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Yanmar 3JH4E Manuals
Manuals and User Guides for Yanmar 3JH4E. We have
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Yanmar 3JH4E manuals available for free PDF download: Service Manual, Operation Manual, Installation Manual
Yanmar 3JH4E Service Manual (350 pages)
Brand:
Yanmar
| Category:
Engine
| Size: 62.45 MB
Table of Contents
Table of Contents
7
Safety Labels
15
Safety Precautions
16
Rotating Parts
19
1 General
21
Exterior Views
21
Specifications
24
Fuel Oil, Lubricating Oil and Coolant
30
Fuel Oil
30
Lubricating Oil
32
Coolant
33
Engine Outline
34
Piping Diagrams
53
Exhaust Gas Emission Regulation in U.S.A. Only
66
Engines under 37Kw: 3JH4E
66
Engines of 37Kw or More: 4JH4-TE and 4JH4-HTE
69
2 Inspection and Adjustment
72
Periodic Maintenance Schedule
72
Periodic Inspection and Maintenance Procedure
74
Check before Starting
74
Inspection after Initial 50 Hours or One Month Operation
80
Inspection Every 50 Hours or Monthly
89
Inspection Every 250 Hours or One Year
94
Inspection Every Two Years
104
Inspection Every 1,000 Hours or Four Years
104
Adjusting the No-Load Maximum or Minimum Speed
114
Sensor Inspection
115
Oil Pressure Switch
115
Thermo Switch
115
Thermostat Inspection
116
Adjusting Operation
117
Preliminary Precautions
117
Adjusting Operation Procedure
117
Check Points and Precautions During Running
118
Long Storage
119
3 Troubleshooting
120
Preparation before Troubleshooting
120
Quick Reference Chart for Troubleshooting
121
Starting Trouble
129
Troubleshooting (Concerning Engine and Fuel Injection Equipment)
137
Troubleshooting by Measuring Compression Pressure
140
4 Disassembly and Reassembly
142
Disassembly and Reassembly Precautions
142
Disassembly and Reassembly Tools
143
General Hand Tools
143
Special Hand Tools
145
Measuring Instruments
151
Other Material
156
Disassembly and Reassembly
158
Disassembly
158
Reassembly
176
5 Inspection and Servicing of Basic Engine Parts
195
Cylinder Block
195
Inspection of Parts
195
Cleaning of Oil Holes
195
Color Check Procedure
196
Replacement of Cup Plugs
197
Cylinder Bore Measurement
198
Cylinder Head
199
Inspecting the Cylinder Head
201
Valve Seat Correction Procedure
202
Intake/Exhaust Valves, Valve Guides
204
Valve Springs
208
Assembling the Cylinder Head
210
Measuring Top Clearance
211
Intake and Exhaust Rocker Arms
212
Adjustment of Valve Clearance
213
Piston and Piston Pins
214
Piston
215
Piston Pin
216
Piston Rings
217
Connecting Rod
220
Inspecting the Connection Rod
221
Crank Pin Metal
222
Piston Pin Bushing
224
Crankshaft and Main Bearing
225
Crankshaft
225
Main Bearing
228
Camshaft and Tappets
229
Camshaft
229
Tappets
231
Timing Gear
232
Inspecting the Gears
232
Gear Timing Marks
232
Flywheel and Housing
233
Position of Top Dead Center and Fuel Injection Timing
234
Damper Disc
234
6 Fuel Injection Equipment
235
Fuel Injection Pump/Governor for 3JH4E and 4JH4E
235
Fuel System Diagram
235
Fuel Injection Pump Service Data
236
Fuel Injection Pump Structure
239
Removing a Fuel Injection Pump
240
Installing a Fuel Injection Pump
241
Adjusting Fuel Injection Timing
241
Troubleshooting of Fuel Injection Pump
241
Tools
242
Fuel Feed Pump
244
Construction of Fuel Feed Pump
244
Fuel Feed Pump Specifications
244
Disassembly and Reassembly of Fuel Feed Pump
245
Fuel Feed Pump Inspection
246
Fuel Injection Pump/ Governor for 4JH4-TE and 4JH4-HTE
247
Fuel System Diagram
247
Fuel Injection Pump Structure
248
Fuel Injection Pump Service Data
253
Removing a Fuel Injection Pump
254
Installing a Fuel Injection Pump
255
Adjusting Fuel Injection Timing
255
Troubleshooting of Fuel Injection Pump
256
Fuel Injection Nozzle
257
Fuel Filter
259
Fuel Filter for 3JH4E and 4JH4E
