Yanmar 3JH4E Manuals

Manuals and User Guides for Yanmar 3JH4E. We have 7 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 MB

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
- 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
- Long Storage
  119
3 Troubleshooting

120
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
- 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
- Turbocharger
  267
8 Lubrication System

272
- Lube Oil Pump
  273
- 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
- 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
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
- 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

Yanmar 3JH4E Service Manual (214 pages)

Marine diesel engine

Brand: Yanmar | Category: Engine | Size: 14 MB

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
2 Inspection and Adjustment

28
3 Troubleshooting

59
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
- 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 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
- 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
- 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 MB

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
- Engine Coolant
  42
- Cranking the Engine
  45
- Daily Checks
  46
Engine Operation

49
- Starting the Engine
  50
- Remote Control Handle Operation
  52
- Shutting down the Engine
  54
  - Emergency Shutdown
    54
- Checking the Engine after Operation
  55
Periodic Maintenance

57
Troubleshooting

83
Long-Term Storage

89
- Prepare Engine for Long-Term Storage
  89
- Drain Seawater Cooling System
  90
Specifications

93
- Principal Engine Specifications
  93
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

Yanmar 3JH4E Installation Manual (30 pages)

Brand: Yanmar | Category: Engine | Size: 3 MB

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)

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Yanmar 3JH4E Service Manual (350 pages)

Table of Contents

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

Yanmar 3JH4E Service Manual (214 pages)

Table of Contents

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 Cooling Water System

10 Reduction and Reversing Gear

11 Remote Control (Optional)

12 Electrical System

13 Service Standards

14 Tightening Torque for Bolts and Nuts

Yanmar 3JH4E Operation Manual (142 pages)

Table of Contents

Introduction

Safety

Product Overview

Before You Operate

Engine Operation

Periodic Maintenance

Troubleshooting

Long-Term Storage

Specifications

System Diagrams

EPA Warranty USA Only

Emission System Warranty

Yanmar 3JH4E Installation Manual (30 pages)

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