YANMAR 3JH3 4JH3 Series Marine Diesel Engine COMPLETE Workshop Repair Manual

S fRVICEMAM ωL MOD 黯 L 3dH3( 酶 )(C哩 494dH3(B)(C)

Printed in Japan HINSffi-H8009 FOREWORD This service manual has been complied lor engineers engaged in sales , service , inspection and maintenance. Accordingly , descriptions 01 the construction and lunctions 01 the engine are emphasized in this manual while items which should already be common knowledge are omitted One characteristic 01 a marine diesel engine is that its pe付。 rmance in a vessel is governed by the applicability 01 the vessel's hull construction and its steering system. Engine installation , litting out and propeller selection have a substantial effect on the performance 01 the engine and the vesse l. Moreover, when the engine runs unevenly or when trouble occurs , it is essential to check a wide range 01 operating conditions - such as installation to the hull and suitability 01 the ship's piping and propeller - and not just the engine itsell. To get maximum performance Irom this engine , you should com pletely understand its lunctions, construction and capabilities, as well as proper use and servicing Use this manual as a handy relerence in daily inspecti口 n and maintenance , and as a text lor engineering guidance. Model 4JH3E has been used lor the illustrations in this service manual , but they apply to models 3JH3E , 3JH3BE , 3J H3CE, 4J H3BE, and 4JH3CE as wel l. METRIC ALL DIMENSIONS IN MILLIMETERS UNLESSOTHERvnSESPECll在ED The contens 01 this service manual may not be copied or reproduced without permission.

