Yanmar 4JH4-HTE Manuals

Manuals and User Guides for Yanmar 4JH4-HTE. We have 8 Yanmar 4JH4-HTE manuals available for free PDF download: Service Manual, Operation Manual

Yanmar 4JH4-HTE Service Manual

Yanmar 4JH4-HTE 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
- 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

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Yanmar 4JH4-HTE Operation Manual

Yanmar 4JH4-HTE Operation Manual (164 pages)

JH Series

Brand: Yanmar | Category: Engine | Size: 16.27 MB

Table of Contents

Table of Contents
3
Introduction

7
- JH Series Emission Control System Warranty-USA, the Environmental Protection Agency (EPA) Only
  8
- Record of Ownership
  9
Safety

11
- Safety Precautions
  12
  - General Information
    12
  - Before You Operate
    12
  - During Operation and Maintenance
    12
- Location of Safety Decals
  16
Product Overview

21
Before You Operate

37
- Introduction
  37
- Safety Precautions
  37
- Diesel Fuel
  38
  - Diesel Fuel Specifications
    38
  - Handling of Diesel Fuel
    39
  - Filling the Fuel Tank
    41
  - Bleeding the Fuel System
    41
- Engine Oil
  43
  - Engine Oil Specifications
    43
  - Engine Oil Viscosity
    43
  - Checking the Engine Oil
    43
  - Adding Engine Oil
    44
- Marine Gear or Sail Drive Oil
  44
- Engine Coolant
  45
- Cranking the Engine
  49
Engine Operation

51
- Introduction
  51
- Safety Precautions
  51
- Starting the Engine
  53
  - Before Starting the Engine
    53
  - To Start the Engine
    53
  - If the Engine Fails to Start
    54
  - Starting at Low Temperatures
    54
  - After the Engine Has Started
    55
- Remote Control Handle Operation
  55
- Cautions During Operation
  57
- Shutting down the Engine
  58
  - Normal Shutdown
    58
  - Emergency Shutdown
    58
- Checking the Engine after Operation
  59
Periodic Maintenance

61
Troubleshooting

89
- Safety Precautions
  89
- Troubleshooting after Starting
  89
- Troubleshooting Information
  90
- Troubleshooting Chart
  91
Long-Term Storage

95
Specifications

99
- Principal Engine Specifications
  99
System Diagrams

109
- Piping Diagrams
  109
- Wiring Diagrams
  139
EPA Warranty USA Only

155
- Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
  155
  - Your Warranty Rights and Obligations
    156
  - Warranty Period
    156
  - Warranty Coverage
    156
  - Exclusions
    157
  - Owner's Responsibility
    157
  - Customer Assistance
    157
Emission System Warranty

159
- Non-Road Emission System Warranty
  159
  - Yanmar Co., Ltd. Limited Emission Control System
    159
  - Warranty - USA Only
    159
  - Warranted Parts
    160
  - Maintenance Log
    162

Yanmar 4JH4-HTE Operation Manual

Yanmar 4JH4-HTE Operation Manual (166 pages)

Brand: Yanmar | Category: Engine | Size: 22.5 MB

Table of Contents

Marine Engines
1
Table of Contents
5
Introduction

9
- Jh Series Emission Control System Warranty-Usa, the Environmental Protection Agency (Epa) Only
  10
- Record of Ownership
  11
Safety

13
- Safety Precautions
  14
  - General Information
    14
  - Before You Operate
    14
  - During Operation and Maintenance
    14
- Location of Safety Decals
  18
Product Overview

23
Before You Operate

41
- Introduction
  41
- Safety Precautions
  41
- Diesel Fuel
  42
  - Diesel Fuel Specifications
    42
  - Filling the Fuel Tank
    45
  - Bleeding the Fuel System
    46
- Engine Oil
  47
  - Engine Oil Specifications
    47
  - Engine Oil Viscosity
    48
  - Checking the Engine Oil
    48
  - Adding Engine Oil
    48
- Marine Gear or Sail Drive Oil
  49
- Engine Coolant
  50
- Cranking the Engine
  55
Engine Operation

57
- Introduction
  57
- Safety Precautions
  57
- Starting the Engine
  59
- Remote Control Handle Operation
  62
- Cautions During Operation
  63
- Shutting down the Engine
  65
  - Normal Shutdown
    65
  - Emergency Shutdown
    66
- Checking the Engine after Operation
  66
Periodic Maintenance

