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3jh4e manualModel 3JH4E has been used for the illustrations in this service manual, but they apply to other models in the JH4 series engines. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures. Damage to the engine, shortened engine life and or personal injury may result. Check the customer ledger file for the history of the engine. General rules are described here.: User-maintenance: Parts replacement: Shop-inspection. Unit: liter(pint) Dipstick Marine gear oil capacity KM35P Full: 0.50 (1.0) KM35A Full: 0.65 (1.4) b) When the level is low, remove a filler port cap at the top of the housing, and fill it with marine gear-. Increase in the water level of the coolant recovery tank during operation is not abnormal. Brfore and after starting the engine, check the leakage of cooling water and seawater from cooling water system.To adjust the V-belt tension, loosen the set bolt for Belt adjuster the belt adjuster and move the alternator to tighten Set bolt the V-belt. 3) Visually check the V-belt for cracks, oiliness or wear. Lock nut (Use it as the data for estimating the wear state.) d) Adjusting other cylinders Turn the crankshaft 240 and make adjustment. The cable will become stretched and the attachments loose after long hours of use causing deviation. Air bleeding bolt 1) Close the fuel cock of the fuel tank. Replenish if Insufficient. When fuel, which does not contain air bubbles, comes out of the bolt hole, tighten the air bleeding bolt. GREASE When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. Otherwise, it results in engine damage, uneven engine performance and shorten engine life. (3) Replace the engine lube oil and the lube oil filter.http://www.transrent.pl/userfiles/3m-accuglide-3-tape-head-manual.xml
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Model Fresh water line Seawater line 3JH4E Drain cock for Fresh water pump Coolant tank fresh water Drain cock for seawater Drain cock for fresh water Seawater pump. Be sure the cooler hose is securely connected and there is no Rubber hose looseness or damage. When the hose is not watertight, an excessive FULL amount of cooling water will be used. Check whether each connection part doesn't have looseness. Alternator Neutral safety switch (Fitting to marine gear) Optional Optional C.W. temp. sensor Starter B terminal Battery Battery switch C.W. temp. switch Starter S terminal Optional Starting motor Air heater. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it. Remove the cap only after the water cools down.The thermostat is functioning normally if it starts to open between 75-78 deg C, and opens until 8mm or more at 90 deg C Replace the thermostat if it not functioning normally. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause. TROUBLE AND TROUBLESHOOTING (I-1) Add fuel oil and prime. (II-1) Replace. (I-2) Bleed air. (II-2) Clean carefully to insure good working order. (I-3) Remove water from drain and fuel oil system and prime. (I-4) Check and make necessary repairs. (I-5) Clean. Please use them as instructed. 4.2.1 General Handtools Name of tool Illustration Remarks Wrench Size: 10 x 13 Wrench Size: 12 x 14 Wrench Size: 17 x 19. Three Bond 200g Non-drying liquid gasket;. Test indicator Measures narrow and deep places which cannot be measured with dial gauge.http://www.widerbet.pl/userfiles/3m-accuglide-tape-head-manual.xml Magnetic stand Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles. Torque wrench Used to tighten bolts and nuts to standard torque. Thickness gauge Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling. Photoelectric Measures rotation speed by using a type reflector mark which is placed on the Revolving shaft exterior of the revolving shaft. Seawater 2) Remove the mixing elbow from the exhaust manifold. L-type mixing elbow Gasket Exhaust manifold (7) Removing the starting motor Flywheel housing Remove the starting motor from the flywheel housing. Heat exchanger Mixing elbow Exhaust manifold. NOTE: Fuel injection nozzle If the fuel nozzle protector stays in the cylinder head, Bolt make a note of the cylinder number and be sure to remove it when disassembling the cylinder head. Washer 2) Remove the engine mounting feet. Crankshaft V-pully Gear case (23) Removing the crankshaft V-pulley Loosen the bolt tightening the crankshaft V-pulley and remove the crankshaft V-pulley with an extraction tool. Idle gear shaft Idle gear (29) Removing the camshaft 1) Push up tappet by turning a camshaft to remove it from the cylinder block easily. 