Yanmar JH4 Series Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the JH4 Series 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 4JH4AE
Yanmar 4JH4-TE
Yanmar 4JH4-HTE


TABLE OF CONTENTS :

Introduction
Safety
General Service Information
Periodic Maintenance
Engine
Fuel System
Cooling System
Lubrication
Turbocharger
Starter Motor
Alternator
Electrical
Troubleshooting
Service Standards


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Code No. : OBJH4-U00102
Total Pages : 394


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
Table of Contents
Introduction
Revision History
Revision Control Table
Safety
Safety Statements
Safety Precautions
Location of Safety Labels
General Service Information
Safety Precautions
Engine Outline Drawings
3JH4E Models
4JH4AE Models
4JH4-TE Models
4JH4-HTE Models
Engine Piping Diagrams
3JH4E Models
4JH4AE Models
4JH4-TE Models
4JH4-HTE Models
Location of Nameplates
Engine Nameplates (Typical)
Diesel Fuel
Diesel Fuel Specifications
Bleeding the Fuel System
Engine Oil
Engine Oil Specifications
Engine Coolant
Engine Coolant Specifications
Principal Engine Specifications
3JH4E Engine Specifications
4JH4AE Engine Specifications
4JH4AE Specifications (Continued)
4JH4AE Specifications (Continued)
4JH4-TE Engine Specifications
4JH4-HTE Engine Specifications
Tightening Torques for Standard Bolts and Nuts
Hexagon Bolts and Nuts
Hose Clamps
Prepare Engine for Long-Term Storage
Abbreviations And Symbols
Symbols
Unit Conversions
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Periodic Maintenance
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Required EPA Maintenance
EPA Requirements
Conditions to Ensure Compliance with EPA Emission Standards
Inspection and Maintenance
Periodic Maintenance Schedule
Inspection and Maintenance of EPA Emission-Related Parts
Inspection and Maintenance of EPA Emission-Related Parts for Non-Road and CI Marine Engines
Periodic Maintenance Procedures
After Initial 50 Hours of Operation
Every 50 Hours of Operation
Every 250 Hours of Operation
Every 500 Hours of Operation
Every 1000 Hours of Operation
Engine
Safety Precautions
Introduction
Specifications
General Information
Test and Adjustment Specifications
Repair Specifications
Special Torque Chart
Standard Torque Chart (without Lubricating Oil)
Special Service Tools
Measuring Instruments
Sealants and Compounds
Tests and Adjustments
Test Compression
Disassembly
Inspection
Cylinder Block
Cylinder Head
Piston and Piston Rings
Connecting Rod
Crankshaft and Main Bearings
Camshaft and Tappets
Timing Gear
Flywheel and Housing
Assembly
Check and Adjust the Remote Control Operation
Fuel System
Safety Precautions
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Fuel System Components
Fuel Flow Diagram
Fuel System Tests
Measure Fuel Feed Pump Pressure Procedure
Test Return Fuel Pressure
Fuel System Service
Fuel Injection Nozzle Removal
Cleaning Fuel Injection Nozzle Cavities
Fuel Injection Nozzle Installation
Fuel Injection Lines Removal
Fuel Injection Line Installation
Fuel Injection Pump Replacement
Adjust Fuel Injection Timing
Fuel Line Replacement Filter
Replace Injection Nozzle Return
Bleeding the Fuel System
MP Fuel Injection Pump System
Introduction
Fuel Injection Pump
Stop Solenoid
Trochoid Fuel Pump
Fuel System Specifications
Special Torque Chart
Fuel Injection Pump Service Data
Test and Adjustment Specifications
Special Service Tools
Measuring Instruments
Fuel System Diagram
Fuel System Components
Fuel Injection Pump
Fuel Injection Pump Removal
Fuel Injection Pump Installation
Checking and Adjusting Fuel Injection Timing
Determining the Fuel Injection Timing Specification
