M9961-03E090 Service Manual 3JH4(B)(C)(M)E
M9961-03E090
Publication No.
FOREWORD This service manual has been complied for engineers engaged in sales, service, inspection and maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized in this manual, while items, which should already be common knowledge, are omitted. One characteristic of a marine diesel engine is that its performance in a vessel is governed by the applicability of the vessel's hull construction and its steering system.
FOR SAFTY 1. SAFETY LABELS • Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures. Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
2. Safety Precautions (1) SERVICE AREA • Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas. • Safe / Adequate Work Area The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip" or "trip and fall" type accidents.
(2) WORK - WEAR (GARMENTS) • Safe Work Clothing Well fitting !! Appropriate safety wear (gloves, special shoes/boots, eye/ear protection, head gear, harness', clothing, etc.) should be used/worn to match the task at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes around moving machinery. A serious accident may occur if caught in moving/rotating machinery. (3) TOOLS • Appropriate Lifting / Holding When lifting an engine, use only a lifting device (crane, jack, etc.
(5) FASTENER TORQUE • Torqueing Fasteners Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury. (6) Electrical • Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system. An accidental "short circuit" may cause damage, fire and or personal injury.
(8) FURTHER PRECAUTIONS • Fueling / Refueling Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result. • Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down. Scalding / serious burns may result. Allow the engine to cool down before attempting to approach the unit. • Rotating Parts Be careful around moving/rotating parts.
3. Precautions for Service Work (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work. (2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.
CONTENTS 1. GENERAL ....................................................................................................................... 1 1.1 Exterior Views ..........................................................................................................................1 1.2 Specifications ...........................................................................................................................2 1.3 Engine Outline ................................................................
4.2.2 Special Handtools ........................................................................................................................... 62 4.2.3 Measuring Instruments ................................................................................................................... 65 4.2.4 Other material ................................................................................................................................. 66 4.2.5 Measuring Instruments ................................
5.7 Timing Gear .........................................................................................................................119 5.7.1 Inspecting the gears...................................................................................................................... 119 5.7.2 Gear timing marks .................................................................. 119 5.8 Flywheel and Housing .....................................................................................................
8.2.3 Lube oil pump disassembly and reassembly ................................................................................ 142 8.2.4 Lube oil pump inspection .............................................................................................................. 143 8.2.5 Oil pressure control valve construction ......................................................................................... 143 8.3 Lube Oil Filter .........................................................................
9.6.3 Characteristics of thermostat ........................................................................................................ 157 9.6.4 Thermostat inspection................................................................................................................... 157 9.6.5 Testing the thermostat .................................................................................................................. 157 9.7 Bilge Pump and Bilge Strainer (Optional) ..........................
12.6 Instrument Panel ................................................................................................................185 12.6.1 B-type instrument panel (optional).................................................... 185 12.6.2 C-type instrument panel ............................................................ 185 12.7 Warning Devices ................................................................................................................186 12.7.1 Oil pressure alarm.................
1. GENERAL 1. GENERAL 1.1 Exterior Views (1) 3JH4E 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 Non-Operating Side Engine name plate (on the rocker arm cover) Fresh water filler cap Coolant tank / Heat exchanger Alternator Exhaust manifold Mixing elbow Starter motor Sea water pump This illustration shows the 3JH4E with Yanmar marine gear (Model:KM35P).
1. GENERAL 1.2 Specifications (1) 3JH3E, 3JH3BE, 3JH3CE, 3JH4ME Official engine model name unit 3JH4E Company internal model name - 3JH4E 3JH4BE 3JH4CE 3JH4ME Marine gear model - KM35P KM35A SD40 Bobtail Use - Pleasure use Type - Vertical water cooled 4 cycle diesel engine Combustion system - Direct injection Air charging - Naturally aspirated Number of cylinders - 3 Bore x stroke mm(inch) 88 x 90 (3.46 x 3.54) Displacement L 1 .
1. GENERAL (Note) 1. Rating condition : ISO 3046-1, 8665 2. 1HP (metric horse power) ≒ 0.7355 kW 3. Fuel condition : Density at 15°C = 0.842 * Fuel temperature 25°C at the inlet of the fuel injection pump. (ISO 3046-1) ** Fuel temperature 40°C at the inlet of the fuel injection pump. (ISO 8665) 4. The "Total" oil quantity 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.
78 3-M10 X 1.5 DEPTH 14 / 20 7 120 +0.025 0 60 50 210 PC 210 10.5 100 50 +0.025 0 32 4- 7.5 4 DETAIL OF COUPLING SCALE 1:3 DETAIL OF PULLEY SCALE 1:3 12 X 30 MOUNTING BLOCKS ID#100 174 206 538.6 517.6 (274) 169.3 243.6 412 143 190 4 194.1 (202.5) 16 7 191.2 65 32 MIN. 100 MAX. 110 NOTE 1. The original height of mounting blocks is shown in this drawing. Engine weight will compress blocks by 4mm (approx). 2.
