Yanmar 3JH3(8)E Operation Manual Download

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Summary of Contents for 3JH3(8)E

Page 1: ... is an EPA Certified Engine It meets the low emission standards set by the EPA OPERATION MANUAL California Proposition 65 Warning Diesel engine exhaust and some of its constituents are recognized by the State of California to cause cancer birth defects and other reproductive harm ...

Page 2: ... 24 3 3 Operating your Engine 25 3 3 1 Inspection Before Starting 25 3 3 2 How to Start the Engine 26 2 3 3 3 Operation 28 3 3 4 Cautions during Operation 29 3 3 5 Stopping the Engine 29 3 4 Long term Storage 30 4 MAINTENANCE INSPECTION 32 4 1 General Inspection Rules 32 4 2 List of Periodic Inspection Items 33 4 3 Periodic Inspection Items 35 4 3 1 Inspection on Initial 50 Hrs of Operation or aft...

Page 3: ... dealer or distributor Make sure this manual is transfered to subsequent owners It should be considered as a permanent part of the engine and remain so E Constant efforts are made to improve the quality and performance of Yanmar products so some details included in this Operation Manual may differ slightly from your engine If you have any questions about this please contact your Yanmar dealer or d...

Page 4: ... death or serious injury A WARNING WARNING indicates a potentially hazardous situa tion which if not avoided COULD result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This sign is also be used to alert against unsafe practices NOTICE The descriptions captioned by are particularly important cauti...

Page 5: ...ls properly Wash your hands thorougly with soap and water Never place oil or other flammable material in the engine room Install a fire extinguisher near the engine room and familiarize yourself with its use IiIiI Exhaust Gas Exhaust gas contains poisonous carbon monoxide and should not be inhaled Be sure to install ventilation ports or ventilators in the engine room and ensure good ventilation du...

Page 6: ...ou service it Turn the battery switch off If you must inspect while the engine is in operation never touch moving parts Keep your body and clothing well clear of all moving parts Scalds If extracting oil from the engine while it is still hot don t let the oil splash on you Wait until the temperature has dropped before extracting cooling water from the engine Don t let it splash on you Forbidden Mo...

Page 7: ...s be visible Please replace if damaged or lost CD 3JH3 8 C E CD 4JH3 8 C E Warning Device Labels Parts Numbers No eD Part Code No 128296 07260 120324 07350 CD AWARNING A I Iii ttil hJlt Rolatlng parI Can Cau injury T282915 07350 DANGER a1l 1 J 1 7 l1l11 t I t Fl e aIJl WI I1C T laft H o e Naver ramov th cap while th engine il 11111 hoi eHol wal r ma spurt out end burn you 1211296 07150 7 ...

Page 8: ...se size and cruising area of the boat The installation fitting and surveying of this engine all require specialized knowledge and engineering skills Consult Yanmar s local subsidiary in your region or your distributor or dealer A WARNING Never modify this product or release the limit devices which limit engine speed fuel injection quantity etc Modification will impair the safety and performance of...

Page 9: ...ricating oil Total capacity Effective Engine weight without marine gear sail drive mm e kW rpm hp rpm kg cm m sec kW rpm hp rpm kg cm m sec kg cm rpm rpm standard unite long reach unite kg mm mm mm e e kg Note 1 Rating condition ISO 3046 1 2 1 hp 0 7355 kW 3JH3E 3JH3BE Vertical 4 cycle water cooled diesel engine Direct injection 3 84x90 1 496 26 5 3650 36 3650 5 93 10 95 29 4 3800 40 3800 6 33 11 ...

Page 10: ...verall length Dimensions Overall width Overall height Lubricating oil Total capacity Effective Engine weight without marine gear sail drive mm e kW rpm hp rpm kg cm m sec kW rpm hp rpm kg cm m sec kg cm rpm rpm standard unite long reach unite kg mm mm mm e e kg Note 1 Rating condition ISO 3046 1 2 1hp O 7355 kW 10 3JH3CE Vertical4 cycle water cooled diesel engine Direct injection 3 84x90 1 496 26 ...

Page 11: ...ve Engine weight without marine gear sail drive mm e kW rpm hp rpm kg cm m sec kW rpm hp rpm kg cm m sec kg cm rpm rpm standard unite long reach unite kg mm mm mm e e kg 4JH3E 4JH3BE 4JH3WE Vertical4 cycle water cooled diesel engine Direct injection 4 84x90 1 995 36 8 3650 50 3650 6 18 10 95 41 2 3800 56 3800 6 65 11 4 17 7 12 1 220 5 At Flywheel side At Crankshaft V pulley side Counter clockwise ...