MODELS 3 .J H3(B)(C) Chapter 1 GENERAL 1. Exterior Views.............. ……...…..... ………… 1-1 2. Specilications .... …..... …………1-3 3. Engine Ou tling ..... ……………..................... 1-6 4. Piping Diagrams ...........…......…………… ....... 1-10 Chapter 2 INSPECnON AND SERVICING OF BASIC ENGINE PARTS 1. Cylinder Block…..……........... ……… 2-1 2. Cylinder Head …........ .…........... …… '2-4 3. Piston and Piston Pins ..…-………E ……… 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 ……………........ ……............ ……....... 3-4 3. Disassembly, Reassembly and Inspection 01 Fuel i叫ection pump.... ………-…… 3-14 4. Adjustment 01 Fuellnjection Pump and Governor "'3-24 5. Fuel Feed Pump ………........ …………"'3-30 6. Fuel injection Nozzle ……………… 3-32 7. Troubleshooting ……........…....................……3-36 8. Tools ..... ……..……........ ……...... …"3-38 9. Fuel Filter ……………....... …………"3-40 10. Fuel Tank ……………………….................... … '3-41 11.Troubleshooting …………................ …3-42 Chapter 4 INTAKE AND EXHAUST SYSTEM 1. Intank System …...........................… _............4-1 2. Exhaust System …………........ ……..……"4-2 4I，句，』noauGG RJMRJURURJWKJW M …………" 'hhttttqG nE …… -m sh忡忡KN·……"时酬凹 s""O N叮叫叮ιJ叫吁o叶仆仆咔啊啊H川川."X』泊m…….n队们K咀eE.川川 l1.' > m阳r血陌川p~剧E阻丘且趴dm阳d恒 •. ‘、川u"HnueeLmPRC归 itlllth w ，川川门川臼OOOiγasnHae。口号vao川叶川』U』UhM』U呻H协川甲Uuuuc MLLLLR c123a4吨E Chapter 6 COOLl NG WATER SYSTEM 1. Cooling Water System ..……………...... ………6-1 2. Sea Water Pump .... ……………...…… ....6-3 3. Fresh Water Pump............ ………........ … "6-5 4. Heat Exchanrger .……..…………..……… 6-8 5. Pressure Cap and Sub Tank ........... ……..... 6-10 6. Thermostat …….................. ………… 6-12 7. Bilge pump and Bilge Strainer (Optional) … ......... 6-14 Printed in japan IflNSHI-H8009 49 4 .J H3(B)(C Chapter 7 REDUCTION AND REVERSING GEAR Marine Gear Models [KM3A) 1. Construction .....…………-……… E … ......7斗 2. Shifting Device . ..... ….... ….... ………… "7-7 3. Inspection and Servicing ........………-……..…在 12 4. Disassembly ……..........................……......... 7-20 5. Reassembly …·………..... …............ 7-25 nueronU内Mund肉，-mdaa『da守F0 7'''7'?''' ..... ..... ..... ..... ..... .... .... ···-· ···-· ···EE ---- 2····· F··· ne--- •• M ..... vn·UE-u [·· eaHHHUU --IJJl awn--u duuuhuu 内M·M-uM仆"guμ r··m· 组MHH户LV-uιWH…例……au--R喝d·· ·me4 … Mn阻nuyhm附aNUL叩 pte--: 且D町阳刚ng划由@叫川nHMAea咱mmmmm唱出oum且由ae FMCJVHEHnUEn 4E句，』内飞MA吨EG Chapter 8 REMOTE CONTROL (OPTIONAL) 1 . Remote Control System …......... ……………8-1 2. Remote Controllnstallation ……......... ……........ …'8-2 3. Remote Control Inspection ……………..…8-4 4. Remote Control Adjust ment ….... …… ....8-5 Chapter 9 ELECTRICAL SYSTEM 1. Electrical System ........................... ……… 9-1 2. Battery …………............................... ……………'9-5 3. Starter Motor .... ............. ……......... …… ............. 9-8 4. Alternator Standard , 12VJ55A …………… 9-22 5. Alternator 12V/80A (OPTIONAL) ………… "9-30 6. Instrument Panel ........ …………..…..………… .....9-40 7. Warning Devices ..……………-……… 9-42 8. Air Heater (Optional) .………..……… .......... 9-45 9. Electric type Engine Stopping Device (Optional) ...... 9-46 10.Tachometer ……………·…… "9-48 Chapter 10 DISASSEMBLY AND REASSEMBL Y 1. Disassembly and Reassembly Precautions" ..........10-1 2. Disassembly and Reassembly Tools ...... ……… 10-2 3. Disassembly and Reassembly" ……..... …...... 10-14 4. Table 01 Standard Measurements lor Maintenance … 10-35 5. Tightening torque ...........……....…........…"10-40 6. Test Running ………........................ … ..........10-41 Chapter 11 TROUBLESHOOTING 1. Troubleshooting …·…………-…........11-1

Printed jn japan IDNSID-H扳回9 CHAPTER 1 GENERAL 1. Exterior Vi ews ………………...…………… 1-1 1-1 3J H3E ..................……………….......… '1-1 1-2 4J H3E ……........ ……........ ……… "1-2 2. Specifications ....... …·……………………… '1-3 2-1 3J H3E, 3J H3BE, 3JH3CE …………....... … "1-3 2-2 4J H3E, 4J H3BE ，乱JH3CE ………·……'-1-4 2-3 Sales condition , Marine gear ........ ….......... 1-5 3. Engine OutJine ……......... ………………………1-6 3-1 3J H3E (with KM3P Marine gear) …............ 1-6 3-2 3JH3BE (with KM3A Marine gear) ........… '1-7 3-3 4J H3E (with KM3P Marine gear) ............... 1-8 3-4 4J H3BE (with KM3A Marine gear) …… "1-9 4. Piping diagrams ……………..................… "1-10 4-1 3,4J H3(B)(C)E ...................…………"1-1 0