U-MIXING ELBOW DIRECTION OF ROTATION 7.5 210 6 3-M10 X 1.5 DEPTH 14 / 20 60 210 +0.025 0 +0.025 0 7 DETAIL OF PULLEY SCALE 1:3 DETAIL OF COUPLING SCALE 1:3 12 X 30 174 206 538.6 517.6 (274) 168 243.6 5 MOUNTING BLOCKS ID#100 143 412 190 622.6 (202.5) 431.4 ) AL N IO PT (O 194.1 (2) 3JH4BE(with KM35A Marine gear) MOUNTING BLOCKS ID#150 MIXING ELBOW ASTERN 79.5 NOTE 1. The original height of mounting blocks is shown in this drawing.
210 210 3-M10 X 1.5 DEPTH 14 / 20 60 +0.025 0 DIRECTION OF ROTATION MOUNTING BLOCKS ID#200 538.6 517.6 (274) 12 X 30 174 DETAIL OF PULLEY SCALE 1:3 206 185 243.6 143 (202.5) (266.4) 1036.4 641.4 605 7 210 32 (112.5) 372 420 480 395 MAX. 110 MIN. 105 431.4 6 16 (202.5) ) AL N IO PT (O 194.1 538 (185) 538 143 47 973 Available propeller dia. 181 inch max. NOTE 1. The original height of mounting blocks is shown in this drawing.
1.General 1.4 Piping Diagrams (1) 3JH4(B) E Note: The following piping diagram is for the 3JH4E model. 7.8 x t4.5 rubber hose Overflow 7.8 x t4.5 rubber hose Screw joint (Union) Check valve Flange joint 7.8 x t4.5 rubber hose Fuel oil filter (cartridge type) Eye joint 5 x t4.5 rubber hose Fuel injection pump 26 4.76 x t0.7 steel pipe C Insertion joint Drill hole Fuel feed pump 30 Marks of piping Fuel oil inlet 7.8 x t4.5 rubber hose 7.8 x t4.5 rubber hose Detail of part A 9 x t3.
1.General (2) 3JH4CE (with sail drive SD40) 7.8 x t4.5 rubber hose Overflow 7.8 x t4.5 rubber hose Screw joint (Union) Check valve Flange joint Eye joint 7.8 x t4.5 rubber hose Fuel oil filter (cartridge type) Insertion joint 7.8 x t4.5 rubber hose Fuel oil inlet 7.8 x t4.5 rubber hose Marks of piping Fuel feed pump 5 x t4.5 rubber hose Fuel injection pump 4.76 x t0.7 steel pipe C 9 x t3.
1.general 1.5 Exhaust Gas Emission Regulation The EPA and ARB (,California Air Resources Board) Off-road Compression Ignition engines regulations 1.5.
1.General 1.5.2 Exhaust Gas Regulations This engine conforms to the EPA exhaust gas regulations (19kW and under 37kW). Engine Power Tier Model Year NOx HC NMHC + NOx CO PM 19 <= kW < 37 (25 <= hp < 50) Tier 1 1999 - - 9.5 (7.1) 5.5 (4.1) 0.80 (0.60) Tier 2 2004 - - 7.5 (5.6) 5.5 (4.1) 0.60 (0.45) Note 1. The transit smoke (ACC/LUG/PEAK) is not applicable. 2. The EPA recommended fuel is used. 3. The ARB standard is the same as the EPA's. 1.5.
1.general (5) Quality guarantee period for exhaust emission related parts For exhaust emission related parts, follow the inspections 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.
2. Inspection and Adjustment 2. Inspection and Adjustment 2.1 Periodic Maintenance Schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here.
2. Inspection and Adjustment { : User-maintenance System Cylinder head, etc. Item Check the leakage of water, lube oil and fuel. Before starting *2 Initial *2 Every *2 Every *2 Every 50hrs. or 50hrs. or 250 hrs. or 1000 hrs. or one month one month one year 4 years { (After starting) Retighten all major nuts and bolts z Adjust intake/exhaust valve clearance Check/adjust the remote control Remote operation control system, etc.
2. Inspection and Adjustment 2.2 Periodic Inspection and Maintenance Procedure 2.2.1 Check before starting Be sure to check the following points before starting an engine every day. No. Inspection Item (1) Visual inspection of engine outside (2) Check the fuel level, and refill (3) Check the lube oil level (Crankcase/Marine gear) (4) Seawater outlet (5) Check cooling water level (6) Check the alarm lamps & devices (7) Check the leakage of water, lube oil and fuel.