2) Loosen the thrust metal bolts through the holes of the camshaft gear, and remove. NOTE 1) When mounting the gear case flange, match up the two knock pins for cylinder block. NOTE: The thrust metal (lower) is mounted to the base main bearing cap. (36) Removing the crankshaft 1) Remove the crankshaft. NOTE: 1) If the dust remain with the parts, engine may cause the seizing or damage. 2) The cleaning agent removes even carbon adhering to disassembled parts. Lower NOTE: Thrust metal 1) The lower main bearing metal does not have an oil hole. NOTE: 1) When mounting the gear case flange, match up the two knock pins of the cylinder block.http://www.drupalitalia.org/node/66460 2) Be sure to coat the O-ring for the cylinder block lube oil line with grease when assembling, so that it does not get out of place. NOTE: 1) Insert the piston so that the match mark on the large end of the connecting rod faces the fuel nozzle, and the manufacture’s embossed mark on the stem faces toward the flywheel. NOTE: The idle gear shaft must be mounted with the mark of the shaft upward. (Idle gear shaft) 2) Align the “A”. Marine gearbox 2) Align the damper disk with the input shaft spline and insert. Mount the marine gearbox to the flywheel housing. NOTE: Be careful not to scratch the O-ring between the fuel injection pump and gear case flange. The side walls are Cap plug 50 mm save shaped to maximize rigidity for strength and low (Camshaft hole) Cap plug 30 mm. NOTE: Without fail, read the instructions for the color check kit before use. 5.1.4 Replacement of cup plugs Step Description Procedure Tool of material used Clean and remove grease from the hole into Screw driver or saw which the cup plug is to be driven. If crack is suspected, perform color check. Special alloy stellite with superior resistance to heat and wear is fitted on the seats, and the area between the valves is cooled by the water jet. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts. Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit.Free length (Valve spring) 3) Measure inclination. Inclination Square gauge (Valve spring) 4) Measure spring tension. The piston pin can be pressed into the piston pin hole at room temperature (Coat with oil to make it slide easily). 5.3.2 Piston pin Measure at positions a and b Measure the outer diameter and replace the pin if it is. Measure the thickness and width of the rings, and the ring-to-groove clearance after installation. Replace if wear exceed the limit. Standard Limit Groove width 2.060-2.075 2.170 Width First Ring width 1.970-1.990 1.950.CFDCNV.COM/images/3jh2e-service-manual.pdf The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing. Standard Limit Connecting rod. Excessive piston pin bushing wear may result in damage to the piston pin or the piston itself. Measure the piston pin bushing inside diameter and the piston pin outside diameter. Crank shaft The crankshaft main veering is of the hanger type. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. The cams have a curve that minimized the repeated shocks on the valve seats and maximizes valve seat life. The oil clearance shall be calculated by Flywheel side subtracting the measured camshaft outside diameter Micrometer from the inside diameter of the camshaft bearing or bushing. Check the contact of each tappet and replace if excessively or unevenly worn.Pump flange bolts. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system. Clean immediately stops. (2) Fuel filter is clogged. Disassemble and clean, or replace the element Replace packing repair (3) Improper air- tightness of the fuel pipe pipe connection. Adjust (2) Injection from nozzle is improper. Adjust Fuel drips after each injection. (3) Injection nozzle starting pressure is too high Adjust (4) Uneven injection. The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft. NOTE: Replace parts as an assembly. The fuel filter element must be changed periodiically. A fuel return connection is provided on top of the tank of which a rubber hose can be connected to retun fuel from the fuel nozzles. Exhaust gas goes into exhaust manifold (in the fresh water tank) mounted on the cylinder head outlet. When the internal pressure of the crankcase decreases too much due to the damage of a spring, much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning. The mixing elbow is attached to