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Yanmar 3JH4BE, Service Manual

The Yanmar 3JH4BE Service Manual is an essential resource for boat owners and mechanics. This comprehensive manual provides step-by-step instructions, diagrams, and troubleshooting tips for maintaining and repairing your Yanmar 3JH4BE engine. Download it for free from our website, ensuring you have the information you need at your fingertips.

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6.  FUEL INJECTION EQUIPMENT

129

Fault

Cause

Remedy

2. Engine starts, but 

immediately stops.

(1) Fuel pipe is clogged.
(2) Fuel filter is clogged.

(3) Improper air- tightness of the fuel pipe 

connection. or pipe is broken and air is being 
sucked in.

(4) Insufficient fuel delivery from the feed pump

Clean
Disassemble and clean, 
or replace the element
Replace packing repair 
pipe

Repair or replace

3. Engine’s 

output is 
insufficient.

Defective 
injection timing 
and other 
failures.

(1) Knocking sounds caused by improper (too 

fast) injection timing.

(2) Engine overheats or emits large amount of 

smoke due to improper (to slow) injection 
timing.

(3) Insufficient fuel delivery from feed pump.

Inspect and adjust

Inspect and adjust

Repair or replace

Nozzle 
movements is 
defective.

(1) Case nut loose.
(2) Defective injection nozzle performance.
(3) Nozzle spring is broken.
(4) Excessive oil leaks from nozzle.

Inspect and retighten
Repair or replace nozzle 
Replace
Replace nozzle assembly

Injection pump 
is defective.

(1) Max delivery limit boll is screwed in too far.
(2) Plunger is worn
(3) Injection amount is not uniform.
(4) Injection timings are not even.
(5) The 1st and 2nd levers of the governor and 

the control rack or the injection pump are 
improperly lined up.

(6) Delivery stopper is loose.
(7) Delivery packing is defective.
(8) Delivery valve seat is defective.
(9) Delivery spring is broken.

Adjust
Replace
Adjust
Adjust
Repair

Inspect and retighten
Replace packing
Repair or replace
Replace

4. Idling is rough.

(1) Movement of control rack is defective.

1) Stiff plunger movement or sticking.
2) Rack and pinion fitting is defective.
3) Movement of governor is improper
4) Delivery stopper is too tight.

(2) Uneven injection volume.
(3) Injection timing is defective.
(4) Plunger is worn and fuel injection adjustment 

is difficult.

(5) Governor spring is too weak.
(6) Feed pump can’t feed oil at low speeds.
(7) Fuel supply is insufficient at low speeds due 

to clogging of fuel filter.

Repair or replace
Repair 
Repair
Inspect and adjust
adjust
adjust
Replace

Replace
Repair or replace
Disassemble and clean, 
or replace element

5. Engine runs at high 

speeds, but cuts out at low 
speeds.

(1) The wire or rod of the accel. is caught.
(2) Control rack is caught and can’t be moved.

Inspect and repair
Inspect and repair

6. Engine doesn’t reach max. 

speed

(1) Governor spring is broken or excessively 

worn.

(2) Injection performance or nozzle is poor

Replace

Repair or replace

Summary of Contents for 3JH4BE

Page 1: ...3JH4 B C M E M9961 03E090 Service Manual ...

Page 2: ...M9961 03E090 ...

Page 3: ...61 03E090 History of Revision Manual Name Service Manual for Marine Diesel Engine Engine Model 3JH4 B C M E Number of revision Date of revision Reason for correction Outline of correction Correction item No page Corrected by New edition January 2004 ...

Page 4: ...y of the ship s piping and propeller and not just the engine itself To get maximum performance from this engine you should completely understand its functions construction and capabilities as well as proper use and servicing 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...

Page 5: ...ce in the manual Sufficient consideration for safety is required in addition to the matters marked Especially for safety precautions in a repair or maintenance job not described in this manual receive instructions from a knowledgeable leader Safety marks used in this manual and their meanings are as follows DANGER indicates an imminent hazardous situation which if not avoided WILL result in death ...

Page 6: ...ll type accidents Clean orderly arranged place No dust mud oil or parts should be left on the floor surface Failure to Observe An unexpected accident may be caused Bright Safely Illuminated Area The work area should be well lit or illuminated in a safe manner For work in enclosed or dark areas a drop cord should be utilized The drop cord must have a wire cage to prevent bulb breakage and possible ...

Page 7: ...ap as an attaching device Do not use rope serious injury may result To hold or support an engine secure the engine to a support stand test bed or test cart designed to carry the weight of the engine Do not overload this device serious injury may result Never run an engine without being properly secured to an engine support stand test bed or test cart serious injury may result Appropriate Tools Alw...

Page 8: ...of ignition away Explosion may occur causing severe personal injury Battery Electrolyte Batteries contain sulfuric acid Do NOT allow it to come in contact with clothing skin and or eyes severe burns will result 7 WASTE MANAGEMENT Observe the following instructions with regard to hazardous waste disposal Negligence of these will have a serious impact on environmental pollution concerns 1 Waste flui...

Page 9: ...ng jewelry ties or tools may become entangled causing damage to the engine and or severe personal injury Preventing burns from scalding 1 Never open the radiator filler cap shortly after shutting the engine down Steam and hot water will spurt out and seriously burn you Allow the engine to cool down before attempt to open the filler cap 2 Securely tighten the filler cap after checking the radiator ...

Page 10: ...ed check the part installed state deformation damage roughening surface defect etc Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again Parts to be used again shall be washed and cleaned sufficiently Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump 5 Precautions for I...

Page 11: ...ar 26 2 2 5 Inspection every 1 000 hours or four years 31 2 3 Adjusting the no load maximum or minimum speed 38 2 4 Sensor Inspection 38 2 4 1 Oil pressure switch 38 2 4 2 Thermo switch 38 2 5 Thermostat inspection 39 2 6 Adjusting Operation 40 2 6 1 Preliminary Precautions 40 2 6 2 Adjusting operation procedure 40 2 6 3 Check Points and Precautions During Running 41 2 7 Long storage 42 3 Troubles...

Page 12: ... head 97 5 2 2 Valve seat correction procedure 98 5 2 3 Intake exhaust valves valve guides 99 5 2 4 Valve springs 101 5 2 5 Assembling the cylinder head 102 5 2 6 Measuring top clearance 102 5 2 7 Intake and exhaust rocker arms 103 5 2 8 Adjustment of valve clearance 103 5 3 Piston and Piston Pins 104 5 3 1 Piston 104 5 3 2 Piston pin 105 5 3 3 Piston rings 105 5 4 Connecting Rod 108 5 4 1 Inspect...

Page 13: ... 128 6 1 8 Major faults and troubleshooting 128 6 1 9 Tools 131 6 2 Fuel Feed Pump 133 6 2 1 Construction of fuel feed pump 133 6 2 2 Fuel feed pump specifications 133 6 2 3 Disassembly and reassembly of fuel feed pump 134 6 2 4 Fuel feed pump inspection 134 6 3 Fuel Filter 136 6 3 1 Fuel filter specifications 136 6 3 2 Fuel filter inspection 136 6 4 Fuel Tank 137 7 INTAKE AND EXHAUST SYSTEM 138 7...

Page 14: ...1 Fresh water pump construction 150 9 3 2 Specifications of fresh water pump 151 9 3 3 Fresh water pump disassembly 151 9 3 4 Fresh water pump inspection 151 9 4 Heat Exchanger 153 9 4 1 Heat exchanger construction 153 9 4 2 Specifications of heat exchanger 153 9 4 3 Disassembly and reassembly of the heat exchanger 153 9 4 4 Heat exchanger inspection 153 9 5 Pressure cap and coolant recovery tank ...

Page 15: ...ponents 165 11 2 Remote Control Installation 167 11 3 Remote Control Inspection 169 11 4 Remote Control Adjustment 170 12 Electrical System 171 12 1 Electrical System 171 12 1 1 Wiring diagram 172 12 2 Battery 174 12 3 Starting Motor 175 12 3 1 Specifications 175 12 3 2 Characteristics 175 12 3 3 Structure 176 12 3 4 Wiring diameter of a starting motor 177 12 4 Alternator Standard 12V 60A 178 12 4...

Page 16: ... 4 Sender unit for the cooling water temperature gauge 188 12 8 Air Heater Optional 189 12 9 Electric Engine Stopping Device Optional 190 13 SERVICE STANDARDS 191 13 1 Engine Tuning 191 13 2 Engine Body 192 13 2 1 Cylinder head 192 13 2 2 Camshaft and gear train 193 13 2 3 Cylinder block 194 13 3 Lubricating Oil System Trochoid Pump 196 14 TIGHTENING TORQUE FOR BOLTS AND NUTS 197 14 1 Main Bolt an...

Page 17: ...e on the rocker arm cover Fresh water filler cap Non Operating Side Coolant tank Heat exchanger Alternator Exhaust manifold Mixing elbow Starter motor Sea water pump Operating Side Intake silencer Intake manifold Dipstick Fuel filter Fuel injection pump Oil filter cap Fuel feed pump Lubricating oil filter Shift lever Marine gear Oil cooler ...

Page 18: ...a kgf cm2 21 6 0 5 2 12 0 05 Main power take off At flywheel side Direction of rotation Crankshaft Counter clockwise viewed from stern Propeller shaft Ahead Clockwise viewed from stern Cooling system Fresh water cooling with heat exchanger Lubrication system Complete enclosed forced lubrication Cooling water capacity fresh L quart Engine 4 5 4 8 Coolant recovery tank 0 8 0 8 Lubricating oil capaci...

Page 19: ... includes oil in oil pan and oil in channels coolers and filter 5 The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale 2 Sales condition Marine gear Reduction ratio Marine gear model No of blades Outer diameter of propeller inch Moment of propeller inertiaI GD2 N m2 kgf m2 propeller materials Engine application 2 61 KM35P 2 64 KM35A 3 A R 0 52 18 2 94...