2. Inspection and Adjustment 2) Checking marine gear lube oil level a) Check the lube oil level of the marine gear with a dipstick. Oil filler cap Unit: liter(pint) Dipstick Marine gear oil capacity KM35P Full : 0.50 (1.0) KM35A Full : 0.65 (1.4) b) When the level is low, remove a filler port cap at the top of the housing, and fill it with marine gearclutch- lube oil to the upper limit on the dipstick. c) Tighten the filler port cap securely by hand.
2. Inspection and Adjustment IMPORTANT: If the cooling water runs short quickly or when the coolant tank runs short of water with the coolant recovery tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the water level of the coolant recovery tank during operation is not abnormal. The increased water in the coolant recovery tank returns to the coolant tank when the engine is cooled down.
2. Inspection and Adjustment (7) Check the leakage of water, lube oil and fuel. Brfore and after starting the engine, check the leakage of cooling water and seawater from cooling water system. Also check the leakage of lube oil and fuel. (8) Check/adjust the remote control operation Make sure that the accelerator of a boat can be operated smoothly before starting the engine. If it feels heavy to manipulate, lubricate the accelerator cable joints and pivots.
2. Inspection and Adjustment 3) Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface, and tighten it further to 3/4 of a turn with the filter wrench. Tightening torque: 20-24N•m (177-212 lb-in) Applicable oil filter Part No. 119305-35150 4) Fill with new lubricating oil. 5) Perform a trial run of the engine and check the oil leakage.
2. Inspection and Adjustment 2) If necessary, adjust the V-belt tension (deflection). To adjust the V-belt tension, loosen the set bolt for the belt adjuster and move the alternator to tighten the V-belt. 3) Visually check the V-belt for cracks, oiliness or wear. If any, replace the V-belt with new one. Belt adjuster Set bolt Alternator [Notice] When the V-belt will be replaced with new one, loosen the set bolt and move the alternator and also loosen the V-pulley set bolts for the cooling water pump.
2. Inspection and Adjustment c) Valve clearance measurement Rocker arm Adjusting screw Insert a thickness gage between the rocker arm Valve and valve cap, and record the measured valve clearance Lock nut clearance. (Use it as the data for estimating the wear state.) d) Adjusting other cylinders Turn the crankshaft 240° and make adjustment for the No.3 cylinder. Then adjust the No.2 cylinder in this order. (Valve clearance) The cylinder to be adjusted first does not have to be the No.1 cylinder.
2. Inspection and Adjustment (6) Check and adjust the remote control operation The various control levers on the engine side are connected to the remote control lever by the remote control cable. The cable will become stretched and the attachments loose after long hours of use causing deviation. It is dangerous to control operation under these conditions, and the remote control cable must be checked and adjusted periodically.
2. Inspection and Adjustment 2.2.3 Inspection every 50 hours or monthly Be sure to check the following points every 50 hours or monthly, whichever comes first. No. Inspection Item (1) Drain the fuel/water separator. (2) Check the electrolyte level in the battery (1) Drain the fuel/water separator. Air bleeding bolt 1) Close the fuel cock of the fuel tank. 2) Loosen the drain plug and drain off any water and dirt collected inside.
2. Inspection and Adjustment Fuel System Air bleeding Procedures 1) Check the fuel level in the fuel tank. Replenish if Insufficient. 2) Loosen the air bleeding bolt at the top of the fuel/ water separator by turning it 2 or 3 turns. When fuel, which does not contain air bubbles, comes out of the bolt hole, tighten the air bleeding bolt. 3) Loosen the air bleeding bolt of the fuel filter by turning it 2 or 3 turns.
2. Inspection and Adjustment Battery structure Terminal Cap Cover Cathode plate Separator Glass mat Battery case Anode plate (1) Electrolyte level • Check the level of fluid in the battery. When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode.
2. Inspection and Adjustment (b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of battery electrolyte is defined with 20°C as the standard. Since the specific gravity increases or decreases by 0.0007 when the temperature varies by 1°C, correct the value according to the equation below. Float S20 = St + 0.
2. Inspection and Adjustment 2.2.4 Inspection every 250 hours or one year Be sure to check the following points every 250 hours or one year operation, whichever comes first. No. Inspection Item (1) Drain the fuel tank (2) Replace the fuel filter (3) Replace the engine lube oil and the lube oil filter. (4) Replace the marine gear lube oil and the lube oil filter.
2. Inspection and Adjustment (5) Check the impeller of the cooling water pump (seawater pump). 1) Remove the seawater pump cover and take out Cover the O-ring, impeller and wear plate, O-ring 2) Inspect the rubber impeller, checking for splitting around the outside, damage or cracks, and replace Impeller if necessary. Wear plate Depending on the use, the inside parts of a seawater pump may deteriorate and the discharge performance may drop.