the exhaust manifold.Inner rotor Crankshaft The lube oil flows from the intake filter mounted on the bottom of the cylinder block through the holes in the Pump cover cylinder block and engine plate, and out from the holes. Outside clearance Standard Limit 0.12-0.21 0.30 (Outer diameter clearance) (2) Side clearance of outer rotor When measuring a side clearance, put a right-angle gage. The cartridge type filter is easy to remove. To prevent seizure in the event of the filter clogging up, a bypass circuit is provided in the oil filter. The cylinders, cylinder heads and exhaust manifold are cooled with fresh water, and fresh water cooler (heat exchanger) use seawater. The two kinds of seawater pumps are prepared. The standard one is mounted on the gear case and the other (optional) is mounted on the gear case flange. (Option) Seawater pump Pump drive gear. The fresh water pump consists of the pump body, impeller, pump shaft, bearing unit and mechanical seal. It is difficult to disassemble and, once disassembled, even more difficult to reassemble. Thickness gauge Measuring clearance between impeller and pump body bracket. Straightedge Standard Limit Clearance between impeller 0.3-1.1 and body Clearance between impeller and plate Thickness gauge. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating. When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it. The coolant recovery tank maintains the water level by preventing this discharge of water. The pump can be run continuously for a period of 10 minutes After this time it must shut off for a period of 2 hours before reusing. The hose attached at the nozzle should be 1.8m or less and should reach without any strain, therefore care should be taken in deciding on the best position. Check to be sure that the strainer is in the water before turning on the switch. Problem Cause Countermeasure 1. Pump does not turn Faulty wiring Check the wiring between the motor and battery. Faulty battery Check to see if the specific gravity of the battery fluid is greater than 1.25. Reduction and Reversing Gear Marine gear KM35P and KM35A are applied to the 3JH4E series engines. Specifications Model. This engineered system of Worse cables, control head and engine connection kits ensures dependable, smooth operation with an absolute minimum of backlash. If they do not coincide, adjust the fittings as necessary (first engine side, then controller side). Electrical System 12.1 Electrical System Alternator Neutral safety switch (Fitting to marine gear) Optional Optional C.W. temp. sensor Starter B terminal Battery Battery switch C.W. temp. switch Starter S terminal Optional Starting motor Air heater (Intake manifold) Relay Optional Stop solenoid. Battery capacity minimum 12V-80AH. The pinion engages with the ring gear of a engine, and the engine is started. Magnetic Switch Center Bracket (A) Torsion Spring Shift Lever Brush. It contains diodes that convert AC to DC, and an IC regulator that keeps the generated voltage constant even when the engine speed changes. 12.4.1 Specifications Yanmar code 128271-77200 Model of alternator LR160-741 (HITACHI) Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed with new panel is activated by alternator B terminal pulse. Oil pressure is measured when the oil enters into the main gallery after being fed from the lube oil cooler and passing through the oil pressure control valve Be sure OPTIONAL. A high thermal expansion material is set on the end of the water temperature unit. The air heater is mounted to the intake manifold. The device is operated by the glow switch on the instrument panel. Air heater Gasket Relay. The device is operated by the stop switch on the instrument panel. Governor The emergency stop button is integrated with the Stop solenoid solenoid. We reserve the right to make any change at any time without notice.During Operation and Maintenance. Location of Safety Decals.Product Overview. 