Page 20: ...4 517 6 243 6 ROTATION MIN 100 MAX 110 65 32 1 6 7 120 4 93 2 330 480 191 2 431 4 622 6 NOTE 1 The original height of mounting blocks is shown in this drawing Engine weight will compress blocks by 4mm approx 2 The figures marked with show the dimensions with u mixing elbow or optional coupling O P T I O N A L MIXING ELBOW MOUNTING BLOCKS ID 150 MOUNTING BLOCKS ID 100 210 120 50 0 025 0 210 60 7 U ...

Page 21: ...6 243 6 ROTATION MIN 100 MAX 110 32 1 6 7 120 4 93 2 330 480 191 2 431 4 622 6 NOTE 1 The original height of mounting blocks is shown in this drawing Engine weight will compress blocks by 4mm approx 2 The figures marked with show the dimensions with u mixing elbow or optional coupling O P T I O N A L MIXING ELBOW MOUNTING BLOCKS ID 150 MOUNTING BLOCKS ID 100 210 0 025 0 210 60 7 U MIXING ELBOW 174...

Page 22: ... MAX 110 MIN 105 32 274 3 M10 X 1 5 DEPTH 14 20 DIRECTION OF ROTATION DETAIL OF PULLEY SCALE 1 3 NOTE 1 The original height of mounting blocks is shown in this drawing Engine weight will compress blocks by 4mm approx 2 The figures marked with show the dimensions with u mixing elbow or optional coupling O P T I O N A L MOUNTING BLOCKS ID 200 MOUNTING BLOCKS ID 200 0 025 0 185 538 60 143 12 X 30 206...

Page 23: ...rt C 76 3 45 Detail of part B Detail of part D Detail of part A Screw joint Union Marks of piping Flange joint Eye joint Insertion joint Drill hole Cooling fresh water piping Cooling seawater piping Lubricating oil piping Fuel oil piping To oil pan Seawater inlet 5 x t4 5 rubber hose 7 8 x t4 5 rubber hose 7 8 x t4 5 rubber hose 7 8 x t4 5 rubber hose 4 76 x t0 7 steel pipe 9 x t3 5 rubber hose 5 ...

Page 24: ... Detail of part D Screw joint Union Marks of piping Flange joint Eye joint Insertion joint Drill hole Cooling fresh water piping Cooling seawater piping Lubricating oil piping Fuel oil piping To oil pan 5 x t4 5 rubber hose 7 8 x t4 5 rubber hose 7 8 x t4 5 rubber hose 7 8 x t4 5 rubber hose 4 76 x t0 7 steel pipe 9 x t3 5 rubber hose 5 x t4 5 rubber hose Fuel high pressure pipe 9 x t3 5 rubber ho...

Page 25: ...d 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 Engine family name as assigned by EPN ARB identifying engine family group 4YDXM1 64D3N and this identifies 2 Label location YYDXM1 64D3N and th...

Page 26: ...869 A1 or A2 Cetane No 45 min b Lube oil API grade class CD 3 Do not remove the caps restricting injection quantity and engine speed 4 Perform maintenance without fail Note Inspections to be carried out by the user and by the maker are divided and set down in the List of Periodic Inspection on the operation manual and should be checked carefully EPA allows to apply Maintenance schedule for Emissio...

Page 27: ...tions 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 Whichever comes first is the guarantee period The specific emissions related parts are a Fuel injection nozzle b Fuel injection pump 19 kW 37 3000 hours or 5 years ...

Page 28: ...ter Å Check the injection timing z Check the injection spray condition z 1 Lubricating system Check the lube oil level Crankcase Marine gear Replace the lube oil Crankcase Å Å Marine gear Å Å Replace the engine lube oil filter Å Å Cooling system Seawater outlet During operation Check cooling water level Check the impeller of the cooling water pump seawater pump Å Replace the fresh water Every year...

Page 29: ...ting 2 Initial 50hrs or one month 2 Every 50hrs or one month 2 Every 250 hrs or one year 2 Every 1000 hrs or 4 years Cylinder head etc Check the leakage of water lube oil and fuel After starting Retighten all major nuts and bolts z Adjust intake exhaust valve clearance z z Remote control system etc Check adjust the remote control operation z Adjust the propeller shaft alignment z z ...

Page 30: ...sity No cooling water or diesel fuel shall be mixed Standard The level shall be between the upper and lower limit lines on the dipstick 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 NOTICE The engine oil should not be overfilled to exceed the upper limit line If engine oil is overfilled the engine may intake...

Page 31: ...r tank If the cap is tightened loosely steam can spurt out during operation 1 Checking cooling water volume Check the cooling water level in the coolant recovery tank If the water level is close to the LOW mark open the coolant recovery tank cap and replenish the coolant recovery tank with clean soft water to the FULL mark Standard The water level of the coolant recovery tank shall be between the ...

Page 32: ...t as shown below Check that the alarm lamps and buzzer are working normally when the key is turned on Battery low charge alarm When the alternator output is too low the lamp will come on When charge begins the lamp will turn off The alarm buzzer will not sound when the lamp comes on Coolant high temperature alarm When the temperature reaches the maximum 95 C 203F or higher the lamp will light Cont...

Page 33: ...kly contaminated due to the initial wear of internal parts The lubricating oil must therefore be replaced early It is easiest and most effective to drain the engine lubricating oil after operation while the engine is still warm Replace the lubricating oil filter at the same time Beware of oil splashes if extracting the Lubricating oil while it is hot 1 Remove the lubricating oil dipstick and also ...

Page 34: ...The lubricating oil must therefore be replaced early 1 Remove the cap from the filler port and attach the oil drain pump Drain off the oil 2 Fill with new lubricating oil 3 Perform a trial run of the engine and check the oil leakage 4 Adjust the tension of the alternator drive belt When there is not enough tension in the V belt it will slip and the cooling water pump will fail to supply cooling wa...

Page 35: ... head b Set the No 1 cylinder in the compression TDC Turn the crankshaft to bring the piston of the No 1 cylinder to its compression top dead center while watching the rocker arm motion the timing mark of the flywheel housing and the top mark of the flywheel Position where both the intake and exhaust valves are closed Notes The crankshaft shall be turned clockwise as seen from the gear case side T...

Page 36: ...rder of 3 cylinder engines 1 3 2 2 Valve clearance inspection and adjustment a Loosen adjusting bolts Loosen the lock nut and adjust the screw And check the valve for any inclination of valve cap entrance of dirt or wear b Measure valve clearance Insert a 0 2 mm thickness gage between the rocker arm and valve cap and adjust the valve clearance Tighten the adjusting bolt c Apply oil to the contact ...

Page 37: ...e remote control lever Never adjust the high speed limiting bolt This will void warranty 2 Adjusting the Clutch Remote Control Cable Check that the shift lever moves to the correct position when the remote control handle is put in NEUTRAL FORWARD and REVERSE position Use the NEUTRAL position as the standard for adjustment When there is deviation loosen the clamp for the remote control cable and ad...

Page 38: ...If no drain drips when the drain plug is opened loosen the air bleeding plug on the top of the fuel water separator by turning counter clockwise 2 3 times This may occur in case of the fuel water separator position is higher than the fuel oil level in the fuel tank 3 After draining be sure to tighten the air bleeding plug 4 Be sure to bleed air in the fuel system No Inspection Item 1 Drain the fue...

Page 39: ...electrolyte level in the battery Fire due to electric short circuit Make sure to turn off the battery switch or disconnect the negative cable before inspecting the electrical system Failure to do so could cause short circuiting and fires Always disconnect the Negative battery cable first before disconnecting the battery cables from battery An accidental Short circuit may cause damage fire and or p...

Page 40: ...achine unit leave in the place that the ambient temperature could drop at 15 C or less And store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature 2 Battery charge Use a battery tester or hydrometer and check the battery condition If the battery is discharged recharge it a Measurement with a battery tester When checking the battery with t...

Page 41: ...fic gravity and remaining battery charge 3 Terminals Clean if corroded or soiled 4 Mounting bracket Repair or replace it if corroded Retighten if loosened 5 Battery appearance Replace the battery if cracked or deformed Clean with fresh water if contaminated Specific gravity 20 C Dischargedquantity of electricity Remaining charge 1 28 0 100 1 26 10 90 1 24 20 80 1 23 25 75 Float Battery charge meas...

Page 42: ... new fuel filter manually turning until it comes into contact with the mounting surface and tighten it further to one turn using a filter wrench Tightening torque 20 24N m 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 a...

Page 43: ... beneath the seawater pump during engine operation check the oil seal inside the seawater pump Notice The seawater pump turns in the counterclockwise direction but the impeller must be installed by turning in the clockwise direction If the impeller has been removed for any reason and must be reassembled be very careful not to make a mistake and turn it in the wrong direction Additionally if the en...

Page 44: ...ooling water replace the filler cap and tighten it firmly To reassemble the cap align the tabs on the bottom of the cap with the notches on the filler port and turn clockwise 1 3 of a turn 6 Remove the coolant recovery tank cap and fill with coolant mix to the lower limit Replace the cap to the coolant recovery tank Coolant recovery tank capacity 0 8 L 1 7 pints Model Fresh water line Seawater lin...

Page 45: ...elbows the L type and the U type The mixing elbow is attached to the exhaust manifold The exhaust gas is mixed with seawater in the mixing elbow 1 Clean dirt and scale out of the air pass and seawater pass of the mixing elbow 2 Repair the crack or damage of the mixing elbow by welding or replace if necessary 3 Inspect the gasket and replace if necessary 8 Adjust the tension of the alternator drivi...

Page 46: ...l Sail drive Flywheel housing Starting motor Optional Starter S terminal Starter B terminal Fitting to marine gear Battery switch Battery S T O P S T A R T O N O F F 20 30 40 10 50 0 G L O W Alternator Optional Optional Optional Air heater Intake manifold C W temp sensor C W temp switch Relay Stop solenoid Earth bolt Extension wire harness Magnetic relay Safety relay ...

Page 47: ...der while turning the crankshaft clockwise and stop turning it at the same time when the fuel comes out 7 Read the timing scale on the flywheel from the hole on the flywheel housing It is standard fuel injection timing if the timing mark position meets the fuel injection timing of the below table 8 Repeat the step 5 to 7 a few times Note Injection timing check for one cylinder is generally suffici...

