Yanmar 3JH25A Manuals

Manuals and User Guides for Yanmar 3JH25A. We have 1 Yanmar 3JH25A manual available for free PDF download: Service Manual

Yanmar 3JH25A Service Manual (309 pages)

Marine Diesel Engine

Brand: Yanmar | Category: Engine | Size: 11.12 MB

History of Revision
3
Exterior Views
3
Injection Pump
3
Intake and Exhaust System
3
Contents
5
General/Contents
6
Exterior Views 3JH2E
7
Exterior Views 3JH2-TE
8
Exterior Views 3JH25A/30A
9
Sea Water Pump
9
Exterior Views with KM3P1/KM35P1
10
Fresh Water Pump
10
Specifications
11
Lubrication System
12
Marine Gear
13
Applicability of Marine Gear and Reduction Ratio
13
Engine Outline 3JH2-E (KBW10-E)
15
Engine Outline 3JH2-BE (KM3A)
16
Engine Outline 3JH2TE (KBW10-E)
17
Engine Outline 3JH2-TB (KM3A)
18
Engine Outline 3JH25A/30A
19
Mixing Elbow
19
Dimensions of Flywheel
20
Performance Curves 3JH2-(B)E
21
Performance Curves 3JH2-T(B)E
22
Performance Curve 3JH25A
23
Performance Curve 3JH30A
24
Piping Diagrams 3JH2-(B)E
25
Piping Diagrams 3JH2-TE
26
Piping Diagrams 3JH2-TBE
27
Piping Diagrams 3JH25A/30A
28
Fuel Feed Pump
28
Basic Engine Parts/Contents
29
Cylinder Block
30
Inspection of Parts
30
Cleaning of Oil Holes
30
Color Check Procedure
30
Replacement of Cup Plugs
31
Cylinder Bore Measurement
32
Cylinder Head
33
Inspecting the Cylinder Head
34
Distortion of the Combustion Surface
34
Checking for Cracks in the Combustion Surface
34
Checking the Intake and Exhaust Valve Seats
34
Valve Seat Correction Procedure
35
Intakes/Exhaust Valves, Valve Guides
35
Wearing and Corrosion of Valve Stem
35
Inspection of Valve Seat Wear and Contact Surface
36
Valve Sinking/Guide
36
Checking Valve Springs
37
Spring Tension Tester
37
Assembling the Cylinder Head
38
Measuring Top Clearance
38
Intake and Exhaust Valave Arms
38
Adjustment of Valve Head Clearance
39
Pistons and Piston Pins
40
ID Marks for Piston/Piston Pin
40
Piston Head and Combustion Surface
41
Measurement of Piston Outside Diameter/Inspection
41
Replacing the Piston
41
Measuring the Rings/Ring Gap
42
Replacing the Piston Rings
43
Inspecting the Connecting Rod
44
Twist and Parallelism of the Large and Small Ends
44
Checking Thrust Clearance
44
Piston Pin Bushing
45
Checking Crank Pin Bushing
45
Measuring Crank Pin Oil Clearance
45
Precautions on Replacement of Crank Pin Bushing
45
Assembling Piston and Connecting Rod
46
Crankshaft
47
Color Check of Shaft
47
Bending of the Crankshaft
48
Measuring the Crank Pin and Journal
48
Checking Side Clearance of the Crankshaft
49
Inspecting the Main Bearing
49
Measuring the Inner Diameter of Metal
49
Checking the Camshaft Side Gap
50
Camshaft Height
50
Tappets
51
Timing Gear
53
Inspecting the Gears
53
Gear Timing Marks
54
Specifications of Flywheel
55
Dimensions of Flywheel and Mounting Flange
56
Ring Gear
57
Position of Top Dead Center and Fuel Injection Timing
57
Damper Disc and Cooling Fan
58
Applicability of Cooling Fan
58
Fuel Injection Equipment/Contents
59
Fuel Injection Pump Service Data (Yanmar Type: YPES-3CL)
60
Governor Exploded View
62
Governor Disassembly
63
Inspection/Assembling of Governor
67
Governor Spring Spec. Table
67
Fuel Injection Pump Exploded View
71
Disassembly of Fuel Injection Pump
72
Inspection of Fuel Injection Pump
76
Reassembly of Fuel Injection Pump
77
Adjustment of Fuel Injection Pump and Governor
81
Preparations
81
Adjustment of Top Clearance
82
Adjusting of Injection Timing
83
Plunger Pressure Type
84
Delivery Valve Pressure Test
84
Adjusting/Measuring/Adjustment of Injection Volume (Uniformoty of each Cylinder)
84
Adjustment of Governor
85
Adjusting Fuel/Rpm Limit Bolt
85
Adjusting Idling
