Yanmar 4JH-TE Manuals

Manuals and User Guides for Yanmar 4JH-TE. We have 1 Yanmar 4JH-TE manual available for free PDF download: Service Manual

Yanmar 4JH-TE Service Manual

Yanmar 4JH-TE Service Manual (318 pages)

Brand: Yanmar | Category: Engine | Size: 20.51 MB

Table of Contents

Contents
3
General: Contents
4
Exterior Views: 4JHE
5
Exterior Views: 4JH-TE
6
Exterior Views: 4JH-HTE and 4JH-DTE
7
Specifications
8
Construction
9
Performance Curves: 4JHE
10
Performance Curves: 4JH-TE
11
Performance Curves: 4JH-HTE
12
Performance Curves: 4JH-DTE
13
Engine Cross Section
14
Dimensions: 4JHE
15
Dimensions: 4JH-TE
16
Dimensions: 4JH-HTE
17
Dimensions: 4JH-DTE
18
Piping Diagrams: 4JHE
19
Piping Diagrams: 4JH-TE
20
Piping Diagrams: 4JH-HTE and 4JH-DT(B)E
21
Parts Interchangeability
22
Inspection and Servicing of Basic Engine Parts: Contents
23
Cylinder Block
24
Cleaning of Oil Holes
24
Color Check Procedure
24
Replacement of Cup Plugs
25
Cylinder Bore Measurement
26
Cylinder Liners
27
Measuring Cylinder Liners
27
Measuring Cylinder Liner Projection
28
Cylinder Head
29
Inspecting the Cylinder Head
30
Checking the Intake and Exhaust Valve Seats
30
Checking for Cracks in the Combustion Surface
30
Valve Seat Correction Procedure
31
Intake/Exhaust Valves, Valve Guides
31
Wearing and Corrosion of Valve Stem
31
Inspection of Valve Seat Wear and Contact Surface
32
Valve Sinking
32
Valve Guide
32
Assembling the Cylinder Head
34
Intake and Exhaust Valve Arms
34
Measuring Top Clearance
34
Adjustment of Valve Head Clearance
35
Pistons and Piston Pins
36
Piston Pin
37
Piston Head and Combustion Surface
37
Measurement of Piston Outside Diameter/Inspection
37
Replacing the Piston
37
Piston Rings
38
Measuring Piston Ring Gap
38
Measuring the Rings
38
Replacing the Piston Rings
39
Connecting Rod
40
Inspecting the Connection Rod
40
Twist and Parallelism of the Large and Small Ends
40
Checking Thrust Clearance
40
Crank Pin Bushing
41
Piston Pin Bushing
41
Measuring Crank Pin Oil Clearance
41
Precautions on Replacement of Crank Pin Bushing
41
Crankshaft and Main Bearing
43
Camshaft and Tappets
46
Timing Gear
49
Inspecting the Gears
49
Gear Timing Marks
50
Flywheel and Housing
51
Specifications of Flywheel
51
Dimensions of Flywheel and Mounting Flange
52
Ring Gear
53
Position of Top Dead Center and Fuel Injection Timing
53
Fuel Injection Equipment: Contents
55
Fuel Supply System
56
Fuel Injection Pump Construction
58
Fuel Injection Pump Specifications
59
Functioning of Fuel Injection Pump
59
Injection Volume Control
59
Governor Construction
60
Function of Governor
62
Disassembly, Reassembly and Inspection of Governor
64
Governor Disassembly
65
Inspection of Governor
69
Assembling Governor
69
Disassembly, Reassembly and Inspection of Fuel Injection Pump
73
Disassembly of Fuel Injection Pump
74
Inspection of Fuel Injection Pump
78
Reassembly of Fuel Injection Pump
79
Adjustment of Fuel Injection Pump and Governor
83
Adjustment of Top Clearance
84
Adjusting of Injection Timing
85
Plunger Pressure Test
86
Delivery Valve Pressure Test
86
Adjusting Injection Volume (Unifomity of each Cylinder)
86
Adjustment of Governor
87
Adjusting Fuel Limit Bolt
87
Adjusting RPM Limit Bolt
87
Adjusting Idling
87
Check Injection Volume When Starting
88
Automatic Timer (Automatic Advancing Timer)
