Page 3 Publication No. 0BJH4-G00101 History of Revision Manual Name Service Manual for Marine Diesel Engine Engine Model: 3JH4E / 4JH4E / 4JH4-TE / 4JH4-HTE Number Date of Reason for Correction item Outline of correction Corrected by revision correction No (page) revision...
Page 5 Use this manual as a handy reference in daily inspection and maintenance, and as a text for engineering guidance. 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.
Page 7: Table Of Contents
1.4 Engine outline ....................... 14 1.5 Piping diagrams ....................33 1.6 Exhaust Gas Emission Regulation in U.S.A. only ..........46 1.6.1 Engines under 37kw: 3JH4E..............46 1.6.2 Engines of 37kW or more: 4JH4-TE and 4JH4-HTE......... 49 2. Inspection and adjustment ..................... 52 2.1 Periodic maintenance schedule ................
Page 8 3.2 Quick reference chart for troubleshooting ............101 3.3 Troubleshooting (Concerning engine and fuel injection equipment) ....117 3.4 Troubleshooting by measuring compression pressure ........120 4. Disassembly and reassembly ..................122 4.1 Disassembly and reassembly precautions ............122 4.2 Disassembly and reassembly tools ..............123 4.2.1 General hand tools..................
Page 9 5.8.1 Position of top dead center and fuel injection timing....... 214 5.8.2 Damper disc .................... 214 6. Fuel Injection equipment ..................... 215 6.1 Fuel Injection pump/governor for 3JH4E and 4JH4E ......... 215 6.1.1 Fuel system diagram................215 6.1.2 Fuel injection pump service data............. 216 6.1.3 Fuel injection pump structure ..............
Page 10 7.1.3 4JH4-HTE ....................242 7.1.4 Breather system (A reductor to intake air system of blowby gas) ... 243 7.1.5 Diaphragm assy inspection (only for 3JH4E and 4JH4E) ....... 244 7.2 Exhaust system ....................245 7.2.1 Exhaust system for 3JH4E and 4JH4E ........... 245 7.2.2 Exhaust system for 4JH4-TE and 4JH4-HTE..........
Page 11 8.5 Piston cooling oil nozzle ..................259 8.6 Rotary waste oil pump (Optional) ............... 260 9. Coolant system ......................261 9.1 Coolant system ....................261 9.2 Seawater pump ....................263 9.2.1 Specifications of seawater pump ............264 9.2.2 Seawater pump disassembly ..............265 9.2.3 Seawater pump Inspection..............
Page 12 9.7.5 Cautions for assembling................283 9.7.6 Troubleshooting ..................285 10. Reduction and reversing gear ................... 286 10.1 Specifications of 3JH4E marine gears .............. 286 10.2 Specifications of 4JH4E and marine gears ............287 10.3 Specifications of 4JH4-TE and 4JH4-HTE marine gears ........288 11.
Page 13 12.5.2 Structure....................309 12.5.3 Wiring diagram ..................310 12.5.4 Standard output characteristics............. 310 12.6 Instrument panel ....................311 12.6.1 B-type instrument panel (Selectable optional) ........311 12.6.2 C-type instrument panel (Selectable optional) ........311 12.7 Warning devices ....................312 12.7.1 Oil pressure alarm................. 312 12.7.2 Sender unit for lube oil pressure gauge ..........
Page 15: Safety Labels
FOR SAFETY 1. SAFETY LABELS • Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures.
Page 16: Safety Precautions
2. Safety Precautions (1) SERVICE AREA • Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas. • Safe / Adequate Work Area The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip"...
Page 17 (4) GENUINE PARTS and MATERIALS • Genuine Parts Always use genuine YANMAR parts or YANMAR recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result.
Page 18 (5) FASTENER TORQUE • Torquing Fasteners Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury. (6) Electrical • Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system.
Page 19: Rotating Parts
(8) FURTHER PRECAUTIONS • Fueling / Refueling Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling / refueling the unit. Fire and or an explosion may result. • Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down.
Page 20 3. Precautions for Service Work (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work. (2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.
Page 21: General
(1) Coolant filler cap (4) Starter motor (7) Alternator (2) Engine name plate (5) Exhaust mixing elbow (8) Coolant tank/Heat exchanger (on the rocker arm cover) (3) Seawater pump (6) Exhaust manifold <Note> This illustration shows the 3JH4E with Yanmar marine gear (Model:KM35P).
Page 22 • Non operation side 008832-01X Engine name plate Seawater pump Exhaust mixing elbow (on the rocker arm cover) Coolant filler cap Alternator Coolant tank/Heat exchanger Belt cover Starter motor <Note> This illustration shows the 4JH4-TE with Yanmar marine gear (Model: KMH4A).
Page 23 (1) Engine name plate (4) Seawater pump Starter motor (on the rocker arm cover) (2) Coolant filler cap (5) Alternator Exhaust mixing elbow (3) Belt cover (6) Intercooler Coolant tank/Heat exchanger <Note> This illustration shows the 4JH4-HTE with Yanmar marine gear (Model: KMH4A).
Page 24: Specifications
1. General 1.2 Specifications (1) 3JH4E series (3JH4E, 3JH4BE, 3JH4CE, 3JH4ME) Official engine model name unit 3JH4E Company internal model name 3JH4E 3JH4BE 3JH4CE 3JH4ME Marine gear model KM35P KM35A SD50 Bobtail Pleasure use Type Vertical water cooled 4 cycle diesel engine...
Page 25 1. General (2) 4JH4E series (4JH4E, 4JH4FE, 4JH4BE, 4JH4B4E, 4JH4CE, 4JH4ME) Official engine model name unit 4JH4E Company internal model name 4JH4E 4JH4FE 4JH4BE 4JH4B4E 4JH4CE 4JH4ME KM35P ZF30M KM35A2 KM4A1 SD50 Bobtail Marine gear model Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion system Direct injection Air charging...
Page 26 1. General Marine gear and sail drive for 3JH4E and 4JH4E KM35A KM35A2 Model KM35P (down angle: 7) (down angle: 7) Type Mechanical cone clutch Reduction ratio 2.36/3.16 2.61/3.16 2.33/3.04 2.64/3.04 2.33/3.06 2.64/3.06 (Forward/Reverse) Propeller speed 1231/921 1114/921 1246/955 1103/955 1246/950 1103/950...
Page 27 1. General (3) 4JH4-TE series (4JH4-TFE, 4JH4-TBE, 4JH4-THE, 4JH4-TIE, 4JH4-TCE, 4JH4M-TE) Official engine model name unit 4JH4-TE Company internal model name 4JH4-TFE 4JH4-TBE 4JH4-THE 4JH4-TIE 4JH4-TCE 4JH4M-TE Marine gear model ZF30M KM4A2 KMH4A ZF25A SD50-4T Bobtail Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion system Direct injection Air charging...
Page 28 1. General (4) 4JH4-HTE series (4JH4-HTFE, 4JH4-HTBE, 4JH4-HTHE, 4JH4-HTIE, 4JH4M-HTE) Official engine model name unit 4JH4-HTE Company internal model name 4JH4-HTFE 4JH4-HTBE 4JH4-HTHE 4JH4-HTIE 4JH4M-HTE Marine gear model ZF30M KM4A2 KMH4A ZF25A Bobtail Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion system Direct injection Air charging...
Page 29 1. General Marine gear and sail drive for 4JH4-TE and 4JH4-HTE SD50-4T (coupled at Model ZF30M KM4A2 KMH4A ZF25A boat builder) Down angle deg. Applicable 4JH4-TE 4JH4-TE engine model 4JH4-HTE Mechanical Hydraulic wet Hydraulic wet Mechanical Mechanical Type wet multiple multiple disk multiple disk cone clutch...
Page 30: Fuel Oil, Lubricating Oil And Coolant
1. General 1.3 Fuel oil, lubricating oil and coolant 1.3.1 Fuel oil IMPORTANT: Only use the recommended fuel to obtain the best engine performance and to keep the durability of the engine, also to comply with the emission regulations. (1) Selection of fuel oil Diesel fuel oil should comply with the following specifications.
Page 31 1. General (2) Fuel handling • Water and dust in the fuel oil can cause operation failure. Use containers which are clean inside to store fuel oil. Store the containers away from rain water and dust. • Before supplying fuel, let the fuel container rest for several hours so that water and dust in the fuel are deposited on the bottom.
Page 32: Lubricating Oil
ZF30N, ZF25A for 4JH4-TE and 4JH4- HTE. (3) Selection of lube oil for sail drive unit SD50 (or SD40) for 3JH4E and 4JH4E • API service grade ..GL4, 5 • SAE Viscosity .....#90 or 80W90 or QuickSilver High Performance Gear Lube...
Page 33: Coolant
1. General 1.3.3 Coolant (1) Choose antifreeze, which will not have Consult your Yanmar dealer or distributor on the any adverse effects on the materials use of coolant/antifreeze, and detergents. (cast iron, aluminum, copper, etc.) of the Coolant/antifreeze, which provides good perfor- mance for example, are shown below.
Page 34: Engine Outline
1. General 1.4 Engine outline (1) 3JH4E (with KM35P marine gear)
Page 35 1. General (2) 3JH4BE (with KM35A marine gear)
Page 36 1. General (3) 3JH4CE (with SD50/SD40 sail drive)
Page 37 1. General (4) 3JH4ME (Bobtail)
Page 38 1. General (5) 4JH4E (with KM35P marine gear)
Page 39 1. General (6) 4JH4FE (with ZF30M marine gear)
Page 40 1. General (7) 4JH4BE (with KM35A2 marine gear)
Page 41 1. General (8) 4JH4B4E (with KM4A1 marine gear)
Page 42 1. General (9) 4JH4CE (with SD50/SD40 sail drive)
Page 43 1. General (10) 4JH4ME (Bobtail)
Page 44 1. General (11) 4JH4-TFE (with ZF30M marine gear)
Page 45 1. General (12) 4JH4-TBE (with KM4A2 marine gear)
Page 46 1. General (13) 4JH4-THE (with KMH4A marine gear)
Page 47 1. General (14) 4JH4-TIE (with ZF25A marine gear)
Page 48 1. General (15) 4JH4-TCE (with SD50-4T sail drive)
Page 49 1. General (16) 4JH4-HTFE (with ZF30M marine gear)
Page 50 1. General (17) 4JH4-HTBE (with KM4A2 marine gear)
Page 51 1. General (18) 4JH4-HTHE (with KMH4A marine gear)
Page 52 1. General (19) 4JH4-HTIE (with ZF25A marine gear)
Page 53: Piping Diagrams
1. General 1.5 Piping diagrams (1) 3JH4 (B) E Note: The following piping diagram is for the 3JH4(B)E model.
Page 54 1. General (2) 3JH4CE (with SD50/SD40 sail drive)
Page 55 1. General (3) 4JH4(B)E (with KM35P, KM35A2 marine gear)
Page 56 1. General (4) 4JH4B4E (with KM4A1 marine gear)
Page 57 1. General (5) 4JH4FE (with ZF30M marine gear)
Page 58 1. General (6) 4JH4CE (with SD50/SD40 sail drive)
Page 59 1. General (7) 4JH4-TE (with KM4A2 marine gear)
Page 60 1. General (8) 4JH4-TE (with KMH4A and ZF25A marine gear)
Page 61 1. General (9) 4JH4-TE (with ZF30M marine gear)
Page 62 1. General (10) 4JH4-TE (with SD50-4T sail drive)
Page 63 1. General (11) 4JH4-HTE (with KM4A2 marine gear)
Page 64 1. General (12) 4JH4-HTE (with KMH4A and ZF25A marine gear)
Page 65 1. General (13) 4JH4-HTE (with ZF30M marine gear)
Page 66: Exhaust Gas Emission Regulation In U.s.a. Only
• The tamper resistance device is installed with THIS ENGINE IS CERTIFIED TO OPERATE ON "TYPE2-D" FUEL. ENGINE FAMILY : 6YDXM1.64D3N DISPLACEMENT : 1.642 LITERS EPA/ARB certified 3JH4E series engines to ENGINE MODEL : 3JH4E EMISSION CONTROL SYSTEM : EM prevent illegal change of fuel injection volume FUEL RATE : 33.8 MM...
Page 67 1. General b) Label location: Emission control label 010330-00E (2) Emission standard The below table shows the emission standard of the EPA Off-road CI engines regulations for 19kW and under 37kW engines. g/kWh (g/HPhr) Engine power Tier Model year NMHC + NOx Tier 1 1999 - 9.5 (7.1)
Page 68 19 kW<37 Every 1500 hours Every 3000 hours Note: The inspection and maintenance shown above are to be performed at Yanmar dealer or distributor. 5) Quality guarantee period for exhaust emission related parts. For exhaust emission related parts, follow the inspections outlined in the "List of Periodic...