Page 12: ...out marine gear sail drive mm e kW rpm hp rpm kg cm m sec kW rpm hp rpm kg cm m sec kg cm rpm rpm standard unite long reach unite kg mm mm mm C C kg Note 1 Rating condition ISO 3046 1 2 1hp 0 7355 kW 12 1 47 1 47 2485 2483 4JH3B4E 4JH3CE 4JH3CE1 Vertical4 cycle water cooled diesel engine Direct injection 4 84x90 1 995 36 8 3650 34 6 3650 36 8 3650 50 3650 47 3 3650 50 3650 6 18 5 81 6 18 10 95 41 ...

Page 13: ...ifold Dipstick Fuel filter Fuel oil pump Oil filler cap Fuel feed pump Lube oil filter Note This illustration shows Yanmar marine gear Model KM3A after it has been attached Non Operation Side 3JH3 B C E Fresh water pump V belt Fresh water tank Alternator Exhaust manifold Starter motor Seawater pump 13 ...

Page 14: ...ntake manifold Fuel filter Fuel oil pump Oil filler cap Fuel feed pump Lube oil filter Note This illustration shows Yanmar marine gear Model KM3A after it has been attached Non Operation Side 4JH3 8 C E Fresh water pump 14 V belt Fresh water tank Alternator Exhaust manifold Starter motor Seawater pump ...

Page 15: ...ns to the engine after it is cooled with seawater in the fresh water cooler Filler cap The filler cap on the cooling water tank covers the water supply port The cap has a pressure regulating valve When the cooling water temp rises the pressure rises inside the fresh water cooler Subtank The pressure regulating valve releases vapor and hot water overflow to the subtank Rubber hose The hose connects...

Page 16: ...l cable to each of the engine control levers and the stopping equipment 2 5 1 Control Panel Electric Operation There are two control panel options The controls and alarm lamps included are shown below 8 2 type CD Water Proof sail drive High temp cooling water Low lube oil pressure Charge Key switch start 16 Buzzer J Stop button Tachometre Illumination switch l Cooling water temperature C type Lube...

Page 17: ... control panel lamps Tachometre The engine s rotation speed is indicated by the needle Hour Metre The number of hours of operation is indicated and can be used as a guide for periodic optional maintenance checks The hour meter is at the bottom of the tachometre 2 Alarm Equipment lamps and buzzer Mechanism When the sensor detects a problem during operation the lamps come on and the buzzer goes off ...

Page 18: ... controlled without engaging the clutch clutch remains in the NEUTRAL no load position 18 NOTICE Yanmar recommends the use of a single lever type for the remote con trol lever If only the two lever type is available in the market operate the engine at 1000 rpm or lower before engaging and disengaging the marine gear clutch 2 5 3 Stopping Equipment Manual Operation Engine stopping by engine stop ca...

Page 19: ...ct the clear filtered fuel from the top of the container for use Use the clear filtered fuel from the upper middle section of the container only leaving any contaminated fuel at the bottom 3 Fuel Tank optional Be sure to attach a drain cock to the fuel tank to enable dirt and water to settle at the bottom of the tank to be drained off The fuel outlet should be positioned 20 30mm above the bottom o...

Page 20: ... already in the tank Use new lube oil 3 Lube oil supplied to the engine will undergo natural degeneration with time even when the engine is not used Lube oil should be replaced at the specified intervals regardless of whether the engine is being used or not 20 Air temperature Single grade Multi grade C F L11 10 i 15 _ 10 25 30 35 31 41i 40 55 llJy67 If you operate your equipment at temperatures be...

Page 21: ...e of antifreeze also lowers the cooling efficiency of the engine Be sure to use the mixing ratios specified by the antifreeze maker for your temper ature range 3 2 Before Initial Operation Perform the following before using the engine for the first time 3 2 1 Supply Fuel Oil Using gasoline etc may cause a fire To avoid mistakes be sure to double check the kind of fuel before insert ing Wipe off an...

Page 22: ...urely by hand Marine gear oil capacity KM3P KM3A 22 Full 0 35 e Effective 0 05 e Full 0 45 e Effective 0 05 e CD Oil filler port cap Dipstick Upper limit Lower limit 3 2 4 Supply Cooling Water Supply cooling water according to the following procedures Be sure to add antirust or antifreeze to the cooling water 1 Be sure to close the 3 water drain cocks Fresh Seawater Model water line line 3JH3 B E ...

Page 23: ...cting the subtank to the fresh water cooler Be sure the hose is securely connected 3 2 5 Cranking When the engine has not been used for a long period of time lube oil will not be distributed to all of the operating parts Using the engine in this condition will lead to seizure After a long period of disuse distribute lube oil to each part by cranking Perform in accordance with the following pro ced...

Page 24: ...ds and check for abnormal noise during that time If you remove your hand from the stop knob or stop button while crank ing the engine will start 3 2 6 Check and Resupply Lube Oil and Cooling Water When engine oil clutch oil or cooling water is supplied for the first time or when they must be replaced conduct a trial operation of the engine for about 5 minutes and check the quantity of lube oil and...

