Yanmar 3JH4E Service Manual
  1. Manuals
  2. Brands
  3. Yanmar Manuals
  4. Engine
  5. 3JH4E
  6. Service manual

Yanmar 3JH4E Service Manual

Marine diesel engine
Hide thumbs Also See for 3JH4E:
Table of Contents

Advertisement

Quick Links

See also: Service Manual , Operating Manual
M9961-03E090
Service Manual
3JH4(B)(C)(M)E

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 3JH4E and is the answer not in the manual?

Questions and answers

שפע זאב
March 23, 2025

מחפש תושבות מנוע ל3jh4e

0
1 comments:
Mr. Anderson
March 23, 2025

You can find engine mounts for the Yanmar 3JH4E at AB Marine Service.

This answer is automatically generated

0

Related Manuals for Yanmar 3JH4E

Summary of Contents for Yanmar 3JH4E

  • Page 1 M9961-03E090 Service Manual 3JH4(B)(C)(M)E...
  • Page 2 M9961-03E090...
  • Page 3 Publication No. M9961-03E090 History of Revision Manual Name Service Manual for Marine Diesel Engine Engine Model: 3JH4(B)(C)(M)E Number Date of Reason for Correction item Corrected Outline of correction revision correction No (page) revision New edition January 2004 Printed in Japan M9961-03E090...
  • Page 4 Use this manual as a handy reference in daily inspection and maintenance, and as a text for engineering guidance. Model 3JH4E has been used for the illustrations in this service manual, but they apply to other models in the JH4 series engines.

  • Page 5: Safety Labels

    FOR SAFTY 1. SAFETY LABELS • Most accidents are caused by negligence of basic safety rules and precautions. 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.

  • Page 6: Safety Precautions

    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"...
  • Page 7 (4) GENUINE PARTS and MATERIALS • Genuine Parts Always use genuine YANMAR parts or YANMAR recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result.
  • Page 8 (5) FASTENER TORQUE • Torqueing Fasteners Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury. (6) Electrical • Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system.

  • Page 9: Rotating Parts

    (8) FURTHER PRECAUTIONS • Fueling / Refueling Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result. • Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down.
  • Page 10 3. Precautions for Service Work (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work. (2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.

  • Page 11: Table Of Contents

    1.2 Specifications ...........................2 1.3 Engine Outline ..........................4 1.4 Piping Diagrams ........................7 1.5 Exhaust Gas Emission Regulation ...................9 1.5.1 Engine identification (3JH4E)......................9 1.5.2 Exhaust Gas Regulations ....................... 10 1.5.3 Guarantee Conditions for Emission Standard................. 10 2. Inspection and Adjustment .................... 12 2.1 Periodic Maintenance Schedule .....................12...
  • Page 12 4.2.2 Special Handtools ........................... 62 4.2.3 Measuring Instruments ........................65 4.2.4 Other material ..........................66 4.2.5 Measuring Instruments ........................69 4.3 Disassembly and Reassembly ....................72 4.3.1 Disassembly............................ 72 4.3.2 Reassembly ............................ 82 5. Inspection and Servicing of Basic Engine Parts ............93 5.1 Cylinder Block ........................93 5.1.1 Inspection of parts...........................
  • Page 13 5.7 Timing Gear .........................119 5.7.1 Inspecting the gears........................119 5.7.2 Gear timing marks ..............119 5.8 Flywheel and Housing ......................120 5.8.1 Position of top dead center and fuel injection timing..............120 5.8.2 Damper disc and cooling fan ......................121 6. FUEL INJECTION EQUIPMENT ................. 122 6.1 Fuel Injection Pump/Governor .....................122 6.1.1 Fuel system diagram ..............
  • Page 14 8.2.3 Lube oil pump disassembly and reassembly ................142 8.2.4 Lube oil pump inspection ......................143 8.2.5 Oil pressure control valve construction ..................143 8.3 Lube Oil Filter ........................144 8.3.1 Lube oil filter construction ............144 8.3.2 Lube oil filter replacement......................144 8.4 Lube oil Cooler ........................144 8.4.1 Lube oil cooler construction ......................
  • Page 15 9.6.3 Characteristics of thermostat ......................157 9.6.4 Thermostat inspection........................157 9.6.5 Testing the thermostat ........................157 9.7 Bilge Pump and Bilge Strainer (Optional) ................158 9.7.1 Introduction ........................... 158 9.7.2 Description ............................ 159 9.7.3 Cautions............................159 9.7.4 Assembly Procedure........................160 9.7.5 Cautions for Assembling ....................... 162 9.7.6 Troubleshooting ..........................
  • Page 16 12.6 Instrument Panel ........................185 12.6.1 B-type instrument panel (optional)............ 185 12.6.2 C-type instrument panel ............185 12.7 Warning Devices ........................186 12.7.1 Oil pressure alarm........................186 12.7.2 Sender unit for lube oil pressure gauge ..........187 12.7.3 Cooling water temperature alarm....................188 12.7.4 Sender unit for the cooling water temperature gauge ........

  • Page 17: General

    Non-Operating Side Engine name plate (on the rocker arm cover) Fresh water filler cap Coolant tank / Heat exchanger Alternator Exhaust manifold Mixing elbow Starter motor Sea water pump <Note> This illustration shows the 3JH4E with Yanmar marine gear (Model:KM35P).

  • Page 18: Specifications

    1. GENERAL 1.2 Specifications (1) 3JH3E, 3JH3BE, 3JH3CE, 3JH4ME Official engine model name unit 3JH4E Company internal model name 3JH4E 3JH4BE 3JH4CE 3JH4ME Marine gear model KM35P KM35A SD40 Bobtail Pleasure use Type Vertical water cooled 4 cycle diesel engine...
  • Page 19 1. GENERAL (Note) 1. Rating condition : ISO 3046-1, 8665 2. 1HP (metric horse power) ≒ 0.7355 kW 3. Fuel condition : Density at 15°C = 0.842 * Fuel temperature 25°C at the inlet of the fuel injection pump. (ISO 3046-1) ** Fuel temperature 40°C at the inlet of the fuel injection pump.

  • Page 20: Engine Outline

    MOUNTING BLOCKS ID#150 MIXING ELBOW U-MIXING ELBOW DIRECTION OF ROTATION 10.5 3-M10 X 1.5 DEPTH 14 / 20 DETAIL OF PULLEY DETAIL OF COUPLING SCALE 1:3 SCALE 1:3 12 X 30 MOUNTING BLOCKS ID#100 538.6 517.6 169.3 (274) 243.6 194.1 ROTATION NOTE 1.
  • Page 21 MIXING ELBOW MOUNTING BLOCKS ID#150 U-MIXING ELBOW DIRECTION OF ROTATION 3-M10 X 1.5 DEPTH 14 / 20 DETAIL OF PULLEY SCALE 1:3 DETAIL OF COUPLING SCALE 1:3 12 X 30 MOUNTING BLOCKS ID#100 538.6 517.6 (274) 243.6 194.1 ASTERN ROTATION NOTE 1.
  • Page 22 MOUNTING BLOCKS ID#200 DIRECTION OF ROTATION 3-M10 X 1.5 DEPTH 14 / 20 DETAIL OF PULLEY MOUNTING BLOCKS ID#200 12 X 30 SCALE 1:3 538.6 517.6 (274) 243.6 194.1 (112.5) (185) NOTE 1. The original height of mounting blocks is shown in this drawing.

  • Page 23: Piping Diagrams

    1.General 1.4 Piping Diagrams (1) 3JH4(B) E Note: The following piping diagram is for the 3JH4E model. 7.8 x t4.5 rubber hose 7.8 x t4.5 rubber hose Fuel feed pump 7.8 x t4.5 rubber hose Marks of piping 7.8 x t4.5 rubber hose 5 x t4.5...
  • Page 24 1.General (2) 3JH4CE (with sail drive SD40) 7.8 x t4.5 rubber hose 7.8 x t4.5 rubber hose Fuel feed pump 7.8 x t4.5 rubber hose Marks of piping 7.8 x t4.5 rubber hose Screw joint (Union) 5 x t4.5 Fuel injection pump rubber hose Check valve Flange joint...