Chapter 1 GeneraI 1. Exterior Views 1. Exterior Views 1-1 3J H3E • Operation Side 十一-1 Shitt lever • Non Operation Side Fresh water pυmp Intake manifold V-belt 广一一 f 11 A ~-LJ扩 Fuel filter Fuel oil pump Oil filter cap Fuel feed pump Lube 口il filter Exhaust ma叩 fold Starter motor Sea water pump <Note>τñis illustration shows Yanmar marine gear (Model : KlV口的 when it has been attached Printed 臼 }apa.n HINSHI-Hí<<109 1-1 3.4JH3(B)(C)E

Chapter 1 General 1. ExterÍor VÍews 3.4JH3(B)(C)E 1-2 4JH3E Dipstick • Operation Side Intake manifold Fuel filter Marine gear Fuel oil pump Shift lever Oil filter cap Fuel feed pump Lube oil filter Oil Filter cap (Marine gear) • Non Operation Side V-belt Fresh water tank Fresh water pump Alternator Exhaust manifold Starter motor Sea water pump ( Note)ηlis iI1ustration shows Yanmar marine gear 仙10del : KM3P) when it has been attached 1-2 Printed in ]apan HINSIlI-HSOO9

Chapter 1 General Z Speciflcatío旧 3,4JH3(B)(C)E 2. Specifications 2-1 3J H3E, 3J H3BE, 3J H3CE Model 3JH3E 3JH3BE 3JH3CE Type Vertical 4-cycle water cooled diesel engine Combustion system Direct injection Aspirat阳n Normal aspiration Number 01 cylinders 3 Bore X stroke n内n同 84 X 90 Displacement a 1.496 Ospuetepd utfc「anltShan (KHWP/Nrppmm ) 26.5/3650 One hour rating (36/365日) output Brake mean effective kgf/cm 2 (flywheel oulpul) pressure 5.93 Piston speed m/sec 1 日 95 Continuous rali咱 ospuepeMud wcrankshaft (KHWPN/rppmrn ) 29.4/380日 (40/3800) outpot 日rake mean effective 。 621 (DIN6270A) kgflcm 2 flywheel output pressure (6.33) Piston speed m/sec 11.4 Compression ratio 17.7 Fire order 240' 240' 240' 1 • 3 - 2 - 1 Fuel injection pump YPES.CL (wilh Timer) Fuel injection timing degree 12' (b.T.D.C.) Fuel injection p用自ure kg/cm 2 2口口 :!:5 Fuel injection nozzle Hole type Direc1 ion 01 (Crankshaff) Counter-clock wise rotation viewed from stern power take off At Flywheel side Constant high temperature fresh water cooling Cooling system Fresh water : Cenlrifugal pump Sea water :Rubber impeller pump Lubrication system Forced lubrication 叫th trochoid pump Sla巾ng syslem Slarting motor DC 12V,I.2kW AC generato 12V.55A (12V80A: Oplion) Model KM3P KM3A (缸il 由响也31 can be 峰时) Type Mechanical cone clulch Mechae nlticmail tecr one clutch directly ∞民a阳n (lorque limiter no angle) Reduction rate (aheadlastern) 训 2.36/3.16 2.61且 16 3.20/3.16 2.33 归口4 2.6413.04 pro阳l阳 speed (ahea曲 slem) rpm 1610/1 囚31457门却31188/1 却3 162911249 144111249 Standard propeller Marine Gear (Dia. XpitchXnumber) mm Propeller shaft dia. X Countershatt dia. mm Lubrication system Splash LubeαI pan I Tolal capacif)' E 0.35 0.45 1 Effective capacity e 0.05 口口5 Cooling system Weighl [kg[ [13[ [13J Overall length mm 755.6 752.8 545.8 Dimensions Overall width m"飞 52口 6 520.6 Overall height mn同 628.6 628.6 Engine weight without marine gear (dry) kg 186 173 Lubricating oil capacity EffecVmax z 4.411.8 7 4.9尼 1 4.9/2.1 W LK r3 Fhd qu 7' nu .一- Dr UH 1 / au A铀Y nu 内d O CJu n o AU n 。 "u gmh ntM lpwm tak a18 R11H 12· iz 、JJUUH Benb 副川N川、阳阻 1-3