Page 25: ...l level with the oil dipstick 2 If the oil level is low supply with the recommended lube oil using the filler port Supply oil up to the top mark on the oil dipstick See 3 2 2 4 Checking and Resupplying Clutch Lube Oil 1 Check the clutch oil level with the oil dipstick 2 If the oil level is low supply with the recommended lube oil using the filler port Supply oil up to the top mark on the oil dipst...

Page 26: ... lubricate the joints of the remote control cable and also the lever bearings If the lever comes out or there is play in the lever adjust the remote control cable See 4 3 4 3 7 Checking the Alarm Devices Electric Operation When operating the key switch check that the alarm devices work normally See 2 5 1 3 8 Preparing Fuel Lube Oil and Cooling Fresh Water in Reserve Prepare sufficient fuel for the...

Page 27: ...el System After Starting Failure If the engine only idles and won t start after several attempts there may be air in the fuel system If air is in the fuel system fuel cannot reach the fuel injection pump Vent the air in the system according to the following procedures Fuel System Air Venting Procedures 1 Check the fuel level in the fuel tank Replenish if insufficient 2 Loosen the air vent bolt at ...

Page 28: ...a loose joint NOTICE The engine will seize if it is operated when cooling seawater discharge is too small or if load is applied without any warming up operation 3 3 3 Operation 1 Engine Acceleration and Deceleration Use the governor handle to control acceleration and deceleration Move the handle slowly 2 FORWARD NEUTRAL boat stopped REVERSE Clutch Use the clutch handle to change from FORWARD to NE...

Page 29: ... room periodically for any problems 6 Is there sufficient fuel oil in the fuel oil tank Replenish fuel oil in advance to avoid running out of fuel during operation 7 When operating the engine at low speed for long periods of time race the engine once every 2 hours Note Racing the Engine With the clutch in NEUTRAL accel erate from the low speed position to the high speed position and repeat this pr...

Page 30: ... cause it to sink Be sure to close the cock 3 4 Long Term Storage 1 In cold temperatures or before long term storage be sure to drain the water from the seawater cooling system A CAUTION Drain water from the cooling system after the engine has cooled down Be careful to avoid burns NOTICE If water is left inside it may freeze and damage parts of the cooling system fresh water cooler sea water pump ...

Page 31: ...er For seawater CD Drain plug 4JH3E series only Drain plug 3JH3E series only CD For fresh water 3 Carry out the next periodic inspection before placing the engine in storage Clean the outside of the engine wiping off any dust or oil 4 To prevent condensation inside the fuel tank either drain off the fuel or fill the tank 5 Grease the exposed area and joints of the remote control cable and the bear...

Page 32: ...technicians are ready to assist you with periodic inspections and mainte nance Consult your YANMAR dealer or distributor in accordance with the service agreement Servicing Tools Prepare servicing tools onboard to be ready for inspecting and serviCing the engine and other equipment Tightening Torque of Bolts Nuts Over tightening of bolts and nuts causes them to come off or their threads to be damag...

Page 33: ...o establish definitively The following should be treated as a general standard only Section 4 3 gives a detailed explanation of which parts must be inspected and the procedure for doing so for each interval NOTICE Schedule your own periodic inspection plan according to the operational conditions of your engine and inspect every item Neglect of periodic inspection may lead to engine troubles and sh...

Page 34: ...t the tension of cooling water pump o first 0 driving belt Check the impeller of the cooling water 0 pump seawater pump Replace the fresh water cooling Every year Clean the element of the air intake silencer 0 Clean the exhaust water mixing elbow 0 Air intake and Clean the breather pipe 0 exhaust system 0 Check the exhaust gas condition During operation Check the charge lamp function 0 Check the e...

Page 35: ...il leakage 7 Approximately 10 minutes after stop ping the engine remove the oil dipstick and check the oil level Add oil if the level is too low A CAUTION Beware of oil splashes if extracting the lube oil while it is hot 2 Replacing the Clutch Lube Oil and Cleaning the Clutch Filter 1 st time During initial operation the oil is quickly contaminated due to the initial wear of internal parts The lub...

Page 36: ...ernor Remote Control Cable Check to see that the control lever on the engine side moves to the high speed bolt position and low speed bolt position when the remote control lever is moved to H high speed and L low speed respec tively When there is deviation loosen the bracket for the remote control cable on the engine side and adjust Adjust the high speed bolt position first and then adjust the low...

Page 37: ...d by charging the battery must be replaced NOTICE The capacities of the standard alternator and the recommended battery assume only the power necessary for regular operation If the power is also used for inboard lighting or other purpos es the generating and charging capacities may be insufficient In such cases consult your Yanmar dealer or distributor 4 3 3 Inspection Every 150 hours Replace the ...