13 Yanmar JH4 Features and Applications. New Engine Break-In.Component Identification.Service Side - 3JH4E.Non-Service Side - 3JH4E. Engine Oil.Engine Oil Specifications. Engine Oil Viscosity.Checking the Engine Oil.Adding Engine Oil. Marine Gear or Sail Drive Oil.Marine Gear Oil Specifications. Your Warranty Rights and Obligations:.Warranty Period:. Warranty Coverage:. Engine Model: Engine Serial No.: Date Purchased: Dealer: Dealer Phone: JH4 Series Operation Manual. JH4 Series Operation Manual. NEVER WARNING level hazards.ALWAYS use a piece of wood or at hand and use the correct size tool for cardboard. Have your authorized Yanmar loosening or tightening machine parts.Failure to do so may angle that exceeds the specifications stated. Check the engine's model,. Drain the filter periodically. The filter element should be replaced periodically. The water separator (if equipped) should be drained periodically. Fuel Feed Pump Pumps fuel from the tank to the fuel injection system. It consists of the instrument panel, which is connected to the engine by a wire harness, and the remote control handle, which is connected by control cables to the engine control lever and marine gear. When the key is released, the switch will automatically move to the ON position. When between the seals of the sail drive, the charging begins, the indicator will turn off. If only a two-lever type is available Note: Direction of travel will vary depending in the market, reduce engine rpm to 1000 on installation location. It also describes the daily NOTICE: Only use diesel fuels engine checks.Only use clean diesel fuel. NOTICE: Hold the hose nozzle firmly against the filler port while filling. This prevents static electricity buildup which could cause sparks and ignite fuel vapors. Tighten the air bleed screw. Note: After engine start-up, the automatic air-bleeding device works to purge the air in the fuel system. The oil level should aids. Remove the filler cap at the top of the housing (Figure 10, (1)). Fill with oil to the upper limit on the dipstick (Figure 10, (3)). See Marine Gear Oil Specifications on page 34. See your smoothly. authorized Yanmar dealer or distributor.Fire and Explosion Hazard NEVER block windows, vents Avoid serious personal injury.A light load on a cold engine or distributor for service before provides better combustion and faster operating the engine. During normal operation, the marine gear should only be shifted with the engine at idle. When moving the handle between FORWARD (Figure 2, (1)) and REVERSE (Figure 2, (3)), bring the clutch to NEUTRAL (Figure 2, (2)) and pause before slowly shifting to the desired position. NOTICE: Avoid engine damage. Do not stop NOTICE: Be sure to close the seacock.Yanmar Neglecting to close the seacock could recommends that when shutting the engine allow water to leak into the boat and down, allow the engine to run, without load, may cause it to sink. WARNING Crush Hazard If you need to transport an engine for repair, have a helper assist you attach it to a hoist and load it on a truck. Connect the weld clamp to the component to be welded and as close as possible to the welding point. NEVER block windows, needed. Genuine replacement parts help vents, or other means of ventilation if ensure long engine life. Applying bolts with a “7” head (JIS excessive torque may damage the fastener strength classification: 7T). Inspection and maintenance procedures not shown in the Inspection and Maintenance of EPA Emission-Related Parts section are covered in Periodic Maintenance Schedule on page This maintenance must be performed to keep the emission values of your engine in the standard values during the warranty. JH4 Series Operation Manual. It is very important that the initial oil replacement is performed as Perform the following maintenance after the scheduled. Consult your authorized 3JH4E and 4JH4AE (Attach to Hull) Yanmar marine dealer or distributor. 0004564 Figure 10 Close the fuel cock of the fuel tank. System on page 30. Checking the Battery Electrolyte Level (Serviceable Batteries Only) 4JH4-TE and 4JH4-HTE WARNING. Batteries contain sulfuric acid. JH4 Series Operation Manual. Figure 14 Use a filter wrench and tighten to 20 - Close the fuel cock of the fuel tank. JH4 Series Operation Manual. Equipped) Contamination of the turbocharger causes Replacing Rubber Hoses revolutions to drop and engine output to fall. Checking the Remote Control Cable Operation See your authorized Yanmar marine dealer or distributor. Refer to the SYMPTOM AFTER STARTING column in the Troubleshooting Chart to identify the problem.If the tank runs out of fuel, bleed the fuel system. Yanmar marine dealer or distributor.Note: If the engine is close to a periodic maintenance interval, perform those maintenance procedures before putting the engine into long-term storage. Marine gear ZF25A does not have a drain cock on the clutch cooler.The owner may elect to VESSELS FLAGGED OR REGISTERED IN have maintenance, replacement