85
Check Injection Volume When Starting
86
Construction of Fuel Feed Pump
87
Fuel Feed Pump Specifications
87
Disassembly/Reassembly/Inspection of Fuel Feed Pump
88
Functioning of Fuel Injection Nozzle
89
Fuel Injection Nozzle Disassembly/Inspection
90
Washing
90
Fuel Injection Nozzle Reassembly
91
Nozzle Inspection
91
Adjusting Fuel Injection Nozzle
92
Adjusting Opening Pressure
92
Injection Test
92
Troubleshooting of Fuel Injection Pump
93
Major Faults and Troubleshooting
93
Tools
95
Fuel Filter Specifications/Inspection
97
Fuel Tank
98
Intake and Exhaust System/Contents
99
JHE Engine Intake/Exhaust System
100
3JH25A/30A Intake/Exhaust System
101
3JH-TE Engine Intake System
102
Turbocharger Specifications/Construction
103
Interchangeability of Turbochargers
104
Turbocharger Model Name Plate
104
Interchangeability of Turbochargers Components
105
Turbocharger Preparation for Disassembly
106
Inspection Prior to Disassembly
107
Disassembly
107
Preparation for Reassembly
107
Reassembly
108
Turbocharger Inspection and Maintenance
109
Disassembly/Reassembly Precautions
109
Inspection Procedure
111
Periodic Inspection
112
Turbocharger Troubleshooting
115
Excessive/White Exhaust Smoke
115
Excessive Oil Consumption
115
Decrease in (Engine) Output
115
Turbocharger Blower Washing Procedure
116
Poor (Slow) Turbochrger Responsiveness
116
Abnormal Noise or Vibration
116
Mixing Elbow Construction/Inspection
117
Lubrication System/Contents
118
Lubrication System
119
3JH2-TE Lubrication Points
120
3JH25A/30A Lubrication Points
121
Lube Oil Pump Construction
122
Specifications of Lube Oil Pump
123
Lube Oil Pump Disassembly/Inspection
124
Lube Oil Filter Construction
125
3JH25A/30A Lube Oil Filter Construction
126
Cylinderblock
126
Lube Oil Filter Replacement
127
Oil Pressure Control Valve Construction/Replacement
128
Vibration Preventing Damper
128
Lube Oil Cooler Construction/Inspection
129
Piston Cooloing Nozzle Construction/Inspection (Only 3JH2TE)
130
Rotary Waste Oil Pump Construction/Inspection
131
Cooling Water System/Contents
132
Cooling Water System
133
Fresh Water Line (4JH2E&4JH2-TE)
134
Sea Water Line (3JH2E&3JH2-TE)
135
Sea Water Line (3JH25A/30A)
136
Heat Exchanger
136
Sea Water Pump Construction
137
Specifications of Sea Water Pump
137
Sea Water Pump Disassembly/Inspection
137
Sea Water Pump Reassembly
139
Fresh Water Pump Construction
140
Specifications of Fresh Water Pump
141
Fresh Water Pump Disassmebly/Inspection
141
Heat Exchanger Construction
143
Specifications of Heat Exchanger
144
Disassembly and Reassembly of the Heat Exchanger
144
Heat Exchanger Inspection
144
Pressure Cap Construction/Inspection
145
Pressure Cap Pressure Control
145
Function of the Sub Tank
145
Sub Tank Construction
146
Specifications of Sub Tank
146
Mounting the Sub Tank
146
Precautions on Usage of the Sub Tank
146
Functioning of Thermostat
147
Thermostat Construction
147
Characteristics of Thermostat
147
Thermostat Inspection
148
Testing the Thermostat
148
Kingston Cock Construction/Inspection
149
Kingston Cock Handling Precautions
149
Sea Water Filter Construction
150
Bilge Pump and Bilge Strainer Construction
151
Bilge Pump Specifications
151
Performance of Pump (in Pure Water)
151
Reduction and Reversing Gear/Contents
152
Marine Gear Models KM3A for Engine Models 3JH2BE/3JHE-TBE
153
Gear Construction
153
Gear Specifications
154
Power Transmission System
155
Arrangement of Shafts and Gears
155
Reduction Ration
155
Power Transmission Routine (Forward/Reverse)
156
Power Transmission Drawing
157
Power Transmission Sectional View
158
Construction of Shifting Mechanism
