Yanmar 3JH4E Service Manual Page 6
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- Table of contents
- TROUBLESHOOTING
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2. Safety Precautions
(1) SERVICE AREA
• Sufficient Ventilation
Inhalation of exhaust fumes and dust particles may be hazardous to ones
health. Running engines welding, sanding, painting, and polishing tasks
should be only done in well ventilated areas.
• Safe / Adequate Work Area
The service area should be clean, spacious, level and free from holes in
the floor, to prevent "slip" or "trip and fall" type accidents.
• Clean, orderly arranged place
No dust, mud, oil or parts should be left on the floor surface.
[Failure to Observe]
An unexpected accident may be caused.
• Bright, Safely Illuminated Area
The work area should be well lit or illuminated in a safe manner. For work
in enclosed or dark areas, a "drop cord" should be utilized. The drop cord
must have a wire cage to prevent bulb breakage and possible ignition of
flammable substances.
• Safety Equipment
Fire extinguisher(s), first aid kit and eye wash / shower station should be
close at hand (or easily accessible) in case of an emergency.
- 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
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