Page 48: ...ndard value of the above table when adjusting a new fuel nozzle of a spare part Remove carbon deposit at the nozzle hole thoroughly before measurement a Connect the fuel injection valve to the high pressure pipe of the nozzle tester b Operate the nozzle tester lever slowly and read the pressure at the moment when the fuel injection from the nozzle starts c If the measured injection pressure is low...

Page 49: ...a little before the valve opening pressure of 1 96 MPa 20kgf cm2 and check to see that oil does not drip from the tip end of the nozzle If extreme oil leak from the overflow joint exists during injection by the nozzle tester check after retightening If much oil is leaking replace the nozzle assembly Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat F O return pipe joint Valve ...

Page 50: ...move the seal peel and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thoroughly remove rust preventive oil before using the nozzle Note that a new nozzle is coated with rust preventive oil and is pasted with the seal peel to shut off outer air 4 Nozzle punch mark 3 Check the impeller of the cooling water pump seawater pump The impeller must be replaced wit...

Page 51: ...d replace if leaking d Clean any scale or rust off the outside of the tubes 2 Heat exchanger body water Leakage test a Check heat exchanger body and side cover for dirt and corrosion Replace if excessively corroded or cracked b Inspect seawater and fresh water inlets and outlets retighten any joints as necessary and clean the insides of the pipes c Check the exhaust gas intake flange and line and ...

Page 52: ...ck for oil and contaminants between the diaphragm and the cover If oil and contaminants enter into the diaphragm assembly the diaphragm will not operate as designed 2 Inspect the diaphragm rubber and spring for damage If necessary replace with new ones Notice 1 When a diaphragm is damaged pressure control inside the crankcase becomes insufficient and troubles such as combustion defect and so on oc...

Page 53: ...e 10 Adjust the propeller shaft alignment 1 The rubber tension of the flexible engine mounts is lost after many hours use This leads to a drop in vibration absorption performance and also causes centering misalignment of the propeller shaft 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 ye...

Page 54: ...eter probes in contact with the switch terminal and cylinder block while operating the engine It is abnormal if circuit is closed 2 4 2 Thermo switch Place the thermo switch in a container filled with antifreeze or oil Heat it while measuring the fluid temperature The switch is normal if the voltammeter shows continuity when the fluid temperature is 97 103 deg C Standards Unit min 1 No load maximu...

Page 55: ...ning temperature is carved on the flange 2 Normally the thermostat should be inspected every 500 hours or operation but it should be inspected before this if the cooling temperature rises abnormally or white smoke is emitted for a long time after engine starting 3 Replace the thermostat every year or 2000 hours of operation whichever comes first Valve opening Temperature deg C Full open lift Tempe...

Page 56: ...ion in the engine room 2 6 2 Adjusting operation procedure 1 Supply the fuel oil lubricating oil and cooling water Note Check the levels of the lubricating oil and cooling water again after test running for about 10 minutes and add as required 2 Start the engine and carry out idling at a low speed 700 to 900 min 1 for a few minutes 3 Run in the engine for about five minutes at the rated speed no l...

Page 57: ...he intake exhaust valves fuel injection nozzle and cylinder head 3 Do not raise the engine speed abruptly 3 Cruising load operation 1 Do not operate the engine at full load yet but raise the speed gradually for about 10 minutes until it reaches the rated speed 2 Make sure that exhaust gas color and temperature are normal 3 Check the instrument panel and see if the water temperature and oil pressur...

Page 58: ...he silencer air cleaner and electric parts with PVC Poly Vinyl Chloride cover to prevent water and dust from depositing or entrance 7 Select a well ventilated location without moisture and dust for storage 8 Perform recharging once a month during storage to compensate for self discharge 9 When storing an engine for long time run the engine periodically according to the following procedure Because ...

Page 59: ... the engine number Mentioned in the engine label Examine the machine unit name and its number in the same way When was the engine maintained last time How much period and or time has it been used after it was maintained last time What kind of problem was there on the engine last time and what kind of maintenance was dane 3 Hear the occurrence phenomenon from the operator of the engine in detail 5W...

Page 60: ... trouble in order to save time in determining their cause Begin by checking the most easily identifiable causes of difficulty Where the cause of the difficulty is not readily apparent make a thorough examination of the system from the very beginning proceeding until the point of trouble can be determined While experience is an important factor in pinpointing engine problems careful study and under...

Page 61: ...fety valve III 4 Remove and repair or replace III 5 Return to original condition I Fuel oil supply cut off III Emergency stoppage device in operation IV Miscellaneous 1 Insufficient oil in fuel oil tank 1 Loose lube oil pressure adjustment valve 2 Clogging of lube oil filter 3 Water in fuel oil tank Relay operation triggered by low lube oil pressure 5 4 Trouble with lube oil pump 3 Leakage from lu...

Page 62: ...injected Countermeasure CYLINDER OUTPUT IS UNEVEN COUNTERMEASURE Chart 2 I 1 Bleed air I 2 Disassemble and clean I 3 Replace I 4 Repair or replace I 5 Replace I 6 Tighten firmly I 7 Disassemble and clean and repair replace 1 Air in the fuel injection pump I Faulty fuel injection pump III 1 Clean IV 1 Reduce load IV 2 Adjust quantity of oil IV 3 Clean IV 4 Clean IV 5 Reduce with new oil IV 6 Clean ...

Page 63: ...iscosity of lube oil is too high 2 Damaged holding spring of pipe 1 Not enough warp in steel plate 3 Oil leakage where there is remote control 7 Worn sliding parts of forward reverse conversion valve 8 Damaged O ring V ring in oil pressure pipe 9 Low speed valve handle slips TROUBLE WITH MARINE GEAR 6 Incorrect positioning of forward reverse conversion valve I Low clutch oil pressure clutch slips ...

Page 64: ...diment to valve needle movement 1 Faulty operation of fuel pump plunger 5 Clogging of fuel filter 6 Damaged fuel cam 7 Air in fuel injection system 8 Faulty operation of adjustment rack 9 Uneven amount of fuel to cylinders 2 Damaged fuel pump plunger 3 Damaged plunger spring 4 Inaccurate assembly of fuel injection pump III Faulty operation of governor IV Miscellaneous 3 Sticking of governor sleeve...

Page 65: ...pressure I 2 Replace I 3 Disassemble and lap I 4 Disassemble and repair II 1 Delay injection timing II 2 Adjust standard injection pressure 1 Low injection pressure 1 Early fuel injection III Excessive quantity of fuel injected each time IV Miscellaneous 1 Excessive quantity of fuel is ejected from fuel pump 4 Poor quality fuel oil KNOCKING I Faulty fuel injection valve 1 Insufficient cooling wate...

Page 66: ...n pump 3 Plunger sticks 4 Oil leakage from exhaust valve 5 Air inside pump 6 Damaged exhaust valve spring 1 Worn plunger 2 Damaged plunger spring STARTING TROUBLE I Pinion gears do not mesh II 1 Tighten II 2 Repair using sandpaper II 3 Replace II 4 Repair using sandpaper Type 500 600 II 5 Replace II 6 Undercut and repair or replace II 7 Replace II 8 Replace with thicker or shorter wire II 9 Charge...

Page 67: ...V Leakage of pressurized gas from inside cylinder 3 Worn upper part of cylinder liner 4 Worn piston ring 5 Sticking of piston ring INSUFFICIENT POWER OUTPUT I Amount of oil supply from fuel injection pump inadequate 1 Worn plunger 6 Inaccurate positioning of adjustment rack 7 Clogging of fuel filter 8 Clogging of fuel oil pipe 9 Damaged valve spring 10 Faulty supply pump 2 Sticking of plunger 3 Oi...

Page 68: ...ghten safety valve III 6 Change lube oil III 7 Add lube oil III 8 Replace 1 Cooling water temperature has risen 2 Overloading 3 Faulty lube oil temperature adjustment valve IV Lube oil temperature is too high I Abnormal noise 1 Loose flywheel installment bolt 2 Loose crank pin bearing bolt 3 Worn crank pin metal 4 Faulty gear meshing II Low fuel oil pressure 1 Loose pressure adjustment 1 Clogged l...

Page 69: ...iming is incorrect 1 The drive gear or belt connections are incorrect 2 The injection pump is incorrectly installed on the engine 3 The roller holder assembly s roller or pin is worn excessively 4 The plunger is worn excessively Repair Repair and adjust injection timing Replace the assembly Replace the distributor assembly 3 The nozzle does not operate 1 The nozzle or nozzle holder is functioning ...

Page 70: ...e delivery valve spring is broken 10 The delivery valve is not sliding properly 11 The nozzle or the nozzle holder is not functioning properly 12 The injection timing is incorrect Clean or replace Inspect and repair Inspect and repair Replace Replace the distributor assembly Replace Repair or replace Repair or replace Replace Repair or replace Inspect and then repair or replace Readjust Insufficie...

Page 71: ... is not smooth Readjust or replace Repair or replace Idling is unstable 1 The injection quantities are not uniform the delivery valve is not operating properly 2 The governor s idling adjustment is improperly adjusted 3 The plunger is worn 4 The plunger spring IS broken 5 The rubber damper is worn 6 The governor lever shaft pin is worn excessively 7 The feed pump blades are not operating properly ...

Page 72: ...iagnose presence of any abnormality in the engine 1 Compression pressure measurement method 1 After warming up the engine remove the fuel injection pipe and valves from the cylinder to be measured 2 Crank the engine before installing the compression gage adapter a Perform cranking with the stop handle at the stop position no injection state b See 12 2 18 in Chapter 12 for the compression gage and ...

Page 73: ...lve timing Incorrect valve clearance Adjust the valve clearance See 3 5 in Chapter 3 4 Cylinder head gasket Gas leak from gasket Replace the gasket Retighten the cylinder head bolts to the specified torque See 4 2 2 12 in Chapter 4 5 Intake exhaust vale Valve seat Gas leak due to worn valve seat or foreign matter trapping Sticking valve Lap the valve seat See 4 2 6 in Chapter 4 Replace the intake ...

Page 74: ...nd lube oil Close the Kingston cock 2 Reassembly Sufficiently clean and inspect all parls to be assembled Coat sliding and rotating parts with new engine oil when assembling Replace all gaskets and O rings Use a liquid packing agent as necessary to prevent oil water leaks Check the oil and thrust clearances etc of parts when assembling Make sure you use the correct bolt nut washer Tighten main bol...