  • Page 25: Exhaust Gas Emission Regulation

    (EPA and ARB label) (Note) Emission Control is accomplished through Engine Modification (EM-Design) • The tamper resistance device is installed with EPA/ARB certified 3JH4E series engines to prevent illegal change of fuel injection volume and high idling speed. (Fuel injection volume : cap type, High idling speed : cap type) •...

  • Page 26: Exhaust Gas Regulations

    1.General 1.5.2 Exhaust Gas Regulations This engine conforms to the EPA exhaust gas regulations (19kW and under 37kW). Engine Power Tier Model Year NMHC + NOx Tier 1 1999 9.5 (7.1) 5.5 (4.1) 0.80 (0.60) 19 <= kW < 37 (25 <= hp <...
  • Page 27 1.general (5) Quality guarantee period for exhaust emission related parts For exhaust emission related parts, follow the inspections outlined in the "List of Periodic Inspections", on the operation manual, and use the table below to carry out inspections based on operation hours or time in years.

  • Page 28: Inspection And Adjustment

    2. Inspection and Adjustment 2. Inspection and Adjustment 2.1 Periodic Maintenance Schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. : User-maintenance : Parts replacement : Shop-inspection...
  • Page 29 2. Inspection and Adjustment : User-maintenance : Parts replacement : Shop-inspection *2 Initial *2 Every *2 Every *2 Every Before System Item 50hrs. or 50hrs. or 250 hrs. or 1000 hrs. or starting one month one month one year 4 years Check the leakage of water, (After lube oil and fuel.

  • Page 30: Periodic Inspection And Maintenance Procedure

    Engine oil capacity Model at rake angle 8 degree Full : 5.0 ± 0.3 (5.3 ± 0.3) 3JH4E with KM35P 3JH4E with KM35A Full : 5.5 ± 0.3 (5.8 ± 0.3) 3JH4E with SD40 b) If the remaining engine oil level is low, fill the oil pan with the specified engine oil to the specified level through the filler port.
  • Page 31 2. Inspection and Adjustment 2) Checking marine gear lube oil level a) Check the lube oil level of the marine gear with a Oil filler cap dipstick. 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-...
  • Page 32 2. Inspection and Adjustment IMPORTANT: If the cooling water runs short quickly or when the coolant tank runs short of water with the coolant recovery tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the water level of the coolant recovery tank during operation is not abnormal.

  • Page 33: Inspection After Initial 50 Hours Or One Month Operation

    2. Inspection and Adjustment (7) Check the leakage of water, lube oil and fuel. Brfore and after starting the engine, check the leakage of cooling water and seawater from cooling water system. Also check the leakage of lube oil and fuel. (8) Check/adjust the remote control operation Make sure that the accelerator of a boat can be operated smoothly before starting the engine.
  • Page 34 2. Inspection and Adjustment 3) Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface, and tighten it further to 3/4 of a turn with the filter wrench.
  • Page 35 2. Inspection and Adjustment 2) If necessary, adjust the V-belt tension (deflection). 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.
  • Page 36 2. Inspection and Adjustment c) Valve clearance measurement Rocker arm Insert a thickness gage between the rocker arm Adjusting screw and valve cap, and record the measured valve Valve clearance clearance. Lock nut (Use it as the data for estimating the wear state.) d) Adjusting other cylinders Turn the crankshaft 240 and make adjustment...
  • Page 37 2. Inspection and Adjustment (6) Check and adjust the remote control operation The various control levers on the engine side are connected to the remote control lever by the remote control cable. The cable will become stretched and the attachments loose after long hours of use causing deviation.

  • Page 38: Inspection Every 50 Hours Or Monthly

    2. Inspection and Adjustment 2.2.3 Inspection every 50 hours or monthly Be sure to check the following points every 50 hours or monthly, whichever comes first. Inspection Item Drain the fuel/water separator. Check the electrolyte level in the battery (1) Drain the fuel/water separator. Air bleeding bolt 1) Close the fuel cock of the fuel tank.
  • Page 39 2. Inspection and Adjustment Fuel System Air bleeding Procedures 1) Check the fuel level in the fuel tank. Replenish if Insufficient. Air bleeding bolt 2) Loosen the air bleeding bolt at the top of the fuel/ water separator by turning it 2 or 3 turns. When fuel, which does not contain air bubbles, comes out of the bolt hole, tighten the air bleeding bolt.
  • Page 40 2. Inspection and Adjustment Battery structure Terminal Cover Cathode plate Separator Glass mat Battery case Anode plate (1) Electrolyte level • Check the level of fluid in the battery. GREASE When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit.
  • Page 41 2. Inspection and Adjustment (b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of Float battery electrolyte is defined with 20 C as the standard. °...

  • Page 42: Inspection Every 250 Hours Or One Year

    5) Bleed the fuel system. Refer to 2.2.3.(1). IMPORTANT: Be sure to use genuine Yanmar part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shorten engine life. (3) Replace the engine lube oil and the lube oil filter.
  • Page 43 2. Inspection and Adjustment (5) Check the impeller of the cooling water pump (seawater pump). 1) Remove the seawater pump cover and take out Cover the O-ring, impeller and wear plate, O-ring 2) Inspect the rubber impeller, checking for splitting around the outside, damage or cracks, and replace Impeller if necessary.
  • Page 44 2. Inspection and Adjustment 2) Close the three water cocks for fresh water. 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...
  • Page 45 2. Inspection and Adjustment 7) Check the rubber hose connecting the coolant To fresh water recovery tank to the fresh water cooler. 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.
  • Page 46 2. Inspection and Adjustment (9) Check the wiring connectors. 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...

  • Page 47: Inspection Every 1,000 Hours Or Four Years

    2. Inspection and Adjustment 2.2.5 Inspection every 1,000 hours or four years Be sure to check the following points every 1,000 hours or four years operation, whichever comes first. Inspection Item Check the injection timing Check the injection spray condition of a fuel nozzle Check the impeller of the cooling water pump(seawater pump) Clean &...
  • Page 48 2. Inspection and Adjustment (2) Check the injection spray condition of a fuel nozzle Wear protective glasses when testing injection from the fuel injection nozzle. 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.
  • Page 49 2. Inspection and Adjustment [Informative: Fuel injection valve structure] F.O. return pipe joint Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Valve stop spacer Nozzle valve Nozzle Nozzle body Nozzle case nut Tightening torque: 39.2 to 44.1 N m (4 to 4.5 kgf m) 2) Spray pattern inspection After adjustment to the specified valve opening Normal...
  • Page 50 Injection angle Nozzle insertion angle CodeA: angled No code: no angle YANMAR Punch mark (3) Check the impeller of the cooling water pump(seawater pump) The impeller must be replaced with new one periodically (every 1000 hrs or four years whichever comes first).
  • Page 51 2. Inspection and Adjustment (4) Clean & check the water passages When it is used for a long time, cleaning of the cooling water passages is periodically necessary, because trash, scales, rust, and so on collect in the cooling water passages and the cooling performance declines.
  • Page 52 2. Inspection and Adjustment 4) Pressure cap inspection Do not open the pressure cap while the engine is running or right after stopping because high temperature steam will be blown out. Remove the cap only after the water cools down. a) Remove scale and rust and check the seat and seat valve, etc.
  • Page 53 (Refer to 5. "Flexible Engine Mount" in the installation manual for pleasure boat use.) Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years, whichever comes first.

  • Page 54: Adjusting The No-Load Maximum Or Minimum Speed

    2. Inspection and Adjustment 2.3 Adjusting the no-load maximum or minimum speed 1) After warming the engine up, gradually raise the Fuel injection pump speed and set it at the no-load maximum speed. 2) If the no-load maximum speed is out of the Remote standard, adjust it by turning the high idle limiting control cable...

  • Page 55: Thermostat Inspection

    2. Inspection and Adjustment 2.5 Thermostat inspection (1) Put the thermostat in a beaker with fresh water, and heat it on an electric stove. 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.

