Yanmar 3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE Marine Engine Service Manual

Description

• Model List:
  • 3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE Marine Engine

• 1. Table of Contents
• 2. Introduction
• 2.1. Revision History
• 2.1.1. Revision Control Table
• 2.2. Safety Statements
• 2.3. Safety Precautions
• 2.4. Location of Safety Labels
• 3. General Service Information
• 3.1. Safety Precautions
• 3.2. Engine Outline Drawings
• 3.2.1. H5E Models
• 3.2.2. H5E Models
• 3.2.3. H4-TE Models
• 3.2.4. H4-HTE Models
• 3.3. Piping Diagrams
• 3.3.1. H5E Models
• 3.3.2. H5E Models
• 3.3.3. H4-TE Models
• 3.3.4. H4-HTE Models
• 3.4. Exhaust Gas Emission Regulations
• 3.4.1. Engine Identification (EPA / CARB)
• 3.4.2. Emission Control Label (EPA / CARB)
• 3.5. Location of Nameplates
• 3.5.1. Engine Nameplates (Typical)
• 3.6. Diesel Fuel
• 3.6.1. Diesel Fuel Specifications
• 3.6.2. Bleeding the Fuel System
• 3.7. Engine Oil
• 3.7.1. Engine Oil Specifications
• 3.8. Engine Coolant
• 3.8.1. Engine Coolant Specifications
• 3.9. Principal Engine Specifications
• 3.9.1. H5E Engine Specifications
• 3.9.2. H4-HTE Engine Specifications
• 3.10. Tightening Torques
• 3.10.1. Hexagon Bolts and Nuts
• 3.10.2. Hose Clamps
• 3.11. Prepare Engine for Long-Term Storage
• 3.12. Abbreviations and Symbols
• 3.12.1. Symbols
• 3.13. Unit Conversions
• 3.13.1. Unit Prefixes
• 3.13.2. Units of Length
• 3.13.3. Units of Volume
• 3.13.4. Units of Mass
• 3.13.5. Units of Force
• 3.13.6. Units of Torque
• 3.13.7. Units of Pressure
• 3.13.8. Units of Power
• 3.13.9. Units of Temperature
• 4. Periodic Maintenance
• 4.1. Safety Precautions
• 4.2. Introduction
• 4.2.1. The Importance of Periodic Maintenance
• 4.2.2. Performing Periodic Maintenance
• 4.2.3. Yanmar Replacement Parts
• 4.2.4. Required EPA Maintenance
• 4.3. EPA Requirements
• 4.3.1. Conditions to Ensure Compliance with EPA Emission Standards
• 4.3.2. Inspection and Maintenance
• 4.4. Periodic Maintenance Schedule
• 4.4.1. Inspection and Maintenance of EPA Emission-Related Parts
• 4.4.2. Inspection and Maintenance of EPA Emission-Related Parts for Non-Road and CI Marine Engines
• 4.5. Periodic Maintenance Procedures
• 4.5.1. After Initial 50 Hours of Operation
• 4.5.2. Every 50 Hours of Operation
• 4.5.3. Every 250 Hours of Operation
• 4.5.4. Every 500 Hours of Operation
• 4.5.5. Every 1000 Hours of Operation
• 4.6. Safety Precautions
• 4.7. Introduction
• 4.8. Specifications
• 4.8.1. General Information
• 4.8.2. Test and Adjustment Specifications
• 4.8.3. Repair Specifications
• 4.9. Special Torque Chart
• 4.10. Standard Torque Chart (w/o Lubricating Oil)
• 4.11. Special Service Tools
• 4.12. Measuring Instruments
• 4.13. Sealants and Compounds
• 4.14. Tests and Adjustments
• 4.14.1. Test Compression
• 4.15. Disassembly
• 4.16. Inspection
• 4.16.1. Cylinder Block
• 4.16.2. Cylinder Head
• 4.16.3. Piston and Piston Rings
• 4.16.4. Connecting Rod
• 4.16.5. Crankshaft and Main Bearings
• 4.16.6. Camshaft and Tappets
• 4.16.7. Timing Gear
• 4.16.8. Flywheel and Housing
• 4.17. Assembly
• 4.17.1. Checking and Adjusting Remote Control Operation
• 5. Fuel System
• 5.1. Safety Precautions
• 5.2. Introduction
• 5.3. Specifications
• 5.3.1. Test and Adjustment Specifications