159
Forward and Reverse Clutch Operation
160
Engagement and Disengagement of Clutch
160
Clutch Shifting Force
161
Adjustment of Shifting Device
161
Measurement and Adjustment of Clearance
162
Inspect for the Following Points (Every 2-3 Months)
162
Adjustment of the Remote Control Head, Marine Gear Box Control Side
163
Inspection and Servicing
164
Clutch Case/Bearing/Gear
164
Forward and Reverse Large Gears
164
Drive Cone
164
Lapping Procedure for Drive Cone
165
Thrust Collar Construction
166
Cup Spring
167
Oil Seal of Output Shaft
167
Input/Output Shaft
167
Intermediate Shaft
168
Shifter
168
Shift Lever Shaft and Location Pin
168
Damper Disc
169
Shim Adjustment for Output and Input Shafts
169
Shifter Spring and Stopper Bolt
169
Side Cover and Oil Seal
169
Torque Limiter
171
Dismantling the Clutch
172
Removal of the Output Shaft
174
Removal of the Intermediate Shaft
176
Dismantling the Shifting Device
176
Reassembly of the Output Shaft
177
Reassembly of the Clutch
178
Reassembly of the Shifting Device
180
Marine Gear Models KM3P1, KM3P3, KM35P1 for Engine Models 3JH25A/30A Construction
181
Marine Gear Models KM3P1, KM3P3, KM35P1 for Engine Models 3JH25A/30A Specifications
182
Remoto Control/Contents
209
Construction of Remote Control System
210
Remote Control Device Components
210
Speed Control
211
Clutch Control
212
Engine Stop
213
Remote Control Inspection
214
Remote Control Adjustment
215
Electrical System/Contents
216
System Diagram of Electric Parts (B2-Type)
217
System Diagram of Electric Parts (C-Type)
218
Wiring Diagram for B-Type Instrument Panel
219
Wiring Diagram for C-Type Instrument Panel
220
Wiring Diagram for 3JH25A/30A
221
Battery
221
Battery Construction/Inspection
222
Battery Capacity and Battery Cables
222
Checking the Electrolyte
223
Voltage Test
223
Washing the Battery
223
Charging Methods/Procedure/Precautions
224
Battery Storage Precautions
224
The Reduction Starters
225
The Engagement Mechanism
226
Troubleshooting the Starter System
227
Starter Motor Disassembly
228
Check the Diameter of the Commutator
232
Continuity/Insulation Test for the Armature Coil
232
Check for Surface Distortion on the Armature and the Commutator
232
Check the Surface of the Commutator
233
Check the Depth of Insulating Material from the Commutator Surface
233
Continuity/Insulation Test for the Field Coil
233
Brushes
234
Brush Holder
234
Magnetic Switch
234
Continuity Test for the Shunt Coil
234
Continuity Test for the Series Coil/Contact-Points
235
Inspection of the Pinion
235
Pinion Sliding Test
235
Inspection of the Ball Bearings
236
Starter Motor Reassembly
237
Kind of Grease
237
Reassembly of the Nagnetic Switch
238
Operation Specifications Check
239
The No-Load Test
239
Sterter Motor Specifications
240
Alternator Standard Features/Specifications/Characteristics
241
Alternator Construction
242
Handling Precautions
243
IC Regulator
243
Charge Lamp
243
Alternator Circuit Diagram
243
Disassembling the Alternator
244
Alternator Inspection and Adjustment
245
Diode
245
Inspecting the Slip Ring Surface
245
Rotor Coil Continuity Test
245
Brush/Brush Wear
246
Rotor Coil Insulation Test
246
Check the Rear Side Ball Bearing
246
Stator Coil Continuity/Insulation Test
246
Reassembling the Alternator
247
Performance Test
248
Alternator Troubleshooting
249
Charging Failure
249
Overcharging
250
Charge Lamp Failure
250
B2-Type Instrument Panel with Wiring
251
C-Type Instrument Panel
251
Extension Codes
252
Warning Devices
253
Oil Pressure Alarm/Inspection
253
Cooling Water Temperature Alarm
254
Sender Unit for Lube Oil Pressure Gauge
254
Sender Unit for Cooling Water Temperature Gauge