  • Page 56: Adjusting Operation

    (1) Warm the engine up. (2) Remove any precipitation from the F.O. filter. water separator, and F.O tank. (3) Use only lube oil recommended by Yanmar. (4) Be sure to add Long Life Coolant Antifreeze (LLC) to cooling fresh water.

  • Page 57: Check Points And Precautions During Running

    2. Inspection and Adjustment 2.6.3 Check Points and Precautions During Running Step Item Instructions Precautions Checks before 1) Make sure that the sea cock is open. 3) Lamp should go off operation 2) Make sure there is enough lube oil and (fresh) when engine is cooling water.

  • Page 58: Long Storage

    2. Inspection and Adjustment 2.7 Long storage Observe the following instructions when the engine is to be stored for a long period without operation: 1) Do not drain cooling water in the cold season or before the long storage. [NOTICE] Negligence of adding anti-freeze will cause the cooling water remaining inside the engine to be frozen and expanded to damage the engine parts.

  • Page 59: Troubleshooting

    3. Troubleshooting 3. Troubleshooting 3.1 Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. 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.

  • Page 60: Quick Reference Chart For Troubleshooting

    3. Troubleshooting 3.2 Quick Reference Chart for Troubleshooting It is important to thoroughly under stand each system and the function of all of the parts of terse systems. A careful study of the engine mechanism will make this possible. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause.
  • Page 61 Chart 1 THE ENGINE SUDDENLY STOPS. 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.
  • Page 62 Chart 2 Chart 3 Trouble and Troubleshooting TROUBLE AND TROUBLESHOOTING CYLINDER OUTPUT IS UNEVEN COUNTERMEASURE POOR EXHAUST COLOR (I-1) Bleed air. (I -7) Disassemble and clean (I-1) Check, repair or replace. (II-1) Clean. (I-2) Disassemble and clean. and repair replace. (I-2) Replace.
  • Page 63 Chart 4 TROUBLE AND TROUBLESHOOTING TROUBLE WITH MARINE GEAR (II-1) Review (I-1, I-11). (I-1) Disassemble and clean. (I-7) Replace. (III -1) Replace. (II-2) Reduce load. (I-2) Repair or replace. (I-8) Replace. (III -2) Replace. (II-3) Replace. (I-3) Repair or replace. (I-9) Adjust to correct position.
  • Page 64 Chart 5 ROTATION IS NOT SMOOTH TROUBLE AND TROUBLESHOOTING (I-1) Lap. (II-1) Clean. (II-7) Bleed air and prime. (I-2) Replace. (II-2) Replace. (II-8) Adjust. (II-3) Replace. (II-9) Adjust. (II-4) Correctly install pump. (II-5) Clean. (II-6) Replace. (I) Faulty operation of injection valve (II) Uneven supply of fuel oil injected (1) Faulty operation of fuel pump plunger...
  • Page 65 Chart 6 KNOCKING TROUBLE AND TROUBLESHOOTING (I-1) Increase injection pressure. (II-1) Delay injection timing. (I-2) Replace. (II-2) Adjust standard injection pressure. (I-3) Disassemble and lap. (I-4) Disassemble and repair. (I) Faulty fuel injection valve (II) Faulty fuel injected (1) Early fuel injection (1) Low injection pressure (3) Sticking of valve needle (2) Fuel pressure is too high...
  • Page 66 Chart 7 TROUBLE AND TROUBLESHOOTING TROUBLE WITH STARTING (I-1) Tighten. (II-1) Tighten. (III-1) Prime well. (IV-1) Lap. (I-2) Repair using sandpaper or replace. (II-2) Repair using sandpaper. (III-2) Adjust. (IV-2) Lap. (I-3) Replace. (II-3) Replace. (III-3) Clean out matter causing clogging. (IV-3) Replace.
  • Page 67 Chart 8 INSUFFICIENT POWER OUTPUT TROUBLE AND TROUBLESHOOTING (I-1) Replace. (II-1) Clean nozzle hole or replace. (III-1) Replace. (I-2) Disassemble and repair or replace. (II-2) Lap or replace. (III-2) Repair. (I-3) Lap valves. (II-3) Lap or replace. (I-4) Tighten firmly. (II-4) Tighten firmly.
  • Page 68 Chart 9 TROUBLE AND TROUBLESHOOTING MISCELLANEOUS TROUBLE (I-1) Tighten nuts. (II-1) Tighten adjustment valve. (III-1) Clean. (I-2) Tighten nuts and insert pins. (II-2) Check and repair. (III-2) Add cooling water. (I-3) Remove adjustment liner and adjust aperture, (II-3) Clean. (III-3) Disassemble and repair or replace. or replace.

  • Page 69: Troubleshooting (Concerning Engine And Fuel Injection Equipment)

    3. Troubleshooting 3.3 Troubleshooting (Concerning engine and fuel injection equipment) Malfunctions Causes Remedies The engine does not operate 1. Fuel Oil is not injected from the 1. There is no fuel oil in the fuel Supply fuel and bleed the system injection pump tank 2.
  • Page 70 3. Troubleshooting Malfunctions Causes Remedies The engine exhaust contains 1. The injection timing is incorrect Readjust the timing smoke and the engine “knocks” 2. The nozzle or nozzle holder is Inspect, then repair or replace functioning incorrectly 3. The injection quantity is Readjust excessive The engine output is unstable...
  • Page 71 3. Troubleshooting Malfunctions Causes Remedies 4. The nozzle or the nozzle holder Inspect and then repair or replace is not functioning properly The engine cannot reach its 1. The governor spring is too weak Readjust or replace maximum speed or is improperly adjusted 2.

  • Page 72: Troubleshooting By Measuring Compression Pressure

    3. Troubleshooting 3.4 Troubleshooting by measuring Compression Pressure Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pres- sure is affected by the following factors: 1) Degree of clearance between piston and cylinder 2) Degree of clearance at intake/exhaust valve seat 3) Gas leak from nozzle gasket or cylinder head gasket...
  • Page 73 3. Troubleshooting (3) Engine speed and compression pressure (for reference) 3JH4E Engine speed (min (4) Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective action •...

  • Page 74: Disassembly And Reassembly

    4. Disassembly and Reassembly 4. Disassembly and Reassembly 4.1 Disassembly and Reassembly Precautions (1) Disassembly • Take sufficient time to accurately pin-point the cause of the trouble, and disassemble only those parts which are necessary. • Be careful to keep all disassembled parts in order. •...

  • Page 75: Disassembly And Reassembly Tools

    4. Disassembly and Reassembly 4.2 Disassembly and Reassembly Tools The following tools are required when disassembling and reassembling the engine. 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...
  • Page 76 4. Disassembly and Reassembly Name of tool Illustration Remarks Copper hammer Local supply Mallet Local supply Nippers Local supply Pliers Local supply Offset wrench Local supply 1 set Box spanner Local supply 1 set Scraper Local supply...
  • Page 77 4. Disassembly and Reassembly Name of tool Illustration Remarks Lead rod Local supply File Local supply 1set Rod spanner for Local supply hexagon socket Size : 6 mm head screws 8 mm 10 mm Stariing Pliers Local supply Hole type Shaft type S - 0 S = Hole type...

  • Page 78: Special Handtools

    4. Disassembly and Reassembly 4.2.2 Special Handtools Name of tool Illustration Remarks Piston pin insertion/ extraction tool (Piston pin extractor) (Extraction of piston pin) (Insertion of piston pin) Connecting rod small end bushing insertion/extraction tool (Extraction) Intake and exhaust valve insertion/ extraction tool Lubricating oil No.2 filter case remover...
  • Page 79 4. Disassembly and Reassembly Name of tool Illustration Remarks Piston ring compressor Piston ring replacer (for removal / installation of piston ring) Valve lapping tool (Rubber cap type) Valve lapping powder Feeler gauge Pulley puller (Removing the coupling) (Local supply)
  • Page 80 4. Disassembly and Reassembly Name of tool Illustration Remarks Press tool 1 for filler neck (Tool 1) Press tool 2 for filler neck copper tube (Tool 2) Stem seal insertion (for inserting stem seal) 16.2 13.5 18.8...