2. Inspection and Adjustment 2) Close the three water cocks for fresh water. Model Fresh water line Seawater line 3JH4E 3 1 Fresh water pump Drain cock for fresh water Coolant tank Drain cock for fresh water Drain cock for seawater Seawater pump Flywheel housing 3) Remove the filler cap of the fresh water cooler by turning the cap counterclockwise 1/3 of a turn.
2. Inspection and Adjustment 7) Check the rubber hose connecting the coolant recovery tank to the fresh water cooler. Be sure the hose is securely connected and there is no looseness or damage. When the hose is not watertight, an excessive amount of cooling water will be used. Cap To fresh water cooler Rubber hose FULL Coolant recovery tank LOW (7) Clean the exhaust/water mixing elbow. There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold.
2. Inspection and Adjustment (9) Check the wiring connectors. Check whether each connection part doesn't have looseness. Alternator Neutral safety switch (Fitting to marine gear) Optional Optional Battery Battery switch C.W. temp. sensor Starter B terminal C.W. temp.
2. Inspection and Adjustment 2.2.5 Inspection every 1,000 hours or four years Be sure to check the following points every 1,000 hours or four years operation, whichever comes first. No.
2. Inspection and Adjustment (2) Check the injection spray condition of a fuel nozzle Wear protective glasses when testing injection from the fuel injection nozzle. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it. 1) Injection pressure measurement Standard MPa(kgf/cm2) 21.1-22.
2. Inspection and Adjustment [Informative: Fuel injection valve structure] F.O. return pipe joint Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Pin Valve stop spacer Nozzle valve Nozzle Nozzle body Nozzle case nut Tightening torque: 39.2 to 44.1 N m (4 to 4.5 kgf m) 2) Spray pattern inspection After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness.
2. Inspection and Adjustment b) Spray and injection states • Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection. • If normal injection as shown below cannot be obtained, replace the fuel injection valve. • No extreme difference in angle(Θ) • No extreme injection angle difference(α) • Finely atomized spray • Excellent spray departure 3) Nozzle valve sliding test Wash the nozzle valve in clean fuel oil.
2. Inspection and Adjustment (4) Clean & check the water passages When it is used for a long time, cleaning of the cooling water passages is periodically necessary, because trash, scales, rust, and so on collect in the cooling water passages and the cooling performance declines. (a) Cleaning and inspection of cooling water rubber hoses. 1) Remove the cooling water rubber hoses for the fresh water line and the seawater line. 2) Check the dust and trash inside the hoses. If necessary, clean it.
2. Inspection and Adjustment 4) Pressure cap inspection Do not open the pressure cap while the engine is running or right after stopping because high temperature steam will be blown out. Remove the cap only after the water cools down. a) Remove scale and rust and check the seat and seat valve, etc. for scratches or wear. Check the spring for corrosion or settling. Replace if necessary. [NOTE] Clean the pressure cap with fresh water as it will not close completely if it is dirty.
2. Inspection and Adjustment (7) Retighten all major nuts and bolts. Retighten the major nuts and bolts bellow by the standard tightening torques. (See the table in 4.5.) 1) Cylinder head bolts 2) Crankshaft pulley bolts 3) Fuel injection nozzle set bolts 4) Fuel pump gear set bolts 5) Fuel injection line sleeve nut Retighten the following major bolts as requested. 1) Rod bolts 2) Flywheel set bolts 3) Metal cap bolts (8) Adjust intake/exhaust valve clearance. Refer to 2.2.2(5) for the procedure.
2. Inspection and Adjustment 2.3 Adjusting the no-load maximum or minimum speed 1) After warming the engine up, gradually raise the speed and set it at the no-load maximum speed. 2) If the no-load maximum speed is out of the standard, adjust it by turning the high idle limiting bolt. 3) Then set the no-load minimum speed by adjusting the low idle limiting bolt.
2. Inspection and Adjustment 2.5 Thermostat inspection (1) Put the thermostat in a beaker with fresh water, and heat it on an electric stove. The thermostat is functioning normally if it starts to open between 75-78 deg C, and opens until 8mm or more at 90 deg C Replace the thermostat if it not functioning normally. Thermostat cover Thermometer Gasket Thermostat Thermostat Gasket Valve opening Temperature (deg C)* 75.0-78.
2. Inspection and Adjustment 2.6 Adjusting Operation Perform the adjusting operation for an engine as follows after the maintenance job: 2.6.1 Preliminary Precautions Before making a test run, make sure of the following points. (1) Warm the engine up. (2) Remove any precipitation from the F.O. filter. water separator, and F.O tank. (3) Use only lube oil recommended by Yanmar. (4) Be sure to add Long Life Coolant Antifreeze (LLC) to cooling fresh water. (5) Provide good ventilation in the engine room. 2.
