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4JHE
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Yanmar 4JHE Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
General: Contents
Exterior Views: 4JHE
Exterior Views: 4JH-TE
Exterior Views: 4JH-HTE and 4JH-DTE
Specifications
Construction
Performance Curves: 4JHE
Performance Curves: 4JH-TE
Performance Curves: 4JH-HTE
Performance Curves: 4JH-DTE
Engine Cross Section
Dimensions: 4JHE
Dimensions: 4JH-TE
Dimensions: 4JH-HTE
Dimensions: 4JH-DTE
Piping Diagrams: 4JHE
Piping Diagrams: 4JH-TE
Piping Diagrams: 4JH-HTE and 4JH-DT(B)E
Parts Interchangeability
Inspection and Servicing of Basic Engine Parts: Contents
Cylinder Block
Cleaning of Oil Holes
Color Check Procedure
Replacement of Cup Plugs
Cylinder Bore Measurement
Cylinder Liners
Measuring Cylinder Liners
Measuring Cylinder Liner Projection
Cylinder Head
Inspecting the Cylinder Head
Checking the Intake and Exhaust Valve Seats
Checking for Cracks in the Combustion Surface
Valve Seat Correction Procedure
Intake/Exhaust Valves, Valve Guides
Wearing and Corrosion of Valve Stem
Inspection of Valve Seat Wear and Contact Surface
Valve Sinking
Valve Guide
Assembling the Cylinder Head
Intake and Exhaust Valve Arms
Measuring Top Clearance
Adjustment of Valve Head Clearance
Pistons and Piston Pins
Piston Pin
Piston Head and Combustion Surface
Measurement of Piston Outside Diameter/Inspection
Replacing the Piston
Piston Rings
Measuring Piston Ring Gap
Measuring the Rings
Replacing the Piston Rings
Connecting Rod
Inspecting the Connection Rod
Twist and Parallelism of the Large and Small Ends
Checking Thrust Clearance
Crank Pin Bushing
Piston Pin Bushing
Measuring Crank Pin Oil Clearance
Precautions on Replacement of Crank Pin Bushing
Crankshaft and Main Bearing
Camshaft and Tappets
Timing Gear
Inspecting the Gears
Gear Timing Marks
Flywheel and Housing
Specifications of Flywheel
Dimensions of Flywheel and Mounting Flange
Ring Gear
Position of Top Dead Center and Fuel Injection Timing
Fuel Injection Equipment: Contents
Fuel Supply System
Fuel Injection Pump Construction
Fuel Injection Pump Specifications
Functioning of Fuel Injection Pump
Injection Volume Control
Governor Construction
Function of Governor
Disassembly, Reassembly and Inspection of Governor
Governor Disassembly
Inspection of Governor
Assembling Governor
Disassembly, Reassembly and Inspection of Fuel Injection Pump
Disassembly of Fuel Injection Pump
Inspection of Fuel Injection Pump
Reassembly of Fuel Injection Pump
Adjustment of Fuel Injection Pump and Governor
Adjustment of Top Clearance
Adjusting of Injection Timing
Plunger Pressure Test
Delivery Valve Pressure Test
Adjusting Injection Volume (Unifomity of each Cylinder)
Adjustment of Governor
Adjusting Fuel Limit Bolt
Adjusting RPM Limit Bolt
Adjusting Idling
Check Injection Volume When Starting
Automatic Timer (Automatic Advancing Timer)
Timer Construction
Functioning and Characteristics of Timer
Timer Disassembly, Reassembly
Timer Inspection
Fuel Feed Pump
Construction of Fuel Feed Pump
Fuel Feed Pump Specifications
Disassembly and Reassembly of Fuel Feed Pump
Fuel Feed Pump Inspection
Fuel Injection Nozzle
Functioning of Fuel Injection Nozzle
Fuel Injection Nozzle Disassembly/Inspection
Fuel Injection Nozzle Reassembly
Adjusting Fuel Injection Nozzle
Adjusting Opening Pressure
Injection Test
Troubleshooting of Fuel Injection Pump
Fuel Injection Pump Service Data
Tools
Fuel Filter Inspection
Fuel Filter Specifications
Fuel Tank
Design Change of Fuel Piping Line
Modification of Fuel Piping Line
Applicable Engine Models and Serial Numbers
Intake and Exhaust System: Contents
Intake and Exhaust System: Overview
4JH-TE Engine
Air Cooler for Models 4JH-HTE and 4JH-DTE
Intake Silencer Inspection
Intake Manifold Inspection
Turbocharger Specifications, Construction
Turbocharger Function
Interchangeability of Turbochargers
Interchangeability of Turbocharger Components
Turbocharger: Preparations for Disassembly
Turbocharger: Inspection Prior to Disassembly
Turbocharger Disassembly
Turbocharger: Preparation for Reassembly
Turbocharger Reassembly
Turbocharger Disassembly/Reassembly Precautions
Turbocharger Inspection and Maintenance
Turbocharger Inspection Procedure
Turbocharger Periodic Inspection
Turbocharger: Troubleshooting
Turbocharger: Excessive Smoke, White Exhaust Smoke
Turbocharger: Excessive Oil Consumption
Turbocharger: Decrease in Engine Output
Turbocharger Blower Washing Procedure
Turbocharger: Poor (Slow) Turbocharger Responsiveness
Turbocharger: Abnormal Noise or Vibration
Mixing Elbow Inspection
Breather Inspection
Lubrication System: Contents
Lubrication System: Overview
Lube Oil Pump Construction
Lube Oil Pump Specifications
Lube Oil Pump Disassembly, Inspection
Lube Oil Filter Construction
Lube Oil Filter Replacement
Oil Pressure Control Valve Construction
Oil Pressure Control Valve Replacement