  • Page 81: Measuring Instruments

    4. Disassembly and Reassembly 4.2.3 Measuring Instruments Name of tool Illustration Remarks Vernier calipers 0.05mm 0-150mm Micrometer 0.01mm 0-25mm 25-50mm 50-75mm 75-100mm 100-125mm 125-150mm Cylinder gauge 0.01mm 18-35mm 35-60mm 50-100mm Thickness gauge 0.05-2mm Torque wrench 128 N•m (0-13kgf•m) Nozzle tester 0-49 Mpa (0-500kgf/cm...

  • Page 82: Other Material

    4. Disassembly and Reassembly 4.2.4 Other material Items Usual Contents Features and application Liquid gasket Three Bond 200g Non-drying liquid gasket; solvent less type, easy to No.1 (1kg also remove, superior in seawater resistance, applicable TB1101 available) to various mating surfaces. Three Bond 200g Non-drying liquid gasket;...
  • Page 83 4. Disassembly and Reassembly Items Usual Contents Features and application Scale solvent Scale solvent 1 box • The scale solvent removes scale in a short time. (1 to 10 hours) (4 kg × 4 • Prepare water (seawater is possible) in an removers) amount that is about 10 times the weight of the Neutralizer...
  • Page 84 4. Disassembly and Reassembly Items Usual Contents Features and application Cleaning agent for 4L x 4 Special cleaning agent that requires no water, turbocharger specially designed for blower of turbocharger and 18L x 1 inter cooler. 15sets : 1, 500cc x 6 [Notice] It is recommended that the liquid gasket of Three Bond TB1212 should be used for service work.

  • Page 85: Measuring Instruments

    4. Disassembly and Reassembly 4.2.5 Measuring Instruments Name of tool Illustration Dial gauge Measures shaft bending, distortions of levelness, and gaps. Test indicator Measures narrow and deep places which cannot be measured with dial gauge. Magnetic stand Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles.
  • Page 86 4. Disassembly and Reassembly Name of tool Illustration V Block Measures shaft distortion. 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.
  • Page 87 4. Disassembly and Reassembly Name of tool Illustration Rotation Contact type Measures rotation speed by placing gauge at the indentation hole of the revolving shaft. Photoelectric Measures rotation speed by using a type reflector mark which is placed on the Revolving shaft exterior of the revolving shaft.

  • Page 88: Disassembly And Reassembly

    4. Disassembly and Reassembly 4.3 Disassembly and Reassembly 4.3.1 Disassembly • Preparation on a boat For engines mounted in an engine room of a ship, remove the piping and wiring connecting them to the ship. 1) Remove the remote control cable (from engine and marine gearbox). 2) Unplug the extension cord for the instrument panel from the engine.
  • Page 89 4. Disassembly and Reassembly (3) Removing (electrical) wiring Remove the wiring from the engine. (Refer to 2.2.4(9) ) (4) Removing the fuel filter & fuel pipe 1) Remove the fuel pipes (fuel filter-fuel feed pump, fuel filter-fuel injection pump and fuel nozzle-fuel Air bleeding bolt filter) 2) Remove the fuel filter.
  • Page 90 4. Disassembly and Reassembly (6) Removing the mixing elbow 1) Remove the seawater rubber hose connecting to a heat exchanger- a mixing elbow. 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.
  • Page 91 4. Disassembly and Reassembly (9) Removing the cooling water pipe (seawater/ fresh water) 1) Remove the seawater pipe (seawater pump-heat exchanger). 2) Remove the fresh water pipe (fresh water pump- heat exchanger. exhaust manifold-fresh water pump). 3) Remove the fresh water pipe (cylinder block-lube oil cooler, lube oil cooler-fresh water pump). Heat exchanger Mixing elbow Exhaust manifold...
  • Page 92 4. Disassembly and Reassembly (12) Removing the lube oil filter and lube oil cooler 1) Remove the fresh water pipe (cylinder block-lube Cylinder block oil cooler, lube oil cooler outlet) 2) Remove the lube oil filter from the lube oil cooler. 3) Remove the lube oil cooler nut and lube oil cooler.
  • Page 93 4. Disassembly and Reassembly (16) Removing the fuel injection nozzles Remove the bolt for the fuel nozzle retainer, and pull out the fuel nozzle retainer and fuel injection nozzle. 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.
  • Page 94 4. Disassembly and Reassembly (22) Turning the engine over Bolt 1) Place a wood block of appropriate size on the floor, and stand up the engine on the flywheel housing. 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.
  • Page 95 4. Disassembly and Reassembly (28) Removing the idle gear Loosen the three bolts holding the idle gear and pull out Bolt the idle gear and shaft. 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.
  • Page 96 4. Disassembly and Reassembly (31) Removing the gear case flange Liquid gasket 1) Remove the gear case flange from the cylinder block. 2) Remove the O-rings from the lube oil passage. NOTE 1) When mounting the gear case flange, match up the two knock pins for cylinder block.
  • Page 97 4. Disassembly and Reassembly (35) Removing the main bearing. 1) Remove the main bearing bolts. 2) Remove the main bearing cap and lower main bearing metal. NOTE: The thrust metal (lower) is mounted to the base main bearing cap. (36) Removing the crankshaft 1) Remove the crankshaft.

  • Page 98: Reassembly

    4. Disassembly and Reassembly 4.3.2 Reassembly (1) Clean all parts Clean all parts using by the cloth and diesel oil(or cleaning agent) before reassembly. 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.
  • Page 99 4. Disassembly and Reassembly (5) Mounting the main bearing cap Upper main bearing metal Coat the lower main bearing metal with engine oil, and Oil hole mount it to the main bearing cap. Lower NOTE: Thrust metal 1) The lower main bearing metal does not have an oil hole.
  • Page 100 4. Disassembly and Reassembly (8) Mounting the gear case flange Apply the liquid gasket to the gear case flange and mount the gear case flange and lube oil line O-ring onto the cylinder block. NOTE: 1) When mounting the gear case flange, match up the two knock pins of the cylinder block. 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.
  • Page 101 4. Disassembly and Reassembly 2) Coat the outside of the piston and the inside of the Piston ID mark connecting rod crank pin metal with engine oil and insert the piston with the piston insertion tool. 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...
  • Page 102 4. Disassembly and Reassembly (11) Mounting the idling gear Upside Mark 1) Mount the idling gear so that the oil hole of the idle gear shaft faces up. NOTE: The idle gear shaft must be mounted with the mark of the shaft upward. (Idle gear shaft) 2) Align the “A”...
  • Page 103 4. Disassembly and Reassembly (14) Mounting the lube oil inlet pipe Mount the lube oil inlet pipe on the bottom of the cylinder block, using new gasket. Tightening torque N•m (kgf•m) Lube oil inlet pipe 26 (2.6) (15) Mounting the spacer and the oil pan Cylinder block 1) Apply the liquid gasket to the surfaces of the gear case cover, gear case flange and oil seal case on...
  • Page 104 4. Disassembly and Reassembly (19) Mounting the marine gearbox Damper disk 1) Mount the fan and damper disk to the flywheel. Marine gearbox 2) Align the damper disk with the input shaft spline and insert. Mount the marine gearbox to the flywheel housing.
  • Page 105 4. Disassembly and Reassembly (22) Mounting the fuel injection pump Fuel injection pump 1) Lightly fit the fuel injection pump on the gear case drive gear flange. (After adjusting injection timing, tighten the Camshaft gear fuel injection pump). NOTE: Be careful not to scratch the O-ring between the fuel injection pump and gear case flange.
  • Page 106 4. Disassembly and Reassembly (25) Mounting the intake manifold Thoroughly clean the inside of the intake manifold, and mount the gasket packing and intake manifold. (26) Mounting the fuel injection pipe and fuel No.1 return pipe No.2 Fuel injection pipe 1) Mount the fuel injection pipe and then assemble No.3 the fuel injection pipe retainer to prevent the pipe...
  • Page 107 4. Disassembly and Reassembly (30) Mounting the cooling water pipes (seawater / fresh water) 1) Mount the seawater pipes with the hose clips (seawater pump-heat exchanger). Mixing elbow 2) Mount the fresh water pipes with the hose clips (exhaust manifold – fresh water pump, fresh water pump heat exchanger).
  • Page 108 4. Disassembly and Reassembly (38) Filling with lube oil Fill the engine with lube oil from the supply port on top of the gear case and fill the marine gearbox from the supply port on top of the clutch case. (39) Filling with cooling water 1) Open the coolant (fresh water) tank cap and fill with water.

