Yanmar JH Series Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the 3JH5E, 4JH5E, 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 3JH5E
Yanmar 4JH5E
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. : OBJHM-G00200
Total Pages : 380


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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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
3JH5E Models
3JH5E - Inboard Version (KM35P)
3JH5E - Inboard Version (KM35P) with KMG65E Generator (Optional)
3JH5E - Inboard Version (KM35A)
3JH5E - Inboard Version (KM35A) with KMG65E Generator (Optional)
3JH5E - Sail Drive Version (SD50)
3JH5E - Sail Drive Version (SD50) with KMG65E Generator (Optional)
3JH5E - without Marine Gear
4JH5E Models
4JH5E - Inboard Version (ZF30M)
4JH5E - Inboard Version (KM35A2)
4JH5E - Inboard Version (KM35A2) with KMG65E Generator (Optional)
4JH5E - Inboard Version (KM35P)
4JH5E - Inboard Version (KM35P) with KMG65E Generator (Optional)
4JH5E - Inboard Version (KM4A1)
4JH5E - without Marine Gear
4JH5E - Sail Drive Version (SD50)
4JH5E - Sail Drive Version (SD50 with KMG65E Generator (Optional))
4JH4-TE Models
4JH4-TE - Inboard Version (ZF30M)
4JH4-TE - Inboard Version (KM4A2)
4JH4-TE - Inboard Version (KMH4A)
4JH4-TE - Inboard Version (ZF25A)
4JH4E-TE - Sail Drive Version (SD50-4T)
4JH4E-TE - without Marine Gear
4JH4-HTE Models
4JH4-HTE - Inboard Version (ZF30M)
4JH4-HTE - Inboard Version (KM4A2)
4JH4-HTE - Inboard Version (KMH4A)
4JH4-HTE - Inboard Version (ZF25A)
4JH4E-HTE - without Marine Gear
Piping Diagrams
3JH5E Models
3JH5E (KM35P, KM35A)
3JH5E (KM4A1)
3JH5E (SD50 Sail Drive)
4JH5E Models
4JH5E (KM35P, KM35A2)
4JH5E (KM4A1)
4JH5E (ZF30M)
4JH5E (SD50 Sail Drive)
4JH4-TE Models
4JH4-TE (ZF30M)
4JH4-TE (KM4A2)
4JH4-TE (KMH4A, ZF25A)
4JH4-TE (SD50 / SD40 Sail Drive)
4JH4-HTE Models
4JH4-HTE (KM4A2)
4JH4-HTE (KMH4A, ZF25A)
4JH4-HTE (ZF30M)
Exhaust Gas Emission Regulations
Engine Identification (EPA / CARB)
Emission Control Label (EPA / CARB)
Location of Nameplates
Engine Nameplates (Typical)
Engine Data and Drive Information Nameplates
Diesel Fuel
Diesel Fuel Specifications
Bio-Diesel Fuels
Additional Technical Fuel Requirements
Diesel Fuel Lines
Diesel Fuel Lines for 3JH5E and 4JH5E Only
Bleeding the Fuel System
Engine Oil
Engine Oil Specifications
Service Categories
Definitions
Engine Coolant
Engine Coolant Specifications
Engine Coolant Mixture
Recommended Engine Coolant
Principal Engine Specifications
3JH5E Engine Specifications
4JH4-HTE Engine Specifications
Tightening Torques
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
Safety Precautions
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 (w/o Lubricating Oil)
Special Service Tools
Measuring Instruments
Sealants and Compounds
Tests and Adjustments
Test Compression
Disassembly
Inspection
Cylinder Block
Inspecting the Cylinder Block
Inspecting Oil Passages and Cap Plugs
Dye Penetrant Inspection Procedure
Replacement of Cup Plugs
Cylinder Bore Measurements
Cylinder Head
General Guidelines
Cylinder Head Inspection
Valve Seat Correction Procedure
Inspecting Intake / Exhaust Valves and Valve Guides
Replace the Valve Guide
Valve Guide Projection
Valve Stem Seals
Valve Springs
Cylinder Head Assembly
Measuring Top Clearance
Intake / Exhaust Rocker Arms
Valve Clearance Adjustment
Piston and Piston Rings
Piston
Matching Cylinder and Piston
Piston Pin
Piston Rings
Connecting Rod
Connecting Rod Bearing Alignment Inspection
Inspecting Crank Pins
Crankshaft and Main Bearings
Crankshaft
Main Bearing
Camshaft and Tappets
Camshaft
Tappets
Push Rods
Timing Gear
Gear Inspection
Gear Timing Marks
Flywheel and Housing
Position of Top Dead Center and Fuel Injection Timing
Damper Disk and Cooling Fan
Assembly
Checking and Adjusting Remote Control Operation
Fuel System
Safety Precautions
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Fuel System Components
4JH4E-HT / 4JH4-HTE Engines
Fuel System Diagram
Fuel System Tests
Measuring Fuel Feed Pump Pressure
Results
Testing Return Fuel Pressure
Results
Servicing the Fuel System
Removing the Fuel Injection Nozzle
Cleaning Fuel Injection Nozzle Cavities
Installing Fuel Injection Nozzles
Removing Fuel Injection Lines
Installing Fuel Injection Lines
Replacing the Fuel Feed Pump
Replacing the Fuel Injection Pump
Removal
Installation
Adjusting Fuel Injection Timing
MP2 Fuel Injection Pump System (3 / 4JH5E)
Introduction
Fuel Injection Pump
Stop Solenoid
Trochoid Fuel Pump
Fuel System Specifications
Special Torque Chart
Test and Adjustment Specifications
Special Service Tools
Measuring Instruments
Fuel System Components
Fuel Injection Pump
Removing the Fuel Injection Pump