Page 75: ...lowing 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 Wrench Size 22 x 24 Screwdriver Steel hammer Local supply ...

Page 76: ...Reassembly 60 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: ...Name of tool Illustration Remarks Lead rod Local supply File Local supply 1set Rod spanner for hexagon socket head screws Local supply Size 6 mm 8 mm 10 mm Stariing Pliers Hole type Shaft type Local supply S 0 H Shaft type S Hole type ...

Page 78: ...on pin insertion extraction tool Connecting rod small end bushing insertion extraction tool Intake and exhaust valve insertion extraction tool Lubricating oil No 2 filter case remover 20 12 25 80 Piston pin extractor Extraction of piston pin Insertion of piston pin 20 80 Extraction 20 7 5 11 75 ...

Page 79: ...ame 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 Local supply Removing the coupling ...

Page 80: ...arks Press tool 1 for filler neck Press tool 2 for filler neck copper tube Stem seal insertion for inserting stem seal Tool 1 25 27 5 35 5 40 89 2 1 105 30 30 170 24 2 28 30 Tool 2 Chamfer mm d1 16 2 22 13 5 18 8 65 4 d2 d3 L1 L2 L3 L2 L1 d1 d2 L2 L1 L3 d1 d2 d3 ...

Page 81: ... 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 cm2 ...

Page 82: ...Solvent less type silicone base sealant applicable to high temperature areas 50 C to 250 C Three Bond TB1212 100g Silicone base non fluid type thick application possible Adhesive Three Bond TB1401 200g Prevention of loose bolts gas leakage and corrosion Torque required to loosen bolt 10 to 20 larger than tightening torque Lock tight SUPER TB1324 50g Excellent adhesive strength locks bolt semi perm...

Page 83: ...with new remover mixture Neutralize used mixture and then dispose of it To judge cleaning performance of mixture put pH test paper into mixture If test paper turns red remover mixture is still effective Neutralizer caustic soda 1 box 2 kg 4 neutralizers pH test paper Antirust Add antirust to fresh water system Then operate engine for approximately 5 minutes Antirust will be effective for 6 months ...

Page 84: ...tionally Three Bond TB1104 gray or Three Bond TB1102 yellow is used for paper packing though single use of one of these bounds is not effective 4 If conventional packing is used do not use liquid packing Items Usual Contents Features and application Cleaning agent for turbocharger 4L x 4 Special cleaning agent that requires no water specially designed for blower of turbocharger and inter cooler 18...

Page 85: ...c stand Keeps the dial gauge firmly in position thereby permitting it to be used at various angles 4 Micrometer Measures the outer diameter of the crank shaft piston piston pin etc 5 Cylinder gauge Measure the inner diameter of the cylinder liner and rod metal 6 Vernier calipers Measures various outer diameters thicknesses and widths 7 Depth micrometer Measures sinking of valves 8 Square Measures ...

Page 86: ... for leakage in the fresh water system 13 Battery current tester Checks density of antifreeze and charging condition of battery fluid 14 Nozzle tester Checks the shape and pressure of spray emitted from the fuel injection valve at the time of injection 15 Digital thermostat Measures temperature of various parts abcdefghijklmn abcdefghijklmn abcdefghijklmn abcdefghijklmn abcdefghijklmn abcdefghijkl...

Page 87: ...ctor mark which is placed on the exterior of the revolving shaft High pressure fuel pipe clamp type Measures rotation speed without reference to revolving shaft center or the exterior of the revol 17 Circuit tester Measures the resistance voltage and continuity of the electric circuit 18 Compression gauge Measures the pressure of the compression Revolving shaft Reflection mark Gauge set code No TO...

Page 88: ...e and remove it from the engine base Leave the flexible mount attached to the engine base Disassembling an engine in a workshop 1 Drain cooling water 1 Open a seawater drain cock to drain the seawater 2 Open a drain cock on the cylinder body to drain the fresh water from the cylinder head and cylinder body 3 Open a fresh water drain cock on the lower part of the coolant tank to drain the fresh wat...

Page 89: ...pump and fuel nozzle fuel filter 2 Remove the fuel filter 5 Removing the intake silencer 1 Remove the breather hose attached to the intake silencer rocker arm cover 2 Remove the intake silencer from intake manifold Fuel nozzle Air bleeding bolt To fuel tank Fuel filter Fuel injection pump Fuel feed pump Removing intake silencer Intake silencer Clamp Clamp Clamp Clamp Breather hose Rocker arm cover...

Page 90: ...the starting motor from the flywheel housing 8 Removing the alternator 1 Loosen the alternator adjuster bolt and remove the V belt 2 Removing the adjuster from the fresh water pump and remove the alternator from the gear case with distance piece L type mixing elbow Gasket Seawater Exhaust manifold Removing starting motor Flywheel housing Starting motor Fresh water pump Adjuster Adjuster bolt Alter...

Page 91: ... cooler lube oil cooler fresh water pump 10 Removing the heat exchanger exhaust manifold fresh water tank unit Remove the heat exchanger and gasket packing 11 Removing the seawater pump 1 Pull out the bearing mounts receptacles from the seawater pump mounting side and from the opposite side of the gear case 2 Remove the seawater pump Seawater pipe Seawater inlet Seawater pump Heat exchanger Mixing...

Page 92: ...osen the cap nuts on both ends of the fuel injection pipe and remove the fuel injection pipe 3 Remove the fuel return pipe fuel nozzle fuel oil filter 14 Removing the intake manifold Remove the intake manifold and gasket 15 Removing the fresh water pump Remove the fresh water pump and gasket Lube oil filter and cooler Cylinder block Fresh water To fresh water pump Clamp Lube oil cooler Lube oil co...

Page 93: ...ange 18 Removing the rocker arm shaft assembly 1 Remove the rocker arm cover 2 Remove the bolts s for the rocker arm shaft support and remove the entire rocker arm shaft assembly 3 Pull out the push rods 19 Removing the cylinder head 1 Loosen the cylinder head bolts with a torque wrench and remove the cylinder head 2 Remove the cylinder head gasket 20 Removing the marine gearbox Loosen the bolts f...

Page 94: ...emoving the oil pan Remove the oil pan and spacer 25 Removing the lube oil inlet pipe Remove the lube oil inlet pipe and gasket 26 Removing the gear case Loosen the gear case bolts and remove the gear case from the gear case flange 27 Removing the lube oil pump Remove the lube oil pump from the gear case Bolt Washer Crankshaft V pully Gear case Oil pan Wood block Flywheel housing Gasket Gear case ...

Page 95: ...camshaft assembly from the cylinder block NOTE The camshaft gear and camshaft are shrunk fit They must be heated to 180 200 C to disassemble 30 Removing the pistons and connection rods 1 Loosen the rod bolts and remove the large end cap 2 Push the connecting rod and pull out the piston connecting rod assembly NOTE Place a tool for the piston cooling nozzle to make sure the nozzle position does not...

Page 96: ...ssembling so that it does not get out of place 32 Loosening the main bearing bolts Loosen the main bearing bolts Don t remove them 33 Turning the engine over Turn the engine over with the cylinder head mounting surface facing down NOTE Make sure that the cylinder head positioning pins on the cylinder block do not come in contact with the wood block 34 Removing the flywheel housing and oil seal cas...

Page 97: ... mounted to the standard main bearing 2 Remove the main bearing metal upper from the cylinder block 37 Removing the tappets Remove the tappets from the tappet holes in the cylinder black Precautions when disassembly 1 Be careful to keep all disassembled parts in order 2 Clear and adequate area for parts and prepare a container S 3 Prepare a cleaner and cleaning can before disassembling start Remov...

Page 98: ...nting the crankshaft 1 The crankshaft and the crankshaft gear are shrink fitted If the crankshaft and the crankshaft gear have been disassembled they have to be shrink fitted heat the crank shaft gear to 180 200 deg C in the hot oil and press fit to the crankshaft 2 Coat the crank journal part of the cylinder block and the upper main bearing metal with oil and fit the upper main bearing metal onto...

Page 99: ... the flywheel housing 1 Replace the used oil seal with new one Press fit the oil seal in the oil seal case and coat the lip of the oil seal with engine oil 2 Apply the liquid gasket on the mounting surface of the oil seal case and mount the oil seal case to the cylinder block while matching up with the cylinder block positioning pins NOTE Be careful that the liquid gasket does not protrude onto th...

Page 100: ...unting the piston and connecting rod 1 Reassemble the piston and connecting rod NOTE 1 When reassembling the piston and connecting rod make sure that the parts are assembled with the correct orientation 2 Install each piston ring on the piston with the punched manufacturer s mark facing upward 3 The piston ring joints shall be staggered at by 120 intervals Do not position the top ring joint vertic...

Page 101: ...e camshaft and the camshaft gear have been disassembled shrink fit the camshaft and the camshaft gear heat the camshaft gear to 180 220 deg C in the hot oil and press fit NOTE When mounting the camshaft and the camshaft gear be sure not to forget assembly of the thrust metal Also make sure they are assembled with the correct orientation 2 Coat the cylinder block camshaft bearings and camshaft with...

Page 102: ...ay come to the cover side 3 Confirm that the rotor rotates smoothly 13 Mounting the gear case cover 1 Replace the used oil seal with new one Coat the inside and outside of the oil seals with engine oil and press fit it into the gear case cover 2 Apply the liquid gasket to the gear case cover Position the two knock pins and tighten the bolts of the gear case cover NOTE Trim the liquid gasket if it ...

Page 103: ...ng with the oil pan 5 Mount the dipstick and dipstick guide 16 Mounting the crankshaft V pulley 1 Coat the oil seal with oil 2 Make sure to wipe off oil on the taper surface 3 Tighten to the specified torque 17 Mounting the engine mounting feet and turning the engine upright 1 Mount the engine mounting feet 2 Turn the engine upright Oil pan is the bottom side 18 Mounting the flywheel 1 Coat the fl...