Page 69: Engines Of 37Kw Or More: 4Jh4-Te And 4Jh4-Hte
ENGINE MODEL : 4JH4-TE DISPLACEMENT PER CYLINDER : 0.499 LITERS ENGINE FAMILY : 6YDXM2.00D4T APPLICATION:COMMERCIAL STANDARDS THC+NOx:7.5g/kWh CO:5.0g/kWh PM:0.40g/kWh REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. YANMAR CO.,LTD. 008439-02X • 4JH4-HTE EPA label EPA recreational MARINE ENGINE EMISSION CONTROL INFORMATION...
Page 70 Number of cylinders 8 : 2008 Combustion chamber design 9 : 2009 Displacement (liter) 0 : 2010 Marine engine Yanmar Method of air aspiration *2006 model year T: Turbocharged H: Turbocharged with intercooler (2) Emission standard The below table shows the emission standard of the EPA Emission Regulations for Marine CI Engines for engines with less than 0.9 liter per...
Page 71 "List of Periodic Inspection" on the operation manual and should be checked carefully. The inspection and maintenance shown below are to be performed at Yanmar dealer or distributor. EPA allows to apply Maintenance schedule for Emission related parts as follows.
Page 72: Inspection And Adjustment
2. Inspection and adjustment 2. Inspection and adjustment 2.1 Periodic maintenance schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. : User-maintenance : Parts replacement : Shop-inspection...
Page 73 2. Inspection and adjustment : User-maintenance : Parts replacement : Shop-inspection Initial Every Every Every Every Before System Item 50hrs. or 50hrs. or 250 hrs. or 500 hrs. or 1000 hrs. or starting one month one month one year 2 years 4 years Check the alarm lamps and devices...
Page 74: Periodic Inspection And Maintenance Procedure
2. Inspection and adjustment 2.2 Periodic inspection and maintenance procedure 2.2.1 Check before starting Be sure to check the following points before starting an engine every day. Inspection item (1) Visual inspection of engine outside (2) Check the fuel level, and refill (3) Check the lube oil level (Crankcase/Marine gear) (4) Seawater outlet (5) Check cooling water level...
Page 75 Total Oil pan only Effective 5.0 ± 0.3 4.5 ± 0.3 KM35P （5.3 ± 0.3）（4.8 ± 0.3） (1.2) 3JH4E 5.5 ± 0.3 5.0 ± 0.3 KM35A (5.8 ± 0.3) (5.3 ± 0.3) SD50 (SD40) (1.3) 5.0 ± 0.3 4.5 ± 0.3 KM35P (5.3 ±...
Page 76 2. Inspection and adjustment (4) Seawater outlet Check whether seawater comes out just after the engine has started. If seawater doesn't come out, shut down the engine immediately. Check the leakage of seawater in the seawater pass and the damage of the seawater pump impeller.
Page 77 Usually do not open the filler cap to check or replenish. Standard Cooling water volume Unit: liter (quart) Engine model Engine Coolant recovery tank 3JH4E 4.5 (4.8) 0.8 (0.8) 4JH4E 6.0 (6.3) 0.8 (0.8) 4JH4-TE/4JH4-HTE 7.2 (7.6) 0.8 (0.8)
Page 78 2. Inspection and adjustment (6) Check the alarm lamps and devices Before and after starting the engine, check to see that the alarm functions normally. Failure of alarm cannot warn the lack of the engine oil or the coolant. Make it a rule to check the alarm operation before and after starting engine every day.
Page 79 2. Inspection and adjustment (7) Check the leakage of water, lube oil and fuel. Before and after starting the engine, check the leakage of coolant and seawater from coolant system. Also check the leakage of lube oil and fuel. (8) Check/adjust the remote control operation Make sure that the accelerator of a boat can be operated smoothly before starting the engine.
Page 80: Inspection After Initial 50 Hours Or One Month Operation
2. Inspection and adjustment 2.2.2 Inspection after initial 50 hours or one month operation Be sure to check the following points after initial 50 hours or one month operation, whichever comes first. Inspection item (1) Drain the fuel tank. (2) Replace the engine lube oil and the lube oil filter. Replace the marine gear lube oil and the lube oil filter.
Page 81 2. Inspection and adjustment 1) Remove the lubricating oil dipstick and also the oil filler cap at the top of the rocker arm cover. Attach the oil drain pump to the dipstick guide and drain off the lube oil. [NOTICE] Dipstick guide For easier draining, remove the oil filler cap (yellow) at the top of the rocker arm cover.
Page 82 2. Inspection and adjustment (3) Replace the marine gear lube oil and the lube oil filter. During initial operation, the oil is quickly KMH4A contaminated due to the initial wear of internal parts. The lube oil must therefore be replaced early.
Page 83 Measure and adjust while the engine is cold. Valve clearance is defined as follows: • 2 valves system (3JH4E, 4JH4E): gap between valve cap and rocker arm. • 4 valves system (4JH4-TE, 4JH4-HTE): gap between valve bridge and rocker arm.
Page 84 2. Inspection and adjustment c) Valve clearance measurement and adjustment 2-valve head (c-1) For 2 valves system (3JH4E, 4JH4E), Adjusting screw insert a thickness gage between the Rocker arm rocker arm and valve cap, and record Valve Lock nut the measured valve clearance.
Page 85 2. Inspection and adjustment (d-2) 4JH4E/ 4JH4-TE/ 4JH4-HTE Turn the crankshaft 180 and make ° measurement and adjustment for the No.3 cylinder. Then adjust the No.4 and No.2 cylinders according to the order of injection. The cylinder to be adjusted first does not have to be the No.1 cylinder.
Page 86 2. Inspection and adjustment 3) Valve clearance adjustment - 4 valves system 4 valve cylinder head a) Loosen adjusting bolts The 4-valve cylinder head has a valve bridge. Remove the injector to make space for Adjusting Loosen inserting a wrench in order to hold valve screw bridge.
Page 87 2. Inspection and adjustment d) Adjusting other cylinders See adjustment method for other cylinders on page 64. (6) Check and adjust the remote control operation The various control levers on the engine side are connected to the remote control lever by the remote control cable.
Page 88 2. Inspection and adjustment (7) Adjust the propeller shaft alignment The flexible engine mounts is compressed a little in the initial engine operation and it may cause the centering misalignment between the engine and the propeller shaft. 1) Check unusual noise and vibration of the engine/boat hull, while increasing the engine speed gradually and lowering it.
Page 89: Inspection Every 50 Hours Or Monthly
Drain the fuel filter. Check the electrolyte level in the battery (1) Drain the fuel filter [3JH4E and 4JH4E] 1) Close the fuel cock of the fuel tank. Air bleeding bolt 2) Loosen the cartridge type fuel filter by a filter wrench.
Page 90 2. Inspection and adjustment [4JH4-TE and 4JH4-HTE] When water and dirt are mixed in with the fuel, it becomes impossible for the fuel injection pump and the fuel injection valve to work. Drain periodically to keep the filter from becoming clogged.
Page 91 2. Inspection and adjustment (2) Check the electrolyte level in the battery Fire due to electric short-circuit •Make sure to turn off the battery switch or disconnect the negative cable (-) before inspecting the electrical system. Failure to do so could cause short-circuiting and fires.
Page 92 2. Inspection and adjustment (1) Electrolyte level • Check the level of fluid in the battery. When the amount of fluid nears the lower limit, Grease fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and Grease...
Page 93 2. Inspection and adjustment (b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must corrected according to the temperature at the time of measurement. The specific gravity of battery electrolyte is defined with 20 ° C as the standard.
Page 94: Inspection Every 250 Hours Or One Year
(1) Drain the fuel tank Refer to 2.2.2(1) for the procedure. (2) Replace the fuel filter [3JH4E and 4JH4E] Replace the fuel filter with new one at the specified interval, before it is clogged with dust to adversely affect the fuel flow. Also, replace the fuel filter after the engine has fully been cooled.
Page 95 2. Inspection and adjustment 5) Bleed the fuel system. Refer to 2.2.3.(1). IMPORTANT: Be sure to use genuine Yanmar part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shorten engine life. [4JH4-TE and 4JH4-HTE] Replace the fuel filter periodically before there is clogging and the fuel flow is reduced.
Page 96 2. Inspection and adjustment (5) Check the impeller of the seawater pump. 1) Remove the seawater pump cover and take Cover out the O-ring, impeller and wear plate. O-ring 2) Inspect the rubber impeller, checking for splitting around the outside, damage or Impeller cracks, and replace if necessary.
Page 97 1) Open the cocks for fresh water and extract the fresh water. Note: One drain cock is behind the belt cover only for 3JH4E and 4JH4E. Remove the belt cover and open the cock.
Page 98 2) Close the cocks for fresh water. Drain cocks Model Drain cocks in seawater line in fresh water line 3JH4E 3 cocks 2 places (1 cock and a side cover of seawater pump) 2 places (a side cover of seawater pump and 1 cock on 4JH4E/4JH4-TE...
Page 99 2. Inspection and adjustment 4JH4-HTE Coolant tank Drain cocks for fresh water Fresh water pump Drain cock for seawater Intercooler Drain seawater from seawater pump cover 008792-00J Drain cock for seawater Fuel pump Drain cock for Clutch cooler fresh water 008793-00J 3) Remove the filler cap of the fresh water cooler by turning the cap counterclockwise 1/3 of a...
Page 100 2. Inspection and adjustment 4) Pour cooling water slowly into the coolant tank so that air bubbles do not develop. Pour until the water overflows from the filler port. Refer to 2.2.1(5) for the coolant capacity. If the filler cap is loose, hot steam and water will spout out which may cause burns.
Page 101 2. Inspection and adjustment (7) Wash turbocharger blower When engine speed seems sluggish or the exhaust color poor, the blades of the turbocharger blower may be dirty. Wash the blower in the following manner. 1) Prepare blower wash　(liquid detergent), fresh water, and a small pitcher. Intake silenser Blower wash (4L) Blower wash...
Page 102 2. Inspection and adjustment (9) Clean air cleaner Occasionally, disassemble the intake silencer (air cleaner) and inspect it. Because the element filters the air, if it is used over a long period of time it will become clogged and this decreases the amount of intake air, and may also be a cause of decreased output and poor emission.
Page 103 2. Inspection and adjustment (12)Check the wiring connectors. Check whether each connection part doesn't have looseness. Alternator Neutral safety switch (Fitting to marine gear) Optional Optional C.W. temp. sensor Starter B terminal Battery Battery switch C.W. temp. switch Starter S terminal Optional Air heater Starting motor...
Page 104: Inspection Every Two Years
Adjust intake/exhaust valve clearance Check/adjust the remote control operation Adjust the propeller shaft alignment (1) Check the injection timing [3JH4E and 4JH4E] The fuel injection timing is adjusted so that engine performance may become the best condition. As for the inspection and adjustment...
Page 105 If it is to be checked for all cylinders, check each cylinder in the ignition order. (1-3-2-1 for 3JH4E, 1-3-4-2-1 for 4JH4E) The cylinder to be checked is not limited to the No.1 cylinder and any cylinder may be checked.
Page 106 2. Inspection and adjustment 1) For the measurement of plunger lift , remove the plug and gasket of a VE pump and install Dial gage a dial gage. 010426-00X (mm) 95.5 M8 x 1.0 ø4 CSD lever Plug 010424-00E 2) Insert a screw driver or a steel bar in the C.S.D.
Page 107 2. Inspection and adjustment Part code of C.S.D. cancel spacer: C.S.D. cancel spacer 129671-51990. 010626-00X (mm) 7.5 ± 0.1 (150) (20) 1. Never turn the screw driver or steel bar to the right for W-C.S.D. release. The C.S.D. lever or wax pellet will be damaged. 2.
Page 108 2. Inspection and adjustment When removing the spacer, never draw the spacer by force. Wax pellet will be damaged by the reaction shock. Remove the spacer and return the C.S.D. lever carefully, while turning the C.S.D. lever by using a screw driver or steel bar. 8) Remove the dial gage, and screw driver or steel bar.
Page 109 2. Inspection and adjustment [Informative: Fuel injection valve structure] 4-valve head (4JH4-TE and 4JH4-HTE) 2-valve head (3JH4E and 4JH4E) 010353-00E 010628-00E 2) Spray pattern inspection After adjustment to the specified valve opening Normal pressure, use a nozzle tester and check the spray pattern and seat oil-tightness.
Page 110 2. Inspection and adjustment b) Spray and injection states • Operate the nozzle tester lever at a rate of Abnormal once or twice a second and check no abnormal injection. • If normal injection as shown below cannot be obtained, replace the fuel injection valve. •...
Page 111 2. Inspection and adjustment (b) Heat exchanger (fresh water cooler) inspection Inspect the fresh water cooler by the following procedure. The intercooler only for 4JH4-HTE can be inspected by the same way. 1) Cooler core inspection a) Inspect the inside of the tubes for rust or scale buildup from seawater, and clean with a wire brush if necessary.
