YANMAR 3JH2E 3JH2TE Marine Diesel Engine Service Manual

3JH2 Series 2000. 3. 10 MARINE DIESEL ENGINE SERVICE MANUAL 0000A0A1015-9112

series

Publication No. A0A1015 Page No 1 Manual Name Service Manual for Marine Diesel Engine History of Revision Engine Model : 3JH2 series Number of revision Reason for correction Corrected by Outline of correction Date of revision Correction item No. (page) 1st Apr. 2001 2nd Feb. 2003 ● Crank shaft V-pulley bolt tightening torque ● Clutch lever control cable connectlion. ● Add the model 3JH25A & 3JH30A 10-32 8-3 1-3, 10-31 Quality Assurance Dept. ● Added the standard V-pulley (material: casting iron) tightening torque and general use nuts & bolts tightening torque. ● Added the tightening torque of nut for the remote control cable connec- tion of clutch shifting lever. ● Injection timing changed. ● Added the Exterior Views ● Added the Specifieations ● Added the Engine Outiine ● Added the Pertomance Curves ● Added the Piping Diagrams ● Added the Fuel Injection Pump Sewice Data ● Added the Intake and Exhaust System figure ● Added the Lubrieation System figure ● Added the Lube Oil Filter figure ● Added theSea water line flgure ● Added the Marine Gear Models KM3P1,KM3P3,KM35P1 ● Added the Wiring diagrams 1-2-1, 1-2-2 1-3-1, 1-4-1 1-8-1 1-11-1, 1-11-2 1-14-1 3-1-1 4-1-1 5-2-1 5-6-1 6-3-1 7-29~7-56 9-4-1 Quality Assurance Dept. Printed in Japan A0A1015-0302 Printed in Japan A0A1015-0302

CONTENTS CHAPTER 1 GENERAL 1.Exterior Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.Engine Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 4.Performance Curves . . . . . . . . . . . . . . . . . . . . . . . 1-10 5.Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 CHAPTER 2 BASIC ENGINE PARTS 1.CylinderBlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 3.Piston and Piston Pins . . . . . . . . . . . . . . . . . . . . . . 2-11 4.Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 5.Crankshaft and Main Bearing . . . . . . . . . . . . . . . . 2-18 6.Camshaft and Tappets . . . . . . . . . . . . . . . . . . . . . . 2-21 7.Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 8.Flywheel and Housing . . . . . . . . . . . . . . . . . . . . . . 2-26 CHAPTER 3 FUEL INJECTION EQUIPMENT 1.Fuel Injection Pump Service Data . . . . . . . . . . . . . . 3-1 2.Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.Disassembly Reassembly and Inspection of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 4.Adjustment of Fuel Injection Pump and Governor . . 3-21 5.Fuel Feed Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 6.FuelInjection Nozzle . . . . . . . . . . . . . . . . . . . . . . . 3-29 7.Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 8.Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 9.Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 10.Fuel Tank (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 3-38 CHAPTER 4 INTAKE AND EXHAUST SYSTEM 1.Intake and Exhaust System . . . . . . . . . . . . . . . . . . 4-1 2.Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 3.Mixing Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 CHAPTER 5 LUBRICATION SYSTEM 1. Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 2.Lube Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 3.Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 4.Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . 5-8 5.Lube Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 6.Piston Cooling Nozzle . . . . . . . . . . . . . . . . . . . . . . 5-10 7.Rotary Waste Oil Pump (Optional) . . . . . . . . . . . . . 5-11 CHAPTER 6 COOLING WATER SYSTEM 1.Cooling Water System . . . . . . . . . . . . . . . . . . . . . . 6-1 2.Sea Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 3.Fresh Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 4.Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 5.Pressure Cap and Sub Tank . . . . . . . . . . . . . . . . . 6-12 6.Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 7.Kingston Cock (Optional) . . . . . . . . . . . . . . . . . . . 6-16 8.Sea Water Filter (Optional) . . . . . . . . . . . . . . . . . . 6-17 9.Bilge Pump and Bilge Strainer (Optional) . . . . . . . 6-18 CHAPTER 7 REDUCTION AND REVERSING GEAR KM3A 1.Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 2.Shifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 3.Inspection And Servicing . . . . . . . . . . . . . . . . . . . . 7-12 4.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 5.Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 KM3P1,KM3P3,KM35P1 1.Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 2.Shifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 3.Inspection And Servicing . . . . . . . . . . . . . . . . . . . . 7-40 4.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 5.Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53 CHAPTER 8 REMOTE CONTROL 1.Remote Control System . . . . . . . . . . . . . . . . . . . . . . 8-1 2.Remote Control Installation . . . . . . . . . . . . . . . . . . . 8-2 3.Remote Control Inspection . . . . . . . . . . . . . . . . . . . 8-5 4.Remote Control ADJUSTMENT . . . . . . . . . . . . . . . . 8-6 5.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 CHAPTER 9 ELECTRICAL SYSTEM 1.Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 2.Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 3.Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 4.Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 5.Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 6.Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36 7.Air Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . 9-39 8.Electric Type Engine Stop Device (Optional) . . . . . 9-40 9.Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42 10.AIternator 12V/80A(Optional) . . . . . . . . . . . . . . . . . 9-45 CHAPTER 10 DISASSEMBLY AND REASSEMBLY 1.Disassembly and Reassembly Precautions . . . . . . 10-1 2.Disassembly and Reassembly Tools . . . . . . . . . . . 10-2 3.Disassembly and Reassembly . . . . . . . . . . . . . . . . 10-9 4.Bolt/nut Tightening Torque . . . . . . . . . . . . . . . . . . 10-32 5.Test Running . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Printed in Japan A0A1015-0302 Printed in Japan A0A1015-0302

1-2-1 3JH2 Series Chapter 1 General 1. Exterior Views 1-3 3JH25A/30A With KM3P3 Operating side Operating side Fuel injection pump Air intake manifold Mist separator KM3P3 Torque limiter Dipstic (clutch side) Dipstic (engine side) Lube filter Fuel priming pump Fuel filter Fresh water pump Alternator Pressure cap Fresh water tank Exhaust manifold Mixing elbow Clutch handle Starting motor Seawater pump Printed in Japan A0A1015-0302 Printed in Japan A0A1015-0302

1-2-2 3JH2 Series Chapter 1 General 1. Exterior Views With KM3P1/ KM35P1 Operating side Operating side Fuel injection pump Air intake manifold Mist separator KM3P1 KM35P1 Dipstic (clutch side) Dipstic (engine side) Lube filter Fuel priming pump Fuel filter Fresh water pump Alternator Pressure cap Fresh water tank Exhaust manifold Mixing elbow Clutch handle Starting motor Seawater pump Printed in Japan A0A1015-0302 Printed in Japan A0A1015-0302

You're Reading a Preview

YANMAR 3JH2E 3JH2TE Marine Diesel Engine Service Manual

Description

Reviews

Q&A

Recently Viewed