259
Fuel Filter for 4JH4-TE and 4JH4-HTE
260
Fuel Tank
261
7 Intake and Exhaust System
262
Intake System
262
3JH4E and 4JH4E
262
4Jh4-Te
262
4Jh4-Hte
262
Breather System (a Reductor to Intake Air System of Blowby Gas)
263
Diaphragm Assy Inspection (Only for 3JH4E and 4JH4E)
264
Exhaust System
265
Exhaust System for 3JH4E and 4JH4E
265
Exhaust System for 4JH4-TE and 4JH4-HTE
266
Mixing Elbow Inspection
266
Turbocharger
267
8 Lubrication System
272
Lube Oil Pump
273
Lube Oil Pump Construction
273
Specifications of Lube Oil Pump
273
Lube Oil Pump Disassembly and Reassembly
274
Lube Oil Pump Inspection
275
Oil Pressure Control Valve Construction
276
Lube Oil Filter
277
Lube Oil Filter Construction
277
Lube Oil Filter Replacement
277
Lube Oil Cooler
278
Lube Oil Cooler Construction
278
Inspecting the Lube Oil Cooler
278
Piston Cooling Oil Nozzle
279
Rotary Waste Oil Pump (Optional)
280
9 Coolant System
281
Seawater Pump
283
Specifications of Seawater Pump
284
Seawater Pump Disassembly
285
Seawater Pump Inspection
285
Seawater Pump Reassembly
286
Fresh Water Pump
287
Fresh Water Pump Construction
287
Specifications of Fresh Water Pump
288
Fresh Water Pump Disassembly
288
Fresh Water Pump Inspection
289
Heat Exchanger
291
Heat Exchanger Construction
291
Specifications of Heat Exchanger
291
Disassembly and Reassembly of the Heat Exchanger
291
Heat Exchanger Inspection
292
Pressure Cap and Coolant Recovery Tank
293
Pressure Cap Construction
293
Pressure Cap Pressure Control
293
Pressure Cap Inspection
293
Replacing Filler Neck
294
Function of the Coolant Recovery Tank
295
Specifications of Coolant Recovery Tank
295
Mounting the Coolant Recovery Tank
296
Precautions on Usage of the Coolant Recovery Tank
296
Thermostat
297
Functioning of Thermostat
297
Thermostat Construction
297
Characteristics of Thermostat
297
Thermostat Inspection
297
Testing the Thermostat
297
Bilge Pump and Bilge Strainer (Optional)
298
Introduction
298
Description
299
Cautions
300
Assembly Procedure
301
Cautions for Assembling
303
Troubleshooting
305
10 Reduction and Reversing Gear
306
Specifications of 3JH4E Marine Gears
306
Specifications of 4JH4E and Marine Gears
307
Specifications of 4JH4-TE and 4JH4-HTE Marine Gears
308
11 Remote Control System (Optional)
310
Remote Control System
310
Construction of Remote Control System
310
Remote Control Device Components
310
Remote Control Installation
312
Remote Control Inspection
315
Remote Control Adjustment
316
12 Electrical System
317
Wiring Diagram
318
Battery
320
Starting Motor
321
Specifications
321
Characteristics
321
Structure
322
Wiring Diameter of a Starting Motor
323
Alternator 12V/60A (Optional)
324
Specifications
324
Structure
325
Wiring Diagram
326
Standard Output Characteristics
326
Inspection
327
Alternator 12V/80A (Standard)
328
Specifications
328
Structure
329
Wiring Diagram
330
Standard Output Characteristics
330
Instrument Panel
331
B-Type Instrument Panel (Selectable Optional)
331
C-Type Instrument Panel (Selectable Optional)
331
Warning Devices
332
Oil Pressure Alarm
332
Sender Unit for Lube Oil Pressure Gauge
333
Coolant Temperature Alarm
334
Sender Unit for the Coolant Temperature Gauge
334
Air Heater (Optional)
335
Electric Engine Stopping Device
336
13 Service Standards
337
Engine Tuning
337
Engine Body
339
Cylinder Head
339
Camshaft and Gear Train
341
Cylinder Block
342
Lubricating Oil System (Trochoid Pump)
346
14 Tightening Torque for Bolts and Nuts
347
Main Bolt and Nut
347
Standard Bolts and Nuts (Without Lube Oil)
347
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Yanmar 3JH4E Service Manual (214 pages)
Marine diesel engine
Brand:
Yanmar
| Category:
Engine
| Size: 14.59 MB
Table of Contents
Safety Labels
5
Safety Precautions