Page 104: ...rance 21 Mounting the rocker arm shaft assembly and pushrods 1 Fit the pushrod to the tappet 2 Coat the top of the pushrod and the adjusting screw of the rocker arm with engine oil Mount the rocker arm shaft assembly to the cylinder head Apply lube oil to the screw and lock nut 3 Adjust valve clearance 4 Coat the rocker arm and valve spring with engine oil and mount the rocker arm cover Tightening...

Page 105: ...rotector to the nozzle tip Mount the fuel injection nozzle to the cylinder head 2 Tighten the fuel nozzle retainer bolt to the specified torque Do not apply lube oil to the bolt 24 Mounting the fresh water pump 1 Thoroughly coat both sides of the gasket with adhesive 2 Replace the O ring for the connecting part of the pump which is inserted in the cylinder block and tighten the fresh water pump to...

Page 106: ...d tighten the lube oil cooler nut 3 Mount the fresh water pipes cylinder block lube oil cooler lube oil cooler fresh water pump 4 Mount the lube oil filter with the tool of the filter case remover 28 Mounting the seawater pump 1 Mount the seawater pump assembly and gasket to the gear case 2 Lightly tap the gear case side bearing rest with a wood hammer and tighten the bolts 29 Mounting the heal ex...

Page 107: ... the cooing seawater pipe rubber hose with the hose clips heat exchanger mixing elbow 34 Mounting the intake silencer 1 Mount the intake silencer on the intake manifold inlet coupling 2 Mount the breather hose with the hose clips intake silencer rocker arm cover 35 Mounting the fuel filter and fuel pipe 1 Mount the fuel filter 2 Mount the fuel pipe fuel feed pump fuel filter fuel filter fuel injec...

Page 108: ...the clutch case 39 Filling with cooling water 1 Open the coolant fresh water tank cap and fill with water 2 Fill with water until the level in the coolant recovery tank is between the full and low marks 40 Check fuel injection timing Refer to 2 2 5 1 in chapter 2 41 Test Running Refer to Adjusting operation of 2 4 in chapter 2 L Engine capacity 4 5 L Coolant recovery tank capacity full 0 8 ...

Page 109: ...cted 2 Color check kit The color check test kit consists of an aerosol cleaner penetrant and developer 3 Clean the area to be inspected with the cleaner Either spray the cleaner on directly and wipe or wipe the area with a cloth moistened with cleaner 4 Spray on red penetrant After cleaning spray on the red penetrant and allow 5 10 minutes for penetration Spray on more red penetrant if it dries be...

Page 110: ...sually check the nick around the plug Thinner 3 Apply Threebond No 4 to the seat surface where the plug is to be driven in Apply over the whole outside of the plug Threebond No 4 4 Insert the plug into the hole Insert the plug so that it sits correctly 5 Place a driving tool on the cup plug and drive it in using a hammer Using the special tool drive the cup plug so that the edge of the plug is 2mm...

Page 111: ...d as follows though it is the simple method Measure cylinder diameters of the A direction and the B direction on each section of a b and c Roundness is the maximum value among those difference values Cylindricity Cylindricity is found as follows though it is the simple method Measure cylinder diameters of a b and c sections in the A direction and calculate the difference in maximum value and minim...

Page 112: ...al 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 2 Valve cylinder head Rocker arm support Rocker arm Rocker arm shaft Valve cap Cotter Spring retainer Valve spring Stem seal Valve guide Cylinder head Exhaust valve Suction valve Rocker arm cover Rocker arm spring ...

Page 113: ...agonal Measure the clearance between the straight edge and combustion surface with a feeler gauge 2 Checking for cracks in the combustion surface Remove the fuel injection nozzle intake and exhaust valve and clean the combustion surface Check for discoloration or distortion and conduct a color check test to check for any cracks 3 Checking the intake and exhaust valve seats Check the surface and wi...

Page 114: ... then grind the seat 2 Knead valve compound with oil and finish the valve seat with a lapping tool 3 Final finishing should be done with oil only Lapping tool Use a rubber cap type lapping tool for cylinders without a lapping tool groove with oil only NOTE Clean the valve and cylinder head with light oil or the equivalent after valve seat finishing is completed and make sure that there are no grin...

Page 115: ... if the valve seat contact surface is much smaller than the width of the valve seat NOTE Keep in mind the fact that the intake and discharge valve have different diameters 3 Valve sink Over long periods of use and repeated lapping combustion efficiency may drop Measure the sinking distance and replace the valve and valve seat if the valve sink exceeds the tolerance mm Valve stem outside dia Standa...

Page 116: ...n The valve guide should project 15mm from the top of the cylinder head 4 Valve stem seals The valve stem seals in the intake exhaust valve guides cannot be re used once they are removed be sure to replace them When assembling the intake exhaust valves apply an adequate quantity of engine oil on the valve stem before inserting them Exhaust stem seal is marked by yellow Intake stem seal is not mark...

Page 117: ...ler pitch painted yellow should face down cylinder head NOTE The pitch of the valve spring is not even The side with the smaller pitch yellow should face down cylinder head when assembled Valve spring Unit Standard Limit Free length A mm 44 4 43 0 Inclination B mm 1 1 Tension 1mm pressure Smaller pitch Larger pitch N mm kgf mm 26 6 35 4 2 71 3 61 Free length Valve spring Inclination Valve spring B...

Page 118: ... Use the positioning pins to line up the head gasket with the cylinder block 5 Match up the cylinder head with the head gasket and mount 5 2 6 Measuring top clearance 1 Place a high quality fuse Ø1 5mm 10mm long in three positions on the flat part of the piston head 2 Assemble the cylinder head gasket and the cylinder block and tighten the bolts in the specified order to the specified torque 3 Tur...

Page 119: ... Inspect the contact surface of the rocker arm and replace it if there is abnormal wear or flaking 5 2 8 Adjustment of valve clearance 1 Make adjustments when the engine is cool Refer to 2 2 2 5 2 Be sure that the opening and closing angles for both the intake and the exhaust valves are checked when the timing gear is disassembled The gauge on the flywheel can be read mm Standard Limit Outside dia...

Page 120: ... ring grooves are worn 2 Measure the outside diameter in the position of 22mm from the piston bottom in the right angle direction of the piston pin If the piston outside diameter exceed the limit replace the piston with new one Selective pairing of cylinder and piston Piston must be paired with cylinder according to the below table The size mark of a piston is shown on the top surface of the pisto...

Page 121: ...Piston rings There are 2 compression rings and 1 oil ring The absence of an oil ring on the piston skirt prevents oil from being kept on the thrust surface and in turn provides good lubrication Standard Limit Piston pin hole inside dia Ø26 000 26 009 Ø26 020 Piston pin outside dia Ø25 995 26 000 Ø25 965 Clearance 0 0 014 0 074 Piston pin hole A a Measure at positions a and b in directions A and B ...

Page 122: ... rings 2 The side with the manufacturer s mark should face up mm Standard Limit First piston ring Groove width 2 060 2 075 2 170 Ring width 1 970 1 990 1 950 Clearance 0 070 0 105 0 200 Second piston ring Groove width 2 025 2 040 2 140 Ring width 1 970 1 990 1 950 Clearance 0 035 0 070 0 190 Oil ring Groove width 4 015 4 030 4 130 Ring width 3 970 3 990 3 950 Clearance 0 025 0 060 0 180 mm Standar...

Page 123: ...one of them line up with the piston 5 The oil ring is provided with a coil expander The coil expander joint should be opposite staggered 180 the oil ring gap 1st piston ring 2st piston ring Oil ring 2st piston ring 120 120 120 Oil ring 1st piston ring 120 120 120 1st piston ring 2nd piston ring Oil ring Direction of piston pin Direction of side pressure Gap Joint of coil expander ...

Page 124: ... of the large and small ends Insert the measuring tool into the large and small ends of the connecting rod Measure the extent of twist and parallelism and replace if they exceed the tolerance mm Standard Limit Connecting rod twist and parallelism Less than 0 03 at 100 mm 0 08 Piston pin bushing Crank pin metal Connecting rod bolt Connecting rod Connecting rod bid end cap Twist and parallelism meas...

Page 125: ...place the crank pin metal if the oil clearance becomes about the limit dimension of the below table Correct by grinding if unevenly wear roundness exceeding the limit or insufficient outside diameter is found Also use an undersized metal if necessary NOTICE When measuring the inside diameter of the rod big end install the crank pin metal in the rod big end not to mistake the top and bottom of the ...

Page 126: ...nk pin metal and make sure that it fits tightly on the large end cap 3 When assembling the connecting rod match up the large end and large end cap number Coat the bolts with engine oil and gradually tighten them alternately to the specified torque If a torque wrench is not available make match marks on the bolt heads and large end cap before disassembling to indicate the proper torque position and...

Page 127: ...o not insert the bush on site No piston pin bush spare part is available It is included in the connecting rod assembly supplied as a spare part 5 4 4 Assembling piston and connecting rod The piston and connecting rod should be assembled so that the match mark on the connecting rod large en faced the fuel injection pump side and the combustion chamber above the piston is close to the fuel injection...

Page 128: ...he thrust load 5 5 1 Crankshaft 1 Color check after cleaning the crankshaft and replace the crank shaft if there is any cracking or considerable damage 2 Bending of the crankshaft Support the crankshaft with V blocks at both ends of the journals Measure the deflection of the center journal with a dial gauge while rotating the crankshaft to check the extent of crankshaft bending mm Crankshaft bend ...

Page 129: ...ess of the journal and crankpin metals are normal or if partial uneven wear is observed re grind the crankshaft and use an oversized metals 2 lf rust or surface roughening exists on the rear side of the metals coat it with blue or minimum Then assemble the crankpin metal to the connecting rod and tighten the rod bolt to the specified torque to check the metal for contact lf the contact surface occ...

Page 130: ... of the shaft to measure thrust clearance Replace the thrust bearing if it is worn beyond the limit Other measurement method can also be effective Insert the thickness gauge directly into the clearance between the thrust metal and crankshaft thrust face mm Standard Limit Crankshaft side gap 0 14 0 22 0 30 Side gap measurement 1 Side gap measurement 2 Cylinder block Crankshaft Thrust metal Bearing ...