  • Page 109: Inspection And Servicing Of Basic Engine Parts

    5. Inspection and Servicing of Basic Engine Parts 5. Inspection and Servicing of Basic Engine Parts 5.1 Cylinder Block The cylinder block is a thin-skinned, (low-weight), short skirt type with rationally placed ribs. The side walls are Cap plug 50 mm save shaped to maximize rigidity for strength and low (Camshaft hole) Cap plug 30 mm...

  • Page 110: Replacement Of Cup Plugs

    5. Inspection and Servicing of Basic Engine Parts (6) Clean the surface with the cleaner. 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.

  • Page 111: Cylinder Bore Measurement

    5. Inspection and Servicing of Basic Engine Parts 5.1.5 measurement Cylinder bore Especially clean head surface, cylinder bores and oil holes, and check the below items after removing any carbon deposit and bonding agent. (a) Appearance inspection Check if there is any discoloration or crack. If crack is suspected, perform color check.

  • Page 112: Cylinder Head

    5. Inspection and Servicing of Basic Engine Parts 5.2 Cylinder Head The cylinder head is of 3-cylinder integral construction, mounted with 14 bolts. 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.

  • Page 113: Inspecting The Cylinder Head

    5. Inspection and Servicing of Basic Engine Parts 5.2.1 Inspecting the cylinder head The cylinder head is subjected to very severe operating conditions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts.

  • Page 114: Valve Seat Correction Procedure

    5. Inspection and Servicing of Basic Engine Parts 5.2.2 Valve seat correction procedure The most common method for correcting unevenness of the seat surface with a seat grinder is as follows: (1) Use a seat grinder to make the surface even. As the valve seat width will be enlarged, first use a 70 °...

  • Page 115: Intake/Exhaust Valves, Valve Guides

    5. Inspection and Servicing of Basic Engine Parts 5.2.3 Intake/exhaust valves, valve guides (1) Wearing and corrosion of valve stem Replace the valve stem is excessively worn or corroded. 30 mm 60 mm Valve stem Standard Limit outside dia. Intake Ø7.955-Ø7.975 Ø7.90 Exhaust...
  • Page 116 5. Inspection and Servicing of Basic Engine Parts (4) Valve guide 1) Measuring inside diameter of valve guide. Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit. Standard Limit Intake Ø8.010-Ø8.025 Ø8.2 Valve guide inside dia.

  • Page 117: Valve Springs

    5. Inspection and Servicing of Basic Engine Parts 5.2.4 Valve springs (1) Checking valve springs 1) Check the spring for scratches or corrosion. 2) Measure the free length of the spring. Free length (Valve spring) 3) Measure inclination. Inclination Square gauge (Valve spring) 4) Measure spring tension.

  • Page 118: Assembling The Cylinder Head

    5. Inspection and Servicing of Basic Engine Parts 6) Spring retainer and spring cotter Inspect the inside face of the spring retainer, the outside surface of the spring cotter, the contact area of the spring cotter inside surface and the notch in the head of the valve stem.

  • Page 119: Intake And Exhaust Rocker Arms

    5. Inspection and Servicing of Basic Engine Parts 5.2.7 Intake and exhaust rocker arms The wear of rocker arm and rocker arm bushing may change opening/closing timing of the valve, and may in turn affect the engine performance according to the extent of the change.

  • Page 120: Piston And Piston Pins

    Be sure to check the applicable engine Oil ring model identification mark “V88” on the piston for 3JH4E series to insure use of the correct part. I.D. mark ID marks for piston Piston Piston pin 5.3.1 Piston...

  • Page 121: Piston Pin

    5. Inspection and Servicing of Basic Engine Parts (3) Removing the piston pin A floating type piston pin is used in this engine. 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...
  • Page 122 5. Inspection and Servicing of Basic Engine Parts (1) Measuring the rings. 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...
  • Page 123 5. Inspection and Servicing of Basic Engine Parts 3) After fitting the piston ring, make sure it moves easily and smoothly. 4) Stagger the piston rings at 120° intervals, making 1st piston ring sure none of them line up with the piston. 1st piston ring 2st piston ring Direction of...

  • Page 124: Connecting Rod

    5. Inspection and Servicing of Basic Engine Parts 5.4 Connecting Rod Piston pin bushing The connecting rod is made of high-strength forged carbon steel. The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing.

  • Page 125: Crank Pin Metal

    5. Inspection and Servicing of Basic Engine Parts (2) Checking the side clearance of a connecting Fit the respective crank pins to the connecting rod and check to make sure that the side clearance in the crankshaft direction is correct. Standard Limit Connecting rod...
  • Page 126 5. Inspection and Servicing of Basic Engine Parts • Other procedure of measuring crank pin oil clearance 1) Use the press gauge (Plastic gauge) for measuring the oil clearance of the crank pin. 2) Mount the connecting rod on the crank pin (tighten to specified torque).

  • Page 127: Piston Pin Bushing

    5. Inspection and Servicing of Basic Engine Parts 5.4.3 Piston pin bushing (1) Measuring piston pin clearance. 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.

  • Page 128: Crankshaft And Main Bearing

    5. Inspection and Servicing of Basic Engine Parts 5.5 Crankshaft and Main Bearing The crank pin and crank journal have been induction hardened for superior durability, and the crankshaft is Balance weight provided with for balance weights for optional balance. Crank shaft The crankshaft main veering is of the hanger type.
  • Page 129 5. Inspection and Servicing of Basic Engine Parts (3) Measuring the crank pin and journal Measure the outside diameter, roundness and taper at each crank pin and journal. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found.
  • Page 130 5. Inspection and Servicing of Basic Engine Parts (4) Checking the side gap of a crankshaft After assembling the crankshaft, tighten the main bearing cap to the specified toque, and move the crankshaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance.

  • Page 131: Main Bearing

    5. Inspection and Servicing of Basic Engine Parts 5.5.2 Main bearing Block side main (1) Inspecting the main bearing bearing metals Cap side main Check for flaking, seizure or burning of the contact bearing metals surface and replace if necessary. (2) Measuring the inner diameter of metal Tighten the cap to the specified torque and measure the inner diameter of the metal.

  • Page 132: Camshaft And Tappets

    5. Inspection and Servicing of Basic Engine Parts 5.6 Camshaft and Tappets 5.6.1 Camshaft Push rod The camshaft is normalized and the cam and bearing surfaces are surface hardened and ground. The cams have a curve that minimized the repeated shocks on the valve seats and maximizes valve seat life.
  • Page 133 5. Inspection and Servicing of Basic Engine Parts (3) Camshaft and bearing hole measurement Measure the camshaft outside diameter with a micrometer. 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.

  • Page 134: Tappets

    5. Inspection and Servicing of Basic Engine Parts 5.6.2 Tappets (1) The tappets are offset to rotate during operation and thereby prevent uneven wearing. Check the contact of each tappet and replace if excessively or unevenly worn. NOTE: When removing tappets, be sure to keep them separate for each cylinder and intake/exhaust valve.

  • Page 135: Timing Gear

    5. Inspection and Servicing of Basic Engine Parts 5.7 Timing Gear The timing gear is helical type for minimum noise and specially treated for high durability. 5.7.1 Inspecting the gears (1) Inspect the gears and replace if the teeth are damaged or worn. (2) Measure the backlash of all gears that mesh, and replace the meshing gears as a set if wear exceeds the limit.

  • Page 136: Flywheel And Housing

    5. Inspection and Servicing of Basic Engine Parts 5.8 Flywheel and Housing The function of the flywheel is through inertia, to rotate the crankshaft in a uniform and smooth manner by absorbing the turning force created during the combustion stroke of the engine, and by compensating for the decrease in turning force during the other strokes.