6
Rotating Parts
9
Table of Contents
11
1 General
17
Exterior Views
17
Specifications
18
Engine Outline
20
Piping Diagrams
23
Exhaust Gas Emission Regulation
25
Engine Identification (3JH4E)
25
Exhaust Gas Regulations
26
Guarantee Conditions for Emission Standard
26
2 Inspection and Adjustment
28
Periodic Maintenance Schedule
28
Periodic Inspection and Maintenance Procedure
30
Check before Starting
30
Inspection after Initial 50 Hours or One Month Operation
33
Inspection Every 50 Hours or Monthly
38
Inspection Every 250 Hours or One Year
42
Inspection Every 1,000 Hours or Four Years
47
Adjusting the No-Load Maximum or Minimum Speed
54
Sensor Inspection
54
Oil Pressure Switch
54
Thermo Switch
54
Thermostat Inspection
55
Adjusting Operation
56
Preliminary Precautions
56
Adjusting Operation Procedure
56
Check Points and Precautions During Running
57
Long Storage
58
3 Troubleshooting
59
Preparation before Troubleshooting
59
Quick Reference Chart for Troubleshooting
60
Troubleshooting (Concerning Engine and Fuel Injection Equipment)
69
Troubleshooting by Measuring Compression Pressure
72
4 Disassembly and Reassembly
74
Disassembly and Reassembly Precautions
74
Disassembly and Reassembly Tools
75
General Handtools
75
Special Handtools
78
Measuring Instruments
81
Other Material
82
Measuring Instruments
85
Disassembly and Reassembly
88
Disassembly
88
Reassembly
98
5 Inspection and Servicing of Basic Engine Parts
109
Cylinder Block
109
Inspection of Parts
109
Cleaning of Oil Holes
109
Color Check Procedure
109
Replacement of Cup Plugs
110
Cylinder Bore Measurement
111
Cylinder Head
112
Inspecting the Cylinder Head
113
Valve Seat Correction Procedure
114
Intake/Exhaust Valves, Valve Guides
115
Valve Springs
117
Assembling the Cylinder Head
118
Measuring Top Clearance
118
Intake and Exhaust Rocker Arms
119
Adjustment of Valve Clearance
119
Piston and Piston Pins
120
Piston
120
Piston Pin
121
Piston Rings
121
Connecting Rod
124
Inspecting the Connection Rod
124
Crank Pin Metal
125
Piston Pin Bushing
127
Assembling Piston and Connecting Rod
127
Crankshaft and Main Bearing
128
Crankshaft
128
Main Bearing
131
Camshaft and Tappets
132
Camshaft
132
Tappets
134
Timing Gear
135
Inspecting the Gears
135
Gear Timing Marks
135
Flywheel and Housing
136
Position of Top Dead Center and Fuel Injection Timing
136
Damper Disc and Cooling Fan
137
6 Fuel Injection Equipment
138
Fuel Injection Pump/Governor
138
Fuel System Diagram
138
Fuel Injection Pump Service Data
139
Fuel Injection Pump Structure
141
Removing a Fuel Injection Pump
143
Installing a Fuel Injection Pump
143
Adjusting Fuel Injection Timing
143
Troubleshooting of Fuel Injection Pump
144
Major Faults and Troubleshooting
144
Tools
147
Fuel Feed Pump
149
Construction of Fuel Feed Pump
149
Fuel Feed Pump Specifications
149
Disassembly and Reassembly of Fuel Feed Pump
150
Fuel Feed Pump Inspection
150
Fuel Filter
152
Fuel Filter Specifications
152
Fuel Filter Inspection
152
Fuel Tank
153
7 Intake and Exhaust System
154
Intake System
154
Breather System (a Reductor to Intake Air System of Blowby Gas)
154
Diaphragm Assy Inspection
155
Exhaust System
156
Construction
156
3Mixing Elbow Inspection
156
8 Lubrication System
157
Lube Oil Pump
158
Lube Oil Pump Construction
158
Specifications of Lube Oil Pump
158
Lube Oil Pump Disassembly and Reassembly
158
Lube Oil Pump Inspection
159
Oil Pressure Control Valve Construction
159
Lube Oil Filter
160
Lube Oil Filter Construction
160
Lube Oil Filter Replacement
160
Lube Oil Cooler
160
Lube Oil Cooler Construction
160
Inspecting the Lube Oil Cooler
160
Rotary Waste Oil Pump (Optional)
161
9 Cooling Water System
162
Seawater Pump
164
Specifications of Seawater Pump
164
Seawater Pump Disassembly
165