Page 112 007141-00X (5) Diaphragm assembly inspection Inspect the diaphragm assembly on the rocker arm cover only for 3JH4E and 4JH4E. 1) Loosen screws, remove the diaphragm Diaphragm cover Spring assembly, and check for oil and contaminants Center plate between the diaphragm and the cover.
Page 113 (Refer to 5. "Flexible Engine Mount" in the installation manual for pleasure boat use.) Note: Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years, whichever comes first. 2) After replacing the flexible engine mounts,...
Page 114: Adjusting The No-Load Maximum Or Minimum Speed
3) Then set the no-load minimum speed by adjusting the low idle limiting bolt. -1 ) Standards (Unit: min Control lever Model No-load maximum No-load minimum Cable joint 3JH4E 010615-00E 3325±25 825±25 4JH4E 4JH4-TE 3775 800±25 4JH4-HTE...
Page 115: Sensor Inspection
2. Inspection and adjustment 2.4 Sensor inspection 2.4.1 Oil pressure switch Disconnect the connector from the oil pressure switch. Keep the voltameter probes in contact with Oil pressure switch Cylinder block the switch terminal and cylinder block while (flywheel side) operating the engine.
Page 116: Thermostat Inspection
2. Inspection and adjustment 2.5 Thermostat inspection (1) Put the thermostat in a beaker with fresh Thermometer water, and heat it on an electric stove. The thermostat is functioning normally if it starts to open between 75-78 deg C, and opens until 8 mm or more at 90 deg Thermostat C.
Page 117: Adjusting Operation
(2) Remove any precipitation from the fuel filter. water separator, and fuel tank. (3) Use only lube oil recommended by Yanmar. (4) Be sure to add Long Life Coolant Antifreeze (LLC) to cooling fresh water. (5) Provide good ventilation in the engine room.
Page 118: Check Points And Precautions During Running
2. Inspection and adjustment 2.6.3 Check points and precautions during running Step Item Instructions Precautions Checks before 1) Make sure that the sea cock is open. 3) Lamp should go off operation. 2) Make sure there is enough lube oil and (fresh) when engine is coolant.
Page 119: Long Storage
2. Inspection and adjustment 2.7 Long storage Observe the following instructions when the engine is to be stored for a long period without operation: 1) Do not drain fresh water (coolant) in the cold season or before the long storage. [NOTICE] Negligence of adding anti-freeze will cause the fresh water remaining inside the engine to be frozen and expanded to damage the engine parts.
Page 120: Troubleshooting
3. Troubleshooting 3. Troubleshooting 3.1 Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting.
Page 121: Quick Reference Chart For Troubleshooting
3. Troubleshooting 3.2 Quick reference chart for troubleshooting It is important to thoroughly under stand each system and the function of all of the parts of terse systems. A careful study of the engine mechanism will make this possible. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause.
Page 122 3. Troubleshooting THE ENGINE SUDDENLY STOPS (I) Fuel oil supply cut off (II) Governor trouble (IV) Miscellaneous (III) Emergency stoppage device in operation (I) Fuel oil supply cut off Cause and effect Countermeasure Insufficient oil in fuel oil tank. Add fuel oil and prime. Air in fuel oil system and fuel injection pump.
Page 123 3. Troubleshooting CYLINDER OUTPUT IS UNEVEN COUNTERMEASURE (I) Uneven quantity of fuel oil injected (II) Faulty fuel injection valve (I) Uneven quantity of fuel oil injected Cause and effect Countermeasure Air in the fuel injection pump. Bleed air. Faulty operation of plunger. Disassemble and clean.
Page 124 3. Troubleshooting POOR EXHAUST COLOR (I) Faulty fuel injection pump (II) Faulty fuel injection valve (III) Clogged intake air filter (IV) Miscellaneous (I) Faulty fuel injection pump Cause and effect Countermeasure Faulty plunger operation. Check, repair or replace. Worn plunger. Replace.
Page 125 3. Troubleshooting TROUBLE WITH MARINE GEAR (I) Low clutch oil pressure (II) Overheating (III) Abnormal noise (clutch slips) (IV) Difficulty changing into forward, (V) Dragging (VI) Abnormal lube neutral, and reverse oil pressure (I) Low clutch oil pressure (clutch slips) Cause and effect Countermeasure Clogging of filter on suction side.
Page 126 3. Troubleshooting (IV) Difficulty changing into forward, neutral, and reverse Cause and effect Countermeasure Damaged holding spring of pipe. Replace. Foreign material in pipe system. Clean. Oil leakage where there is remote control. Replenish oil and check. Replace seal. Phase slippage. Repair link system.
Page 127 3. Troubleshooting ROTATION IS NOT SMOOTH (I) Faulty operation of (II) Uneven supply of (III) Faulty operation (IV) Miscellaneous injection valve fuel oil injected of governor (I) Faulty operation of injection valve Cause and effect Countermeasure Impediment to valve needle movement. Lap.
Page 128 3. Troubleshooting KNOCKING (I) Faulty fuel injection valve (II) Faulty fuel injected (III) Excessive quantity of fuel (IV) Miscellaneous injected each time (I) Faulty fuel injection valve Cause and effect Countermeasure Low injection pressure. Increase injection pressure. Damaged fuel valve spring. Replace.
Page 129: Starting Trouble
3. Troubleshooting STARTING TROUBLE (I) Pinion gears (II) Ring gears do (III) Fuel oil not (IV) Faulty fuel injection do not mesh not mesh injected valve (V) Faulty fuel injection (VI) Faulty fuel injection (VII) Leakage of (VIII) Miscellaneous pump system pressurized air (I) Pinion gears do not mesh...
Page 130 3. Troubleshooting (IV) Faulty fuel injection valve Cause and effect Countermeasure Faulty valve seat. Lap. Sticking of valve needle. Lap. Worn valve needle. Replace. Clogged outlet. Clean or replace. Low injection pressure. Adjust. (V) Faulty fuel injection pump Cause and effect Countermeasure Worn plunger.
Page 131 3. Troubleshooting INSUFFICIENT POWER OUTPUT (I) Amount of oil supply from fuel (II) Amount of fuel injection (III) Faulty governor (IV) Leakage of pressurized injection pump inadequate inadequate gas from inside cylinder (V) Irregular fuel (VI) Clogged intake (VII) Miscellaneous injection timing air filter (I) Amount of oil supply from fuel injection pump inadequate...
Page 132 3. Troubleshooting (IV) Leakage of pressurized gas from inside cylinder Cause and effect Countermeasure Leakage of gas from suction/exhaust valves. Lap valves. Inadequate tapper clearance. Adjust. Worn upper part of cylinder liner. Replace. Worn piston ring. Replace. Sticking of piston ring. Disassemble and repair or replace.
Page 133 3. Troubleshooting MISCELLANEOUS TROUBLE (I) Abnormal noise (II) Low fuel oil (III) Low lube oil pressure pressure (IV) Lube oil temperature (V) Cooling water temperature (VI) Cooling water pressure is too high is too high is too low (I) Abnormal noise Cause and effect Countermeasure Loose flywheel installment bolt.
Page 134 3. Troubleshooting (V) Coolant temperature is too high Cause and effect Countermeasure Insufficient amount of coolant. Open closed parts. Trouble with cooling water pump. Check pump and repair. Amount of water returning is too great. Adjust amount of returning water. Clogging in coolant system.
Page 135 3. Troubleshooting TURBOCHARGER BREAKDOWN (I) Drop in intake pressure (II) Increased intake pressure (III) Abnormal vibration (IV) Noise (V)Quick contamination (VI) Pulsation of intake air pressure (VII) Others of lubrication oil (I) Drop in intake pressure Cause and effect Countermeasure Dirty filter.
Page 136 3. Troubleshooting (III) Abnormal vibration Cause and effect Countermeasure Broken turbine impeller. Replace. Broken compressor impeller. Replace. Deposit of oxidized deposit on turbine impeller. Remove and repair or replace. Broken bearing. Replace. Bent turbine shaft. Replace. Loose fixed parts. Tighten. (IV) Noise Cause and effect Countermeasure...
Page 137: Troubleshooting (Concerning Engine And Fuel Injection Equipment)
3. Troubleshooting 3.3 Troubleshooting (Concerning engine and fuel injection equipment) Malfunctions Causes Remedies The engine does not operate. 1. Fuel oil is not injected from the 1. There is no fuel oil in the fuel Supply fuel and bleed the system. injection pump.
Page 138 3. Troubleshooting Malfunctions Causes Remedies The engine exhaust contains 1. The injection timing is incorrect. Readjust the timing. smoke and the engine “knocks”. 2. The nozzle or nozzle holder is Inspect, then repair or replace. functioning incorrectly. 3. The injection quantity is Readjust.
Page 139 3. Troubleshooting Malfunctions Causes Remedies 4. The nozzle or the nozzle holder Inspect and then repair or replace. is not functioning properly. The engine cannot reach its 1. The governor spring is too weak Readjust or replace. maximum speed. or is improperly adjusted. 2.
Page 140: Troubleshooting By Measuring Compression Pressure
Engine compression pressure list (reference value) Compression pressure at 250 min Deviation among cylinders Model MPa (kgf/cm MPa (kgf/cm Standard 3JH4E/ 4JH4E/ 4JH4-TE 3.4 ± 0.1 (35 ± 1) 0.2 to 0.3 (2 to 3) 4JH4-HTE 3.2 ± 0.1 (32 ± 1)
Page 141 3. Troubleshooting (3) Engine speed and compression pressure (for reference) 3JH4E/4JH4E/4JH4-TE 4HJ4-HTE Engine speed (min 015522-00X (4) Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below.
Page 142: Disassembly And Reassembly
4. Disassembly and reassembly 4. Disassembly and reassembly 4.1 Disassembly and reassembly precautions (1) Disassembly • Take sufficient time to accurately pin-point the cause of the trouble, and disassemble only those parts which are necessary. • Be careful to keep all disassembled parts in order. •...
Page 143: Disassembly And Reassembly Tools
4. Disassembly and reassembly 4.2 Disassembly and reassembly tools The following tools are required when disassembling and reassembling the engine. Please use them as instructed. 4.2.1 General hand tools Name of tool Illustration Remarks Wrench Size: 10 x 13 12 x 14 17 x 19 22 x 24 001385-00X...
Page 144 4. Disassembly and reassembly Name of tool Illustration Remarks Box spanner Local supply 1 set 001395-00X Scraper Local supply 001396-00X Lead rod Local supply 001397-00X File Local supply 1 set 001398-00X Rod spanner for Local supply hexagon socket Size: 6 mm head screws 8 mm 10 mm...
Page 145: Special Hand Tools
Extraction of piston pin extraction tool 006943-01X 011221-00X Insertion of piston pin 011222-00X Connecting rod Extraction small end bushing insertion/extraction tool for 3JH4E / 4JH4TE 010365-00X 25.4-25.7 28.4-28.7 010364-00X Connecting rod Extraction small end bushing insertion/extraction tool for 4JH4-TE /...
Page 146 4. Disassembly and reassembly Name of tool Illustration Remarks Intake and exhaust valve guide insertion/extraction tool Tool 006943-01X 008300-00E Lube oil filter case remover 001409-00X 007150-00X Puller A (standard) Puller A: 129671-92110 (standard) for seawater pump impeller M18 x 1.5 threaded 008424-04X 015041-00E...
Page 147 4. Disassembly and reassembly Name of tool Illustration Remarks Puller B (option) for Puller B: 129671-92100 (option) seawater pump impeller 008425-01X 011206-00X Around 110 Around 140 C.S.D. cancel Spacer: 129671-51990 spacer for the adjustment of fuel Screw driver injection timing C.S.D.
Page 148 4. Disassembly and reassembly Name of tool Illustration Remarks Valve lapping tool (Rubber cap type) 001412-00X Valve lapping powder 001413-00X Feeler gauge Lock nut Adjusting screw Feeler gauge 001414-00X 011215-00E Pulley puller Local supply Removing the coupling 001417-00X 001416-01E...
Page 149 4. Disassembly and reassembly Name of tool Illustration Remarks Press tool 1 for filler Tool 1 neck 010331-00X ø35.5 ø27.5 ø25 105 ø40 Press tool 2 for filler Tool 2 neck copper tube 010332-00E ø28 ø24.2 ø30...
Page 150 4. Disassembly and reassembly Name of tool Illustration Remarks Stem seal insertion (for inserting stem seal) 001421-01X 001422-02X 16.2 13.5 18.8 Fuel nozzle extraction tool 010333-00X Part No. 129470-92300...
Page 151: Measuring Instruments
4. Disassembly and reassembly 4.2.3 Measuring instruments (1) Application of tools Name of tool Illustration Application Vernier calipers 0.05 mm 0-150 mm 001423-00X Micrometer 0.01 mm 0-25 mm 25-50 mm 50-75 mm 75-100 mm 001432-00X 100-125 mm 125-150 mm Cylinder gauge 0.01 mm 18-35 mm 35-60 mm...