89
Timer Construction
89
Functioning and Characteristics of Timer
90
Timer Disassembly, Reassembly
90
Timer Inspection
90
Fuel Feed Pump
91
Construction of Fuel Feed Pump
91
Fuel Feed Pump Specifications
91
Disassembly and Reassembly of Fuel Feed Pump
92
Fuel Feed Pump Inspection
92
Fuel Injection Nozzle
93
Functioning of Fuel Injection Nozzle
93
Fuel Injection Nozzle Disassembly/Inspection
94
Fuel Injection Nozzle Reassembly
95
Adjusting Fuel Injection Nozzle
96
Adjusting Opening Pressure
96
Injection Test
96
Troubleshooting of Fuel Injection Pump
97
Fuel Injection Pump Service Data
99
Tools
100
Fuel Filter Inspection
102
Fuel Filter Specifications
102
Fuel Tank
103
Design Change of Fuel Piping Line
104
Modification of Fuel Piping Line
104
Applicable Engine Models and Serial Numbers
104
Intake and Exhaust System: Contents
105
Intake and Exhaust System: Overview
106
4JH-TE Engine
107
Air Cooler for Models 4JH-HTE and 4JH-DTE
108
Intake Silencer Inspection
109
Intake Manifold Inspection
110
Turbocharger Specifications, Construction
111
Turbocharger Function
112
Interchangeability of Turbochargers
113
Interchangeability of Turbocharger Components
114
Turbocharger: Preparations for Disassembly
115
Turbocharger: Inspection Prior to Disassembly
116
Turbocharger Disassembly
116
Turbocharger: Preparation for Reassembly
116
Turbocharger Reassembly
117
Turbocharger Disassembly/Reassembly Precautions
118
Turbocharger Inspection and Maintenance
118
Turbocharger Inspection Procedure
120
Turbocharger Periodic Inspection
121
Turbocharger: Troubleshooting
124
Turbocharger: Excessive Smoke, White Exhaust Smoke
124
Turbocharger: Excessive Oil Consumption
124
Turbocharger: Decrease in Engine Output
124
Turbocharger Blower Washing Procedure
125
Turbocharger: Poor (Slow) Turbocharger Responsiveness
125
Turbocharger: Abnormal Noise or Vibration
125
Mixing Elbow Inspection
126
Breather Inspection
127
Lubrication System: Contents
128
Lubrication System: Overview
129
Lube Oil Pump Construction
131
Lube Oil Pump Specifications
132
Lube Oil Pump Disassembly, Inspection
133
Lube Oil Filter Construction
134
Lube Oil Filter Replacement
135
Oil Pressure Control Valve Construction
136
Oil Pressure Control Valve Replacement
136
Vibration Preventing Damper
136
Lube Oil Cooler Construction
137
Inspecting the Lube Oil Cooler
137
Piston Cooling Nozzle Construction
139
Inspection of Piston Cooling Nozzle
139
Rotary Waste Oil Pump Construction
140
Inspecting the Waste Oil Pump
140
Cooling Water System: Contents
141
Cooling Water System: Overview
142
Fresh Water Line/Sea Water Line
143
Sea Water Pump Construction and Functioning
145
Specifications of Sea Water Pump
146
Sea Water Pump Disassembly, Inspection
146
Sea Water Pump Reassembly
147
Fresh Water Pump Construction
148
Specifications of Fresh Water Pump
149
Fresh Water Pump Disassembly
149
Fresh Water Pump Inspection
149
Heat Exchanger Construction
151
Specifications of Heat Exchanger
152
Disassembly and Reassembly of the Heat Exchanger
152
Heat Exchanger Inspection
152
Pressure Cap and Sub Tank
153
Pressure Cap Construction, Pressure Control
153
Pressure Cap Inspection
153
Function of the Sub Tank
153
Specifications of Sub Tank
154
Mounting the Sub Tank
154
Precautions on Usage of the Sub Tank
154