or repair of THE UNITED STATES. Yanmar Marine USA Corporation 101 International Parkway. Such components Yanmar may deny your warranty coverage may include the following:. Yanmar Marine USA Corporation 101 International Parkway. With this manual, you may maintain, service, diagnose and repair your own. All repair procedures are covered. Applicable Models Covers: Yanmar Marine Diesel Engine 3JH4E Yanmar Marine Diesel Engine 4JH4 AE Yanmar Marine Diesel Engine 4JH4 - TE Yanmar Marine Diesel Engine 4JH4 -H TE Service Repair Manual Covers: Introduction Safety General Service Information Periodic Maintenance Engine Fuel System Cooling System Lubrications Turbocharger Starter Motor Alternator Electrical Troubleshooting Service Standards Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail. You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. All pages are printable.Thank you, for helping us keep this platform clean. The editors will have a look at it as soon as possible. Something went wrong.Learn more - opens in a new window or tab This amount is subject to change until you make payment. 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Refunds by law: In Australia, consumers have a legal right to obtain a refund from a business if the goods purchased are faulty, not fit for purpose or don't match the seller's description. More information at returns. All Rights Reserved. User Agreement, Privacy, Cookies and AdChoice Norton Secured - powered by Verisign. This YANMAR 3JH4E 4JH4AE 4JH4-TE 4JH4-HTE MARINE DIESEL ENGINE Service Manual pays much attention to practicality from the view point of users, and the content is reasonably arranged. No matter you are the end-user or distributor, or professional technician, we have perfect guidance for you. Purposes of This Manual are to let users of YANMAR 3JH4E 4JH4AE 4JH4-TE 4JH4-HTE MARINE DIESEL ENGINE understand the construction, basic maintenance and repair of the YANMAR 3JH4E 4JH4AE 4JH4-TE 4JH4-HTE MARINE DIESEL ENGINE product and professional major repair methods. Click Here to Read the Sample Pages ONLINE If you have this manual, you will have: Easy component identification; Careful disassembly; Accurate adjustments; Correct routine maintenance repairs; Lots of photographs, illustrations and procedure, detailed maintenance and operation instructions, information etc. To guarantee your safety and make the most use of your YANMAR 3JH4E 4JH4AE 4JH4-TE 4JH4-HTE MARINE DIESEL ENGINE, please read the manual carefully. Only in this way, you could fully enjoy the fun of using. Pay Today and Download the complete manual instantly. Please DO NOT CLOSE this BROWSER. FAQ: Why should I purchase this manual. This manual is an easy layout format that covers all repair procedures in great detail. FAQ: What models are covered in this manual. All models for the above stated years and all engine types are included. FAQ: What type of information is covered. FAQ: How long for delivery. You Can Fix It Today. FAQ: How much money will I save. This manual will help you save money upwards into the thousands. FAQ: Is this Manual hard to use. No, not at all. If you can open up an email then you can use this manual, its that simple. The information on this manual covered everything you need to know when you want to repair or service Yanmar Marine Diesel Engine 3JH4E, 4JH4E, 4JH4-TE, 4JH4-HTE. Applicable Models Covers: Yanmar Marine Diesel Engine 3JH4E Yanmar Marine Diesel Engine 4JH4AE Yanmar Marine Diesel Engine 4JH4-TE Yanmar Marine Diesel Engine 4JH4-HTE Service Repair Manual Covers: Introduction Safety General Service Information Periodic Maintenance Engine Fuel System Cooling System Lubrications Turbocharger Starter Motor Alternator Electrical Troubleshooting Service Standards Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail. All pages are printable.By continuing to use this website you are giving consent to cookies being used. Please upgrade your browser. We are still delivering orders and offering click and collect, please read our COVID-19 update for more information. We may be able to help. The inclusion of items on this page does not infer that these items are genuine Yanmar spares. Please check carefully the suitability of the item for your own application. Gasket sets listed do not generally contain gaskets for marinisation components.We may be able to help. Please check carefully the suitability of the item for your. Click to view our Yanmar