Seawater Pump Inspection
165
Seawater Pump Reassembly
165
Fresh Water Pump
166
Fresh Water Pump Construction
166
Specifications of Fresh Water Pump
167
Fresh Water Pump Disassembly
167
Fresh Water Pump Inspection
167
Heat Exchanger
169
Heat Exchanger Construction
169
Specifications of Heat Exchanger
169
Disassembly and Reassembly of the Heat Exchanger
169
Heat Exchanger Inspection
169
Pressure Cap and Coolant Recovery Tank
170
Pressure Cap Construction
170
Pressure Cap Pressure Control
170
Pressure Cap Inspection
170
Replacing Filler Neck
171
Function of the Coolant Recovery Tank
172
Specifications of Coolant Recovery Tank
172
Mounting the Coolant Recovery Tank
172
Precautions on Usage of the Coolant Recovery Tank
172
Thermostat
173
Functioning of Thermostat
173
Thermostat Construction
173
Characteristics of Thermostat
173
Thermostat Inspection
173
Testing the Thermostat
173
Bilge Pump and Bilge Strainer (Optional)
174
Introduction
174
Description
175
Cautions
175
Assembly Procedure
176
Cautions for Assembling
178
Troubleshooting
179
10 Reduction and Reversing Gear
180
11 Remote Control (Optional)
181
Remote Control System
181
Construction of Remote Control System
181
Remote Control Device Components
181
Remote Control Installation
183
Remote Control Inspection
185
Remote Control Adjustment
186
12 Electrical System
187
Wiring Diagram
188
Battery
190
Starting Motor
191
Specifications
191
Characteristics
191
Structure
192
Wiring Diameter of a Starting Motor
193
Alternator Standard, 12V/60A
194
Specifications
194
Structure
195
Wiring Diagram
196
Standard Output Characteristics
196
Inspection
197
Alternator 12V/80A (Optional)
198
Specifications
198
Structure
199
Wiring Diagram
200
Standard Output Characteristics
200
Instrument Panel
201
B-Type Instrument Panel (Optional)
201
C-Type Instrument Panel
201
Warning Devices
202
Oil Pressure Alarm
202
Sender Unit for Lube Oil Pressure Gauge
203
Cooling Water Temperature Alarm
204
Sender Unit for the Cooling Water Temperature Gauge
204
Air Heater (Optional)
205
Electric Engine Stopping Device (Optional)
206
13 Service Standards
207
Engine Tuning
207
Engine Body
208
Cylinder Head
208
Camshaft and Gear Train
209
Cylinder Block
210
Lubricating Oil System (Trochoid Pump)
212
14 Tightening Torque for Bolts and Nuts
213
Main Bolt and Nut
213
Standard Bolts and Nuts (Without Lube Oil)
213
Yanmar 3JH4E Operation Manual (142 pages)
JH4 Series Marine Engines
Brand:
Yanmar
| Category:
Engine
| Size: 18.67 MB
Table of Contents
Table of Contents
3
Introduction
7
Record of Ownership
8
Safety
9
Safety Precautions
10
General Information
10
Before You Operate
10
During Operation and Maintenance
10
Location of Safety Decals
14
Product Overview
19
Yanmar JH4 Features and Applications
19
New Engine Break-In
19
Component Identification
21
Service Side - 3JH4E
21
Non-Service Side - 3JH4E
21
Service Side - 4JH4AE
22
Non-Service Side - 4JH4AE
22
Service Side - 4JH4-TE
23
Non-Service Side - 4JH4-TE
23
Service Side - 4JH4-HTE
24
Non-Service Side - 4JH4-HTE
24
Location of Nameplates
25
Function of Major Components
26
Control Equipment
27
Instrument Panel (Optional)
27
Single Lever Remote Control Handle
32
Before You Operate
33
Diesel Fuel
33
Diesel Fuel Specifications
33
Handling of Diesel Fuel
34
Filling the Fuel Tank
36
Fuel System - 4JH4AE
36
Bleeding the Fuel System
36
Engine Oil
38
Engine Oil Specifications
38
Engine Oil Viscosity
39
Checking the Engine Oil
39
Adding Engine Oil
39
Marine Gear or Sail Drive Oil
40
Marine Gear Oil Specifications
40
Sail Drive Oil Specifications - SD50
40
Checking Marine Gear Oil
41
Adding Marine Gear Oil
41
Checking and Adding Sail Drive Oil
41
Engine Coolant
42
Engine Coolant Specifications
42
Coolant (Closed Cooling System)
42