Page 131: ...ng in mind 1 The lower metal cap side has no oil groove 2 The upper metal block side has an oil groove 3 Check the cylinder block alignment number 4 The FW on the cap lies on the flywheel side mm Inspection item Standard Limit Crank journal Selective pairing Journal outside diameter 49 952 49 962 49 902 Metal inside diameter 51 000 51 010 Metal thickness 1 995 2 010 Clearance 0 038 0 068 0 150 N m...

Page 132: ...shaft by the cam gear resulting in rapid wear of the en of the veering and enlargement of the side gap Therefore measure the thrust gap before disassembly As the cam gear is shrink fitted to the cam be careful when replacing the thrust bearing 2 Measure the cam height and replace the cam if it is worn beyond the limit mm Standard Limit Camshaft side gap 0 05 0 20 0 35 mm Standard Limit Cam height ...

Page 133: ...the camshaft with V blocks place a dial gauge at the central bearing areas and measure bending Replace if excessive NOTE The reading on the dial gauge is divided by two to obtain the camshaft bend mm Place Item Standard Limit Gear side Bushing I D 44 990 45 055 45 130 Camshaft O D 44 925 44 950 44 890 Oil clearance 0 040 0 130 0 240 Intermediate position Bushing I D 45 000 45 025 45 100 Camshaft O...

Page 134: ...2 Measure the outer diameter of the tappet and replace if worn beyond the limit 3 Measuring push rods Measure the length and bending of the push rods mm Standard Limit Tappet stem outside dia 11 975 11 990 11 930 Tappet guide hole inside dia cylinder block 12 000 12 018 12 045 Oil clearance 0 010 0 043 0 090 mm Standard Limit Push rod length 178 25 178 75 Push rod bend Less than 0 03 0 03 Push rod...

Page 135: ... pressure fitted into the idling gear Measure the bushing inner diameter and the outer diameter of the shaft and replace the bushing or idling gear shaft if the oil clearance exceeds the wear limit A B and C are inscribed on the end of the idling gear When assembling these marks should align with those on the cylinder block 5 7 2 Gear timing marks Match up the timing marks on each gear when assemb...

Page 136: ...e on the shaft center must be kept below the specified value for the crankshaft as the flywheel rotates with the crankshaft at high speed To achieve this the valance is adjusted by drilling holes in the side of the flywheel and the unbalanced momentum is adjusted by drilling holes in the circumference The ring gear is shrink fitted onto the circumference of the flywheel and this ring gear serves t...

Page 137: ...er disc and cooling fan Torsional rigidity 219 kgf m rad Max angle of torsion 7 3 x 10 2 rad Stopper torque 20 8 kgf m Flywheel Flywheel side Cooling fan Damper disc 6 8 70 8 92 44 47 61 5 Spline SAE 20 40 146 or less 169 8 170 2 189 928 190 000 7 1 19 5 2 6 16 mm ...

Page 138: ...rnor 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 injection pump Feed pump Fuel nozzle Fuel injection pipe Fuel return pipe Fuel filter From fuel tank Water separator To fuel tank ...

Page 139: ...n 1 200 Average injection volume Qs mm3 st 45 5 0 Rated load Pump speed No min 1 1500 Injection volume Qo mm3 st 32 5 0 75 Nonunifomity 3 Torque rise Pump speed NT min 1 Injection volume QT mm3 st Nonunifomity Hi idle Pump speed NHi min 1 1660 15 10 Injection volume QHi mm3 st 6 7 Idle Pump speed Ni min 1 400 Qi mm3 st 9 10 Nonunifomity 10 Plunger stroke mm 8 0 Plunger dia mm 8 Suction volume of d...

Page 140: ... value tighten the fuel limit bolt lock nut at that position 3 Adjusting fuel limit bolt at starting 1 Adjust the fuel limit bolt at starting to bring the rack position to the specified value Rs while keeping the pump at starting speed Ns 2 Measure fuel injection volume at starting position Rs 3 If the injection volume is at the specified value tighten the fuel limit bolt lock nut at that position...

Page 141: ...ection pump structure 1 Component Control rack Tappet Plunger spring Delivery valve Barrel Plunger Camshaft Pump flange bolt Drive gear nut Fuel pump drive gear Pump flange bolts Pump flange Feed pump Don t disassemble Fuel injection pump Governor ...

Page 142: ...6 FUEL INJECTION EQUIPMENT 126 2 Section of a fuel injection pump governor for 3JH4 B C E ...

Page 143: ...uel injection pump Leave the pump drive gear in the gear case 6 1 5 Installing a fuel injection pump NOTICE Use a new O ring on the fuel pump flange and apply grease Confirm whether the marks of the pump drive gear and the idle gear is correct 1 Turn a camshaft so that the key of the pump camshaft may almost agree in a position of the key groove of a pump drive gear 2 Insert a fuel injection pump ...

Page 144: ...o the fuel due to defective connections in the piping from the fuel tank to the fuel pump 6 Defective valve contact of feed pump 7 Piston spring of feed pump is broken 8 Inter spindle or tappets of feed pump are stuck Re supply Open Clean Disassemble and clean or replace element Repair Repair or replace Replace Repair or replace Fuel delivered to injection pump 1 Defective connection of control le...

Page 145: ...mings are not even 5 The 1st and 2nd levers of the governor and the control rack or the injection pump are improperly lined up 6 Delivery stopper is loose 7 Delivery packing is defective 8 Delivery valve seat is defective 9 Delivery spring is broken Adjust Replace Adjust Adjust Repair Inspect and retighten Replace packing Repair or replace Replace 4 Idling is rough 1 Movement of control rack is de...

Page 146: ...ssion Adjust Adjust Adjust Adjust Repair 8 Engine exhausts too much smoke When exhaust smoke is black 1 Injection timing is too fast 2 Air volume intake is insufficient 3 The amount of injection is uneven 4 Injection from nozzle is improper Adjust Inspect and repair Adjust Repair or replace When exhaust smoke is white 1 Injection timing is too slow 2 Water is mixed in fuel 3 Shortage or lube oil i...

Page 147: ...me 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: ...32 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: ...hen the engine is stopped 6 2 1 Construction of fuel feed pump 6 2 2 Fuel feed pump specifications Head 1m Discharge volume 230 cm3 min at 1500 min 1 cam discharge pressure of 0 020 MPa 0 2 kgf cm2 Closed off pressure 0 029 MPa 0 3 kgf cm2 or more at 400 min 1 cam To fuel filter Fuel feed pump From fuel tank water separator Packing 1 2 5 4 7 8 9 10 11 12 13 14 1 Bottom body 2 Piston spring 4 Diaph...

Page 150: ...ting holes are lined up do not force 5 Align the match marks on the upper body of the pump and cover and tighten the small screws evenly 6 2 4 Fuel feed pump inspection 1 Place the fuel feed pump in kerosene cover the discharge port with your finger move the priming lever and check for air bubbles Repair or replace any part which emits air bubbles 2 Attach a vinyl house to the fuel feed pump intak...

Page 151: ... mounting 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 Inlet valve Outlet valve ...

Page 152: ...ns 6 3 2 Fuel filter inspection The fuel strainer must be cleaned occasionally If there is water or foreign matter in the strainer bowl disassemble the strainer and wash with clean fuel oil to completely remove foreign matter Replace the element every 250 hours of operation Replace the filter prior to this if the filter is very dirty deformed or damaged Filtering method filter paper Filtering area...

Page 153: ...l 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 Fuel return connection Tank Level gauge Pipe joint Clamp Drain cock Cock Clamp Rubber hose 190 230 176 49 36 30 PF 1 2 477 4 82 4 7 0 623 250 362 mm 15 94 87 22 4 ...

Page 154: ...onment Therefore blowby gas reductor is adopted to JH4 series naturally aspirated engines as breather system Some of the combustion gas passes through the clearance between cylinder and piston and flows to the crankcase This is said as blowby gas While it passes into cylinder head and rocker arm cover the blowby gas mixes with splash oil and becomes oil mist blowby gas The gas passes through the b...

Page 155: ...ill occur When a diaphragm is damaged blowby is discharged from the breathing hole on the side of diaphragm cover and not reduced in the intake manifold Therefore be careful of the diaphragm trouble 2 At lubricating oil replacement or lube oil supply The amount of lubricating oil isn t to be beyond the standard upper limit in the engine horizontality the upper limit mark of the dip stick Since the...

Page 156: ...old Refer to the exterior diagrams included here Example assembly diagram L type mixing elbow 7 2 2 3Mixing elbow inspection 1 Clean dirt and scale out of the gas and cooling water lines 2 Repair crack or damage to welds or replace 3 Inspect the gasket packing and replace as necessary L type mixing elbow Gasket Seawater Exhaust manifold U type Mixing elbow Seawater Exhaust manifold ...

Page 157: ...t journal and a option of the oil is fed to the camshaft bearings Oil is sent from the gear case camshaft bearings through the holes in the cylinder block and cylinder head to the valve arm shaft to lubricate the valve arm and valves Oil is also sent from the main gallery through the intermediate gear bearing oil holes to lubricate the intermediate gear bearings and respective gears Lube oil for t...

Page 158: ...the pump rotates smoothly 4 The oil pressure control valve plug is coated with adhesive and screwed in so it cannot be disassembled These parts cannot be reused after disassembly Replace if necessary as an assembly Reassembly NOTICE Always check if the pump rotates smoothly after installation on the gear case Running the engine when the pump rotation is heavy may cause the pump to be burnt 1 Apply...

Page 159: ...der body main gallery When the pressure of lube oil entering the cylinder body main gallery exceeds the standard the control valve piston opens the bypass hole and lube oil flows back into the oil pan Outside clearance mm Standard Limit 0 12 0 21 0 30 Side clearance mm Standard Limit 0 02 0 07 0 12 Item Part Standard dimension mm Standard clearance mm Standard clearance limit mm Inside clearance o...

Page 160: ...above figure The lube oil is cooled by fresh water 8 4 2 Inspecting the lube oil cooler 1 Clean the cooling water path fresh water of the lube oil cooler to prevent the buildup of scale 2 If the rubber hose connection or welds are corroded repair or replace the cooler 3 Apply the following water pressures to the seawater path and lube oil lines to check for any leakage Repair or replace the cooler...