Sales Territory Marine Diesel Parts carries a full line of Yanmar marine engine parts. Please call us, at 508-997-1805 to speak directly to one of our marine engine experts so that you can find the right part for your Yanmar engine. Or simply fill out our BOAT ENGINE PART REQUEST. It is your responsibility to provide references to bona fide sources. For a better experience, please enable JavaScript in your browser before proceeding. It may not display this or other websites correctly. You should upgrade or use an alternative browser. Would something like be suitable? Thanks I changed the oil on our Yanmar 4JH4E this weekend. I have a Pela oil extraction pump. Previously I extracted the oil by inserting the Pela tube in to the dipstick tube. This time I thought I would try by adapting the Pela tube to go over the outside of the dipstick tube and using a hoseclip to secure it. What a difference. Even with the oil cold it was so much easier. The outside dipstick tube diameter is 15mm. The outside diameter of the Pela tube is 10mm so I went to the chandlery to get some approriate tube. Note: The tube has to go far enough over the dipstick tube to cover the tiny breather hole near the top of the dipstick tube. By doing this with the engine cold it also meant changing the oil filter was easier. Most of the oil in it had drained back into the engine. I would have thought this unlikely based on many engines I have worked on. In that case the old oil cannot be completely drained. I hadn't spotted the Mobil oil because if you select Mineral Oil only, it doesn't come up - off to Halfords now. I would have thought this unlikely based on many engines I have worked on. In that case the old oil cannot be completely drained.I would have thought this unlikely based on many engines I have worked on. In that case the old oil cannot be completely drained.As per Vics schematic. A higher spec oil is not a good thing and from what I gleaned from some answers they have higher a higher TBN which causes deposits on the pistons and cause bore glazing which restricts lubrication. I bought a cheap 12v electric oil pump from LIDL. Got max amount out from dipstick and then removed drain plug and got a further 0.5l or so of dirty oil out. Mopped this up with tissues. Not sure engines in boat are mounted horizontal hence a small amount remains. I ended up phoning Morris Lubricants technical dept and ordered 25l can of their fleet mineral oil (IIRC CDX) which is CF grade. It has a TBN of 10 (lower would be better) Its worth looking up previous threads Hope this helps I changed the oil on our Yanmar 4JH4E this weekend. Most of the oil in it had drained back into the engine.I have the 4JH4AE and spec.The other variants use CD or higher so Halfords Mobil Super 1000 is OK for them (API SL CF). Operation manual says: Engine Oil Specifications NOTICE: Using engine oil that does not meet or exceed the following guidelines or specifications may cause seizure of parts, abnormal wear and shorten engine life. Engine oil 10W30 and 15W40 can be used throughout the year. Its the too high a spec oils and synthetic or semi synthetic oils that cause the problems It's not marked with anything else. But it's the normal aspirated engine. It's not marked with anything else. But it's the normal aspirated engine.I did see a 4JH4E listed elsewhere ages ago and it seemed to have the same output and spec.I also saw a comment saying that the AE was a newer version with a mod.So it it's reasonable to expect it to use the same oil as my 2009 54HP 4JH4AE. However, I did find a manual for 4JH3E and that said to use API CD. So no way of knowing correct spec.Did your manual state CD (as per Mobil product you are using) or was it just a guess. Best to check with a Yanmar dealer to be certain of correct spec.I did see a 4JH4E listed elsewhere ages ago and it seemed to have the same output and spec.I also saw a comment saying that the AE was a newer version with a mod.So it it's reasonable to expect it to use the same oil as my 2009 54HP 4JH4AE. Best to check with a Yanmar dealer to be certain of correct spec.This time I've put in Mobil 1000 blended with the remains of partly empty oil containers that were sitting in the shed. Most of these were Halfords semi-synthetic. I don't get too het up about the oil in these marine engines. Apart from avoiding fully synthetic I just stick to approximately the correct viscosity. The manual does give a range of specs to use.