2. Inspection and Adjustment 2.6.3 Check Points and Precautions During Running Step Item Instructions Precautions 3) Lamp should go off 1) Make sure that the sea cock is open. when engine is 2) Make sure there is enough lube oil and (fresh) running. cooling water. 3) Operate the remote control handle and check if the device connected to the engine works property. 1 Checks before operation 2 2) No load operation; 1) When the lube oil temperature is raised to allow • Fit leaks if any.
2. Inspection and Adjustment 2.7 Long storage Observe the following instructions when the engine is to be stored for a long period without operation: 1) Do not drain cooling water in the cold season or before the long storage. [NOTICE] Negligence of adding anti-freeze will cause the cooling water remaining inside the engine to be frozen and expanded to damage the engine parts. 2) 3) 4) 5) 6) Remove the mud, dust and oil deposit and clean the outside.
3. Troubleshooting 3. Troubleshooting 3.1 Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and prevent the recurrence of the trouble.
3. Troubleshooting 3.2 Quick Reference Chart for Troubleshooting It is important to thoroughly under stand each system and the function of all of the parts of terse systems. A careful study of the engine mechanism will make this possible. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause. Begin by checking the most easily identifiable causes of difficulty.
Chart 1 THE ENGINE SUDDENLY STOPS. Countermeasure TROUBLE AND TROUBLESHOOTING (I-1) Add fuel oil and prime. (I-2) Bleed air. (I-3) Remove water from drain and fuel oil system and prime. (I-4) Check and make necessary repairs. (I-5) Clean. (I-6) Replace. (I-7) Check and make necessary repairs. (II-1) Replace. (II-2) Clean carefully to insure good working order.
CYLINDER OUTPUT IS UNEVEN (1) Oil leakage in injection system (2) Damaged valve spring (4) Irregular injection timing Countermeasure Countermeasure (I -7) Disassemble and clean and repair replace.
Chart 4 TROUBLE WITH MARINE GEAR (I-1) Disassemble and clean. (I-2) Repair or replace. (I-3) Repair or replace. (I-4) Replace. (I-5) Repair. (I-6) Adjust. (I-7) Replace. (I-8) Replace. (I-9) Adjust to correct position. (I-10) Reassemble. (I-11) Check for oil leakage and replenish. (II-1) Review (I-1, I-11). (II-2) Reduce load. (II-3) Replace. (II-4) Check oil level and adjust. (II-5) Check water level and adjust. (II-6) Change oil. (II-7) Review manual. (III -1) Replace. (III -2) Replace.
ROTATION IS NOT SMOOTH Countermeasure TROUBLE AND TROUBLESHOOTING (I-1) Lap. (I-2) Replace. (II-1) Clean. (II-2) Replace. (II-3) Replace. (II-4) Correctly install pump. (II-5) Clean. (II-6) Replace.
Chart 6 KNOCKING Countermeasure TROUBLE AND TROUBLESHOOTING (II-1) Delay injection timing. (II-2) Adjust standard injection pressure. (I-1) Increase injection pressure. (I-2) Replace. (I-3) Disassemble and lap. (I-4) Disassemble and repair.
TROUBLE WITH STARTING (I-1) Tighten. (I-2) Repair using sandpaper or replace. (I-3) Replace. (I-4) Repair using sandpaper and then grease. (I-5) Adjust. (I-6) Adjust. (I-7) Replace. (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. (III-1) Prime well. (III-2) Adjust. (III-3) Clean out matter causing clogging.
Chart 8 INSUFFICIENT POWER OUTPUT (I-1) Replace. (I-2) Disassemble and repair or replace. (I-3) Lap valves. (I-4) Tighten firmly. (I-5) (I-6) Adjust. (I-7) (I-8) Clean. (I-9) Replace. (I-10) Repair. (II-1) Clean nozzle hole or replace. (II-2) Lap or replace. (II-3) Lap or replace. (II-4) Tighten firmly. (II-5) Replace. (II-6) lean. (III-1) Replace. (III-2) Repair.
MISCELLANEOUS TROUBLE Countermeasure TROUBLE AND TROUBLESHOOTING (I-1) Tighten nuts. (I-2) Tighten nuts and insert pins. (I-3) Remove adjustment liner and adjust aperture, or replace. (I-4) Check teeth, shaft, and pushrod of gear for wear. Replace where necessary.
3. Troubleshooting 3.3 Troubleshooting (Concerning engine and fuel injection equipment) Malfunctions The engine does not operate 1. Fuel Oil is not injected from the injection pump Causes Remedies 1. There is no fuel oil in the fuel tank 2. The fuel line from the fuel tank is blocked 3. The fuel is clogged 4. There is air in the fuel filter or the pump chamber 5. The accelerator linkage is not properly connected 6. The magnet valve wiring is broken or its armature is Sticking 7.