Chapter 1 GeneraJ z Specifícatíons 2-2 4J H3E, 4JH3BE, 4JH3CE Engine Model Type Combustion system Aspiration Number of cylinders 80re X stroke Displacement One hour rating sOpuetpeud t/crankshan output Brake mean effective (flywheel oulpul) pressure Piston speed Continuous rating sDpuetped ut/C「ankShan outpot Brake rn8an effective (口 IN6270A) fJywheel output pressure Piston speed Compression ratio Fire order Fuel injection pump Fuel injection timing (b .T.D.C.) Fuel injection pressure Fuel injection nozzle Direction of (Crankshaft) rotation Power take off Cooling system Lubrication system Starting system Starting motor AC generato Model Type Reduclion rate (ahead/astern) PrO阴阳r speed (ahead!a创em) Standard propeller Marine Gear (Diao XpitchXnumber) Propeller shaft diao X Countershaft dia Lubrication system LL剧。il pan I Total capacity 1 Effe~~e capacity Cooling system Weight Ov erall length Dimensions Overall width Overall height Engine weight without marine gear (d叩) Lubricating oil capacity EffeCVmax mm a (KHWPNAppm m) kgflcm 2 m/sec lKHWP/Nrppmm ) kgf/cm 2 m/sec. degree kg/cm 2 M rpm mm mm e e [kg] mm mm mm kg a (Note) Rating condition: 150 - 3046 门， 1HP 斗。 7355kW 3. 4J H3(BXC)I 4JH3E 4JH3日E 4JH3CE Ve r1 icaI4-cycle water cooled diesel engine Direct injection Normal aspiration 4 84 X 9口 1.995 36.8/3650 34.6/3650 (50/3650) (47/3650) 6.18 5.81 10.95 4 1.2/38口。 38.213800 (56/3800) (5213800) 6.65 11. 4 17.7 180' 180' 180' 180' 1 ~ 3 ~ 4 • 2 ~ 1 In-line type YPES-CL (with Timer) (b.T. D.C.) 12' 220 :t 5 Hole type Counter-clock wise viewed from stern At Flywheel side Constant high temperature fresh water cooling Fresh water : Cenlrifugal pump Sea waler :Rubber impeller pump Forced lubrication with trochoid pump DC 1 凹，1.2kW 12V,55A (12V, 80A: oplion) KM3P KM3A Mechanical cone clutch Mechanical cone clutch pa川 dir，剧Iy on location (torque limiter no angle) 2.36/3.162.61/3.16 2.33/3.04 2.64/3.04 1610/1203 1457月 203 162911249 1441/1229 Splash 0.35 0.45 0.05 口口5 [13] [13] 849.6 563.1 623.6 223 5.3/1.1 副 engine instaUation angle O' 1~4 639.8 563.6 623.6 210 PnOnted in ]apan HINSHI-H8阳9

Chapter 1 General z SpecificatÍons 2-3 Sales condition , Marine gear 仁￡t…10 gear model) ←一一 3 .20 (KM3P) 3.21 (KM3A) 2.61 (KM3P) 2.64 (KM3A) 2.36 (KM3P) ~ (KM3A) Printed in Japan IIINSIlI-l!8009 No. 01 blades 3 4 3 4 3 L • 4 3, 4]H3(B)( C)E Outer diameter Moment 01 propeller Propeller Engine 01 propeller inertia (GD'kg-m') materìa!s application 二亘 ";490 至 0.23 3JH3(B)仨主豆q\ 460 主至1> 470 至 0.19 Bronze 主至s6 440 ωH3(B)E 主豆s6 450 4JH3(日)E 至 0.15 主豆 ";425 1-5

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YANMAR 3JH3 4JH3 Series Marine Diesel Engine COMPLETE Workshop Repair Manual

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