Checking Fuel Injection Timing
Adjusting Fuel Injection Timing
Fuel Injectors
Fuel Injectors Removal
Fuel Injectors Testing
Fuel Injectors Disassembly and Inspection
Adjusting Fuel Injector Pressure
Fuel Injectors Reassembly
Cooling System
Safety Precautions
Introduction
Specifications
Test and Adjustment Specifications
Repair Specifications
Special Service Tools
Measuring Instruments
Cooling Flow Diagram
Tests and Adjustments
Pressure Testing Cooling System and Filler Cap
Test Thermostat
Drain and Refill Seawater Cooling System
Drain and Fill Closed Cooling System
Remove and Install Intercooler (Only for 4JH4-HTE)
Disassemble and Assemble intercooler
Remove and Install Heat Exchanger
Disassemble and Assemble Heat Exchanger
Remove and Install Coolant Pump
Remove and Install Thermostat
Seawater Pump
Coolant Recovery Tank
Bilge Pump and Bilge Strainer (Optional)
Lubrication
Safety Precautions
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Measuring Instruments
Tests and Adjustments
Engine Oil Flow
Check Engine Oil Pressure
Repair
Engine Lubrication System Components
Change Engine Oil, Replace Engine Oil Filter Element and Clean Engine Oil Cooler
Remove and Install Engine Oil Sump
Engine Oil Pump
Piston Cooling Oil Nozzle Check
Turbocharger
Safety Precautions
Introduction
Specifications
Turbocharger Components
Special Service Tools
Washing the Turbocharger Blower
Clean Air Cleaner
Turbocharger Service
Starter Motor
Safety Precautions
Introduction
Starter Motor Specifications
General Specifications
Special Torque Chart
Characteristics
Starter Motor Troubleshooting
Starter Motor Service
Alternator
Safety Precautions
Introduction
Specifications
General Specifications (Standard)
General Specifications (Optional for 3JH4E, 4JH4-TE and 4JH4-HTE)
Special Torque Chart
Wiring Diagram
Output Characteristics
Alternator Service
Replace V-Belt
Remove and Install Alternator
Electrical
Safety Precautions
Introduction
Component Locations
Sensor and Switch Locations
Wiring Diagram
3JH4E B-Type Instrument Panel
3JH4E - B-Type Instrument Panel
4JH4AE - B-Type Instrument Panel
4JH4AE - B-Type Instrument Panel
4JH4-TE / 4JH4-HTE with Panel B x B Type
4JH4-TE / 4JH4-HTE with Panel B x B Type Instrument Panel
3JH4E - C-Type Instrument Panel
3JH4E - C-Type Instrument Panel
4JH4AE - C-Type Instrument Panel
4JH4AE - C-Type Instrument Panel
4JH4-TE / 4JH4-HTE with Panel C x B Type
4JH4-TE / 4JH4-HTE with Panel C x B Type Instrument Panel
Instrument Panel
B-Type Instrument Panel (Selectable Optional)
C-Type Instrument Panel (Selectable Optional)
Function Description - Warning Devices
Oil Pressure Alarm
Sending Unit for Lubricating Oil Pressure Gauge
Coolant Temperature Alarm
Sending Unit for the Coolant Temperature Gauge
Air Heater (Standard for 4JH4AE, 4JH4-TE and 4JH4-HTE. Optional for 3JH4E)
Electric Engine Stop Solenoid
Troubleshooting
Safety Precautions
Introduction
Troubleshooting Chart
Starting Trouble
Exhaust Color
Vibration - Drive Disengaged
Vibration - Drive Engaged
Engine Knocks
Low Power Output
Engine Overheat
Engine Runs Cold
Coolant Loss
Lubricating Oil Pressure Low
Panel Display
Troubleshooting by Measuring Compression Pressure
After Troubleshooting or Repair
Service Standards
Engine Tuning
ENGINE TUNING
Engine Body
Cylinder Head
Camshaft and Gear Train
Cylinder Block
Lubricating Oil System (Trochoid Pump)
Outside Clearance of Outer Rotor
Tip Clearance Between Outer Rotor and Inner Rotor
Side Clearance of Outer Rotor
Inside Clearance of Inner Rotor
Main Bolt and Nut
Standard Bolts and Nuts (Without Lubricating Oil)

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