Page 152 4. Disassembly and reassembly (2) Use of tools Name of tool Illustration Dial gauge Measures shaft bending, distortions of levelness, and gaps. 001429-00X Test indicator Measures narrow and deep places, which cannot be measured with dial gauge. 001430-00X Magnetic stand Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles.
Page 153 4. Disassembly and reassembly Name of tool Illustration Torque wrench Used to tighten bolts and nuts to standard torque. 001438-00X Thickness gauge Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling.
Page 154 4. Disassembly and reassembly Name of tool Illustration Rotation Contact type Measures rotation speed by using a gauge reflector seal which is placed on the exterior of the revolving shaft. 001443-00X Photoelectric Measures rotation speed by using a Revolving shaft type reflector seal which is placed on the exterior of the revolving shaft.
Page 155 4. Disassembly and reassembly Name of tool Illustration Compression gauge Measures the pressure of the compression. Gauge set code No. TOL-97190080 001448-00X Adapter for direct injection 2-valve head. Adapter code No. 119802-92950 010334-00X Adapter for direct injection 4-valve head. Adapter code No. 129906-92950 010334-00X...
Page 156: Other Material
4. Disassembly and reassembly 4.2.4 Other material Items Usual contents Features and application Liquid gasket Three Bond 200 g Non-drying liquid gasket; solvent less type, easy to No.1 (1 kg also remove, superior in seawater resistance, applicable TB1101 available) to various mating surfaces. Three Bond 200 g Non-drying liquid gasket;...
Page 157 4. Disassembly and reassembly Items Usual contents Features and application Scale solvent Scale solvent 1 box • The scale solvent removes scale in a short time. (4 kg x 4 (1 to 10 hours) removers) • Prepare water (seawater is possible) in an amount that is about 10 times the weight of the Neutralizer 1 box...
Page 158: Disassembly And Reassembly
Don't forget to open a drain cock on a clutch cooler for 4JH4E,4JH4-TE and 4JH4-HTE. 2) Open the cocks for fresh water and extract the fresh water. Note: One drain cock is behind the belt cover only for 3JH4E and 4JH4E. Remove the belt cover and open the cock. Drain cocks...
Page 159 4. Disassembly and reassembly 3JH4E 4JH4-TE Drain cock for Drain cocks Fresh water pump Coolant tank fresh water Fresh water pump Coolant tank for fresh water Drain seawater from seawater pump cover 015029-00E Drain cock for Seawater pump Drain cock for...
Page 160 When not removing a oil filler cap and draining, negative pressure grows big in the crankcase and it may cause the rubber of the diaphragm cracked only for 3JH4E and 4JH4E. 2) Remove the drain plug on the lower part of the case, and drain the lube oil from the marine gearbox.
Page 161 Remove the wiring from the engine. (Refer to 2.2.4(12)) (4) Removing the fuel filter and fuel pipe 1) Remove the fuel pipes (fuel filter-fuel feed 3JH4E pump, fuel filter-fuel injection pump and fuel nozzle-fuel filter) 2) Remove the fuel filter.
Page 162 4. Disassembly and reassembly (5) Removing the intake silencer 3JH4E/ 4JH4E 1) Remove the breather hose attached to the intake silencer-rocker arm cover. Intake silencer Breather hose Rocker arm cover 2) Remove the intake silencer from intake Clamp manifold. Clamp...
Page 163 3JH4E/ 4JH4E connecting a heat exchanger and a mixing elbow. 2) Remove the mixing elbow from the exhaust manifold for 3JH4E and 4JH4E or from the Seawater turbocharger for 4JH4-TE and 4JH4-HTE. L-type mixing elbow Gasket Exhaust manifold...
Page 164 4. Disassembly and reassembly (7) Removing the turbocharger (only for 4JH4-TE and 4JH4-HTE) 1) Remove the intake pipes (turbine-intercooler- 4JH4-TE intake manifold for 4JH4-HTE). 2) Remove the pipes and hoses for the turbine. 3) Remove the turbine. Turbocharger Intake pipes 010539-00E 4JH4-HTE Intake pipes...
Page 165 4. Disassembly and reassembly (9) Removing the starting motor Remove the starting motor from the flywheel housing. Flywheel housing Starting motor 010436-00E (10) Removing the alternator 1) Loosen the alternator adjuster bolt and Adjuster Fresh water pump remove the V-belt. 2) Removing the adjuster from the fresh water pump, and remove the alternator from the gear case (with distance piece).
Page 166 4. Disassembly and reassembly (11) Removing the cooling water pipe (seawater/ fresh water) 3JH4E 3JH4E Fresh water pipe Seawater pipe Heat exchanger Mixing elbow Heat exchanger Exhaust manifold Fresh water pump Seawater pump From lube oil cooler 010389-00E Seawater inlet...
Page 167 4. Disassembly and reassembly 1) Remove the seawater pipe (seawater pump - heat exchanger). 2) Remove the fresh water pipe (fresh water pump - heat exchanger, exhaust manifold - fresh water pump). 3) Remove the fresh water pipe (cylinder block - lube oil cooler, lube oil cooler - fresh water pump).
Page 168 4. Disassembly and reassembly (15) Removing the fuel injection pipe 1) Remove the fuel injection pipe retainer. 3JH4E 2) Loosen the cap nuts on both ends of the fuel Fuel injection pipe injection pipe and remove the fuel injection pipe.
Page 169 4. Disassembly and reassembly (18) Removing the fuel injection nozzles 3JH4E and 4JH4E (2-valve head) Remove the bolt for the fuel nozzle retainer, and pull out the fuel nozzle retainer and fuel injection nozzle. Fuel injection nozzle Note: If the fuel nozzle protector stays in the...
Page 170 Fuel pump gear nut drive gear 015350-00X 2) Remove the fuel injection pump and O-ring from the gear case flange. (3JH4E and Fuel injection pump 4JH4E). Remove the fuel injection pump and O-ring Pump flange from the VE pump bracket, which is fixed to...
Page 171 4. Disassembly and reassembly (22) Removing the marine gearbox Loosen the bolts for the clutch case flange, and remove the gearbox assembly (23) Removing the flywheel Loosen the flywheel bolts and remove the flywheel. Flywheel housing Note: Be careful not to scratch the ring gear. Flywheel 010438-00E (24) Turning the engine over...
Page 172 4. Disassembly and reassembly (27) Removing the lube oil inlet pipe Remove the lube oil inlet pipe and gasket. Gear case flange Gasket Lube oil inlet pipe 010441-00E (28) Removing the gear case Loosen the gear case bolts, and remove the gear case from the gear case flange.
Page 173 4. Disassembly and reassembly (31) Removing the camshaft 1) Push up tappet by turning a camshaft to remove it from the cylinder block easily. 2) Loosen the thrust metal bolts through the holes of the camshaft gear, and remove. 3) Pull out the camshaft gear and camshaft assembly from the cylinder block.
Page 174 4. Disassembly and reassembly (35) Turning the engine over Turn the engine over, with the cylinder head mounting surface facing down. Note: Make sure that cylinder head positioning pins on the cylinder block do not come in contact with the wood block. 010428-00X (36) Removing the flywheel housing and oil seal case...
Page 175 4. Disassembly and reassembly (38) Removing the crankshaft 1) Remove the crankshaft. Note: 1) The thrust metal (upper) is mounted to the standard main bearing. 2) Remove the main bearing metal (upper) from the cylinder block. 010432-00X 010429-00X (39) Removing the tappets Remove the tappets from the tappet holes in the cylinder block.
Page 176: Reassembly
4. Disassembly and reassembly 4.3.2 Reassembly (1) Clean all parts Clean all parts using by the cloth and diesel oil (or cleaning agent) before reassembly. Note: 1) If the dust remain with the parts, engine may cause the seizing or damage. 2) The cleaning agent removes even carbon adhering to disassembled parts.
Page 177 4. Disassembly and reassembly (4) Mounting the crankshaft 1) The crankshaft and the crankshaft gear are shrink-fitted. If the crankshaft and the crankshaft gear have been disassembled, they have to be shrink-fitted [heat the crank shaft gear to 180- 200 deg. C in the hot oil and press fit to the crankshaft].
Page 178 4. Disassembly and reassembly Note: 1) The main bearing cap should be mounted with the arrow on the cap pointing towards the flywheel. 2) Make sure to have the correct cylinder alignment number. 2) Measure the crankshaft side clearance. Mark Position number of reassembling Standard...
Page 179 4. Disassembly and reassembly (8) Mounting the gear case flange Apply the liquid gasket to the gear case flange and mount the gear case flange and lube oil line O-ring onto the cylinder block. Note: 1) When mounting the gear case flange, Liquid gasket match up the two knock pins of the cylinder block.
Page 180 4. Disassembly and reassembly 3) The piston ring joints shall be staggered at 120° in the interval. Do not position the top 1st piston ring gap ring joint vertical to the piston pin. The coil expander joint shall be opposite to the oil ring joint.
Page 181 4JH4-HTE) mounted to the back of the cylinder block. The cooling nozzle may warp or be damaged. Assembly direction of connectingrod and piston 4JH4-TE and 4JH4-HTE 3JH4E and 4JH4E Model mark Size mark Size mark & model mark Cylinder size mark...
Page 182 4. Disassembly and reassembly (10) Mounting the camshaft 1) If the camshaft and the camshaft gear have been disassembled, shrink fit the camshaft and the camshaft gear [heat the camshaft gear to 180-220 deg. C in the hot oil and press fit].
Page 183 4. Disassembly and reassembly 2) Align the “A” and “C” match marks of the idle gear with the match marks of the camshaft Camshaft gear gear and the crankshaft gear. 3) Measure the idle gear, camshaft gear and Seawater pump gear crankshaft gear backlash.
Page 184 4. Disassembly and reassembly (15) Mounting the spacer and the oil pan 1) Apply the liquid gasket to the surfaces of the Cylinder block gear case cover, gear case flange and oil seal case on the flywheel housing side, that contact with the cylinder block.
Page 185 4. Disassembly and reassembly (19) Mounting the marine gearbox 1) Mount the damper disk to the flywheel. 2) Align the damper disk with the input shaft spline and insert. Mount the marine gearbox to the flywheel housing. (20) Mounting the cylinder head 4JH4E 4JH4-TE/ 4JH4-HTE 1) Put the cylinder head gasket on the cylinder...
Page 186 010613-01E (22) Mounting the fuel injection pump For 3JH4E and 4JH4E 1) Lightly fit the fuel injection pump on the gear case flange. (After adjusting injection timing, tighten the fuel injection pump).
Page 187 4. Disassembly and reassembly For 4JH4-TE and 4JH4-HTE 1) Install the VE pump bracket and O-ring to the gear case flange while adjusting both mark-off Gear case flange lines of the bracket and gear case flange. 2) Install the fuel injection pump and O-ring to the VE pump bracket while adjusting both mark-off lines of the bracket and VE pump.
Page 188 4. Disassembly and reassembly Note: In case of 4-valve head the fuel inlet of the 4-valve head fuel nozzle must align the pipe seal, which is installed to the rocker arm cover. Replace the Retainer flange bolt used pipe seal with new one. Fuel injection valve retainer Retainer pedestal 2) Tighten the fuel nozzle retainer bolt to the...
Page 189 4. Disassembly and reassembly 2) Mount the fuel return pipe with the clamp (fuel injection nozzle - fuel filter). 3JH4E and 4JH4E 4JH4-TE and 4JH4-HTE Fuel injection pipe Fuel return pipe Fuel injection nozzle Clamp Fuel injection pipe retainer Fuel return pipe...
Page 190 Mount the gasket and heal exchanger (exhaust manifold) to the cylinder head. (30) Mounting the cooling water pipes (seawater / fresh water) The example shows the seawater / fresh water lines of 3JH4E. Fresh water pipe Seawater pipe Heat exchanger Mixing elbow...
Page 191 4. Disassembly and reassembly 1) Mount the seawater pipes with the hose clips (seawater pump-heat exchanger). 2) Mount the fresh water pipes with the hose clips (exhaust manifold - fresh water pump, fresh water pump - heat exchanger). 3) Mount the fresh water pipes (cylinder block - lube oil cooler, lube oil cooler - fresh water pump).
Page 192 4. Disassembly and reassembly (33) Mounting the intercooler (only for 4JH4-HTE) 1) Mount the intercooler. Air duct 2) Mount the seawater pipes with the hose clips. 3) Mount the air duct from the intercooler to the intake manifold. Mount the air duct from the turbocharger to the intercooler.
Page 193 4. Disassembly and reassembly (35) Mounting the mixing elbow 1) Mount the mixing elbow on the exhaust manifold outlet for 3JH4E and 4JH4E and on the turbocharger for 4JH4-TE and 4JH4-HTE. 2) Mount the cooing seawater pipe (rubber hose) with the hose clips (heat exchanger- mixing elbow).