  • Page 137: Damper Disc And Cooling Fan

    5. Inspection and Servicing of Basic Engine Parts 5.8.2 Damper disc and cooling fan Cooling fan Damper disc Flywheel Flywheel side 6- 8.70 8.92 19.5 Torsional rigidity 219 kgf•m/rad Max. angle of torsion 7.3 x 10 Stopper torque 20.8 kgf•m...

  • Page 138: Fuel Injection Equipment

    6. FUEL INJECTION EQUIPMENT 6. FUEL INJECTION EQUIPMENT 6.1 Fuel Injection Pump/Governor Refer to the JH3E manual of separate volume for the disassembly and assembly, adjustment procedure of a fuel injection pump. 6.1.1 Fuel system diagram Fuel nozzle Fuel injection pipe Fuel return pipe Fuel injection pump Fuel filter...

  • Page 139: Fuel Injection Pump Service Data

    6. FUEL INJECTION EQUIPMENT 6.1.2 Fuel injection pump service data (1) 3JH4(B)(C)E Part code (Back No.) 729271-51450 (TM02) Adjustment SPEC ENG SPEC SERVICE STD Item Fuel valve (Valve pressure) VBG(220) (170) Nozzle type (ID mark) 159P185VAD1 DN-12SD12 Fuel injection pipe Ø...
  • Page 140 6. FUEL INJECTION EQUIPMENT (2) Adjusting fuel limit bolt at rated load Note : The figure in the blank ( ) is the indicator. 1) Adjust the fuel limit bolt to bring the rack position to the specified value (R ) with the governor At starting control lever towards the fuel increase position,...

  • Page 141: Fuel Injection Pump Structure

    6. FUEL INJECTION EQUIPMENT 6.1.3 Fuel injection pump structure (1) Component Delivery valve Plunger spring Barrel Tappet Plunger Control rack Camshaft Fuel injection pump Pump flange bolt Governor Feed pump Pump flange Fuel pump drive gear Drive gear nut Don't disassemble! Pump flange bolts...
  • Page 142 6. FUEL INJECTION EQUIPMENT (2) Section of a fuel injection pump/ governor for 3JH4(B)(C)E...

  • Page 143: Removing A Fuel Injection Pump

    6. FUEL INJECTION EQUIPMENT 6.1.4 Removing a fuel injection pump The procedure to remove a fuel injection pump from the gear case is shown. [NOTICE] Be sure to remove a flange and a fuel injection pump drive gear as a pair without loosening the flange bolts.

  • Page 144: Troubleshooting Of Fuel Injection Pump

    6. FUEL INJECTION EQUIPMENT 6.1.7 Troubleshooting of fuel injection pump Complete repair means not only replacing defective parts, but finding and eliminating the cause of the trouble as well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system.
  • Page 145 6. FUEL INJECTION EQUIPMENT Fault Cause Remedy 2. Engine starts, but (1) Fuel pipe is clogged. 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.
  • Page 146 6. FUEL INJECTION EQUIPMENT Fault Cause Remedy 7. Loud knocking. (1) Injection timing is too fast or too slow. 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.

  • Page 147: Tools

    6. FUEL INJECTION EQUIPMENT 6.1.9 Tools Name of tool Shape and size Application Pump mounting scale for Yanmar tester 158090-51010 for Bosch (tester) 158090-51020 Measuring device (cam backlash) 158090-51050 Plunger insert 158090-51100 Tappet holder 158090-51200 Weight extractor 158090-51400...
  • Page 148 6. FUEL INJECTION EQUIPMENT Name of tool Shape and size Application Rack indicator 158090-51500 Rack lock screw 158090-51010 Dummy nut 158090-51520 Nozzle plate 158090-51700 Plunger gauge 121820-92540 Top clearance gauge 158090-51300 Timer extraction tool...

  • Page 149: Fuel Feed Pump

    6. FUEL INJECTION EQUIPMENT 6.2 Fuel Feed Pump The fuel feed pump pumps fuel from the fuel tank, passes it through the fuel filter element, and supplies it to the fuel injection pump. The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft.

  • Page 150: Disassembly And Reassembly Of Fuel Feed Pump

    6. FUEL INJECTION EQUIPMENT 6.2.3 Disassembly and reassembly of fuel feed pump (1) Disassembly 1) Remove the fuel feed pump mounting nut, and take the fuel feed pump off the fuel injection pump. 2) Clean the fuel feed pump assembly with fuel oil. 3) After checking the orientation of the arrow on the cover, make match marks on the upper body and cover, remove the small screw, and disassemble the cover, upper body and lower body.
  • Page 151 6. FUEL INJECTION EQUIPMENT (4) Valve contact/mounting Inlet valve Outlet valve Clean the valve seat and valve with air to remove any foreign matter. (5) Inspect the diaphragm spring and piston spring for settling and the piston for wear, and replace as necessary. NOTE: Replace parts as an assembly.

  • Page 152: Fuel Filter

    6. FUEL INJECTION EQUIPMENT 6.3 Fuel Filter Inlet from Outlet to fuel The fuel filter is installed between the fuel feed pump feed pump injection pump and fuel injection pump, and removes dirt/foreign matter from the fuel pumped from the fuel tank. The fuel filter element must be changed periodiically.

  • Page 153: Fuel Tank

    6. FUEL INJECTION EQUIPMENT 6.4 Fuel Tank A triangular 30 liter fuel tank with a 2000mm (78.7402 in.) rubber fuel hose to fit all models is available as an option. 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.

  • Page 154: Intake And Exhaust System

    7. INTAKE AND EXHAUST SYSTEM 7. INTAKE AND EXHAUST SYSTEM 7.1 Intake System Air enters in the intake silencer mounted at the end of the intake manifold, is fed to the intake manifold and Rocker arm cover then on to each cylinder. Exhaust gas goes into exhaust manifold (in the fresh water tank) mounted on the cylinder head outlet.

  • Page 155: Diaphragm Assy Inspection

    7. INTAKE AND EXHAUST SYSTEM [NOTICE] 1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. 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.

  • Page 156: Exhaust System

    7. INTAKE AND EXHAUST SYSTEM 7.2 Exhaust System 7.2.1 Construction There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. Refer to the exterior diagrams included here. [Example assembly diagram: L-type mixing elbow.] U-type Mixing elbow Seawater...

  • Page 157: Lubrication System

    8. LUBRICATION SYSTEM 8. LUBRICATION SYSTEM 8.1 Lubrication System The lube oil in the oil pan is pumped up through the intake filter and intake piping by the lube oil pump, through the holes in the cylinder block and on to the lube oil pump, through the holes in the cylinder block and on to the discharge filter.

  • Page 158: Lube Oil Pump

    8. LUBRICATION SYSTEM 8.2 Lube Oil Pump 8.2.1 Lube oil pump construction Outer rotor The trochoid type lube oil pump is mounted in the gear case, and the inner rotor is driven by the crankshaft. 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...

  • Page 159: Lube Oil Pump Inspection

    8. LUBRICATION SYSTEM 8.2.4 Lube oil pump inspection (1) Outside clearance of outer rotor Outer rotor Insert a gap gage between a outer rotor and a pump body, Gear case and measure the clearance. 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...

  • Page 160: Lube Oil Filter

    8. LUBRICATION SYSTEM 8.3 Lube Oil Filter 8.3.1 Lube oil filter construction The lube oil filter is a full-flow paper element type. mounted to the side of the cylinder body with the filter Cylinder block bracket. 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.

  • Page 161: Rotary Waste Oil Pump (Optional)

    8. LUBRICATION SYSTEM 8.5 Rotary Waste Oil Pump (Optional) A rotary waste oil pump to pump out waste oil is available as an option. Oil inlet pipe Outside dia. 16 mm Rotary waste oil pump Delivery capacity pen one revolution 0.057 L Delivery pressure 0.15 MPa (1.5 kg/cm...