Checking and Adding Coolant
42
Cranking the Engine
45
Daily Checks
46
Visual Checks
46
Checking Diesel Fuel, Engine Oil and Engine Coolant Levels
47
Checking and Refilling Marine Gear Oil
47
Checking the Battery Electrolyte Level
47
Checking the Alternator Belt
47
Checking the Remote Control Handle
47
Checking the Alarm Indicators
47
Preparing Fuel, Oil and Coolant in Reserve
47
Engine Operation
49
Starting the Engine
50
Restarting after Starting Failure
51
Starting at Low Temperatures
51
After the Engine Has Started
52
Remote Control Handle Operation
52
Acceleration and Deceleration
52
Shifting the Engine
52
Switching to Trolling (KMH4A Only)
53
Shutting down the Engine
54
Emergency Shutdown
54
Checking the Engine after Operation
55
Periodic Maintenance
57
Safety Precautions
57
Precautions
59
The Importance of Periodic Maintenance
59
Performing Periodic Maintenance
59
The Importance of Daily Checks
59
Keep a Log of Engine Hours and Daily Checks
59
Yanmar Replacement Parts
59
Tools Required
59
Ask Your Authorized Yanmar Marine Dealer or Distributor for Help
59
Tightening Fasteners
60
EPA Maintenance Requirements
61
EPA Requirements for USA and Other Applicable Countries
61
EPA Requirements
61
Conditions to Ensure Compliance with EPA Emission Standards
61
Inspection and Maintenance
62
Periodic Maintenance Schedule
63
Inspection and Maintenance of EPA Emission-Related Parts
66
Periodic Maintenance Procedures
67
After Initial 50 Hours of Operation
67
Control Cables
69
Every 50 Hours of Operation
71
Every 250 Hours of Operation
73
Every 500 Hours of Operation
79
Every 1000 Hours of Operation
80
Troubleshooting
83
Troubleshooting after Starting
83
Troubleshooting Chart
85
Troubleshooting Information
88
Long-Term Storage
89
Prepare Engine for Long-Term Storage
89
Drain Seawater Cooling System
90
Specifications
93
Principal Engine Specifications
93
3JH4E Engine Specifications
93
3JH4E Marine Gear Specifications
95
4JH4AE Engine Specifications
96
4JH4AE Marine Gear or Sail Drive Specifications
100
4JH4-TE Engine Specifications
102
4JH4-HTE Engine Specifications
104
4JH4-TE and 4JH4-HTE Marine Gear or Sail Drive Specifications
106
System Diagrams
107
Piping Diagrams
107
Wiring Diagrams
122
EPA Warranty USA Only
135
Yanmar Co., Ltd. Limited Emission Control System Warranty - Usa Only
135
Your Warranty Rights and Obligations
136
Warranty Period
136
Warranty Coverage
137
Exclusions
137
Owner's Responsibility
137
Customer Assistance
138
Emission System Warranty
139
Non-Road Emission System Warranty
139
Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
139
Warranted Parts
140
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Yanmar 3JH4E Installation Manual (30 pages)
Brand:
Yanmar
| Category:
Engine
| Size: 3.7 MB
Table of Contents
Table of Contents
1
Engine Specifications
2
Marine Gear / Sail Drive Specifications
3
Fuel System Specifications
4
Cooling System Specifications
4
Air Intake and Exhaust Specifications
5
Alarm System Specifications
5
Engine Outline with KM35A
6
Engine Outline with KM35P
7
Engine Outline with SD50
8
Piping Diagrams
10
Electrical System
12
Wiring Diagrams
16
Performance Curves
20
Controls
21
Power Take-Off
24
PTO Performance Curves
25
Engine Mount Specifications
26
Cold Starting Aids
29
Air Venting for V-Drive Applications
29
Water Heater Tank Connection
29
Optional Accessories
29
Yanmar 3JH4E Service Manual (21 pages)
Marine Diesel Engines
Brand:
Yanmar
| Category:
Engine
| Size: 0.89 MB
Table of Contents
Safety Labels
4
Safety Precautions
5
Exterior Views
16
Specifications
17
Lubricating Oil
19
Cooling Water
20
Yanmar 3JH4E Service Manual (6 pages)
Brand:
Yanmar
| Category:
Engine
| Size: 1.16 MB
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