YANMAR 3JH2E 3JH2TE Marine Diesel Engine Workshop Manual
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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
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Print one or all pages of your manual
$39.99
This workshop repair service manual is a comprehensive guide for the YANMAR 3JH2E and 3JH2TE marine diesel engines. It is compatible with various operating systems including Windows 95, 98, 2000, ME, NT, XP, Vista, 7, 8, 10, Mac OS X 10.4 Tiger, Mac OS X 10.5 Leopard, and Mac OS X 10.6 Snow Leopard. Please ensure you have Adobe Acrobat Reader to view the document, which can be downloaded for free from http://get.adobe.com/reader/ if not already installed on your computer.
The manual covers the following engines:
- 1.363L 3-cylinder, vertical 4-cycle, water-cooled, normal aspiration 3JH2E diesel engine
- 1.363L 3-cylinder, vertical 4-cycle, water-cooled, exhaust gas turbocharger 3JH2TE diesel engine
The contents of the manual include:
- General information
- Basic engine
- Cylinder head/block
- Connecting rod
- Piston & piston pin
- Timing gear
- Camshaft/crankshaft
- Fuel system
- Fuel injection
- Intake system
- Turbocharger
- Exhaust system
- Lubrication system
- Cooling system
- Thermostat
- Reduction gear
- Reversing gear
- Shifting device
- Remote control system
- Electrical system
- Starter motor
- Instrument panel
- Operating instructions
- Warning device
- Tightening torque
- Disassembly & assembly
This manual features detailed exploded views, step-by-step written procedures with pictures and diagrams, and is fully printable. It is the same manual used by technicians for vehicle repairs, maintenance, and servicing.