• 5.3.2. Special Torque Chart
• 5.4. Special Service Tools
• 5.5. Fuel System Components
• 5.5.1. H4E-HT / 4JH4-HTE Engines
• 5.6. Fuel System Diagram
• 5.7. Fuel System Tests
• 5.7.1. Measuring Fuel Feed Pump Pressure
• 5.7.2. Testing Return Fuel Pressure
• 5.8. Servicing the Fuel System
• 5.8.1. Removing the Fuel Injection Nozzle
• 5.8.2. Cleaning Fuel Injection Nozzle Cavities
• 5.8.3. Installing Fuel Injection Nozzles
• 5.8.4. Removing Fuel Injection Lines
• 5.8.5. Installing Fuel Injection Lines
• 5.8.6. Replacing the Fuel Injection Pump
• 5.8.7. Adjusting Fuel Injection Timing
• 5.9. MP2 Fuel Injection Pump System (3 / 4JH5E)
• 5.9.1. Introduction
• 5.9.2. Fuel Injection Pump
• 5.9.3. Stop Solenoid
• 5.9.4. Trochoid Fuel Pump
• 5.10. Fuel System Specifications
• 5.10.1. Special Torque Chart
• 5.10.2. Test and Adjustment Specifications
• 5.11. Special Service Tools
• 5.12. Measuring Instruments
• 5.13. Fuel System Components
• 5.14. Fuel Injection Pump
• 5.14.1. Removing the Fuel Injection Pump
• 5.14.2. Installing the Fuel Injection Pump
• 5.15. Checking and Adjusting Fuel Injection Timing
• 5.15.1. Determining the Fuel Injection Timing Specification
• 5.15.2. Checking Fuel Injection Timing
• 5.15.3. Adjusting Fuel Injection Timing
• 5.15.4. Fuel Injection Pump Service Data
• 5.15.5. Fuel Line Replacement Filter
• 5.15.6. Replacing the Injection Nozzle Return
• 5.15.7. Bleeding the Fuel System
• 5.16. Fuel Injectors
• 5.16.1. Removing Fuel Injectors
• 5.16.2. Testing Fuel Injectors
• 5.16.3. Disassembling and Inspecting Fuel Injectors
• 5.16.4. Adjusting Fuel Injector Pressure
• 5.16.5. Reassembling the Fuel Injectors
• 6. Cooling System
• 6.1. Safety Precautions
• 6.2. Introduction
• 6.3. Specifications
• 6.3.1. Test and Adjustment Specifications
• 6.3.2. Repair Specifications
• 6.4. Special Service Tools
• 6.5. Measuring Instruments
• 6.6. Cooling Flow Diagram
• 6.7. Tests and Adjustments
• 6.7.1. Pressure Testing Cooling System and Filler Cap
• 6.7.2. Testing Thermostat
• 6.8. Draining / Refilling Seawater Cooling System
• 6.8.1. Draining and Filling Closed Cooling System
• 6.9. Removing / Installing Intercooler (4JH4-HTE)
• 6.10. Disassembling and Assembling Intercooler
• 6.11. Removing and Installing Heat Exchanger
• 6.12. Disassembling / Assembling Heat Exchanger
• 6.13. Removing and Installing Coolant Pump
• 6.14. Removing and Installing Thermostat
• 6.14.1. Removal
• 6.14.2. Installation
• 6.15. Seawater Pump
• 6.15.1. Inspecting / Replacing Impeller
• 6.15.2. Removing and Installing Seawater Pump and Pump Drive Gear
• 6.15.3. Replacing Coolant Pump Belt and Pulley
• 6.16. Coolant Recovery Tank
• 6.16.1. Coolant Recovery Tank Function
• 6.16.2. Mounting the Coolant Recovery Tank
• 6.16.3. Before Using Coolant Recovery Tank
• 6.17. Bilge Pump and Bilge Strainer (Optional)
• 6.17.1. Description
• 6.17.2. Cautions
• 6.17.3. Assembly
• 6.17.4. Cautions During Assembly
• 7. Lubrication
• 7.1. Safety Precautions
• 7.2. Introduction
• 7.3. Specifications
• 7.3.1. Test and Adjustment Specifications
• 7.3.2. Special Torque Chart
• 7.4. Special Service Tools
• 7.4.1. Measuring Instruments
• 7.5. Tests and Adjustments
• 7.5.1. Engine Oil Flow
• 7.5.2. Checking Engine Oil Pressure