Page 38: ...he belt causes slipping and stretching Replace the belt if it is mar red 4 Replacing the Engine Oil and Lube Oil Filter See 4 3 1 1 5 Cleaning the Intake Silencer Disassemble the intake silencer and clean the inside thoroughly Remove the cover by taking off the clamp Clean the element with a neutral detergent Reassemble after it is completely dry 4 3 5 Inspection Every 600 Hrs 1 Replacing Fresh Wa...

Page 39: ...ot to make a mistake and turn it in the wrong direction Additionally if the engine is being turned manually be careful to turn it in the correct direction Incorrect turning will twist the impeller and damage it 3 Inspection and Adjustment of Intakel Exhaust Valve Clearance When operating for long periods of time the clearance between the intake exhaust valve and the rocker arm will change and affe...

Page 40: ...elative humidity 80 or lower c Permissable value for intake negative pressure 0 5kPa 50mmAq or lower d Permissable value for exhaust back pressure 7 8kPa 800mmAq or lower The fuel and lube oil used should be as follows a Fuel The diesel gas oil ISO 8217 40 DMA BS 2869 A1 or A2 Cetane No 45 minimally b Lube oil Type API class CD Do not remove the seals limiting the amount of fuel injected and the s...

Page 41: ...000 hrs of operation or 5 years Fuel injection valve assembly whichever comes first 4 4 3 Inspection and Maintenance Inspection and maintenance for EPA related parts are shown in the chart below Inspection and maintenance not noted below are the same see 4 2 and 4 3 Item Content Interval term Check fuel valve nozzle clean 1000 Fuel Check adjustment of fuel injection pressure 1000 oil atomizing con...

Page 42: ...Insufficient seawater causing temp to rise Contamination inside cooling system NOTICE Check Lube Oil level Replenish or replace Check and change the rubber mount 3 2 2 4 3 1 1 Check cooling water and replenish 3 2 4 Check seawater system Ask for repairs Do not operate the engine if alarm devices are not repaired Serious accidents may result if difficulties are not spotted due to faulty alarm lamps...

Page 43: ...peller Black smoke Contaminated intake silencer Clean element Improper fuel Replace with recommended fuel Faulty spraying of fuel injection valve Ask for repairs Incorrect intake exhaust valve head Ask for repairs clearance White smoke Improper fuel Ask for repairs Faulty spraying of fuel injection valve Ask for repairs Fuel injection timing off Ask for repairs Lube oil burns excessive consumption...

Page 44: ...ice Manager contact the owner of the dealership or the General Manager m 44 If your problem still has not been resolved to your satisfaction contact your local Yanmar Subsidiary Com pany See the back of this manual for addresses We will need the following information in order to assist you Your name address and telephone number Product model and serial number Purchase date Dealer s name and addres...

Page 45: ...10 Mixing elbow 11 Fresh water cooler 12 Lub oil inlet filter 13 Main bearing 14 Seawater inlet 15 Cooling water pump seawater 16 Hot water connection outlet 17 Thermostat 18 Cooling water pump fresh water 19 Hot water connection inlet 20 Fresh water temperature switch 21 Lub oil pump 22 Pressure control valve 23 Fuel oil filter cartridge type 24 From cilinder head 25 To cam shaft NOTES Dimension ...

Page 46: ...h bolt 18 Sail drive 19 Tachometre sensor 20 Cooling water temperature sender 21 Engine oil pressure sender 22 Wire harness for 2 panel optional 23 Wire harness optional 24 Option 25 Instrument panel 26 Buzzer 27 Tachometre 28 Water proof 29 Oil pressure 30 Cooling Fresh Water temp 31 Charge 32 Switch lamp chklillum 33 Starter switch 34 Stop switch 35 Instrument panel No 2 station optional 36 Tach...

Page 47: ...gral exhaust 8 Inboard engine Essential requirements Annex I B Exhaust Emissions engine identification exhaust emission requirements durability owner s manual Annex I e Noise Emissions Fuel Type 8 Diesel o Petrol Standards Used EN ISO 8178 1 1996 Combustion cycle o 2 stroke 8 4 stroke Other co normative r document used u 2 X see craft manufacturer s Declaration of Conformity ENGINE S COVERED BY TH...

Page 48: ... of Directive 97 68 EC D Directive 88177 EC Module used for noise e ission assess ent Aa G D H D ther Co unity Directives applied _8 9 3 3 6 E E C _______________________ DESCRIPTI N F ENGINE s AND ESSENTIAL REQUIERMENTS Engine Type o Outboard Fuel Type C8 l Diesel Co busion cycle o 2 stroke C8 l z or sterndrive with integral exhaust o Petrol C8 l 4 stroke Essential requil ements Standards Used Ot...

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