Page 194 4. Disassembly and reassembly (41) Filling with coolant 1) Open the coolant (fresh water) tank filler cap and fill with coolant. 3JH4E 4JH4E 4JH4-TE/ 4JH4-HTE 2) Fill with water until the level in the coolant recovery tank is between the full and low marks.
Page 195: Inspection And Servicing Of Basic Engine Parts
5. Inspection and servicing of basic engine parts 5. Inspection and servicing of basic engine parts 5.1 Cylinder block The cylinder block is a thin-skinned, (low-weight), Cap plug 50 mm short skirt type with rationally placed ribs. The side (Camshaft hole) Cap plug 30 mm walls are save shaped to maximize rigidity for strength and low noise.
Page 196: Color Check Procedure
5. Inspection and servicing of basic engine parts 5.1.3 Color check procedure (1) Clean the area to be inspected (2) Color check kit The color check test kit consists of an aerosol cleaner, penetrant and developer. (3) Clean the area to be inspected with the cleaner Either spray the cleaner on directly and wipe, or wipe the area with a cloth moistened with...
Page 197: Replacement Of Cup Plugs
5. Inspection and servicing of basic engine parts 5.1.4 Replacement of cup plugs Step Description Procedure Tool of material used Clean and remove glue from the hole into which Screw driver or saw the cap plug is to be driven. blade (Remove scale and sealing material previously Thinner...
Page 198: Cylinder Bore Measurement
5. Inspection and servicing of basic engine parts 5.1.5 measurement Cylinder bore Especially clean head surface, cylinder bores and oil holes, and check the below items after removing any carbon deposit and bonding agent. (a) Appearance inspection Check if there is any discoloration or crack. If crack is suspected, perform color check.
Page 199: Cylinder Head
5. Inspection and servicing of basic engine parts 5.2 Cylinder head The cylinder head is of 3-cylinder or 4-cylinder integral construction. Special alloy stellite with superior resistance to heat and wear is fitted on the valve seats, and the area between the intake/ exhaust valves is cooled by the water jet.
Page 200 5. Inspection and servicing of basic engine parts 4-valve cylinder head Rocker arm cover Rocker arm shaft Rocker arm Adjusting bolt Valve bridge Cotter Spring holder Valve spring Stem seal Valve guide Rocker arm support Cylinder head Exhaust valve Intake valve 010359-00E...
Page 201: Inspecting The Cylinder Head
5. Inspection and servicing of basic engine parts 5.2.1 Inspecting the cylinder head The cylinder head is subjected to very severe operating conditions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts.
Page 202: Valve Seat Correction Procedure
5. Inspection and servicing of basic engine parts 5.2.2 Valve seat correction procedure most common method correcting unevenness of the seat surface with a seat grinder is as follows: (1) Use a seat grinder to make the surface even. As the valve seat width will be enlarged, first use a 70 grinder, then grind the seat to the °...
Page 203 5. Inspection and servicing of basic engine parts (2) Knead valve compound with oil and finish the valve seat with a lapping tool. (3) Final finishing should be done with oil only. Lapping tool Use a rubber cap type lapping tool for cylinders without a lapping tool groove with oil only.
Page 204: Intake/Exhaust Valves, Valve Guides
(1) Wearing and corrosion of valve stem Replace the valve stem is excessively worn or corroded. Valve stem Standard Limit outside dia. 010548-00X Intake Ø7.955-Ø7.975 Ø7.90 3JH4E 4JH4E Exhaust Ø7.955-Ø7.970 Ø7.90 Intake Ø5.960-Ø5.975 Ø5.90 4JH4-TE 4JH4-HTE Exhaust Ø5.945-Ø5.960 Ø5.90...
Page 205 Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit. Standard Limit Intake 8.010-8.025 Valve guide inside diameter Exhaust 8.015-8.030 3JH4E 4JH4E Intake 0.035-0.070 0.18 Clearance Exhaust 0.045-0.075 0.18 Intake 6.000-6.015 Valve guide...
Page 206 Tool 011230-00E 3) Valve guide projection Check the projection from the cylinder head. Valve guide projection 3JH4E/ 4JH4E -0.3 4JH4-TE/ 4JH4-HTE -0.3 Stem seal Valve guide Valve guide projection Stem seal projection...
Page 207 The stem seal projection is as follows. The clearance between the stem seal and the upper surface of valve guide is around 0.2 mm to 0.8 mm. Stem seal Valve stem seal projection Valve guide 3JH4E/ 4JH4E -0.3 Cylinder head 4JH4-TE/ 4JH4-HTE 10.2 -0.3 011204-00E The intake valve guide and exhaust valve guide are of different dimensions.
Page 208: Valve Springs
1) Check the spring for scratches or corrosion. 2) Measure the free length of the spring. 001509-01X 3) Measure inclination. Inclination Free length 001510-00E 001511-00X 4) Measure spring tension. 3JH4E/4JH4E 4JH4-TE/4JH4-HTE Valve spring Unit Standard Limit Standard Limit Free length A 44.4...
Page 209 5. Inspection and servicing of basic engine parts 5) Assembling valve springs. The side with the smaller pitch (painted Up side yellow) should face down (cylinder head). Note: The pitch of the valve spring is not even. The side with the smaller pitch (yellow) should face down (cylinder head) when assembled.
Page 210: Assembling The Cylinder Head
5. Inspection and servicing of basic engine parts 5.2.5 Assembling the cylinder head Partially tighten the bolts in the specified order and Disassembly (Head bolt loosening order) then tighten to the specified torque, being careful that the head does not get distorted. (1) Clean out the cylinder head bolt holes.
Page 211: Measuring Top Clearance
5. Inspection and servicing of basic engine parts 5.2.6 Measuring top clearance (1) Place a high quality fuse ( 1.2 mm, 10 Ø mm long) in three positions on the flat part of the piston head. (2) Assemble the cylinder head gasket and the cylinder block and tighten the bolts in the specified order to the specified torque.
Page 212: Intake And Exhaust Rocker Arms
5. Inspection and servicing of basic engine parts 5.2.7 Intake and exhaust rocker arms The wear of rocker arm and rocker arm bushing may change opening/closing timing of the valve, and may in turn affect the engine performance according to the extent of the change. (1) Rocker arm shaft and rocker arm bushing Measure the outer diameter of the shaft and the inner-diameter of the veering, and replace...
Page 213: Adjustment Of Valve Clearance
5. Inspection and servicing of basic engine parts 5.2.8 Adjustment of valve clearance (1) Make adjustments when the engine is cool. (Refer to 2.2.2(5).) Intake and exhaust valve clearance 0.15-0.25 (2) Valve timing Be sure that the opening and closing angles for both the intake and the exhaust valves are checked when...
Page 214: Piston And Piston Pins
The ID marks (model mark and size mark) are 2nd compression ring incused on the top surface of the piston. Model mark Oil ring Model Mark 3JH4E I.D. mark (Size mark) I.D. mark (Model mark) 4JH4E 4JH4 Piston 4JH4-TE Piston pin...
Page 215: Piston
2) Measure the outside diameter in the position of 22mm from the piston bottom in the direction vertical to the piston pin. Piston outside diameter Clearance between Model Standard Limit piston and cylinder 3JH4E 87.950-87.960 87.900 0.045-0.075 4JH4E 87.935-87.945 87.885 0.060-0.090 Piston 22 mm bottom 4JH4-TE 83.930-83.940 83.880...
Page 216: Piston Pin
5. Inspection and servicing of basic engine parts 5.3.2 Piston pin Measure the outer diameter and replace the pin if it is excessively worn. 3JH4E/4JH4E 4JH4-TE/4JH4-HTE Standard Limit Standard Limit Piston pin hole inside dia. 26.000-26.009 26.020 28.000-28.009 28.020 Piston pin outside dia.
Page 217: Piston Rings
5. Inspection and servicing of basic engine parts 5.3.3 Piston rings Two compression rings and one oil ring are applied. 3JH4E 4JH4-TE The absence of an oil ring on the piston skirt 4JH4E 4JH4-HTE prevents oil from being kept on the thrust surface and in turn provides good lubrication.
Page 218 5. Inspection and servicing of basic engine parts (2) Measuring piston ring gap (End clearance) Press the piston ring onto a piston liner and measure the piston ring gap with a gauge. Press on the ring about 30mm from the bottom of the liner.
Page 219 5. Inspection and servicing of basic engine parts 1st piston ring 2st piston ring Oil ring Expander joint 1st piston ring gap 2st piston ring gap Oil ring gap 010550-00E 5) The oil ring is provided with a coil expander. The coil expander joint should be opposite (staggered 180°) the oil ring gap.
Page 220: Connecting Rod
5. Inspection and servicing of basic engine parts 5.4 Connecting rod The connecting rod is made of high-strength Piston pin bushing forged carbon steel. The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing.
Page 221: Inspecting The Connection Rod
5. Inspection and servicing of basic engine parts 5.4.1 Inspecting the connection rod (1) Twist and parallelism of the large and 1 0 0 small ends 1 0 0 Insert the measuring tool into the large and small ends of the connecting rod. Measure the extent of twist and parallelism and replace if Parallelism they exceed the tolerance.
Page 222: Crank Pin Metal
5. Inspection and servicing of basic engine parts 5.4.2 Crank pin metal (1) Checking crank pin metal Check for flaking, melting or seizure on the contact surface of the crank pin metal. (2) Measuring crank pin oil clearance Measure the crankpin outside diameter and the crank pin metal inside diameter.
Page 223 5. Inspection and servicing of basic engine parts (3) Precautions on replacement of crank pin metal 1) Wash the crank pin metal. 2) Wash the large end cap, mount the crank pin metal and make sure that it fits tightly on the large end cap.
Page 224: Piston Pin Bushing
Measure the piston pin bushing inside diameter and the piston pin outside diameter. Calculate the oil clearance from the measured values. (Refer to 5.3.2 for the piston pin.) Cylinder gauge 008303-01E 3JH4E/4JH4E 4JH4-TE/4JH4-HTE Standard Limit Standard Limit Piston pin bushing 26.025-26.038...
Page 225: Crankshaft And Main Bearing
5. Inspection and servicing of basic engine parts 5.5 Crankshaft and main bearing The crank pin and crank journal have been induction hardened for superior durability, and the crankshaft is provided with for balance weights for optional balance. The crankshaft main veering is of the hanger type.
Page 226 5. Inspection and servicing of basic engine parts (3) Measuring the crank pin and journal Measure the outside diameter, roundness and taper at each crank pin and journal. Correct grinding unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Replace if the defect is excessive.
Page 227 5. Inspection and servicing of basic engine parts (4) Checking the side gap of a crankshaft After assembling the crankshaft, tighten the main bearing cap to the specified toque, and move the crankshaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance.
Page 228: Main Bearing
5. Inspection and servicing of basic engine parts 5.5.2 Main bearing (1) Inspecting the main bearing Check for flaking, seizure or burning of the Oil hole contact surface and replace if necessary. Upper main Lower main bearing metal bearing metal (2) Measuring the inner diameter of metal Tighten the cap to the specified torque and Thrust metal...
Page 229: Camshaft And Tappets
Thrust metal Standard Limit Camshaft side gap 0.05-0.20 0.35 Side clearance 010643-00E (2) Measure the cam height, and replace the cam if it is worn beyond the limit. 007709-00X 3JH4E/4JH4E 4JH4-TE/4JH4-HTE Standard Limit Standard Limit Intake 39.800-40.000 39.550 Cam height 38.600-38.800 38.350...
Page 230 5. Inspection and servicing of basic engine parts (3) Camshaft and bearing hole measurement Measure the camshaft outside diameter with a micrometer. The oil clearance shall be calculated subtracting the measured camshaft outside diameter from the inside diameter of the camshaft bearing or bushing. The camshaft bushing at gear case side is measured with a cylinder gage after insertion to the cylinder.
Page 231: Tappets
008290-01E surface surface them separate for each cylinder and intake/ exhaust valve. (2) Measure the outer diameter of the tappet, and replace if worn beyond the limit. 006462-00X 3JH4E/4JH4E 4JH4-TE/4JH4-HTE Standard Limit Standard Limit Tappet stem outside dia. 11.975~11.990 11.930 11.975-11.990...
Page 232: Timing Gear
5. Inspection and servicing of basic engine parts 5.7 Timing gear The timing gear is helical type for minimum noise and specially treated for high durability. 5.7.1 Inspecting the gears (1) Inspect the gears and replace if the teeth are damaged or worn. (2) Measure the backlash of all gears that mesh, and replace the meshing gears as a set if wear exceeds the limit.