  • Page 162: Cooling Water System

    9. Cooling Water System 9. Cooling Water System 9.1 Cooling Water System The cooling water system is of the indirect seawater cooled, fresh water circulation type. The cylinders, cylinder heads and exhaust manifold are cooled with fresh water, and fresh water cooler (heat exchanger) use seawater.
  • Page 163 9. Cooling Water System Fresh water line Filler cap Coolant recovery tank Exhaust manifold Heat exchanger Water temperature Water temperature switch sender Fresh water pump Inlet for water heater From lube oil cooler (Fresh water pipe) Seawater line Mixing elbow Heat exchanger Seawater pump Seawater...

  • Page 164: Seawater Pump

    9. Cooling Water System 9.2 Seawater Pump The seawater pump is driven by a gear. 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...

  • Page 165: Seawater Pump Disassembly

    9. Cooling Water System 9.2.2 Seawater pump disassembly Refer to 2.2.4.(5). (1) Remove the rubber hose from the seawater pump outlet and then the seawater pump assembly from the gear case. (2) Remove the seawater pump cover and take out the O-ring, impeller and wear plate, (3) Remove the mechanical seal side stop ring.

  • Page 166: Fresh Water Pump

    9. Cooling Water System 9.3 Fresh Water Pump 9.3.1 Fresh water pump construction The fresh water pump is of the centrifugal (volute) type, and circulates water from the fresh water tank to the cylinders and cylinder head. The fresh water pump consists of the pump body, impeller, pump shaft, bearing unit and mechanical seal.

  • Page 167: Specifications Of Fresh Water Pump

    9. Cooling Water System 9.3.2 Specifications of fresh water pump Pulley ratio Ø120/Ø120 (crank shaft/pump shaft) Pump shaft speed(Max) 4020 min Delivery capacity 70 L/min Total head 9.3.3 Fresh water pump disassembly (1) Do not disassemble the fresh water pump. It is difficult to disassemble and, once disassembled, even more difficult to reassemble.
  • Page 168 9. Cooling Water System Measuring clearance between impeller and pump body. 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...

  • Page 169: Heat Exchanger

    Side cover in air from the overflow pipe when pressure in the fresh water system drops below the normal value. 9.4.2 Specifications of heat exchanger MODEL UNIT 3JH4E Tube dia. Ø6/Ø5 x 54 Tube surface area 0.193 Fresh water flow...

  • Page 170: Pressure Cap And Coolant Recovery Tank

    9. Cooling Water System 9.5 Pressure cap and coolant recovery tank 9.5.1 Pressure cap construction The pressure cap mounted on the fresh water filler neck incorporates a pressure control valve. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating.

  • Page 171: Replacing Filler Neck

    9. Cooling Water System 9.5.4 Replacing filler neck 1) Take out the copper tube inside the filler neck with striking a circumference with a driver and so on. When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it.

  • Page 172: Function Of The Coolant Recovery Tank

    9. Cooling Water System 9.5.5 Function of the coolant recovery tank Coolant recovery tank Filler cap The pressure valve opens to discharge steam when the steam pressure in the fresh water tank exceeds 82-109 kPa (0.84-1.11 kgf/cm This consumes water. The coolant recovery tank maintains the water level by preventing this discharge of water.

  • Page 173: Thermostat

    9. Cooling Water System 9.6 Thermostat 9.6.1 Functioning of thermostat The thermostat opens and closes a valve according to changes in the temperature of the fresh water inside the engine, controlling the volume of water flowing to the heat exchanger from the cylinder head, and in turn maintaining the temperature of the fresh water in the engine at a constant level.

  • Page 174: Bilge Pump And Bilge Strainer (Optional)

    9. Cooling Water System 9.7 Bilge Pump and Bilge Strainer (Optional) 9.7.1 Introduction (1) General Introduction Name Bilge pump Time 10 minutes Rotation direction Right (viewed from the impeller side) Weight Pump 1.4kg Negative pressure detector Diaphragm type Temperature -30°C-80°C (2) Exterior Motor assy Controller...

  • Page 175: Description

    9. Cooling Water System 9.7.2 Description (1) Characteristics 1) Discharge at lift : 0 m discharge capacity : 20 liters/min. or greater. 2) Automatic feeding height : 1 m or greater (Limit for automatic feeding height: new pump with inside parts wet, approx. 2 m) 3) Automatic feeding time : 2 5secs.

  • Page 176: Assembly Procedure

    9. Cooling Water System (7) The pump cannot be used to drain off rain water or large amounts of flood 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.
  • Page 177 9. Cooling Water System (4) Attaching the delivery nozzle (outlet) • Make a fixing hole of Ø21 or less for attaching the Fixing hole Hose nozzle. 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.

  • Page 178: Cautions For Assembling

    9. Cooling Water System 9.7.5 Cautions for Assembling Observe the following cautions for handling. • Do not use gasoline or solvents. 1) gasoline 2) ester 3) benzol 4) battery fluid 5) liquids at 70°C or greater or engine oil • Never run when there is no water in the bilge. Check to be sure that the strainer is in the water before turning on the switch.

  • Page 179: Troubleshooting

    9. Cooling Water System 9.7.6 Troubleshooting Refer to the following countermeasures for difficulties that arise. 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.

  • Page 180: Reduction And Reversing Gear

    10. Reduction and Reversing Gear 10. Reduction and Reversing Gear Marine gear KM35P and KM35A are applied to the 3JH4E series engines. Refer to chapter 7 in the service manual of 3JH3/4JH3 engines for inspection, disassembly and reassembly. Specifications Model...

  • Page 181: Remote Control (Optional)

    Remote control cable Morse 33C x 4m Morse 33C x 7m Engine stop cable Yanmar 4m Yanmar 7m (1) Remote control handle The model MT-3 remote control has been designed so that operation of the clutch (shift) and governor (throttle) can be effected with one lever.
  • Page 182 11. REMOTE CONTROL (OPTIONAL) (2) Remote control cable Use only Super Responsive Morse Control Cables These are designed specifically for use with Morse control heads. This engineered system of Worse cables, control head and engine connection kits ensures dependable, smooth operation with an absolute minimum of backlash.

  • Page 183: Remote Control Installation

    11. REMOTE CONTROL (OPTIONAL) 11.2 Remote Control Installation (1) Speed control Remote control handle Governor Clamp Control lever Cable bracket Remote control cable Remote control bracket Cable joint...
  • Page 184 11. REMOTE CONTROL (OPTIONAL) (2) Clutch control Lock nut Neutral Cable clamp Bolt Oil seal Reverse Forward Remote control head Washer Split pin Shift lever Pivot Note : ( ) Cable shift travel Bolt (M8 X 25) S1 = More than 36 mm (1.42") S2 = More than 36 mm (1.42") Clamp Shims...

  • Page 185: Remote Control Inspection

    11. REMOTE CONTROL (OPTIONAL) 11.3 Remote Control Inspection (1) When the control lever movement does not Neutral coincide with operation of the engine, check Reverse Forward the cable end stop nut to see whither or not it loose, readjust/retighten when Shim in Shim in necessary.

  • Page 186: Remote Control Adjustment

    11. REMOTE CONTROL (OPTIONAL) 11.4 Remote Control Adjustment (1) Shift lever adjustment Move the lever several times-the movement of the clutch lever on the engine from forward, neutral and reverse must coincide with the forward, neutral and reverse on the control lever. If they do not coincide, adjust the fittings as necessary (first engine side, then controller side).

  • Page 187: Electrical System

    12. Electrical System 12. 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...

  • Page 188: Wiring Diagram

    12. Electrical System 12.1.1 Wiring diagram (1) For B-type instrument panel (Color coding) Procured by customer Option Black White Blue Red / Black Alarm lamps Blue / Black Yellow / White Yellow / Black Battery 17 AC switch Yellow / Green White / Blue White / Black White / Green...
  • Page 189 12. Electrical System (2) For C-type instrument panel (Color coding) Procured by customer Option Black White Blue Red / Black Alarm lamps Blue / Black Yellow / White Battery Yellow / Black 17 AC switch Yellow / Green White / Blue White / Black White / Green diodes...

  • Page 190: Battery

    12. Electrical System 12.2 Battery Refer to 2.2.3(2) for electrolyte level and battery charge. Also refer to the service manual of the 3/4 JH3E series for other data regarding battery. (1) Battery capacity Since the battery has a minimum capacity of 12V, 80AH. it can be used for 80-120AH. Battery capacity minimum 12V-80AH...

