Yanmar 3JH4E manuals

Yanmar 3JH4E Service Manual (214 pages)

Brand: Yanmar | Category: Engine | Size: 13.92 MB |

English

Table of contents

3JH4(B)(C)(M)E

1

M9961-03E090

2

Printed in Japan

3

California

4

Proposition 65 Warning

4

FOR SAFTY

5

Well fitting !!

7

CONTENTS

11

1. GENERAL

17

1.2 Specifications

18

1. GENERAL

19

1.3 Engine Outline

20

1.4 Piping Diagrams

23

1.General

24

4 YDX M 1.64 D 3 N

25

1.5.2 Exhaust Gas Regulations

26

(a) Fuel injection nozzle

27

(b) Fuel injection pump

27

2. Inspection and Adjustment

28

2. Inspection and Adjustment

29

2.2.1 Check before starting

30

(4) Seawater outlet

31

(5) Check cooling water level

31

Sediment

33

119305-35150

34

Alternator

35

Set bolt

35

Belt adjuster

35

(Valve clearance)

36

(Normal) (Abnormal)

36

(Valve clearance adjustment)

36

(Fuel/water separator)

38

UPPER LEVEL

40

LOWER LEVEL

40

Battery charge measurement

41

(Hydrometer structure)

41

(How to read hydrometer)

41

(1) Drain the fuel tank

42

(2) Replace the fuel filter

42

3JH4E 3 1

44

Injection nozzle

48

Nozzle tester

48

Non-atomized spray

50

Stagnant spray

50

(b) Heat exchanger inspection

51

(Breather system component)

52

2.4 Sensor Inspection

54

2.5 Thermostat inspection

55

2.6 Adjusting Operation

56

2.7 Long storage

58

3. Troubleshooting

59

3. Troubleshooting

61

Compression

72

4. Disassembly and Reassembly

74

4.2.1 General Handtools

75

Local supply 1 set

76

H = Shaft type

77

S = Hole type

77

4.2.2 Special Handtools

78

(Local supply)

79

(Removing the coupling)

79

(Tool 1)

80

(Tool 2)

80

4.2.3 Measuring Instruments

81

4.2.4 Other material

82

[Notice]

84

4.2.5 Measuring Instruments

85

Revolving shaft

87

Reflection mark

87

4.3.1 Disassembly

88

(Removing intake silencer)

89

(Removing starting motor)

90

(Removing flywheel)

93

(28) Removing the idle gear

95

(29) Removing the camshaft

95

(Removing gear case flange)

96

(36) Removing the crankshaft

97

(37) Removing the tappets

97

4.3.2 Reassembly

98

(Main bearing cap)

99

(Piston ring)

100

(Ring joints)

100

(Camshaft side gap)

101

(Idle gear shaft)

102

(Gear train)

102

(Lube oil pump)

102

(18) Mounting the flywheel

103

(Head bolt tightening order)

104

(Fuel injection nozzle)

105

(Lube oil filter and cooler)

106

(Seawater pipe)

107

(38) Filling with lube oil

108

(41) Test Running

108

5.1 Cylinder Block

109

Plug dia. d D

110

12 19.9-12.0 20

110

30 29.9-30.0 40

110

50 49.5-50.0 60

110

(Cylinder bore)

111

5.2 Cylinder Head

112

Straight-edge

113

Thickness gage

113

(Valve lapping tool)

114

(Valve sink depth)

115

(Valve sink)

115

(4) Valve guide

116

5.2.4 Valve springs

117

5.2.6 Measuring top clearance

118

(Rocker arm hole diameter)

119

5.3 Piston and Piston Pins

120

5.3.2 Piston pin

121

5.3.3 Piston rings

121

(Measuring side clearance)

122

Joint of coil

123

5.4 Connecting Rod

124

5.4.2 Crank pin metal

125

Plastic gauge

126

Alignment mark (Punched mark)