3. Troubleshooting Malfunctions The engine exhaust contains smoke and the engine “knocks” The engine output is unstable Insufficient output 1. The injection quantity is insufficient Causes Remedies 1. The injection timing is incorrect 2. The nozzle or nozzle holder is functioning incorrectly 3. The injection quantity is excessive Readjust the timing Inspect, then repair or replace 1. The fuel filter element is clogged and fuel oil delivery is poor 2.
3. Troubleshooting Malfunctions Causes Inspect and then repair or replace 4. The nozzle or the nozzle holder is not functioning properly The engine cannot reach its maximum speed The engine’s maximum speed is too high Idling is unstable Remedies 1. The governor spring is too weak or is improperly adjusted 2. The control lever is not reaching the maximum-speed position 3. The nozzle’s injection operation is poor Readjust or replace 1. The governor spring is too strong or is improperly adjust 2.
3. Troubleshooting 3.4 Troubleshooting by measuring Compression Pressure Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure.
3. Troubleshooting (3) Engine speed and compression pressure (for reference) 4 40 35 3 30 25 2 20 200 250 300 350 Compression pressure (MPa) Compression pressure (kgf/cm2) 3JH4E 400 Engine speed (min-1) (4) Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. No.
4. Disassembly and Reassembly 4. Disassembly and Reassembly 4.1 Disassembly and Reassembly Precautions (1) Disassembly • Take sufficient time to accurately pin-point the cause of the trouble, and disassemble only those parts which are necessary. • Be careful to keep all disassembled parts in order. • Prepare disassembly tools. • Prepare a cleaner and cleaning can. • Clear an adequate area for parts and prepare a container(s) • Drain cooling water (seawater, fresh water) and lube oil.
4. Disassembly and Reassembly 4.2 Disassembly and Reassembly Tools The following tools are required when disassembling and reassembling the engine. Please use them as instructed. 4.2.
4.
4.
4. Disassembly and Reassembly 4.2.2 Special Handtools Name of tool Illustration Remarks Piston pin insertion/ extraction tool (Piston pin extractor) 80 12 25 20 (Extraction of piston pin) (Insertion of piston pin) Connecting rod small end bushing insertion/extraction tool 20 80 (Extraction) Intake and exhaust valve insertion/ extraction tool 75 11 7.5 20 Lubricating oil No.
4.
4. Disassembly and Reassembly Name of tool Illustration Press tool 1 for filler neck Remarks - 105 89 2 40 25 27.5 35.5 1 (Tool 1) Press tool 2 for filler neck copper tube 170 30 30 24.2 28 30 Chamfer (Tool 2) Stem seal insertion (for inserting stem seal) - mm d1 d2 d3 L1 L2 L3 16.2 22 13.5 18.
4. Disassembly and Reassembly 4.2.3 Measuring Instruments Name of 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.
4. Disassembly and Reassembly 4.2.4 Other material Items Liquid gasket Usual Contents Features and application Three Bond No.1 TB1101 200g (1kg also available) Non-drying liquid gasket; solvent less type, easy to remove, superior in seawater resistance, applicable to various mating surfaces. Three Bond No.2 TB1102 200g (1kg also available) Non-drying liquid gasket; easy to apply, superior in water resistance and oil resistance, especially superior in gasoline resistance. Three Bond No.
4. Disassembly and Reassembly Items Scale solvent Usual Contents Scale solvent 1 box (4 kg × 4 removers) Neutralizer (caustic soda) 1 box (2 kg × 4 neutralizers) Features and application • The scale solvent removes scale in a short time. (1 to 10 hours) • Prepare water (seawater is possible) in an amount that is about 10 times the weight of the solvent. Mix the solvent with water. • Just dipping disassembled part into removes scale. To shorten removal time, stir remover mixture.
4. Disassembly and Reassembly Items Cleaning agent for turbocharger Usual Contents 4L x 4 18L x 1 15sets : 1, 500cc x 6 Features and application Special cleaning agent that requires no water, specially designed for blower of turbocharger and inter cooler. [Notice] It is recommended that the liquid gasket of Three Bond TB1212 should be used for service work. Before providing service, observe the cautions below: 1) Build up each gasket equally.
4. Disassembly and Reassembly 4.2.5 Measuring Instruments No. Name of tool Use 1 Dial gauge Measures shaft bending, distortions of levelness, and gaps. 2 Test indicator Measures narrow and deep places which cannot be measured with dial gauge. 3 Magnetic 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.
4. Disassembly and Reassembly No. Name of tool Use 9 V Block Measures shaft distortion. 10 Torque wrench Used to tighten bolts and nuts to standard torque. 11 Thickness gauge Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling. 12 Cap tester Check for leakage in the fresh water system. 13 Battery current tester Checks density of antifreeze and charging condition of battery fluid.
