.2.1 Cylinder head
13.2.2 Camshaft and gear train
13.2.3 Cylinder block
13.3 Lubricating oil system (Trochoid pump)
14. Tightening torque for bolts and nuts
14.1 Main bolt and nut
14.2 Standard bolts and nuts (without lube oil)
Colophon
Back cover