67
Troubleshooting

97
- Safety Precautions
  97
- Troubleshooting after Starting
  97
- Troubleshooting Information
  98
- Troubleshooting Chart
  99
Long-Term Storage

101
Specifications

105
- Principal Engine Specifications
  105
  - 3JH5E Engine
    106
  - 3JH5E Marine Gears
    107
  - 4JH5E Engine
    108
  - 4JH5E Marine Gear or Sail Drive
    110
  - 4JH4-TE Engine
    111
  - 4JH4-HTE1 Engine
    112
  - 4JH4-HTE Engine
    113
  - 4JH4-TE, 4JH4-HTE1 and 4JH4-HTE Marine Gear or Sail Drive
    114
System Diagrams

115
- Piping Diagrams
  115
- Wiring Diagrams
  145
Epa Warranty Usa Only

157
- Yanmar Co., Ltd. Limited Emission Control System Warranty - Usa Only
  157
  - Your Warranty Rights and Obligations
    158
  - Warranty Period
    158
  - Warranty Coverage
    159
  - Exclusions
    159
  - Owner's Responsibility
    159
  - Customer Assistance
    159
Emission System Warranty

161
- Non-Road Emission System Warranty
  161
  - Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
    161
    
    Warranted Parts
    162
    
    Owners Warranty Responsibilities
    163
  - Maintenance Log
    164

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Yanmar 4JH4-HTE Operation Manual

Yanmar 4JH4-HTE Operation Manual (160 pages)

Brand: Yanmar | Category: Engine | Size: 22.34 MB

Table of Contents

Marine Engines
1
Table of Contents
3
Introduction

7
- Jh Series Emission Control System Warranty-Usa, the Environmental Protection Agency (Epa) Only
  8
- Record of Ownership
  9
Safety

11
- Safety Precautions
  12
  - General Information
    12
  - Before You Operate
    12
  - During Operation and Maintenance
    12
- Location of Safety Decals
  16
Product Overview

21
Before You Operate

39
- Introduction
  39
- Safety Precautions
  39
- Diesel Fuel
  40
  - Diesel Fuel Specifications
    40
  - Filling the Fuel Tank
    43
  - Bleeding the Fuel System
    44
- Engine Oil
  45
  - Engine Oil Specifications
    45
  - Engine Oil Viscosity
    46
  - Checking the Engine Oil
    46
  - Adding Engine Oil
    46
- Marine Gear or Sail Drive Oil
  47
- Engine Coolant
  49
- Cranking the Engine
  53
Engine Operation

55
- Introduction
  55
- Safety Precautions
  55
- Starting the Engine
  57
- Remote Control Handle Operation
  60
- Cautions During Operation
  61
- Shutting down the Engine
  63
  - Normal Shutdown
    63
  - Emergency Shutdown
    64
- Checking the Engine after Operation
  64
Periodic Maintenance

65
Troubleshooting

95
- Safety Precautions
  95
- Troubleshooting after Starting
  95
- Troubleshooting Information
  96
- Troubleshooting Chart
  97
Long-Term Storage

99
Specifications

103
- Principal Engine Specifications
  103
  - 3JH5E Engine
    104
  - 3JH5E Marine Gears
    105
  - 4JH5E Engine
    106
  - 4JH5E Marine Gear or Sail Drive
    108
  - 4JH4-TE Engine
    109
  - 4JH4-HTE1 Engine
    110
  - 4JH4-HTE Engine
    111
  - 4JH4-TE, 4JH4-HTE1 and 4JH4-HTE Marine Gear or Sail Drive
    112
System Diagrams

113
- Piping Diagrams
  113
- Wiring Diagrams
  143
Epa Warranty Usa Only

149
- Yanmar Co., Ltd. Limited Emission Control System Warranty - Usa Only
  149
  - Your Warranty Rights and Obligations
    150
  - Warranty Period
    150
  - Warranty Coverage
    151
  - Exclusions
    151
  - Owner's Responsibility
    151
  - Customer Assistance
    151
Emission System Warranty

153
- Non-Road Emission System Warranty
  153
  - YANMAR CO., LTD. Limited Emission Control System Warranty - USA Only
    153
  - Maintenance Log
    156

Yanmar 4JH4-HTE Operation Manual

Yanmar 4JH4-HTE Operation Manual (169 pages)