4. Disassembly and Reassembly No. 16 Name of tool Rotation gauge Use Contact type Measures rotation speed by placing at the indentation hole of the revolving shaft. Photoelectric type Measures rotation speed by using a reflector mark which is placed on the exterior of the revolving shaft. Illustration Revolving shaft Reflection mark High pressure fuel pipe clamp type Measures rotation speed without reference to revolving shaft center or the exterior of the revol.
4. Disassembly and Reassembly 4.3 Disassembly and Reassembly 4.3.1 Disassembly • Preparation on a boat For engines mounted in an engine room of a ship, remove the piping and wiring connecting them to the ship. 1) Remove the remote control cable (from engine and marine gearbox). 2) Unplug the extension cord for the instrument panel from the engine. 3) Remove the wiring between the starting motor and the battery. 4) Remove the exhaust rubber hose from the mixing elbow.
4. Disassembly and Reassembly (3) Removing (electrical) wiring Remove the wiring from the engine. (Refer to 2.2.4(9) ) (4) Removing the fuel filter & fuel pipe 1) Remove the fuel pipes (fuel filter-fuel feed pump, fuel filter-fuel injection pump and fuel nozzle-fuel filter) 2) Remove the fuel filter. Air bleeding bolt Fuel nozzle To fuel tank Fuel filter Fuel injection pump Fuel feed pump (5) Removing the intake silencer 1) Remove the breather hose attached to the intake silencer- rocker arm cover.
4. Disassembly and Reassembly (6) Removing the mixing elbow 1) Remove the seawater rubber hose connecting to a heat exchanger- a mixing elbow. 2) Remove the mixing elbow from the exhaust manifold. Seawater L-type mixing elbow Gasket Exhaust manifold (7) Removing the starting motor Flywheel housing Remove the starting motor from the flywheel housing. Starting motor (Removing starting motor) (8) Removing the alternator 1) Loosen the alternator adjuster bolt and remove the V-belt.
4. Disassembly and Reassembly (9) Removing the cooling water pipe (seawater/ fresh water) 1) Remove the seawater pipe (seawater pump-heat exchanger). 2) Remove the fresh water pipe (fresh water pump- heat exchanger. exhaust manifold-fresh water pump). 3) Remove the fresh water pipe (cylinder block-lube oil cooler, lube oil cooler-fresh water pump).
4. Disassembly and Reassembly (12) Removing the lube oil filter and lube oil cooler Cylinder block 1) Remove the fresh water pipe (cylinder block-lube oil cooler, lube oil cooler outlet) ter wa 2) Remove the lube oil filter from the lube oil cooler. h s Fre 3) Remove the lube oil cooler nut and lube oil cooler. Joint Loosen the bolts for the filter bracket and remove Clamp Filter bracket Gasket the filter bracket. 4) Remove the lube oil dipstick and guide.
4. Disassembly and Reassembly (16) Removing the fuel injection nozzles Remove the bolt for the fuel nozzle retainer, and pull out the fuel nozzle retainer and fuel injection nozzle. NOTE: If the fuel nozzle protector stays in the cylinder head, make a note of the cylinder number and be sure to remove it when disassembling the cylinder head.
4. Disassembly and Reassembly (22) Turning the engine over Bolt 1) Place a wood block of appropriate size on the floor, and stand up the engine on the flywheel housing. 2) Remove the engine mounting feet. Washer Crankshaft V-pully Gear case (23) Removing the crankshaft V-pulley Loosen the bolt tightening the crankshaft V-pulley and remove the crankshaft V-pulley with an extraction tool. Oil pan (24) Removing the oil pan Remove the oil pan and spacer..
4. Disassembly and Reassembly (28) Removing the idle gear Loosen the three bolts holding the idle gear and pull out the idle gear and shaft. Bolt Idle gear shaft Idle gear (29) Removing the camshaft 1) Push up tappet by turning a camshaft to remove it from the cylinder block easily. 2) Loosen the thrust metal bolts through the holes of the camshaft gear, and remove. 3) Pull out the camshaft gear and camshaft assembly from the cylinder block.
4. Disassembly and Reassembly (31) Removing the gear case flange 1) Remove the gear case flange from the cylinder block. 2) Remove the O-rings from the lube oil passage. Liquid gasket NOTE 1) When mounting the gear case flange, match up the two knock pins for cylinder block. 2) Be sure to coat the O-rings for the cylinder block lube oil passage with grease when assembling, so that it does not get out of place.
4. Disassembly and Reassembly (35) Removing the main bearing. 1) Remove the main bearing bolts. 2) Remove the main bearing cap and lower main bearing metal. NOTE: The thrust metal (lower) is mounted to the base main bearing cap. (36) Removing the crankshaft 1) Remove the crankshaft. NOTE: 1) The thrust metal (upper) is mounted to the standard main bearing. 2) Remove the main bearing metal (upper) from the cylinder block.