Thermostat Construction, Characteristics
155
Functioning of Thermostat
155
Thermostat Inspection
156
Testing the Thermostat
156
Kingston Cock Construction, Inspection
157
Kingston Cock Handling Precautions
157
Sea Water Filter
158
Bilge Pump and Bilge Strainer
159
Bilge Pump Specifications, Performance of Pump
159
Reduction and Reversing Gear: Contents
160
Reduction and Reversing Gear: Construction, Specifications
161
Power Transmission System
162
Reduction and Reversing Gear Drawing
163
Reduction and Reversing Gear: Cross Section
164
Installation Angle
166
Remote Control Unit
166
Clutch Operation Force
166
Reduction and Reversing Gear: Operation and Maintenance
167
Lube Oil, Side Cover
167
Inspection and Servicing
168
Clutch Case, Bearing, Gear
168
Steel Plate
168
Friction Plate
169
Pressure Plate
169
Driving Plate
170
Retainer
170
Plate Spring
170
Thrust Collar
170
Shift Ring
171
Shift Fork and Shift Lever
171
Damper Disc
171
Output Shaft
171
Input Shaft
172
Intermediate Shaft
172
Disassembling the Clutch and Accessories
173
Disassembling the Input/Output Shafts
174
Disassembling the Intermediate Shaft
175
Disassembling the Operating System
176
Reduction and Reversing Gear: Reassembly Precautions
177
Reassembling the Output Shaft
177
Reassembling the Input Shaft
180
Reassembling the Intermediate Shaft
180
Installing the Input Shaft and Output Shaft
180
Reassembling and Installing the Operating System
181
Installing the Output Shaft Coupling
182
Reduction and Reversing Gear: Special Tools
183
Marine Gear Model KM4A: Construction
184
Specifications of Angle Drive Marine Gear
185
KM4A Sectional View
186
Power Transmission System: Arrangement of Shafts and Gear, Reduction Ratio
187
Shifting Device
188
Construction of Shifting Mechanism
188
Clutch Gear a and Clutch Gear B Operation
189
Engagement and Disengagement of Clutch
189
Clutch Shifting Force
190
Adjustment of Shifting Device
190
Measurement and Adjustment of Clearance
191
Inspect for the Following Points
191
Adjustment of the Remote Control Head Marine Gearbox Control Side
192
Reduction and Reversing Gear: Inspection and Servicing
193
Clutch Case and Cover
193
Gears
193
Drive Cone
193
Lapping Procedure for Drive Cone
195
Thrust Coller a and B for Clutch Shaft
196
Input/Output Shaft
197
Shifter Spring, Stopper Bolt, Damper Disc
199
Side Cover and Oil Seal
199
Shim Adjustment for Output and Input Shafts
200
Reduction and Reversing Gear: Tools
203
Reduction and Reversing Gear: Disassembly
205
Disassembling the Clutch Shaft
209
Disassembling the Input/Output Shaft
211
Disassembling the Shifting Device
212
Reduction and Reversing Gear: Reassembly
213
Reassembly of Clutch Shaft
213
Reassembly of Input Shaft
216
Reassembly of the Clutch Case
217
Reassembly of the Bearing Outer Races and Shims in the Clutch Case
217
Reassembly of the Input Shaft
218
Reassembly of the Mounting Flange
218
Reassembly of the Oil Cooler
219
Reassembly of the Shifting Device
220
Reassembly of the Lube Oil Drain Plug and the Dipstick
221
Remote Control: Contents
222
Remote Control System: Construction
223
Remote Control Device Components
223
Remote Control Installation
224
Speed Control
224
Clutch Control
225
Engine Stop
226
Remote Control Inspection
227
Remote Control Adjustment
228
Electrical System: Contents