Page 233: Flywheel And Housing
5. Inspection and servicing of basic engine parts 5.8 Flywheel and housing The function of the flywheel is through inertia, to rotate the crankshaft in a uniform and smooth manner by absorbing the turning force created during the combustion stroke of the engine, and by compensating for the decrease in turning force during the other strokes.
Page 234: Position Of Top Dead Center And Fuel Injection Timing
5. Inspection and servicing of basic engine parts 5.8.1 Position of top dead center and fuel injection timing The marking is applied to the flywheel and flywheel housing to indicate the top dead center of this engine or the fuel injection timing angle. (1) Marking The marking is applied on the flywheel to show the crankshaft angle.
Page 235: Fuel Injection Equipment
6. Fuel Injection equipment 6. Fuel Injection equipment 6.1 Fuel Injection pump/governor for 3JH4E and 4JH4E Refer to the JH3E manual of separate volume for disassembly assembly, adjustment procedure of a fuel injection pump. 6.1.1 Fuel system diagram Fuel nozzle...
Page 236: Fuel Injection Pump Service Data
6. Fuel Injection equipment 6.1.2 Fuel injection pump service data (1) 3JH4E service date Part code (Back No.) 729271-51450 (TM02) Adjustment SPEC ENG SPEC SERVICE STD Item Fuel valve (Valve pressure) VBG (220) (170) Nozzle type (ID mark) 159P185VAD1 DN-12SD12 Fuel injection pipe Ø...
Page 237 6. Fuel Injection equipment (2) 4JH4E service data Part code (Back No.) 729670-51450 (SH79) Adjustment SPEC ENGINE SPEC SERVICE STD Item Fuel valve (Valve pressure) VBG (220) (170) Nozzle type (ID mark) 159P185VAD1 DN-12SD12 Fuel injection pipe Ø1.6 x 400 Ø2 x 600 Injection Starting...
Page 238 6. Fuel Injection equipment (3) Adjusting fuel limit bolt at rated load 1) Adjust the fuel limit bolt to bring the rack Note: The figure in the blank ( ) is the indicator. position to the specified value (R ) with the governor control lever towards the fuel increase position, while keeping the pump at rated speed N...
Page 239: Fuel Injection Pump Structure
6. Fuel Injection equipment 6.1.3 Fuel injection pump structure (1) Component of fuel injection pump for 3JH4E Pump flange Fuel injection Fuel injection pump pump drive gear Pump flange bolt Governor Feed pump Spring washer Don't disassemble Pump drive gear nut...
Page 240: Removing A Fuel Injection Pump
6. Fuel Injection equipment 6.1.4 Removing a fuel injection pump The procedure to remove a fuel injection pump from the gear case is shown. Fuel injection pump [NOTICE] Pump flange Be sure to remove a flange and a fuel injection Fuel injection pump drive gear as a pair without loosening the pump drive gear...
Page 241: Installing A Fuel Injection Pump
6. Fuel Injection equipment 6.1.5 Installing a fuel injection pump [NOTICE] • Use a new O-ring on the fuel pump flange and apply grease. • Confirm whether the marks of the pump drive gear and the idle gear is correct. 1) Turn a camshaft so that the key of the pump camshaft may almost agree in a position of the key groove of a pump drive gear.
Page 242: Tools
6. Fuel Injection equipment 6.1.8 Tools Name of tool Shape and size Application Pump mounting scale for Yanmar tester 158090-51010 for Bosch (tester) 158090-51020 010678-00X 010677-00X Measuring device (cam backlash) 158090-51050 010679-00X Plunger insert 158090-51100 010680-00X 010681-00X Tappet holder 158090-51200...
Page 243 6. Fuel Injection equipment Name of tool Shape and size Application Rack indicator 158090-51500 010686-00X Rack lock screw 158090-51510 010688-00X 010689-00X Dummy nut 158090-51520 010687-00X Nozzle plate 158090-51700 010690-00X 010691-00X Plunger gauge 121820-92540 010693-00X 010692-00X Top clearance gauge 158090-51300 010694-00X 010695-00X...
Page 244: Fuel Feed Pump
6. Fuel Injection equipment 6.2 Fuel feed pump The fuel feed pump pumps fuel from the fuel tank, passes it through the fuel filter element, and supplies it to the fuel injection pump. The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft.
Page 245: Disassembly And Reassembly Of Fuel Feed Pump
6. Fuel Injection equipment 6.2.3 Disassembly and reassembly of fuel feed pump (1) Disassembly 1) Remove the fuel feed pump mounting nut, and take the fuel feed pump off the fuel injection pump. 2) Clean the fuel feed pump assembly with fuel oil.
Page 246: Fuel Feed Pump Inspection
6. Fuel Injection equipment 6.2.4 Fuel feed pump inspection (1) Place the fuel feed pump in kerosene, Measuring cylinder cover the discharge port with your finger, move the priming lever and check for air Air pressure kg/cm bubbles (Repair or replace any part Tappet Container filled which emits air bubbles).
Page 247: Fuel Injection Pump/ Governor For 4Jh4-Te And 4Jh4-Hte
6. Fuel Injection equipment 6.3 Fuel injection pump/ governor for 4JH4-TE and 4JH4-HTE 6.3.1 Fuel system diagram Priming pump Overflow pipe Overflow valve Magnetic valve Fuel filter Injection nozzle Regulating valve Plunger barrel Plunger Feed pump Drive shaft Fuel tank 010344-00E...
Page 248: Fuel Injection Pump Structure
6. Fuel Injection equipment 6.3.2 Fuel injection pump structure (1) Specification The fuel injection pump is VE type (Bosh made). [NOTICE] The disassembly and adjustment of a fuel injection pump need expertise and facilities. Make a request to Bosh service shop for them.
Page 249 6. Fuel Injection equipment (2) Structure and function Governor Control lever Flyweight spring Idling spring Full load adjusting screw Control lever shaft Tension lever Governor lever assembly Regulating valve Magnetic valve Drive shaft Plunger Outlet port Delivery valve Control sleeve Feed pump Drive gear Plunger spring...
Page 250 6. Fuel Injection equipment 2) Governor a) The governor, which is located above the Control lever pump house, consists of a flyweight holder, Governor sleeve Control lever shaft governor lever assembly, etc. The flyweight Retaining pin holder holds four flyweights and governor Tension lever sleeve and is supported by the governor...
Page 251 6. Fuel Injection equipment 4) Boost compensator Boost pressure inlet Boocon Diaphragm Boocon spring Adjusting pin Connecting pin Boocon lever Supporting point A Tension lever Governor spring Flyweight Plunger Control sleeve 010349-00E a) The boost compensator stopper (abbreviated to "boocon") is a device which increases the injection quantity when the air quantity (turbocharging boost) supplied to the suction manifold is increased.
Page 252 6. Fuel Injection equipment 5) Wax type Cold Start Device (W-C.S.D.) This device aids the easier start of engine by advancing the fuel injection timing, when the weather is cold. The wax element is integrated into the body of W-C.S.D. The engine coolant is led to the wax element and flowing around it.
Page 253: Fuel Injection Pump Service Data
6. Fuel Injection equipment 6.3.3 Fuel injection pump service data The expertise and facilities are necessary for the disassembly and adjustment of a fuel injection pump. Make a request to Bosh service shop for them. 4JH4-TE and 4JH4-HTE Adjustment Nozzle type Bosh 105780-0060 (NP-DN0S1510) conditions Nozzle holder...
Page 254: Removing A Fuel Injection Pump
6. Fuel Injection equipment 6.3.4 Removing a fuel injection pump The procedure to remove only a fuel injection pump is shown. Fuel injection pump 1) Remove fuel injection pipes, fuel pipes and a remote control wire. After removing pipes, block the pipe inlet with tape so that trash Flange may not enter the fuel injection pipes and the fuel injection pump.
Page 255: Installing A Fuel Injection Pump
6. Fuel Injection equipment 6.3.5 Installing a fuel injection pump 1) Confirm whether the marks of the pump drive gear and the idle gear agree. 2) Turn a pump camshaft so that the key of the camshaft may almost agree in a position of the key groove of the pump drive gear.
Page 256: Troubleshooting Of Fuel Injection Pump
6. Fuel Injection equipment 6.3.7 Troubleshooting of fuel injection pump Complete repair means only replacing defective parts, but finding and eliminating the cause of the trouble as well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system.
Page 257: Fuel Injection Nozzle
Number of nozzle holes-hole diameter (mm) 5-ø0.18 6-ø0.16 6-ø0.18 21.1-22.1 (215-225) Injection nozzle opening pressure　 MPa (kgf/cm Nozzle stamp mark 159P185VAD1 156-P166VCC0 156P186VCC0 (2) Fuel injection nozzle structure 4-valve head (4JH4-TE and 4JH4-HTE) 2-valve head (3JH4E and 4JH4E) 010628-00E 010353-00E...
Page 258 6. Fuel Injection equipment (3) Nozzle stamp notation 011495-00E Punch mark 010354-00E (4) Adjustment of fuel injection nozzle and injection test Refer to 2.2.6(2) for the procedure. (5) Adjustment of fuel injection timing Refer to 2.2.6(1) for the procedure. (6) Removing the fuel injection nozzle from cylinder head Refer to 4.3.1(18) for the procedure.
Page 259: Fuel Filter
6. Fuel Injection equipment 6.5 Fuel Filter The fuel filter is installed between the fuel feed pump and fuel injection pump for 3JH4E and 4JH4E and between the fuel tank and fuel injection pump (feed pump) for 4JH4-TE and 4JH4-HTE.
Page 260: Fuel Filter For 4Jh4-Te And 4Jh4-Hte
6. Fuel Injection equipment 6.5.2 Fuel filter for 4JH4-TE and 4JH4- Fuel filter (1) Fuel filter specifications Priming pump Item Unit Specifications Air bleeding Part No. 129574-55820 bolt Fuel filter Filtration method Paper element Filtration area 0.24 μ Filtration accuracy Element Maximum flow L/min...
Page 261: Fuel Tank
6. Fuel Injection equipment 6.6 Fuel tank A triangular 30 liter fuel tank with a 2000mm (78.74 Fuel return in.) rubber fuel hose to fit all models is available as connection an option. Tank A fuel return connection is provided on top of the tank of which a rubber hose can be connected to return fuel from the fuel nozzles.
Page 262: Intake And Exhaust System
7. Intake and exhaust system 7. Intake and exhaust system 7.1 Intake system 7.1.1 3JH4E and 4JH4E Air enters in the intake silencer mounted at the end 3JH4E of the intake manifold. It is fed to the intake manifold and then to each cylinder.
Page 263: Breather System (A Reductor To Intake Air System Of Blowby Gas)
7. Intake and exhaust system 7.1.4 Breather system (A reductor to intake air system of blowby gas) Emitting blowby gas is harmful to natural Diaphragm cover environment. Therefore blowby gas reductor is Spring Center plate adopted to 3JH4 and 4JH4 naturally-aspirated Diaphragm engines as breather system.
Page 264: Diaphragm Assy Inspection (Only For 3Jh4E And 4Jh4E)
7. Intake and exhaust system [Reassembly] Replace the diaphragm with new one, when it is damaged. 7.1.5 Diaphragm assy inspection (only for 3JH4E and 4JH4E) Refer to 2.2.6(5) for the inspection procedure.
Page 265: Exhaust System
7. Intake and exhaust system 7.2 Exhaust system 7.2.1 Exhaust system for 3JH4E and 4JH4E L-type Exhaust gas goes from the exhaust manifold to the mixing elbow and is discharged from ship along with seawater. There are two types of mixing elbows, the L-type and the U-type.
Page 266: Exhaust System For 4Jh4-Te And 4Jh4-Hte
7. Intake and exhaust system 7.2.2 Exhaust system for 4JH4-TE and 4JH4-HTE Exhaust gas goes from the exhaust manifold to the Exhaust manifold mixing elbow through the turbocharger, and is discharged from ship along with seawater. There are two types of mixing elbows, the L-type Mixing elbow and the U-type.
Page 267: Turbocharger
7. Intake and exhaust system 7.3 Turbocharger (1) Particulars and structure 1) Specifications 4JH4-TE 4JH4-HTE Model RHB52W (IHI) RHB52W (IHI) Spec. No. 7000VNHP12NFW 7000VHP15NFW Turbine Radial flow type Compressor Centrifugal type Lubricating Engine system oil Bearing Fuel floating Cooling Fresh water cooling Dry mass 3.6 kg (35.3)
Page 268 7. Intake and exhaust system 2) Components (51) (42) (41) (44) (43) (31) (32) (33) (53) (11) (22) (52) (54) (21) 010672-00X 3) Sectional view and tightening torque (44) (43) (57) (58) Tightening torque Components Q’ty Kgf•cm (Ncm) (22) (53) (55) (56) (1) Turbine shaft...