  • Page 191: Starting Motor

    A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start. 12.3.1 Specifications YANMAR Part No. 129608-77010 HITACHI Model No. S114-817A...

  • Page 192: Structure

    12. Electrical System 12.3.3 Structure (1) Disassembly drawing Magnetic switch Internal gear Bracket Pinion Gear housing Rear cover Yoke Armature...

  • Page 193: Wiring Diameter Of A Starting Motor

    12. Electrical System (2) Structure When the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. 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...

  • Page 194: Alternator Standard, 12V/60A

    The type of alternator used in this engine is ideal for high speed engines with a wide range of engine speeds. 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)

  • Page 195: Structure

    12. Electrical System 12.4.2 Structure (1) Disassembly drawing Ball bearing Stator Rotor Front bracket Pulley Rear bracket assembly (12V60A alternator) (2) Structure Bracket Stator Rotor Rectifier assembly assembly assembly Bracket Packing Ball bearing Nut M5 Pulley Through bolt...

  • Page 196: Wiring Diagram

    12. Electrical System 12.4.3 Wiring diagram Condenser 2.2 switch Rotor Diode Stator coil coil Charge lamp 12V3.4W Battery IC regulator Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop.

  • Page 197: Inspection

    12. Electrical System 12.4.5 Inspection (1) V belt inspection Normal Defect 1) Inspect the matter whether there are not crack, stickiness and wear on the belt visually. Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set.

  • Page 198: Alternator 12V/80A (Optional)

    12. Electrical System 12.5 Alternator 12V/80A (Optional) 12.5.1 Specifications Yanmar code 119573-77201 Model of alternator LR180-03C (HITACHI) Model of IC regulator TR1Z-63 (HITACHI) Battery voltage Nominal output 12V/80A Earth polarity Negative earth Direction of rotation Clockwise (viewed from pulley end) Weight 5.4 kg...

  • Page 199: Structure

    12. Electrical System 12.5.2 Structure Disassembly drawing and Structure Brush regulator assy Stator Bearing retainer Rear cover Front cover Diode Condenser Capacitor assembly Brush regulator assembly Rotor Ball bearing Brush holder Spacer Pulley Rear cover assembly Diode assembly Stator assembly Front cover assembly Rotor assembly Brush assembly...

  • Page 200: Wiring Diagram

    12. Electrical System 12.5.3 Wiring diagram switch Diode Rotor Sub- Condenser Charge lamp coil Diode (3.2 12V3.4W Battery switch Battery Stator coil IC regulator Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop.

  • Page 201: Instrument Panel

    12. Electrical System 12.6 Instrument Panel The new type instrument panels are applied for 3JH4E series engines. 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.

  • Page 202: Warning Devices

    12. Electrical System 12.7 Warning Devices 12.7.1 Oil pressure alarm If the engine oil pressure is below 0.01-0.03MPa (0.1- Cylinder block 0.3kgf/cm , 1.42-4.26 lb/in. ), with the main switch in the ON position, the contacts of the oil pressure are closed by a spring and the lamp is illuminated through the lamp oil pressure switch...

  • Page 203: Sender Unit For Lube Oil Pressure Gauge

    12. Electrical System 12.7.2 Sender unit for lube oil pressure Cylinder block gauge The sender unit for the lube oil pressure gauge has a mounting seat for mounting on the lube oil filter bracket. 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...

  • Page 204: Cooling Water Temperature Alarm

    12. Electrical System 12.7.3 Cooling water temperature alarm A water temperature lamp and water temperature gauge, backed up by an alarm in the instrument panel, are used to monitor the temperature of the engine cooling water. A high thermal expansion material is set on the end of the water temperature unit.

  • Page 205: Air Heater (Optional)

    12. Electrical System 12.8 Air Heater (Optional) An air heater is available for warming intake air when starting in cold areas in winter. 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...

  • Page 206: Electric Engine Stopping Device (Optional)

    12. Electrical System 12.9 Electric Engine Stopping Emergency stop button Device (Optional) The electric engine stop device is fitted to the governor. The device is operated by the stop switch on the instrument panel. Governor The emergency stop button is integrated with the Stop solenoid solenoid.

  • Page 207: Service Standards

    Compression pressure (at 250 min 3.63±0.1 2.94±0.1 (37±1) (30±1) MPa (kgf/cm Engine Cooling water Capacity 2.2.1(5) (Liter) Coolant recovery tank 3JH4E with KM35P Liter 5.0±0.3 (rake angle 8 degree) 3JH4E with KM35A/ SD40 5.5±0.3 Liter Lube oil capacity (full) 2.2.1.(3) (rake angle 0 degree)

  • Page 208: Engine Body

    13. SERVICE STANDARDS 13.2 Engine Body 13.2.1 Cylinder head (1) Cylinder head Inspection item Standard Limit Reference page Combustion surface distortion 0.05 or less 0.15 5.2.1(1) Valve sink Intake 0.30-0.50 5.2.3(3) Exhaust Intake Valve seat Seat angle Deg. 5.2.1(3) Exhaust (2) Intake/exhaust valve and guide Inspection item Standard...

  • Page 209: Camshaft And Gear Train

    13. SERVICE STANDARDS 13.2.2 Camshaft and gear train (1) Camshaft Inspection item Standard Limit Reference page Side gap 0.05-0.20 0.35 5.6.1(1) Bending (1/2 the dial gage reading) 0.02 or less 0.05 5.6.1(4) Cam height 38.600-38.800 38.350 5.6.1(2) Shaft outside diameter / Metal inside diameter Bushing inside diameter 44.990-45.055 45.130...

  • Page 210: Cylinder Block

    13. SERVICE STANDARDS 13.2.3 Cylinder block (1) Cylinder block Inspection item Standard Limit Reference page Cylinder inside diameter 88.000-88.030 88.200 Roundness 5.1.5 Cylinder bore 0.01 or less 0.03 Inclination (2) Crankshaft Inspection item Standard Limit Reference page Bending (1/2 the dial gauge reading) 0.02 5.5.1(2) Pin outside diameter...
  • Page 211 13. SERVICE STANDARDS 2) Piston ring Inspection item Standard limit Reference page Ring groove width 2.060-2.075 2.170 Ring width 1.970-1.990 1.950 Top ring Side clearance 0.070-0.105 0.200 End clearance 0.200-0.400 0.490 Ring groove width 2.025-2.040 2.140 Ring width 1.970-1.990 1.950 Second ring 5.3.3(1) Side clearance...

  • Page 212: Lubricating Oil System (Trochoid Pump)

    13. SERVICE STANDARDS 13.3 Lubricating Oil System (Trochoid Pump) (1) Outside clearance of outer rotor Standard Limit Reference page 0.12-0.21 0.30 8.2.4(1) (2) Side clearance of outer rotor Standard Limit Reference page 0.02-0.07 0.12 8.2.4(2) (3) Inside clearance of inner rotor Reference Item Parts...

  • Page 213: Tightening Torque For Bolts And Nuts

    14. TIGHTENING TORQUE FOR BOLTS AND NUTS 14. TIGHTENING TORQUE FOR BOLTS AND NUTS 14.1 Main Bolt and Nut Lubricating oil application Thread diameter Torque Name (thread portion, and seat x pitch (mm) N•m(kgf-m) surface) Head bolt M10 x 1.25 Coat with lube oil 85.2-91.2 (8.69-9.30 ) Rod bolt...
  • Page 214 FAX : 31-36-5493549 YANMAR DIESEL AMERICA CORP. 101 INTERNATIONAL DRIVE ADAIRSVILLE, GA 30103, U.S.A. TEL : 1-770-877-6229 FAX : 1-770-877-9009 YANMAR ASIA (SINGAPORE) CORPORATION PTE LTD. 4 TUAS LANE, SINGAPORE 638613 TEL : 65-6861-3855 FAX : 65-6862-5195 YANMAR CO,. LTD. MARINE FACTORY...

This manual is also suitable for:

3jh4be3jh4me3jh4ce

Table of Contents

Save PDF