Marine Engines

Brand: Yanmar | Category: Engine | Size: 11.07 MB

Table of Contents

Table of Contents
5
Safety Information
13
Location of Safety Decals
18
Product Oveview
23
New Engine Break-In
24
Component Identification
25
Product View
25
Nameplates
29
Function of Major Components
30
Control Equipment
31
Instrument Panel
31
Meters
32
Control Panel Switches
33
Start Switch/Stop Switch
33
Glow Switch
33
Power Switch
33
Indicators and Alarms
34
LCD Control (Hourmeter, Coolant Temperature, Oil Pressure)
35
Setup Screen Sccess and Control
36
Setting the Temperature and Pressure Units and Engine Speed Pulse
36
Alarms
37
Checking the Warning Devices
37
Before Engine Start
37
After Engine Start
37
Accessory Power Outlet
38
Single-Lever Remote Control Handle
39
Before You Operate
41
Diesel Fuel Specifications
42
Biodiesel Fuels
42
Additional Technical Fuel Requirements
43
Handling of Diesel Fuel
43
Fuel Tank
44
Fuel System
44
Filling the Fuel Tank
45
Bleeding the Fuel System
46
Engine Oil Specifications
47
Handling Engine Oil
48
Engine Oil Viscosity
48
Checking the Engine Oil
48
Adding Engine Oil
48
Marine Gear Oil Specifications
49
Sail Drive Oil Specifications
49
Checking Marine Gear Oil
49
Engine Coolant Specifications
50
Adding Marine Gear Oil
50
Checking and Adding Sail Drive Oil
50
Checking and Adding Coolant
51
Cranking the Engine
55
Engine Operation
57
Sudden Movement Hazard
58
Sever Hazard
58
Starting the Engine
59
If the Engine Fails to Start
60
Air Bleeding the Fuel System after Starting Failure
60
Starting at Low Temperatures
60
Starting with Air Heater
61
After the Engine Has Started
61
Remote Control Handle Operation
62
Acceleration and Deceleration
62
Shifting the Engine
62
Switching to Trolling
62
Cautions During Operation
63
Shutting down the Engine
65
Normal Shutdown
65
Checking the Engine after Operation
66
Emergency Shutdown
66
Periodic Maintenance
67
Crush Hazard
67
Welding Hazard
68
Entanglement Hazard
68
Shock Hazard
68
Tool Hazard
68
Tightening Fasteners
70
Inspection and Maintenance
73
Installation of Exhaust Sampling Port
73
Periodic Maintenance Schedule
74
Inspection and Maintenance of EPA Emission-Related Parts
77
Daily Checks
78
Visual Checks
78
After Initial 50 Hours of Operation
79
Preparing Fuel, Oil and Coolant in Reserve
79
Changing the Engine Oil and Replacing the Engine Oil Filter Element
80
Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter
81
Checking and Adjusting the Alternator V-Belt Tension
81
Inspecting and Adjusting Intake/Exhaust Valve Clearance
82
Checking and Adjusting Remote Control Cables
82
Adjusting Clutch Remote Control Cable
83
Adjusting Trolling Remote Control Handle
83
Every 50 Hours of Operation
84
Adjusting Propeller Shaft Alignment
84
Draining Fuel Filte/Water Separator
84
Checking the Battery Electrolyte Level
86
Every 250 Hours of Operation
87
Replacing the Fuel Filter Element
88
Checking or Replacing Seawater Pump Impeller
90
Changing the Coolant
91
Cleaning the Intake Silencer (Air Cleaner) Element
94
Cleaning the Exhaust/Water Mixing Elbow
94
Cleaning the Turbocharger
94
Every 500 Hours of Operation
95
Every 1000 Hours of Operation
95
Replacing Rubber Hoses
95
Cleaning and Checking the Seawater Passages
96
Checking Diaphragm Assembly
96
Troubleshooting
97
Long-Term Storage
101
Drain Seawater Cooling System
102
Returning the Engine to Service
104
Specifications
106
System Diagrams
115
Piping Diagrams
115

Yanmar 4JH4-HTE Operation Manual

Yanmar 4JH4-HTE 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
- 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 4JH4-HTE Operation Manual

Yanmar 4JH4-HTE Operation Manual (164 pages)

JH SERIES

Brand: Yanmar | Category: Engine | Size: 9.47 MB

Yanmar 4JH4-HTE Service Manual

Yanmar 4JH4-HTE Service Manual (6 pages)

Brand: Yanmar | Category: Engine | Size: 1.16 MB

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