229
Electrical System: System Diagrams of Electric Parts
230
B-Type Instrument Panel
230
C-Type and D-Type Instrument Panel
231
Wiring Diagram: B-Type Instrument Panel
232
Wiring Diagram: C-Type Instrument Panel
233
Wiring Diagram: D-Type Instrument Panel
234
Battery Construction
235
Battery Capacity and Battery Cables
235
Battery Inspection
235
Checking the Electrolyte
236
Voltage Test
236
Washing the Battery
236
Battery Storage Precautions
237
Charging Methods
237
Charging Procedure, Precautions
237
Starter Motor Construction
238
Starter Motor Specifications and Performance
238
Starter Motor Overview
239
Starter Motor: Adjustment and Performance Test
240
Starter Motor Operation
240
Starter Motor: Pinion Movement
240
Starter Motor: Plunger Movement
241
Pinion Lock Torque Measurement
241
Mesh Clearance
241
Starter Motor Disassembly
241
Starter Motor: Brush Holder, Yoke, Armature, Pinion
242
Starter Motor Inspection
242
Field Coil
243
Brush
244
Magnetic Switch
245
Starter Motor Reassembly Precautions
245
Starter Motor Testing
246
No Load Test
246
Starter Motor: Maintenance Standard
247
Starter Motor: Various Problems and Their Remedies
248
Alternator Characteristics, Specifications
249
Alternator Construction
250
Alternator Functioning
251
Alternator Handling Precautions
251
Disassembling the Alternator
252
Inspection and Adjustment of Alternator
253
Reassembling the Alternator
255
Alternator Performance Test
256
Alternator Troubleshooting
257
Alternator: Charging Failure
257
Alternator: Overcharging
258
Alternator: Charge Lamp Failure
258
Instrument Panel and Wiring Codes
259
B-Type Instrument Panel and Wire Harness
259
Wire Harness for B-Type Instrument Panel
260
Extension Cord for B-Type Instrument Panel
260
C-Type, D-Type Instrument Panel and Wire Harness
261
Wire Harness for C-Type and D-Type Instrument Panel
263
Extension Cord for C-Type and D-Type Instrument Panel
263
Warning Devices
264
Oil Pressure Alarm
264
Cooling Water Temperature Alarm
265
Sender Unit for Lube Oil Pressure Gauge
265
Sender Unit for the Cooling Water Temperature Gauge
266
Air Heater
267
Electric Type Engine Stopping Device
268
Tachometer: Construction, Specifications and Dimensions
270
Measurement of Sensor Unit Characteristics
271
Alternator Features, Characteristics, Specifications
273
Alternator Constructions
274
Alternator Functioning, Handling Precautions
275
Alternator: Inspection and Adjustment
277
Performance Test: Alternator
280
Alternator: Troubleshooting
281
Disassembly and Reassembly: Contents
283
Disassembly and Reassembly Precautions
284
Disassembly and Reassembly Tools
285
Disassembly: Drain Cooling Water
292
Disassembly: Drain Lube Oil
292
Disassembly: Removing Electrical Wiring
292
Disassembly: Removing the Fuel Oil Filter and Fuel Oil Pipe
293
Disassembly: Removing the Mixing Elbow
293
Disassembly: Removing the Intake Silencer
293
Disassembly: Removing the Turbine
293
Disassembly: Removing the Mixing Elbow and the Turbocharger
294
Disassembly: Removing the Air Cooler
294
Disassembly: Removing the Starting Motor
295
Disassembly: Removing the Alternator
295
Disassembly: Removing the Cooling Water Pipe
295
Disassembly: Removing the Cooling Water (Sea Water) Pipe
296
Disassembly: Removing the High Pressure Fuel Pipe
296