Page 161: ...rotary waste oil pump to pump out waste oil is available as an option Rotary waste oil pump Delivery capacity pen one revolution 0 057 L Delivery pressure 0 15 MPa 1 5 kg cm2 or below Suction head less than 1m Part No 124413 39100 Oil inlet pipe Outside dia 16 mm ...

Page 162: ... line at the cylinder head outlet and is fitted with a thermostat The thermostat is closed when the fresh water temperature is low immediately after the engine is started and during low load operation etc Then the fresh water flows to the fresh water pump inlet and is circulated inside the engine without passing through the heat exchanger When the temperature of the fresh water rises the thermosta...

Page 163: ...esh water pipe Water temperature sender Water temperature switch Exhaust manifold Heat exchanger Filler cap Fresh water pump Coolant recovery tank From lube oil cooler Inlet for water heater Seawater pipe Seawater inlet Seawater pump Heat exchanger Mixing elbow ...

Page 164: ...ty reference data Flow Min 3800 L h at pin 5 kPa 0 05 bar pout 95 kPa 0 95 bar n 3250 min 1 after 1500h duty Self priming ability Max 10 s at Suction head 0 5 m length of pipe 0 6 m n 500 min 1 Tightness test 400 kPa 4bar Impeller Flow drop Min 1500 h Max 10 after 1000h Leakage from seal Lip seal water Lip seal oil Max cm3 h 1000 h 3000 h Cover wear plate Min 3000 h Other parts Min 6000 h Seawater...

Page 165: ...nical seal and replace if the spring is damaged or the seal is corroded Also replace the mechanical seal if there is considerable water leakage during operation 3 Make sure the ball bearings rotate smoothly Replace if there is excessive play 9 2 4 Seawater pump reassembly 1 When replacing the mechanical seal coat the No 1101 oil seal and pressure fit Coat the sliding surface with a good quality si...

Page 166: ...l bearings and cannot be disassembled The totally enclosed mechanical seal spring presses the impeller seal mounted on the impeller side away from the pump body side This prevents water from leaking along the pump shaft As the impeller and pulley flanges are press fit assembled they cannot be disassembled Cylinder head Thermostat To cylinder block O ring Spacer Fresh water pump From heat exchanger...

Page 167: ...peller blade and replace if damaged or corroded or if the impeller blade is worn due to contact with pump body 3 Check the holes in the cooling water and bypass lines clean out any dirt or other foreign matter and repair as necessary 4 Replace the pump as an assembly if there is excessive water leakage due to mechanical seal or impeller seal wear or damage 5 Inspect the fresh water pump body and f...

Page 168: ...nce between impeller and pump body Measuring clearance between impeller and pump body bracket mm Standard Limit Clearance between impeller and body 0 3 1 1 1 5 Clearance between impeller and plate 15 Thickness gauge Straightedge Thickness gauge ...

Page 169: ...pipe when pressure in the fresh water system exceeds the specified value It also takes 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 9 4 3 Disassembly and reassembly of the heat exchanger 1 Remove the side covers on both sides of the cooler core and take out the cooler core and O ring s NOTE Replace the O r...

Page 170: ...essure within the fresh water system exceeds the specified value the pressure valve opens and steam is discharged through the overflow pipe When the fresh water is cooled and the pressure within the fresh water system drops below the normal value atmospheric pressure opens the vacuum valve and air is drawn in through the overflow pipe The coolant recovery tank which sill be described later keeps t...

Page 171: ...eck outside and press the filler neck into the fresh water cooler with the special tool 4 To fix the filler neck on the fresh water cooler press the small copper tube inside the filler neck with the special tool Note The top of this tube should be under the sealing surface of the filler neck for the pressure cap 5 Fit the pressure cap on the filler neck Refer to 4 2 2 for tool 1 and tool 2 Filler ...

Page 172: ...ery tank 9 5 7 Mounting the coolant recovery tank 1 The coolant recovery tank is mounted at approximately the same height as the heat exchanger fresh water tank allowable difference in height 300mm 11 8110 in or less 2 The overflow pipe should be less than 1000mm 39 3701in long and mounted so that it does not sag or bend NOTE Make sure that the overflow pipe of the coolant recovery tank is not sub...

Page 173: ... valve opens and is completely closed when the fresh water temperature reaches 81 5 C valve lifts 4mm 0 1575in sending all of the water to the heat exchanger 9 6 2 Thermostat construction The thermostat used in this engine is of the wax pellet type with a solid wax pellet located in a small chamber When the temperature of the cooling water rises the wax melts and increases in volume This expansion...

Page 174: ...p 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 Pump dimensions Length 225 mm Yoke diameter Ø61 Assembly hole diameter Ø5 3 Assembly pitch 50 x 90 mm Motor assy Inlet Strainer Outlet Green Red Red White White Controller Battery Blue ...

Page 175: ...y Be sure that the strainer is inserted in the drain water before pushing the switch If no water is being drawn up after a period of 10 seconds or more prime the pump Do not run the pump for longer than 10 seconds when no water is being drawn up 3 When the pump has not been used for a long period of time the inside of the pump will be dry and drawing ability will be lowered Before reusing clean th...

Page 176: ...ng into consideration the length of the switch cable approx 3m and its attachment point and the position of the battery Position at a 45 angle as shown in the illustration with the nozzle facing up and 50 70cm from the bottom of the boat 2 Assembling the switch Attach in a place to insure easy operation away from rainwater Connect the terminal to the battery When the cord will not reach the batter...

Page 177: ...d avoid sharp bends 6 Test operation Collect water in the bottom of the boat and check for any problems with the hose or siring After doing this connect the battery Turn on the pump switch and check to see that water is being taken in and discharged properly The pump will stop automatically when there is no water left If the inside of the pump is dry or if the water is not being drawn up initially...

Page 178: ...a longer time for the pump to operate 0 C 5 10 seconds Keep the pump in a dry place away from rain or other water Use the regulation hose do no use thin vinyl hose or hose which is not heat resistant The pump cannot be used to drain off rainwater or large quantities of flood water This pump can be operated continuously for a period of 10 minutes Do not use the pump for showering If the pump outlet...

Page 179: ...s closer to the surface of the water The pump is too high Lower the pump Position the pump so that it is 50 70cm above the bottom of the boat Pump intake is weak If intake is still faulty after priming consult your local dealer 3 Pump turns but the amount of discharge is low Clogged strainer Clean strainer Hose is broken or damaged Check for damage and repair If incorrect hose has been used replac...

Page 180: ... at continuous power Forward min 1 1232 1114 1246 1103 Direction of rotation Input shaft Counter clockwise viewed from stern Output shaft Forward Clockwise viewed from stern Reverse Counter clockwise viewed from stern Remote control Control head Single lever control Cable Morse 33 C cable travel 76 2mm Clamp YANMAR made standard accessory Cable connector YANMAR made standard accessory Output shaft...

Page 181: ...for the governor When warming up the engine to freely control the governor separately from the clutch put the lever in neutral the central position and pull the knob in the center of the control lever When the lever is returned to the neutral position the knob automatically returns to its original position and the clutch is free The governor can then be freely operated The MN type controller has b...

Page 182: ...ly 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 33C ...

Page 183: ...11 REMOTE CONTROL OPTIONAL 167 11 2 Remote Control Installation 1 Speed control Clamp Remote control cable Cable bracket Cable joint Remote control bracket Remote control handle Governor Control lever ...

Page 184: ...ehind the stop solenoid can be pushed and the engine is stopped KM35P marine gear Bolt M8 X 25 Bolt M8 X 25 Shims Stopper bolt Oil seal Lock nut Bolt Split pin Washer Shift lever Pivot Cable clamp Neutral S1 S2 Clamp To engine speed To marine gear Reverse Forward Remote control head Note Cable shift travel S1 More than 36 mm 1 42 S2 More than 36 mm 1 42 Emergency stop button Governor Stop solenoid...

Page 185: ...angle will make it difficult to turn the handle Reroute the cable to reduce the number of bends of enlarge the bending radius as much as possible to 200mm or more 3 Check for loose cable bracket clamp bolts or nuts and retighten as necessary 4 Check cable connection screw heads cable sleeves and other metal parts for rust or corrosion Clean off minor rust and wax or grease the parts Replace if the...

Page 186: ...ntrol lever all the way to full throttle several times and then return The throttle lever on the engine must lightly push against the idle switch when it is returned If it is property adjusted the knob can be easily pulled out when the lever is in the neutral position and will automatically return when the control lever is brought back to the neutral position If the control lever presses too hard ...

Page 187: ...sing Starting motor Optional Starter S terminal Starter B terminal Fitting to marine gear Battery switch Battery S T O P S T A R T O N O F F 20 30 40 10 50 0 G L O W Alternator Optional Optional Optional Air heater Intake manifold C W temp sensor C W temp switch Relay Stop solenoid Earth bolt Extension wire harness Magnetic relay Safety relay ...

Page 188: ... 24 Starter relay 25 Starter 26 Coolant high temperature switch 27 Lubricating oil low pressure switch 28 Alternator Option 29 Alternator 30 Water in sail drive seal sensor on sail drive 31 Water in sail drive seal sensor Amplifier Sail drive only 32 Battery Option 33 Battery 34 35 Alarm lamps Procured by customer diodes YW 4 5 6 7 8 10 2 1 3 WL YG WBr 9 3R R W R L Wire harness L B O P Instrument ...

Page 189: ...olant high temperature switch 27 Lubricating oil low pressure switch 28 Alternator Option 29 Alternator 30 Water in sail drive seal sensor on sail drive 31 Water in sail drive seal sensor Amplifier Sail drive only 32 Battery Option 33 Battery 34 Oil pressure sensor Option Coolant temperature sensor Option 35 Alarm lamps Procured by customer diodes YW 4 5 6 7 8 10 2 1 3 WL YG WBr 9 3R R W R L Wire ...

Page 190: ...y cause the fol lowing troubles The overall length of the wire between the battery terminal and the starter B terminal and between the battery terminal and the engine earth terminal should be determined according to the following table Note Excessive resistance in the key switch circuit between the battery and start S terminals can cause improper pinion engagement To prevent this follow the wiring...