255
Air Heater
256
Electric Type Engine Stopping Device
257
Solenoid
257
Relay
258
Wire Harness of Engine Stop
258
Construction of Tachometer
259
Specifications and Dimensions of Tachometer
259
Measrement of Sensor Unit Characteristics
260
Alternator 12V/80A Features/Specifications/Characteristics
262
Alternator 12V/80A Construction
263
Alternator 12V/80A Functioning
264
Disassembly and Reassembly/Contents
272
Disassembly and Reassembly Precautions
273
Disassembly and Reassembly Tools
274
Special Handtools
277
Measuring Instruments
279
Supplementary Packing Agent
280
Paint
280
Yanmar Cleaner
280
Neji Lock Super
280
Disassembly Drain Cooling Water/Lube Oil
281
Removing (Electrical) Wiring
281
Removing the Fuel Oil Filter/Pipe
282
Removing the Intake Silencer
282
Removing the Mixing Elbow
282
Removing the Turbine (3JH2-TE)
282
Removing the Starting Motor
284
Removing the Alternator
284
Removing the Cooling Water Pipe
284
Removing the Heat Exchanger (Exhaust Manifold, Fresh Water Tank Unit)
284
Removing the Cooling Water Pipe/Sea Water Pump
285
Removing the Lube Oil Filter
285
Removing the High Pressure Fuel Pipe
285
Removing the Intake Manifold
285
Removing the Fresh Water Pump
286
Removing the Fuel Injection Nozzles
286
Removing the Valve Elbow Shaft Assembly
286
Removing the Cylinder Head
286
Removing the Crankshaft V-Pulley
287
Removing the Marine Gearbox
287
Removing the Lube Oil Cooler
287
Removing the Flywheel
287
Turning the Engine over
288
Removing the Oil Pan
288
Removing the Lube Oil Intake Pipe/Pump
288
Removing the Gear Case
288
Remove the Oil Injection Pump
289
Removing the Idling Gear
289
Removing the Pistons and Connecting Rods
289
Removing the Flywheel Housing
290
Removing the Main Bearing
290
Removing the Crankshaft/Camshaft/Tappets
290
Removing the Gear Case Flange
290
Removing/Mounting the Piston Cooling Nozzle
291
Mounting the Gear Case Flange
291
Inserting the Tappets
291
Mounting the Camshaft/Crankshaft
292
Mounting the Main Bearing Metal with Engine Oil and Main Bearing Cap
292
Mounting the Flywheel Housing
293
Stand up the Cylinder Block
293
Mounting the Piston and Connecting Rod
293
Mounting the Idling Gear
294
Mounting the Fuel Injection/Lube Oil Pump
294
Mounting the Fuel Feed Pump Drive Gear and Automatic Advancing Timer
294
Mounting the Gear Case
295
Mounting the Lube Oil Intake Pipe
295
Mounting the Oil Pan/Flywheel
295
Mounting the Engine Mounting Feet and Turning the Engine Upright
295
Mounting the Marine Gearbox
296
Mounting the Crank V-Pulley
296
Mounting the Cylinder Head
296
Mounting the Valve Rocker Arm Shaft Assembly Pushrod
297
Mounting the Fuel Injection Nozzle
297
Mounting the Fresh Water Pump
297
Mounting the Intake Manifold
298
Mounting the High Pressure Fuel Pipe and Fuel Oil Return Pipe
298
Mounting the Lube Oil Cooler/Filter
298
Mounting the Lube Oil/Cooling (Sea) Water Pipe
299
Mounting the Dipstic Guide
299
Mounting the Sea Water Pump
299
Mounting the Heat Exchanger (Exhaust Manifold, Fresh Water Tank Unit)
299
Mounting the Alternator
300
Mounting the Starting Motor
300
Mounting the Turbine (Model 3JH-TE)
300
Mounting the Mixing Elbow and the Turbocharger
301
Mounting the Intake Silencer/Fuel Filter/Oil Pipe
302
Electrical Wiring
302
Installation in the Ship and Completion of the Piping and Wiring
302
Filling with Lube Oil
302
Filling with Cooling Water
303
Check Fuel Injection Timing
303
Bolt/Nut Tightening Torque
304
Test Running
305
Preliminary Precautions
305
Check Points and Precautions During Running
305
Parts Differing in Shape
306

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