126

Matching mark

126

5.4.3 Piston pin bushing

127

5.5.1 Crankshaft

128

(Crankshaft R machining)

129

(Side gap measurement 1)

130

(Side gap measurement 2)

130

5.5.2 Main bearing

131

5.6 Camshaft and Tappets

132

(Camshaft outside diameter)

133

(Camshaft bend)

133

5.6.2 Tappets

134

5.7 Timing Gear

135

5.8 Flywheel and Housing

136

6. FUEL INJECTION EQUIPMENT

138

(1) 3JH4(B)(C)E

139

(1) Component

141

6.1.9 Tools

147

6.2 Fuel Feed Pump

149

N•m(kgf•m)

150

(4) Valve contact/mounting

151

6.3 Fuel Filter

152

6.4 Fuel Tank

153

7. INTAKE AND EXHAUST SYSTEM

154

7.2 Exhaust System

156

8. LUBRICATION SYSTEM

157

8.2 Lube Oil Pump

158

(Outer diameter clearance)

159

(Side clearance)

159

8.3 Lube Oil Filter

160

8.4 Lube oil Cooler

160

8. LUBRICATION SYSTEM

161

9. Cooling Water System

162

(Fresh water pipe)

163

9.2 Seawater Pump

164

(Sea water pump)

165

9.3 Fresh Water Pump

166

9. Cooling Water System

167

9.4 Heat Exchanger

169

9.5.3 Pressure cap inspection

170

9.5.4 Replacing filler neck

171

Filler cap

172

Coolant recovery tank

172

9.6 Thermostat

173

9.7.1 Introduction

174

9.7.2 Description

175

9.7.3 Cautions

175

9.7.4 Assembly Procedure

176

(5) Attaching the hose

177

(6) Test operation

177

(7) Fixing the strainer

177

9.7.5 Cautions for Assembling

178

9.7.6 Troubleshooting

179

11. REMOTE CONTROL (OPTIONAL)

181

(2) Remote control cable

182

(1) Speed control

183

(KM35P marine gear)

184

(2) Throttle lever adjustment

186

(1) Shift lever adjustment

186

12. Electrical System

187

12.1.1 Wiring diagram

188

12.2 Battery

190

12.3 Starting Motor

191

12.3.3 Structure

192

(2) Structure

193

12.4.1 Specifications

194

12.4.2 Structure

195

12.4.3 Wiring diagram

196

12.4.5 Inspection

197

12.5.1 Specifications

198

12.5.2 Structure

199

12.5.3 Wiring diagram

200

12.6 Instrument Panel

201

12.7 Warning Devices

202

12.8 Air Heater (Optional)

205

Device (Optional)

206

13. SERVICE STANDARDS

207

13.2 Engine Body

208

(1) Camshaft

209

(3) Backlash of each gear

209

13.2.3 Cylinder block

210

(5) Connecting rod

211

(6) Tappet

211

13. SERVICE STANDARDS

212

14.1 Main Bolt and Nut

213

YANMAR CO,. LTD

214

YANMAR DIESEL AMERICA CORP

214

Yanmar 3JH4E User Manual (30 pages)

Brand: Yanmar | Category: Engine | Size: 2.92 MB |

English

Table of contents

JUN 2006 (Rev. 1)

1

Engine Specifications

2

Marine Gear / Sail Drive

3

Specifications

3

Alarm System Specifications

5

Engine Outline with KM35A

6

Engine Outline with KM35P

7

Engine Outline with SD50

8

SPECIFICATIONS

10

Piping Diagrams

10

Electrical System

12

(1) (2) (3) (4)

13

(6)(7)(8)

13

Wiring Diagrams

16

Panel: B and C Type (VDO)

18

Figure - 13

18

Figure - 14

20

Controls

21

Power Take-Off

24

PTO Performance Curves

25

Engine Mount Specifications

26

Cold Starting Aids

29

Water Heater Tank Connection

29

Optional Accessories

29

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