Page 191: ...A Nominal power kW Nominal voltage V Rating sec Direction of Rotation Looking from the Pinion side Number of Pinion teeth Weight kg 1 4 12 30 Clockwise 11 3 0 No load Terminal voltage V Electric current A Revolutions min 1 11 90 MAX 2 700 MIN Load Terminal voltage V Electric current A Torque N m Revolutions min 1 8 4 250 8 3 MIN 1 000 MIN Voltage V 0 1000 2000 3000 4000 6000 5000 0 8 16 24 32 48 4...

Page 192: ...12 Electrical System 176 12 3 3 Structure 1 Disassembly drawing Magnetic switch Internal gear Bracket Pinion Gear housing Armature Yoke Rear cover ...

Page 193: ...engages the ring gear because a main contact point is closed and the main electric current flows and a pull coil is short circuited by the main contact point and it stops being charged with electricity the pinion is kept at the position by a holding coil during the start 3 When the starting switch is turned off the main contact point becomes open and the pinion clutch is returned to the stop posit...

Page 194: ...vert 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 Model of IC regulator SA A HITACHI Battery voltage 12V Nominal output 12V 60A Earth polarity Negative earth Direction of rotation viewed from pulley end Clockwise Weight 4 2 kg Rated speed 5000 min 1 Oper...

Page 195: ...mbly drawing 2 Structure 12V60A alternator Pulley Front bracket Rotor Stator Fan Ball bearing Rear bracket assembly Bracket Nut Stator assembly Rectifier assembly Rotor assembly Through bolt Nut M5 Rotative direction Ball bearing Packing Bracket Pulley ...

Page 196: ...ring the alternator stop 12 4 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure B Stator coil Diode Alternator Rotor coil S L F P E 1 IC regulator E Key switch BAT Battery Charge lamp 12V3 4W P IG L Condenser 2 2 F 0 20 100 80 60 40 Alternator speed min 1 Output current A Standard characteristics 0 2 4 6 8 10 12 14 16 18 X 103 13...

Page 197: ...ter 2 2 Visual check of wiring and check of unusual sound 1 Confirm whether wiring is right or there is no looseness of the terminal part 2 Confirm that there is no unusual sound from the alternator during the engine operation 3 Inspection of charge lamp circuit 1 Move a start switch to the position of on Confirm lighting of the charge lamp 2 Start an engine and confirm the lights out of the lamp ...

Page 198: ...TR1Z 63 HITACHI Battery voltage 12V Nominal output 12V 80A Earth polarity Negative earth Direction of rotation viewed from pulley end Clockwise Weight 5 4 kg Rated speed 5000 min 1 Operating speed 1 200 9 000 min 1 Speed for 13 5V at 20 C 1 200 min 1 or less Output current for 13 5V 75A or more 5000 min 1 Regulated voltage 14 5 0 3V at 20 C voltage gradient 0 01V C ...

Page 199: ...ring Spacer Pulley Capacitor assembly Rear cover Brush regulator assembly Brush holder Diode assembly Screw M5 x 0 8 X14 Bearing retainer Front cover assembly Stator assembly Rotor assembly Brush assembly IC regulator assembly Ball bearing Pulley nut assembly Spacer Pulley assembly Rear cover assembly Through bolt Brush set Ball bearing Rear cover Insulating bushing ...

Page 200: ...the alternator stop 12 5 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure Stator coil Diode Sub Diode Alternator Rotor coil L F E IC regulator 50 E Key switch BAT Battery Battery switch Charge lamp 12V3 4W P R L R Condenser 3 2 F 0 20 100 80 60 40 Alternator speed min 1 Output current A Standard characteristics 0 2 4 6 8 10 X 10...

Page 201: ...y switch Panel with cover foil Rubber seal B panel Moisture cap for key switch Stop button switch Coolant high temperature alarm Lubricating oil low pressure alarm Water in sail drive seal alarm Battery low charge alarm 0 10 20 30 40 50 STOP B GLOW START OFF ON Tachometer Hour meter Coolant temperature meter Lubricating oil pressure meter Key switch Panel with cover foil Rubber seal C panel Moistu...

Page 202: ...to ON position and terminals of oil pressure switch grounded Replace the circuit of panel 2 Operation of oil pressure switch Lamp illuminated when checked as described in 2 above Replace oil pressure switch Lamp not extinguished while engine running 1 Oil level low Stop engine and check oil level with dipstick Add oil 2 Oil pressure low Measure oil pressure Repair bearing wear and adjust regulator...

Page 203: ...main gallery after being fed from the lube oil cooler and passing through the oil pressure control valve Be sure to mount a vibration damper when mounting the oil pressure sender unit Lube oil pressure sender unit Part code No 119773 91650 Type Resistance switch Rated voltage DC 12V Max operating pressure 0 98MPa 10kgf cm2 Cylinder block OPTIONAL Oil pressure sender Damper Oil pressure switch VDO ...

Page 204: ...mperature gauge The water temperature sender unit has a mounting seat for mounting on the fresh water pump unit Water temperature is measured when the cooling water flows into the thermostat housing after leaving the cylinder head Operating temperature ON 97 103 deg C OFF 87 deg C or high Electric capacity DC 12V 1A Response time within 60sec Indication color Green Tightening torque 23 5 31 4N m 2...

Page 205: ...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 Parts No 129120 77501 Rated output 390W Rated current 35 5A Rated voltage DC11V 79 2 M6 x 1 terminal 4 9 60 52 22 9 52 5 50 60 79 Relay Air heater Gasket Intake manifold Wire harness ...

Page 206: ...tric engine stop device is fitted to the governor The device is operated by the stop switch on the instrument panel The emergency stop button is integrated with the solenoid When pushing the stop button the engine will shut down Emergency stop button Governor Stop solenoid O ring ...

Page 207: ...er Engine 4 5 2 2 1 5 Coolant recovery tank 0 8 6 Lube oil capacity full 3JH4E with KM35P Liter rake angle 8 degree 5 0 0 3 2 2 1 3 3JH4E with KM35A SD40 Liter rake angle 0 degree 5 5 0 3 Marine gear KM35P Liter 0 5 Marine gear KM35A Liter 0 65 7 Lubricating oil pressure MPa kgf cm2 at rated speed at low idle speed 0 39 0 54 4 5 5 0 06 0 6 or above 8 Oil pressure switch operating pressure MPa kgf ...

Page 208: ... 025 8 10 5 2 3 Valve stem outside diameter 7 955 7 975 7 90 Clearance 0 035 0 070 0 18 Exhaust Guide inside diameter 8 015 8 030 8 10 Valve stem outside diameter 7 955 7 970 7 90 Clearance 0 045 0 075 0 18 Valve guide projection from cylinder head 14 7 15 0 5 2 3 4 Valve guide driving in method Cold fitted mm Inspection item Standard Limit Reference page Free length 44 4 43 0 5 2 4 1 Inclination ...

Page 209: ...4 925 44 950 44 890 Clearance 0 040 0 130 0 240 Intermediate Bushing inside diameter 45 000 45 025 45 100 Camshaft outside diameter 44 910 44 935 44 875 Clearance 0 065 0 115 0 225 Flywheel side Bushing inside diameter 45 000 45 025 45 100 Camshaft outside diameter 44 925 44 950 44 890 Clearance 0 050 0 100 0 210 mm Inspection item Standard Limit Reference page Shaft outside diameter 45 950 45 975...

Page 210: ... 000 48 026 Metal thickness 1 492 1 500 Clearance 0 038 0 074 0 150 Crank journal Selective pairing Journal outside diameter 49 952 49 962 49 902 Metal inside diameter 51 000 51 010 Metal thickness 1 995 2 010 Clearance 0 038 0 068 0 150 mm Inspection item Standard Limit Reference page Crankshaft side gap 0 14 0 22 0 30 5 5 1 4 mm Inspection item Standard Limit Reference page Piston outside diamet...

Page 211: ...490 Oil ring Ring groove width 4 015 4 030 4 130 Ring width 3 970 3 990 3 950 Side clearance 0 025 0 060 0 180 End clearance 0 200 0 400 0 490 mm Inspection item Standard Limit Reference page Side clearance 0 20 0 40 0 55 5 4 1 2 Rod small end mm Item Standard Limit Reference page Bushing inside diameter 26 025 26 038 26 068 5 3 2 5 4 3 1 Pin outside diameter 25 995 26 000 25 965 Clearance 0 025 0...

Page 212: ...erence page 0 12 0 21 0 30 8 2 4 1 mm Standard Limit Reference page 0 02 0 07 0 12 8 2 4 2 mm Item Parts Standard Standard Limit Reference page Inside clearance of inner rotor Gear boss diameter 53 05 53 15 0 3 0 5 0 6 8 2 4 3 Rotor diameter 53 45 53 55 Width across flat clearance of inner rotor Width across flat of Gear boss 49 45 49 75 0 2 0 6 0 7 Width across flat of rotor 49 95 50 05 ...

Page 213: ...lube oil 83 2 93 2 8 48 9 50 6 Fuel pump gear nut M14 x 1 5 Coat with lube oil 78 88 8 9 7 Nozzle fastening bolt M8 x 1 25 No lube oil 24 4 28 4 2 49 2 90 8 Fuel injection pipe joint nut M12 x 1 5 No lube oil 29 4 34 4 3 00 3 51 9 Starter relay terminal nut M6 x 1 No lube oil 3 0 4 2 0 31 0 43 N m kgf m Name Screw dia x pitch mm Tightening torque Remarks Hexagon bolt t 7T and nut M6 x 1 9 8 11 8 1...

Page 214: ...21 5549 YANMAR DIESEL AMERICA CORP 101 INTERNATIONAL DRIVE ADAIRSVILLE GA 30103 U S A TEL 1 770 877 6229 FAX 1 770 877 9009 YANMAR MARINE INTERNATIONAL B V P O BOX 30112 1303 AC ALMERE NL BRUGPLEIN 11 1332 BS ALMERE DE VAART THE NETHERLANDS TEL 31 36 5493211 FAX 31 36 5493549 YANMAR ASIA SINGAPORE CORPORATION PTE LTD 4 TUAS LANE SINGAPORE 638613 TEL 65 6861 3855 FAX 65 6862 5195 ...

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