Yanmar 3JH4(B)(C)(M)E Service Manual

Description

• Model List:
  • 3JH4(B)(C)(M)E

• 1. History of Revision
• 2. FOREWORD
• 3. CONTENTS
• 4. GENERAL
• 4.1. Exterior Views
• 4.2. Specifications
• 4.3. Engine Outline
• 4.4. Piping Diagrams
• 4.5. Exhaust Gas Emission Regulation
• 4.5.1. Engine identification (3JH4E)
• 4.5.2. Exhaust Gas Regulations
• 4.5.3. Guarantee Conditions for Emission Standard
• 5. Inspection and Adjustment
• 5.1. Periodic Maintenance Schedule
• 5.2. Periodic Inspection and Maintenance Procedure
• 5.2.1. Check before starting
• 5.2.2. inspection after initial 50 hours or one month operation
• 5.2.3. Inspection every 50 hours or monthly
• 5.2.4. Inspection every 250 hours or one year
• 5.2.5. Inspection every 1,000 hours or four years
• 5.3. Adjusting the no-load maximum or minimum speed
• 5.4. Sensor Inspection
• 5.4.1. Oil pressure switch
• 5.4.2. Thermo switch
• 5.5. Thermostat inspection
• 5.6. Adjusting Operation
• 5.6.1. Preliminary Precautions
• 5.6.2. Adjusting operation procedure
• 5.6.3. Check Points and Precautions During Running
• 5.7. Long storage
• 6. Troubleshooting
• 6.1. Preparation before troubleshooting
• 6.2. Quick Reference Chart for Troubleshooting
• 6.3. Troubleshooting (Concerning engine and fuel injection equipment)
• 6.4. Troubleshooting by measuring Compression Pressure
• 7. Disassembly and Reassembly
• 7.1. Disassembly and Reassembly Precautions
• 7.2. Disassembly and Reassembly Tools
• 7.2.1. General Handtools
• 7.2.2. Special Handtools
• 7.2.3. Measuring Instruments
• 7.2.4. Other material
• 7.2.5. Measuring Instruments
• 7.3. Disassembly and Reassembly
• 7.3.1. Disassembly
• 7.3.2. Reassembly
• 8. Inspection and Servicing of Basic Engine Parts
• 8.1. Cylinder Block
• 8.1.1. Inspection of parts
• 8.1.2. Cleaning of oil holes
• 8.1.3. Color check procedure
• 8.1.4. Replacement of cup plugs
• 8.1.5. Cylinder bore measurement
• 8.2. Cylinder Head
• 8.2.1. Inspecting the cylinder head
• 8.2.2. Valve seat correction procedure
• 8.2.3. Intake/exhaust valves, valve guides
• 8.2.4. Valve springs
• 8.2.5. Assembling the cylinder head
• 8.2.6. Measuring top clearance
• 8.2.7. Intake and exhaust rocker arms
• 8.2.8. Adjustment of valve clearance
• 8.3. Piston and Piston Pins
• 8.3.1. Piston
• 8.3.2. Piston pin
• 8.3.3. Piston rings
• 8.4. Connecting Rod
• 8.4.1. Inspecting the connection rod
• 8.4.2. Crank pin metal
• 8.4.3. Piston pin bushing
• 8.4.4. Assembling piston and connecting rod
• 8.5. Crankshaft and Main Bearing
• 8.5.1. Crankshaft
• 8.5.2. Main bearing
• 8.6. Camshaft and Tappets
• 8.6.1. Camshaft
• 8.6.2. Tappets
• 8.7. Timing Gear
• 8.7.1. Inspecting the gears
• 8.7.2. Gear timing marks
• 8.8. Flywheel and Housing
• 8.8.1. Position of top dead center and fuel injection timing
• 8.8.2. Damper disc and cooling fan
• 9. FUEL INJECTION EQUIPMENT
• 9.1. Fuel Injection Pump/Governor
• 9.1.1. Fuel system diagram
• 9.1.2. Fuel injection pump service data
• 9.1.3. Fuel injection pump structure
• 9.1.4. Removing a fuel injection pump
• 9.1.5. Installing a fuel injection pump
• 9.1.6. Adjusting fuel injection timing
• 9.1.7. Troubleshooting of fuel injection pump
• 9.1.8. Major faults and troubleshooting
• 9.1.9. Tools
• 9.2. Fuel Feed Pump
• 9.2.1. Construction of fuel feed pump
• 9.2.2. Fuel feed pump specifications
• 9.2.3. Disassembly and reassembly of fuel feed pump
• 9.2.4. Fuel feed pump inspection
• 9.3. Fuel Filter
• 9.3.1. Fuel filter specifications
• 9.3.2. Fuel filter inspection
• 9.4. Fuel Tank
• 10. INTAKE AND EXHAUST SYSTEM
• 10.1. Intake System
• 10.1.1. Breather system (A reductor to intake air system of blowby gas)