Disassembly: Removing the Lube Oil Filter
296
Disassembly: Removing the Intake Manifold
296
Disassembly: Removing the Fresh Water Pump
297
Disassembly: Removing the Valve Elbow Shaft Assembly
297
Disassembly: Removing the Fuel Injection Nozzles
297
Disassembly: Removing the Cylinder Head
297
Disassembly: Removing the Crankshaft V-Pulley
298
Disassembly: Removing the Lube Oil Cooler
298
Disassembly: Removing the Marine Gearbox
298
Disassembly: Removing the Flywheel
298
Disassembly: Turning the Engine over
299
Disassembly: Removing the Oil Pan
299
Disassembly: Removing the Gear Case
299
Disassembly: Removing the Lube Oil Pump
299
Disassembly: Remove the Fuel Injection Pump
300
Disassembly: Removing the Pistons and Connecting Rods
300
Disassembly: Removing the Idling Gear
300
Disassembly: Removing the Cylinder Liner
300
Disassembly: Removing the Crankshaft, Camshaft
301
Disassembly: Removing the Flywheel Housing
301
Disassembly: Removing the Main Bearing
301
Disassembly: Removing the Gear Case Flange
301
Disassembly: Removing the Piston Cooling Nozzle
302
Reassembly: Mounting the Piston Cooling Nozzle
302
Reassembly: Mounting the Gear Case Flange
302
Reassembly: Inserting the Tappets
302
Reassembly: Mounting the Camshaft
303
Reassembly: Mounting the Crankshaft
303
Reassembly: Mounting the Main Bearing Metal with Engine Oil, and Mounting the Main Bearing Cap
303
Reassembly: Mounting the Flywheel Housing
304
Reassembly: Stand Ip the Cylinder Block
304
Reassembly: Inserting the Cylinder Liners
304
Reassembly: Mounting the Piston and Connecting Rod
304
Reassembly: Mounting the Idling Gear
305
Reassembly: Mounting the Fuel Injection Pump
305
Reassembly: Mounting the Fuel Feed Pump Drive Gear and Automatic Advancing Timer
305
Reassembly: Mounting the Lube Oil Pump
305
Reassembly: Mounting the Gear Case
306
Reassembly: Mounting the Oil Pan
306
Reassembly: Mounting the Lube Oil Intake Pipe
306
Reassembly: Mounting the Marine Gearbox
307
Reassembly: Mounting the Cylinder Head
307
Reassembly: Mounting the Crank V-Pulley
307
Reassembly: Mounting the Valve Rocker Arm Shaft Assembly Pushrod
308
Reassembly: Mounting the Fuel Injection Nozzle
308
Reassembly: Mounting the Fresh Water Pump
308
Reassembly: Mounting the Intake Manifold
309
Reassembly: Mounting the Lube Oil Cooler
309
Reassembly: Mounting the High Pressure Fuel Pipe and Fuel Oil Return Pipe
309
Reassembly: Mounting the Lube Oil Filter
309
Reassembly: Mounting the Lube Oil Pipe
310
Reassembly: Mounting the Dipstic Guide
310
Reassembly: Mounting the Sea Water Pump
310
Reassembly: Mounting the Cooling Water Pipe
310
Reassembly: Mounting the Alternator
311
Reassembly: Mounting the Turbine
311
Reassembly: Mounting the Starting Motor
311
Reassembly: Mounting the Mixing Elbow
312
Reassembly: Mounting the Mixing Elbow and the Turbocharger
312
Reassembly: Mounting the Air Cooler
312
Reassembly: Mounting the Intake Silencer
313
Reassembly: Electrical Wiring
313
Reassembly: Mounting the Fuel Filter and Fuel Oil Pipe
313
Reassembly: Filling with Lube Oil
313
Reassembly: Filling with Cooling Water
314
Reassembly: Checking Fuel Injection Timing
314
Bolt/Nut Tightening Torque
315
Test Running
316
Preliminary Precautions
316
Check Points and Precautions During Running
316

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