Page 269 7. Intake and exhaust system (2) Checking and servicing procedures 1) Service interval Item Check cycle Check on conditions of turbine Every 500 h shaft rotation Check on play in the turbine Every 1000 h shaft Overhaul Every 4000 h 2) Checking procedures a) Check on the conditions of turbine shaft rotation Check the conditions of turbine shaft rotation by listening to an abnormal sound during rotation.
Page 270 7. Intake and exhaust system • Radial play in the turbine shaft Service standard: 0.08 to 0.06 mm Wear limit : 0.17 mm Magnet base Dial gauge Move the turbine shaft on the left and right sides simultaneously in the radial direction Turbine housing 010675-00E...
Page 271 7. Intake and exhaust system 4) Service standards 010676-00X (Unit: mm) Check item Usable limit Remarks Turbine shaft Outside diameter (A) of turbine shaft journal 7.98 Seal ring groove width (E) on turbine side 1.29 Seal ring groove width (G1) on compressor side 1.31 Seal ring groove width (G2) on compressor side 1.11...
Page 272: Lubrication System
8. Lubrication system 8. Lubrication system 8.1 Lubrication system The lube oil in the oil pan is pumped up through the intake filter and intake piping by the lube oil pump. The oil pressure is regulated by the oil pressure regulating valve equipped with the lube oil pump. The lube oil, which flows from the holes in the cylinder body to the lube oil cooler, is cooled and sent to the lube oil filter.
Page 273: Lube Oil Pump
The lube oil pump is fitted with a control valve, which controls the discharge pressure. 4JH4-TE and 4JH4-HTE 3JH4E and 4JH4E Pump cover Outer rotor Control valve...
Page 274: Lube Oil Pump Disassembly And Reassembly
4JH4-TE and 4JH4-HTE Mount the lube oil pump assembly to the gear case flange. (3) Fasten the pump cover for 3JH4E and 4JH4E by the standard torque. Tightening torque 6.9 ± 1.5 (0.7 ± 0.15) Nm (kgf•m)
Page 275: Lube Oil Pump Inspection
8. Lubrication system 8.2.4 Lube oil pump inspection The right figures show the examples of lube oil pump of 3JH4E and 4JH4E. It is the same procedure for the 4JH4-TE and 4JH4-HTE lube oil pump as well. (1) Outside clearance of outer rotor...
Page 276: Oil Pressure Control Valve Construction
8. Lubrication system (4) Inner rotor and gear boss clearance for 3JH4E and 4JH4E Width across flat of rotor Crank gear Inner rotor Rotor inner diameter 010544-00E Standard Standard Standard Item Part dimension clearance clearance limit (mm) (mm) (mm) Gear boss diameter 53.05-53.15...
Page 277: Lube Oil Filter
0.08-0.12MPa (0.8-1.2kg/cm ). Then the lube oil will flow in the bypass circuit. 4JH4E Engine model Unit 3JH4E 4JH4-TE 4JH4-HTE Part No. 119305-35150 129150-35152...
Page 278: Lube Oil Cooler
8. Lubrication system 8.4 Lube oil cooler 8.4.1 Lube oil cooler construction The lube oil cooler is located between the lube oil filter and the filter bracket, which is mounted on the cylinder block. The lube oil is cooled by fresh water. Lube oil cooler 010545-00E 4JH4-TE...
Page 279: Piston Cooling Oil Nozzle
8. Lubrication system 8.5 Piston cooling oil nozzle (1) Check the hole (ø1.8mm) in the nozzle end for dust or foreign matters. Piston Splash (2) Check the brazed portion of the copper tube for breakage due to vibration. Cylinder block main gallery Piston cooling oil nozzle 010547-00E...
Page 280: Rotary Waste Oil Pump (Optional)
8. Lubrication system 8.6 Rotary waste oil pump (Optional) A rotary waste oil pump to pump out waste oil is available as an option. Rotary waste oil pump 010649-00E Rotary waste oil pump Delivery capacity per one revolution 0.057 L Delivery pressure 0.15 MPa (1.5 kg/cm ) or below...
Page 281: Coolant System
When the temperature of the fresh water rises, the thermostat opens, the fresh water flows to the heat exchanger, and it is then cooled by the seawater in the cooler tubes. The temperature of the fresh water is thus kept within the constant temperature range by the thermostat. 4JH4-TE 3JH4E and 4JH4E W-CSD Coolant Fresh water cooler...
Page 282 Mixing elbow Inter cooler Clutch cooler Seawater pump Sea cock Fresh water circuit Seawater circuit 014223-00E Example of coolant line for 3JH4E and 4JH4E Seawater line Fresh water line Filler cap Mixing elbow Coolant recovery tank Heat exchanger Exhaust manifold...
Page 283: Seawater Pump
9. Coolant system 9.2 Seawater pump The seawater pump is driven by a gear. 3JH4E and 4JH4E Pump drive gear Gear case Seawater pump 010652-00E 4JH4-TE and 4JH4-HTE Seawater pump Pump drive gear Gear case flange Gear case 010698-00E...
Page 284: Specifications Of Seawater Pump
9. Coolant system 9.2.1 Specifications of seawater pump (1) Performance Flow Min. 3800 L/h at pin = -5 kPa (-0.05 bar) pout = 95 kPa (0.95 bar) n = 3250 min after 1500 h duty Self-priming ability Max. 10 s at Suction head = 0.5 m length of pipe = 0.6 m n = 500 min...
Page 285: Seawater Pump Disassembly
9. Coolant system 9.2.2 Seawater pump disassembly Refer to 2.2.4.(5). (1) Remove the rubber hose from the Side cover seawater pump outlet and then the O-ring Impeller seawater pump assembly from the gear Wear plate case (flange). Retainer Washer Mechanical seal (2) Remove the side cover and take out the Lip seal V-ring...
Page 286: Seawater Pump Reassembly
9. Coolant system 9.2.4 Seawater pump reassembly (1) When replacing the mechanical seal, coat the No.1101 oil seal and pressure- fit. Coat the sliding surface with a good quality silicon oil, taking sufficient care not to cause any scratches. (2) When replacing the lip seal, coat with grease and insert.
Page 287: Fresh Water Pump
9. Coolant system 9.3 Fresh water pump 9.3.1 Fresh water pump construction The fresh water pump is of the centrifugal (volute) type, and circulates water from the fresh water tank to the cylinders and cylinder head. The fresh water pump consists of the pump body, Cylinder head impeller, pump shaft, bearing unit and mechanical seal.
Page 288: Specifications Of Fresh Water Pump
9. Coolant system 9.3.2 Specifications of fresh water pump Model 3JH4E 4JH4-TE 4JH4E 4JH4-HTE Pulley ratio Ø134/Ø120 (crank shaft/pump shaft) Delivery capacity 55 L/min 54 L/min (at fuel stop power) or more or more Total head 9.3.3 Fresh water pump disassembly (1) Do not disassemble the fresh water pump.
Page 289: Fresh Water Pump Inspection
9. Coolant system 9.3.4 Fresh water pump inspection (1) Bearing unit inspection Rotate the impeller smoothly. If the rotation is not smooth or abnormal noise is head due to excessive bearing play or contact with other parts, replace the pump as an assembly (2) Impeller inspection Check the impeller blade, and replace if damaged or corroded, or if the impeller...
Page 290 9. Coolant system Measuring clearance between impeller and pump body. Thickness gauge 001582-01E Measuring clearance between impeller and pump body bracket. Straightedge Standard Limit Clearance between 0.3-1.1 impeller and body Clearance between impeller and plate Thickness gauge 001583-01E...
Page 291: Heat Exchanger
9. Coolant system 9.4 Heat exchanger 9.4.1 Heat exchanger construction 3JH4E The heat exchanger cools the hot fresh water, that has cooled the inside of the engine, with seawater. The cooler core consists of many small diameter Side cover tubes, baffle plates and tube cover.
Page 292: Heat Exchanger Inspection
9. Coolant system (2) Remove the covers on both sides and take out the cooler core and O-ring(s). Note: Replace the O-ring(s) when you have removed the cooler core. 9.4.4 Heat exchanger inspection Refer to 2.2.6(4).
Page 293: Pressure Cap And Coolant Recovery Tank
9. Coolant system 9.5 Pressure cap and coolant recovery tank 9.5.1 Pressure cap construction The pressure cap mounted on the fresh water filler neck incorporates a pressure control valve. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating.
Page 294: Replacing Filler Neck
9. Coolant system 9.5.4 Replacing filler neck 1) Take out the copper tube inside the filler neck with striking a circumference with a driver and so on. When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it.
Page 295: Function Of The Coolant Recovery Tank
9. Coolant system 4) To fix the filler neck on the fresh water cooler, press the small copper tube inside the filler neck with the special tool. Note: The top of this tube should be under the sealing surface of the filler neck for the pressure cap.
Page 296: Mounting The Coolant Recovery Tank
9. Coolant system 9.5.7 Mounting the coolant recovery tank (1) The coolant recovery tank is mounted at approximately the same height as the heat exchanger (fresh water tank). (allowable difference in height : 300 mm Mounting plate (11.8110 in.) or less) (2) The overflow pipe should be less than Overflow tube 1000 mm (39.3701 in) long, and...
Page 297: Thermostat
9. Coolant system 9.6 Thermostat 9.6.1 Functioning of thermostat The thermostat opens and closes a valve according to changes in the temperature of the fresh water inside the engine, controlling the volume of water flowing to the heat exchanger from the cylinder head, and in turn maintaining the temperature of the fresh water in the engine at a constant level.
Page 298: Bilge Pump And Bilge Strainer (Optional)
9. Coolant system 9.7 Bilge pump and bilge strainer (Optional) 9.7.1 Introduction (1) General Introduction Name Bilge pump Time 10 minutes Rotation direction Right (viewed from the impeller side) Weight Pump 1.4 kg Negative pressure detector Diaphragm type Temperature -30°C-80°C (2) Exterior Motor assy Controller...
Page 299: Description
9. Coolant system 9.7.2 Description (1) Characteristics 1) Discharge at lift : 0 m discharge capacity : 20 liters/min. or greater. 2) Automatic feeding height : 1 m or greater (Limit for automatic feeding height: new pump with inside parts wet, approx. 2 m) 3) Automatic feeding time : 2 5 seconds.
Page 300: Cautions
9. Coolant system 9.7.3 Cautions (1) Attach at a position higher than the bilge water away from rain or other water, and 50- 70 cm above the bottom of the boat. (2) Never run the pump dry. Be sure that the strainer is inserted in the drain water before pushing the switch.
Page 301: Assembly Procedure
9. Coolant system 9.7.4 Assembly procedure When bilge is being used, assemble in accordance with the following. (1) Assembling the bilge pump • Select a dry place above the bilge water level. • Select the location for the bilge pump taking into consideration the length of the switch cable (approx.
Page 302 9. Coolant system (4) Attaching the delivery nozzle (outlet) • Make a fixing hole of Ø21 or less for attaching the nozzle. The hose attached at Fixing hole Hose the nozzle should be 1.8 m or less and should reach without any strain, therefore care should be taken in deciding on the best position.
Page 303: Cautions For Assembling
9. Coolant system 9.7.5 Cautions for assembling Observe the following cautions for handling. • Do not use gasoline or solvents. 1) gasoline 2) ester 3) benzol 4) battery fluid 5) liquids at 70°C or greater or engine oil • Never run when there is no water in the bilge. Check to be sure that the strainer is in the water before turning on the switch.
Page 304 9. Coolant system • Do not use the pump for showering. If the pump outlet is deformed for showering, the increase in water pressure will increase the load on the motor and cause motor seizure. • When sludge has built up in the bilge to be drained, position the strainer about 20 cm above the sludge.
Page 305: Troubleshooting
9. Coolant system 9.7.6 Troubleshooting Refer to the following countermeasures for difficulties that arise. Problem Cause Countermeasure 1. Pump does not turn Faulty wiring Check the wiring between the motor and battery. Faulty battery Check to see if the specific gravity of the battery fluid is greater than 1.25.
Page 306: Reduction And Reversing Gear
Refer to the service manuals of the existing JH3 series engines and the marine gear service manual for inspection, disassembly and reassembly procedures. Also refer to the service manual of the sail drive. 10.1 Specifications of 3JH4E marine gears Model...
Page 307: Specifications Of 4Jh4E And Marine Gears
Reverse Counter-clockwise, viewed from stern Remote Control head Single lever control control Cable Morse. 33-C (cable travel 76.2mm) Clamp YANMAR made. standard accessory Cable connector YANMAR made. standard accessory Output shaft Outer diameter 100mm 120mm coupling Pitch circle diameter 78mm...
Page 308: Specifications Of 4Jh4-Te And 4Jh4-Hte Marine Gears
Counter-clockwise Bi-rotation viewed from stern Remote Control head Single lever control control Cable Morse. 33-C (cable travel 76.2mm) Clamp YANMAR made. standard accessory Cable connector YANMAR made. standard accessory Output shaft Outer diameter 102mm 120mm coupling Pitch circle diameter 82.5mm...