Installing the Fuel Injection Pump
Checking and Adjusting Fuel Injection Timing
Determining the Fuel Injection Timing Specification
Checking Fuel Injection Timing
Adjusting Fuel Injection Timing
Fuel Injection Pump Structure for 4JH4-TE and 4JH4-HTE
Fuel Injection Pump Service Data
3MP2 for 3JH5E Service Data
4MP2 for 4JH5E Service Data
4JH4-TE / 4JH4-HTE Fuel Injection Pump Service Data
Adjusting Fuel Limit Bolt at Starting
Fuel Line Replacement Filter
Replacing the Fuel / Water Separator
Replacing the Injection Nozzle Return
Fuel Line
Bleeding the Fuel System
Bleeding the Fuel System - 3JH5E and 4JH5E
Bleeding the Fuel System - 4JH4-TE and 4JH4-HTE
Fuel Injectors
Removing Fuel Injectors
Testing Fuel Injectors
Disassembling and Inspecting Fuel Injectors
Adjusting Fuel Injector Pressure
Reassembling the Fuel Injectors
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
Cooling System
Filler Cap
Testing Thermostat
Draining / Refilling Seawater Cooling System
Draining and Filling Closed Cooling System
Removing / Installing Intercooler (4JH4-HTE)
Disassembling and Assembling Intercooler
Removing and Installing Heat Exchanger
Disassembling / Assembling Heat Exchanger
Removing and Installing Coolant Pump
Removing and Installing Thermostat
Removal
Installation
Seawater Pump
Inspecting / Replacing Impeller
Removing and Installing Seawater Pump and Pump Drive Gear
Replacing Coolant Pump Belt and Pulley
Coolant Recovery Tank
Coolant Recovery Tank Function
Mounting the Coolant Recovery Tank
Before Using Coolant Recovery Tank
Bilge Pump and Bilge Strainer (Optional)
Description
Cautions
Assembly
Cautions During Assembly
Lubrication
Safety Precautions
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Measuring Instruments
Tests and Adjustments
Engine Oil Flow
Checking Engine Oil Pressure
Results:
Repair
Engine Lubrication System Components
4JH5E Engine Shown (3JH5E is Similar)
Changing Engine Oil, Replacing Engine Oil Filter Element and Cleaning Engine Oil Cooler
Removing and Installing Engine Oil Sump
Engine Oil Pump
Removing Engine Oil Inlet Pipe
Removing Engine Oil Pump
Checking Lubricating Oil Pump
Installing Engine Oil Pump
Checking Piston Cooling Oil Nozzle
Turbocharger
Safety Precautions
Introduction
Specifications
Turbocharger Components
Special Service Tools
Washing the Turbocharger Blower
Cleaning the Air Cleaner
Turbocharger Service
Removal
Check and Service Data
Installation
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 4JH4-TE and 4JH4-HTE)
Special Torque Chart
Wiring Diagram
Standard Alternator - 12 Volt / 80 Amps
Optional Alternator - 12 Volt / 60 Amps (for 4JH4-TE and 4JH4-HTE)
Optional Double Alternator - 12 Volt x 80 Amps (for 4JH5E)
Output Characteristics
Standard Alternator - 12 Volt / 80 Amps
Optional Alternator - 12 Volt / 60 Amps (for 4JH4-TE and 4JH4-HTE)
Alternator Service
Replace V-Belt
Removing and Installing the Alternator
Electrical
Safety Precautions
Introduction
Component Locations
Sensor and Switch Locations
Wiring Diagram
3JH5E / 4JH5E - C-Type Instrument Panel (Optional)
3JH5E / 4JH5E 12V B- and B x B-Type Instrument Panel (Optional)
3JH5E / 4JH5E 12V C x B-Type Instrument Panel (Optional)
3JH5E / 4JH5E with Keyless B- and B x B-Type Instrument Panel (Optional)
3JH5E / 4JH5E with Keyless C x B-Type Instrument Panel (Optional)
4JH4-TE / 4JH4-HTE with Panel B x B-Type Instrument Panel
4JH4-TE / 4JH4-HTE with Panel C x B-Type Instrument Panel
Instrument Panel
B-Type Instrument Panel (Selectable Optional)
B-Type (Keyless) Instrument Panel (Selectable Optional)
C-Type Instrument Panel (Selectable Optional)
C-Type (Keyless) Instrument Panel (Selectable Optional)
Function Description - Warning Devices
Oil Pressure Alarm
Inspection
Sending Unit for Lubricating Oil Pressure Gauge
Coolant Temperature Alarm
Sending Unit for the Coolant Temperature Gauge
Air Heater (Standard)
Electric Engine Stop Solenoid
Electric Emergency Stop (for 3JH5E and 4JH5E)
Troubleshooting
Safety Precautions
Introduction
Troubleshooting Chart
Starting Trouble
Exhaust Color
Vibration - Drive Engaged
Engine Knocks
Low Power Output
Engine Overheat
Engine Runs Cold
Coolant Loss
Lubricating Oil Pressure Low
Panel Display
Measuring Compression Pressure
After Troubleshooting or Repair
Service Standards
Engine Tuning
Engine Body
Cylinder Head
Cylinder Head
Intake / Exhaust Valve and Guide
Valve Spring
Rocker Arm and Shaft
Push Rod
Camshaft and Gear Train
Camshaft
Idler Gear Shaft and Bushing
Backlash of Each Gear
Cylinder Block
Cylinder Block
Crankshaft
Thrust Bearing
Piston and Ring
Connecting Rod
Tappet
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 (w/o Lubricating Oil)

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