Vibration Preventing Damper
Lube Oil Cooler Construction
Inspecting the Lube Oil Cooler
Piston Cooling Nozzle Construction
Inspection of Piston Cooling Nozzle
Rotary Waste Oil Pump Construction
Inspecting the Waste Oil Pump
Cooling Water System: Contents
Cooling Water System: Overview
Fresh Water Line/Sea Water Line
Sea Water Pump Construction and Functioning
Specifications of Sea Water Pump
Sea Water Pump Disassembly, Inspection
Sea Water Pump Reassembly
Fresh Water Pump Construction
Specifications of Fresh Water Pump
Fresh Water Pump Disassembly
Fresh Water Pump Inspection
Heat Exchanger Construction
Specifications of Heat Exchanger
Disassembly and Reassembly of the Heat Exchanger
Heat Exchanger Inspection
Pressure Cap and Sub Tank
Pressure Cap Construction, Pressure Control
Pressure Cap Inspection
Function of the Sub Tank
Specifications of Sub Tank
Mounting the Sub Tank
Precautions on Usage of the Sub Tank
Thermostat Construction, Characteristics
Functioning of Thermostat
Thermostat Inspection
Testing the Thermostat
Kingston Cock Construction, Inspection
Kingston Cock Handling Precautions
Sea Water Filter
Bilge Pump and Bilge Strainer
Bilge Pump Specifications, Performance of Pump
Reduction and Reversing Gear: Contents
Reduction and Reversing Gear: Construction, Specifications
Power Transmission System
Reduction and Reversing Gear Drawing
Reduction and Reversing Gear: Cross Section
Installation Angle
Remote Control Unit
Clutch Operation Force
Reduction and Reversing Gear: Operation and Maintenance
Lube Oil, Side Cover
Inspection and Servicing
Clutch Case, Bearing, Gear
Steel Plate
Friction Plate
Pressure Plate
Driving Plate
Retainer
Plate Spring
Thrust Collar
Shift Ring
Shift Fork and Shift Lever
Damper Disc
Output Shaft
Input Shaft
Intermediate Shaft
Disassembling the Clutch and Accessories
Disassembling the Input/Output Shafts
Disassembling the Intermediate Shaft
Disassembling the Operating System
Reduction and Reversing Gear: Reassembly Precautions
Reassembling the Output Shaft
Reassembling the Input Shaft
Reassembling the Intermediate Shaft
Installing the Input Shaft and Output Shaft
Reassembling and Installing the Operating System
Installing the Output Shaft Coupling
Reduction and Reversing Gear: Special Tools
Marine Gear Model KM4A: Construction
Specifications of Angle Drive Marine Gear
KM4A Sectional View
Power Transmission System: Arrangement of Shafts and Gear, Reduction Ratio
Shifting Device
Construction of Shifting Mechanism
Clutch Gear a and Clutch Gear B Operation
Engagement and Disengagement of Clutch
Clutch Shifting Force
Adjustment of Shifting Device
Measurement and Adjustment of Clearance
Inspect for the Following Points
Adjustment of the Remote Control Head Marine Gearbox Control Side
Reduction and Reversing Gear: Inspection and Servicing
Clutch Case and Cover
Gears
Drive Cone
Lapping Procedure for Drive Cone
Thrust Coller a and B for Clutch Shaft
Input/Output Shaft
Shifter Spring, Stopper Bolt, Damper Disc
Side Cover and Oil Seal
Shim Adjustment for Output and Input Shafts
Reduction and Reversing Gear: Tools
Reduction and Reversing Gear: Disassembly
Disassembling the Clutch Shaft
Disassembling the Input/Output Shaft
Disassembling the Shifting Device
Reduction and Reversing Gear: Reassembly
Reassembly of Clutch Shaft
Reassembly of Input Shaft
Reassembly of the Clutch Case
Reassembly of the Bearing Outer Races and Shims in the Clutch Case
Reassembly of the Input Shaft
Reassembly of the Mounting Flange
Reassembly of the Oil Cooler
Reassembly of the Shifting Device
Reassembly of the Lube Oil Drain Plug and the Dipstick
Remote Control: Contents
Remote Control System: Construction
Remote Control Device Components
Remote Control Installation
Speed Control
Clutch Control
Engine Stop
Remote Control Inspection
Remote Control Adjustment
Electrical System: Contents
Electrical System: System Diagrams of Electric Parts
B-Type Instrument Panel
C-Type and D-Type Instrument Panel
Wiring Diagram: B-Type Instrument Panel
Wiring Diagram: C-Type Instrument Panel
Wiring Diagram: D-Type Instrument Panel
Battery Construction
Battery Capacity and Battery Cables
Battery Inspection
Checking the Electrolyte
Voltage Test
Washing the Battery
Battery Storage Precautions
Charging Methods
Charging Procedure, Precautions
Starter Motor Construction
Starter Motor Specifications and Performance
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Quick Links
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Exterior Views: 4Jh-Hte and 4Jh-Dte
2
Specifications
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Table of Contents
Troubleshooting
Troubleshooting Of Fuel Injection Pump
97
Turbocharger: Troubleshooting
124
Alternator Troubleshooting
257
Alternator: Troubleshooting
281
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This manual is also suitable for:
4jh-te
4jh-hte
4jh-dte
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