Page 309 Bi-rotation Reverse Bi-rotation Remote Control head Single lever control control Cable Morse. 33-C (cable travel 76.2mm) Clamp YANMAR made. standard accessory Cable connector YANMAR made. standard accessory Output shaft Outer diameter 120mm 101.6 mm coupling Pitch circle diameter 100mm 82.6 mm Connecting bolt holes 4-10.5mm...
Page 310: Remote Control System (Optional)
Morse MN side mounting single lever Remote control cable Morse 33C x 4m Morse 33C x 7m Engine stop cable Yanmar 4m Yanmar 7m (1) Remote control handle The model MT-3 remote control has been MT-3 Type designed so that operation of the clutch (shift) and governor (throttle) can be effected with one lever.
Page 311 11. Remote control system (Optional) The MN type controller has been designed so that operation of the clutch and throttle can be MN Type effected with one lever. When the button next to the control lever is pulled out with the lever in the central position, it holds the clutch in the neutral position so that the throttle can be opened all the way and warm up the engine.
Page 312: Remote Control Installation
11. Remote control system (Optional) 11.2 Remote control installation (1) Speed control Remote control handle Governor Clamp Control lever Cable bracket Remote control cable Remote control bracket Cable joint 010660-00E...
Page 313 11. Remote control system (Optional) (2) Clutch control Note: ( ) Cable shift travel S1 = More than 36 mm (1.42") S2 = More than 36 mm (1.42") Neutral Reverse Forward Remote control head Clamp To engine speed To marine gear 010661-00E KM35P marine gear Lock nut...
Page 314 Usually, to stop the engine, the stop button of Emergency stop button an instrument panel is pushed, and the engine is stopped. Emergency stop for 3JH4E and 4JH4E When the engine can't be stopped by the stop button on the panel, the emergency stop Governor...
Page 315: Remote Control Inspection
11. Remote control system (Optional) 11.3 Remote control inspection (1) When the control lever movement does Neutral not coincide with operation of the Reverse Forward engine, check the cable end stop nut to Shim in Shim in see whither or not it is loose, and readjust/retighten when necessary.
Page 316: Remote Control Adjustment
11. Remote control system (Optional) 11.4 Remote control adjustment (1) Shift lever adjustment Move the control lever several times. The movement of the clutch lever on the marine gear (forward, neutral and reverse) must coincide with the forward, neutral and reverse on the control lever.
Page 317: Electrical System
Flywheel housing Extension wire harness S T O P Sail drive O F F G L O W 2 place expression (optional) S T A R T 010665-00E Note: This figure shows an example of 3JH4E and 4JH4E electric system.
Page 318: Wiring Diagram
12. Electrical system 12.1.1 Wiring diagram (1) For B-type instrument panel...
Page 319 12. Electrical system (2) For C-type instrument panel...
Page 320: Battery
12. Electrical system 12.2 Battery Refer to 2.2.3(2) for electrolyte level and battery charge. Also refer to the service manual of the previous model 3/4JH3E series for other data regarding battery. (1) Battery capacity Since the battery has a minimum capacity of 12V, 80AH.
Page 321: Starting Motor
12.3.1 Specifications YANMAR Part No. 129608-77010 HITACHI model No. S114-817A Nominal power (kW) Nominal voltage (V)
Page 322: Structure
12. Electrical system 12.3.3 Structure (1) Disassembly drawing Magnetic switch Internal gear Bracket Pinion Gear housing Rear cover Yoke Armature 011063-00E...
Page 323: Wiring Diameter Of A Starting Motor
12. Electrical system (2) Structure When the starting switch is turned on, a magnet Magnetic switch Center bracket (A) switch takes a voltage, and a pinion projects. The Torsion spring pinion engages with the ring gear of a engine, and the engine is started.
Page 324: Alternator 12V/60A (Optional)
The type of alternator used in this engine is ideal for high speed engines with a wide range of engine speeds. It contains diodes that convert AC to DC, and an IC regulator that keeps the generated voltage constant even when the engine speed changes. 12.4.1 Specifications Yanmar code 128271-77200 Model of alternator LR160-741 (HITACHI)
Page 325: Structure
12. Electrical system 12.4.2 Structure (1) Disassembly drawing 12V60A alternator Ball bearing Stator Rotor Front bracket Rear bracket assembly Pulley 011065-00E (2) Structure Stator Rotor Rectifier Bracket assembly assembly assembly Bracket Packing Ball bearing Nut M5 Pulley Through bolt 011066-00SE...
Page 326: Wiring Diagram
12. Electrical system 12.4.3 Wiring diagram switch Rotor Diode Stator coil coil Charge lamp 12V3.4W Battery IC regulator Alternator 011067-00E [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop.
Page 327: Inspection
12. Electrical system 12.4.5 Inspection (1) V belt inspection 1) Inspect the matter whether there are not Normal Defect crack, stickiness and wear on the belt visually. Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set.
Page 328: Alternator 12V/80A (Standard)
12. Electrical system 12.5 Alternator 12V/80A (Standard) 12.5.1 Specifications Yanmar code 119573-77201 Model of alternator LR180-03C (HITACHI) Model of IC regulator TR1Z-63 (HITACHI) Battery voltage Nominal output 12V/80A Earth polarity Negative earth Direction of rotation Clockwise (viewed from pulley end) Weight 5.4 kg...
Page 329: Structure
12. Electrical system 12.5.2 Structure Disassembly drawing and structure Brush regulator assy Stator Bearing retainer Rear cover Front cover Diode Condenser Capacitor assembly Brush regulator Rotor assembly Brush holder Ball bearing Spacer Pulley Diode assembly Rear cover assembly Stator assembly Rotor assembly Brush assembly Front cover...
Page 330: Wiring Diagram
12. Electrical system 12.5.3 Wiring diagram switch Diode Rotor Sub- coil Charge lamp Diode 12V3.4W Battery switch Battery Stator coil IC regulator Alternator 011071-00E [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop.
Page 331: Instrument Panel
12. Electrical system 12.6 Instrument panel The new type instrument panels are applied for JH4E series engines. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed with new panel is activated by alternator P terminal pulse. 12.6.1 B-type instrument panel (Selectable optional) Lubricating oil low Water in sail...
Page 332: Warning Devices
12. Electrical system 12.7 Warning devices 12.7.1 Oil pressure alarm Oil pressure alarm circuit If the engine oil pressure is below 0.01-0.03 MPa (0.1-0.3 kgf/cm , 1.42-4.26 lb/in. ), with the main Pilot lamp Main switch switch in the ON position, the contacts of the oil Fuse pressure switch are closed by a spring and the lamp is illuminated through the lamp...
Page 333: Sender Unit For Lube Oil Pressure Gauge
12. Electrical system Inspection Problem Inspection Item Inspection method Corrective action Lamp not 1. Oil pressure lamp (1) Visual inspection. Replace lamp. illuminated when blown out. (2) Lamp not illuminated even when main switch set to main switch set to ON position and terminals of oil pressure switch grounded.
Page 334: Coolant Temperature Alarm
12. Electrical system 12.7.3 Coolant temperature alarm A water temperature lamp and water temperature Water temperature Water temperature gauge, backed up by an alarm in the instrument switch sender panel, are used to monitor the temperature of the engine coolant. A high thermal expansion material is set on the end of the water temperature unit.
Page 335: Air Heater (Optional)
The air heater is Gasket mounted to the intake manifold. The device is operated by the glow switch on the instrument panel. Relay Intake manifold Wire harness 011084-00E 3JH4E and 4JH4E 3JH4E/4JH4E 4JH4-TE/4JH4-HTE Part No. 129120-77501 129100-77500 Rated output 390W Rated current 35.5A...
Page 336: Electric Engine Stopping Device
Emergency stop button governor. The device is operated by the stop switch on the instrument panel. Electric emergency stop for 3JH4E and 4JH4E The emergency stop button is integrated with the solenoid. When pushing the stop button in a time...
Page 337: Service Standards
Total Effective Engine (with KM35P, at 5.0±0.3 rake angle 8 degrees) Engine (with KM35A/ Lube oil capacity SD40, at rake angle 0 5.5±0.3 of 3JH4E degree) (Liter) KM35P Marine gear KM35A 0.65 Engine (with KM35P/ ZF30M, at rake angle 8 5.0±0.3...
Page 338 Lube oil capacity 2.2.1.(3) of 4JH4-TE/ 4JH4-HTE KMH4A (Liter) KM4A2 Marine gear ZF25A SD50-4T (only for 4JH4-TE) 0.39-0.54 3JH4E/ 4JH4E (4.0-5.5) Lubricating oil pressure 0.06(0.6) 8.2.2 or above MPa (kgf/cm 0.28-0.45 4JH4-TE/ 4JH4-HTE (2.9-4.6) Oil pressure switch operating pressure 0.02±0.01 12.7.1 (0.2±0.1)
Page 339: Engine Body
Valve stem outside diameter 5.945-5.960 5.90 Clearance 0.040-0.070 0.18 Valve guide projection from cylinder head 8.2-8.5 5.2.3(4) Valve guide driving-in method Cold-fitted (3) Valve spring Inspection item Standard Limit Reference page 3JH4E/ 4JH4E 44.4 43.0 Free length 4JH4-TE/ 4JH4-HTE 37.4 36.9 5.2.4(1) Inclination...
Page 340 13. Service standards (4) Rocker arm and shaft Inspection item Standard Limit Reference page Arm shaft hole diameter 16.000-16.020 16.090 Shaft outside diameter 15.966-15.984 15.955 5.2.7(1) Clearance 0.016-0.054 0.140 (5) Push rod Inspection item Standard Limit Reference page Bend Less than 0.03 0.03 5.6.2(3)
Page 341: Camshaft And Gear Train
Limit Reference page Side gap 0.05-0.20 0.35 5.6.1(1) Bending (1/2 the dial gage reading) 0.02 or less 0.05 5.6.1(4) 3JH4E/ 4JH4E 38.600-38.800 38.350 Cam height 5.6.1(2) 4JH4-TE/ 4JH4-HTE 39.800-40.000 39.550 Shaft outside diameter / Metal inside diameter Bushing inside diameter 44.990-45.055...
Page 342: Cylinder Block
13. Service standards 13.2.3 Cylinder block (1) Cylinder block Inspection item Standard Limit Reference page 3JH4E/ 4JH4E 88.000-88.030 88.200 Cylinder inside diameter 4JH4-TE/ 4JH4-HTE 84.000-84.030 84.200 5.1.5 Roundness Cylinder bore 0.01 or less 0.03 Inclination (2) Crankshaft Inspection item Standard...
Page 343 13. Service standards (4) Piston and ring 1) Piston Reference Inspection item Standard Limit page 3JH4E 87.950-87.960 87.900 Piston outside diameter (Measure in the direction 4JH4E 87.935-87.945 87.885 vertical to the piston pin.) 4JH4-TE/ 4JH4-HTE 83.930-83.940 83.880 3JH4E 0.045-0.075 5.3.1(2)
Page 344 Top ring Side clearance 0.070-0.105 0.200 End clearance (gap) 0.200-0.400 0.490 Ring groove width 2.025-2.040 2.140 Ring width 1.970-1.990 1.950 3JH4E Second ring 4JH4E Side clearance 0.035-0.070 0.190 End clearance (gap) 0.200-0.400 0.490 Ring groove width 4.015-4.030 4.130 Ring width 3.970-3.990...
Page 345 Side clearance 0.20-0.40 0.55 5.4.1(2) 2) Rod small end Reference Item Standard Limit page Piston pin bushing inside diameter 26.025-26.038 26.068 3JH4E Piston pin outside diameter 25.995-26.000 25.965 4JH4E Clearance 0.025-0.043 0.101 5.3.2 5.4.3(1) Piston pin bushing inside diameter 28.025-28.038 28.068...
Page 346: Lubricating Oil System (Trochoid Pump)
13. Service standards 13.3 Lubricating oil system (Trochoid pump) (1) Outside clearance of outer rotor Standard Limit Reference page 0.12-0.21 0.30 8.2.4(1) (2) Tip clearance between outer rotor and inner rotor Standard Limit Reference page 0.16 8.2.4(2) (3) Side clearance of outer rotor Standard Limit Reference page...
Page 347: Tightening Torque For Bolts And Nuts
14. Tightening torque for bolts and nuts 14. Tightening torque for bolts and nuts 14.1 Main bolt and nut Lubricating oil application Thread diameter Torque Name (thread portion, and seat x pitch (mm) Nm (kgf-m) surface) 1 Head bolt M10 x 1.25 Coat with lube oil 85.2-91.2 (8.69-9.30) 2 Rod bolt...

This manual is also suitable for:

4jh4e 4jh4-te 4jh4-hte

Yanmar 3JH4E Service Manual

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

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