• 10.1.2. Diaphragm assy inspection
• 10.2. Exhaust System
• 10.2.1. Construction
• 10.2.2. ixing elbow inspection
• 11. LUBRICATION SYSTEM
• 11.1. Lubrication System
• 11.2. Lube Oil Pump
• 11.2.1. Lube oil pump construction
• 11.2.2. Specifications of lube oil pump
• 11.2.3. Lube oil pump disassembly and reassembly
• 11.2.4. Lube oil pump inspection
• 11.2.5. Oil pressure control valve construction
• 11.3. Lube Oil Filter
• 11.3.1. Lube oil filter construction
• 11.3.2. Lube oil filter replacement
• 11.4. Lube oil Cooler
• 11.4.1. Lube oil cooler construction
• 11.4.2. Inspecting the lube oil cooler
• 11.5. Rotary Waste Oil Pump (Optional)
• 12. Cooling Water System
• 12.1. Cooling Water System
• 12.2. Seawater Pump
• 12.2.1. Specifications of seawater pump
• 12.2.2. Seawater pump disassembly
• 12.2.3. Seawater pump Inspection
• 12.2.4. Seawater pump reassembly
• 12.3. Fresh Water Pump
• 12.3.1. Fresh water pump construction
• 12.3.2. Specifications of fresh water pump
• 12.3.3. Fresh water pump disassembly
• 12.3.4. Fresh water pump inspection
• 12.4. Heat Exchanger
• 12.4.1. Heat exchanger construction
• 12.4.2. Specifications of heat exchanger
• 12.4.3. Disassembly and reassembly of the heat exchanger
• 12.4.4. Heat exchanger inspection
• 12.5. Pressure cap and coolant recovery tank
• 12.5.1. Pressure cap construction
• 12.5.2. Pressure cap pressure control
• 12.5.3. Pressure cap inspection
• 12.5.4. Replacing filler neck
• 12.5.5. Function of the coolant recovery tank
• 12.5.6. Specifications of coolant recovery tank
• 12.5.7. Mounting the coolant recovery tank
• 12.5.8. Precautions on usage of the coolant recovery tank
• 12.6. Thermostat
• 12.6.1. Functioning of thermostat
• 12.6.2. Thermostat construction
• 12.6.3. Characteristics of thermostat
• 12.6.4. Thermostat inspection
• 12.6.5. Testing the thermostat
• 12.7. Bilge Pump and Bilge Strainer (Optional)
• 12.7.1. Introduction
• 12.7.2. Description
• 12.7.3. Cautions
• 12.7.4. Assembly Procedure
• 12.7.5. Cautions for Assembling
• 12.7.6. Troubleshooting
• 13. Reduction and Reversing Gear
• 14. REMOTE CONTROL (OPTIONAL)
• 14.1. Remote Control system
• 14.1.1. Construction of remote control system
• 14.1.2. Remote control device components
• 14.2. Remote Control Installation
• 14.3. Remote Control Inspection
• 14.4. Remote Control Adjustment
• 15. Electrical System
• 15.1. Electrical System
• 15.1.1. Wiring diagram
• 15.2. Battery
• 15.3. Starting Motor
• 15.3.1. Specifications
• 15.3.2. Characteristics
• 15.3.3. Structure
• 15.3.4. Wiring diameter of a starting motor
• 15.4. Alternator Standard, 12V/60A
• 15.4.1. Specifications
• 15.4.2. Structure
• 15.4.3. Wiring diagram
• 15.4.4. Standard output characteristics
• 15.4.5. Inspection
• 15.5. Alternator 12V/80A (Optional)
• 15.5.1. Specifications
• 15.5.2. Structure
• 15.5.3. Wiring diagram
• 15.5.4. Standard output characteristics
• 15.6. Instrument Panel
• 15.6.1. B-type instrument panel (optional)
• 15.6.2. C-type instrument panel
• 15.7. Warning Devices
• 15.7.1. Oil pressure alarm
• 15.7.2. Sender unit for lube oil pressure gauge
• 15.7.3. Cooling water temperature alarm
• 15.7.4. Sender unit for the cooling water temperature gauge
• 15.8. Air Heater (Optional)
• 15.9. Electric Engine Stopping Device (Optional)
• 16. SERVICE STANDARDS
• 16.1. Engine Tuning
• 16.2. Engine Body
• 16.2.1. Cylinder head
• 16.2.2. Camshaft and gear train
• 16.2.3. Cylinder block
• 16.3. Lubricating Oil System (Trochoid Pump)
• 17. TIGHTENING TORQUE FOR BOLTS AND NUTS
• 17.1. Main Bolt and Nut
• 17.2. Standard Bolts and Nuts (without lube oil)
• 18. Back cover