• 7.5.3. Engine Lubrication System Components
• 7.5.4. Changing Engine Oil, Replacing Engine Oil Filter Element and Cleaning Engine Oil Cooler
• 7.5.5. Removing and Installing Engine Oil Sump
• 7.5.6. Engine Oil Pump
• 7.5.7. Checking Piston Cooling Oil Nozzle
• 8. Turbocharger
• 8.1. Safety Precautions
• 8.2. Introduction
• 8.3. Specifications
• 8.4. Turbocharger Components
• 8.5. Special Service Tools
• 8.6. Washing the Turbocharger Blower
• 8.7. Cleaning the Air Cleaner
• 8.7.1. Turbocharger Service
• 9. Starter Motor
• 9.1. Safety Precautions
• 9.2. Introduction
• 9.3. Starter Motor Specifications
• 9.3.1. General Specifications
• 9.3.2. Special Torque Chart
• 9.3.3. Characteristics
• 9.4. Starter Motor Troubleshooting
• 9.5. Starter Motor Service
• 10. Alternator
• 10.1. Safety Precautions
• 10.2. Introduction
• 10.3. Specifications
• 10.3.1. General Specifications (Standard)
• 10.3.2. General Specifications (Optional for 4JH4-TE and 4JH4-HTE)
• 10.3.3. Special Torque Chart
• 10.3.4. Wiring Diagram
• 10.3.5. Output Characteristics
• 10.4. Alternator Service
• 10.4.1. Replace V-Belt
• 10.4.2. Removing and Installing the Alternator
• 11. Electrical
• 11.1. Safety Precautions
• 11.2. Introduction
• 11.3. Component Locations
• 11.3.1. Sensor and Switch Locations
• 11.4. Wiring Diagram
• 11.4.1. H5E / 4JH5E – C-Type Instrument Panel (Optional)
• 11.4.2. H5E / 4JH5E 12V B- and B x B-Type Instrument Panel (Optional)
• 11.4.3. H5E / 4JH5E 12V C x B-Type Instrument Panel (Optional)
• 11.4.4. H5E / 4JH5E with Keyless B- and B x B-Type Instrument Panel (Optional)
• 11.4.5. H5E / 4JH5E with Keyless C x B-Type Instrument Panel (Optional)
• 11.4.6. H4-TE / 4JH4-HTE with Panel B x B-Type Instrument Panel
• 11.4.7. H4-TE / 4JH4-HTE with Panel C x B-Type Instrument Panel
• 11.5. Instrument Panel
• 11.5.1. B-Type Instrument Panel (Selectable Optional)
• 11.5.2. B-Type (Keyless) Instrument Panel (Selectable Optional)
• 11.5.3. C-Type Instrument Panel (Selectable Optional)
• 11.5.4. C-Type (Keyless) Instrument Panel (Selectable Optional)
• 11.6. Function Description – Warning Devices
• 11.6.1. Oil Pressure Alarm
• 11.6.2. Sending Unit for Lubricating Oil Pressure Gauge
• 11.6.3. Coolant Temperature Alarm
• 11.6.4. Sending Unit for the Coolant Temperature Gauge
• 11.6.5. Air Heater (Standard)
• 11.6.6. Electric Engine Stop Solenoid
• 12. Troubleshooting
• 12.1. Safety Precautions
• 12.2. Introduction
• 12.3. Troubleshooting Chart
• 12.3.1. Starting Trouble
• 12.3.2. Exhaust Color
• 12.3.3. Vibration – Drive Engaged
• 12.3.4. Engine Knocks
• 12.3.5. Low Power Output
• 12.3.6. Engine Overheat
• 12.3.7. Engine Runs Cold
• 12.3.8. Coolant Loss
• 12.3.9. Lubricating Oil Pressure Low
• 12.3.10. Panel Display
• 12.4. Measuring Compression Pressure
• 12.5. After Troubleshooting or Repair
• 13. Service Standards
• 13.1. Engine Tuning
• 13.2. Engine Body
• 13.2.1. Cylinder Head
• 13.2.2. Camshaft and Gear Train
• 13.2.3. Cylinder Block
• 13.3. Lubricating Oil System (Trochoid Pump)
• 13.3.1. Outside Clearance of Outer Rotor
• 13.3.2. Tip Clearance Between Outer Rotor and Inner Rotor
• 13.3.3. Side Clearance of Outer Rotor
• 13.3.4. Inside Clearance of Inner Rotor
• 13.4. Main Bolt and Nut
• 13.5. Standard Bolts and Nuts (w/o Lubricating Oil)