4. Disassembly and Reassembly 4.3.2 Reassembly (1) Clean all parts Clean all parts using by the cloth and diesel oil(or cleaning agent) before reassembly. NOTE: 1) If the dust remain with the parts, engine may cause the seizing or damage. 2) The cleaning agent removes even carbon adhering to disassembled parts. (2) Putting the cylinder block upside down Place a wood block on the floor and put the cylinder block upside down (with the cylinder head mounting surface facing down).
4. Disassembly and Reassembly (5) Mounting the main bearing cap Coat the lower main bearing metal with engine oil, and mount it to the main bearing cap. NOTE: 1) The lower main bearing metal does not have an oil hole. 2) The base bearing thrust metal is fitted with the oil groove facing outwards. 1) Coat the flange and the thread of the main bearing bolts with engine oil, put them on the crankshaft journal, and tighten the main bearing bolts to the specified torque.
4. Disassembly and Reassembly (8) Mounting the gear case flange Apply the liquid gasket to the gear case flange and mount the gear case flange and lube oil line O-ring onto the cylinder block. NOTE: 1) When mounting the gear case flange, match up the two knock pins of the cylinder block. 2) Be sure to coat the O-ring for the cylinder block lube oil line with grease when assembling, so that it does not get out of place. (9) Mounting the piston and connecting rod 1) Reassemble the piston and connecting rod.
4. Disassembly and Reassembly Tightening torque Connecting rod bolt Nozzle side NOTE: 1) Insert the piston so that the match mark on the large end of the connecting rod faces the fuel nozzle, and the manufacture’s embossed mark on the stem faces toward the flywheel 2) After inserting the piston, make sure the ID mark on the piston top is located at the fuel nozzle side, looking from the top of the piston. 3) Align the large end match mark, mount the cap, and tighten the connecting rod bolts.
4. Disassembly and Reassembly (11) Mounting the idling gear Upside Mark 1) Mount the idling gear so that the oil hole of the idle gear shaft faces up. NOTE: The idle gear shaft must be mounted with the mark of the shaft upward. (Idle gear shaft) 2) Align the “A” and “C” match marks of the idle gear with the match marks of the camshaft gear and the crankshaft gear. 3) Measure the idle gear, camshaft gear and crankshaft gear backlash. mm Backlash Standard Limit 0.07-0.15 0.
4. Disassembly and Reassembly (14) Mounting the lube oil inlet pipe Mount the lube oil inlet pipe on the bottom of the cylinder block, using new gasket. Tightening torque N•m (kgf•m) Lube oil inlet pipe 26 (2.6) (15) Mounting the spacer and the oil pan Cylinder block 1) Apply the liquid gasket to the surfaces of the gear case cover, gear case flange and oil seal case on the flywheel housing side, that contact with the cylinder block. 2) Apply the liquid gasket to the spacer.
4. Disassembly and Reassembly (19) Mounting the marine gearbox Damper disk 1) Mount the fan and damper disk to the flywheel. 2) Align the damper disk with the input shaft spline and insert. Mount the marine gearbox to the flywheel housing. Tightening torque Cylinder head bolt N•m (kgf•m) 1st step Final 39.2-49.1 (4.0-5.0) 85.2-91.2 (8.69-9.
4. Disassembly and Reassembly (22) Mounting the fuel injection pump Fuel injection pump drive gear 1) Lightly fit the fuel injection pump on the gear case flange. (After adjusting injection timing, tighten the fuel injection pump). NOTE: Be careful not to scratch the O-ring between the fuel injection pump and gear case flange. 2) Fit the fuel injection pump drive gear to the fuel pump camshaft. 3) Align the “B” match marks on the fuel injection pump drive gear and idle gear.
4. Disassembly and Reassembly (25) Mounting the intake manifold Thoroughly clean the inside of the intake manifold, and mount the gasket packing and intake manifold. (26) Mounting the fuel injection pipe and fuel return pipe No.1 No.2 1) Mount the fuel injection pipe and then assemble the fuel injection pipe retainer to prevent the pipe vibration. No.3 Clamp NOTE: Lightly tighten the pipe joint nuts on both ends of the fuel injection pipe.
4. Disassembly and Reassembly (30) Mounting the cooling water pipes (seawater / fresh water) 1) Mount the seawater pipes with the hose clips (seawater pump-heat exchanger). 2) Mount the fresh water pipes with the hose clips (exhaust manifold – fresh water pump, fresh water pump heat exchanger).
4. Disassembly and Reassembly (38) Filling with lube oil Fill the engine with lube oil from the supply port on top of the gear case and fill the marine gearbox from the supply port on top of the clutch case. (39) Filling with cooling water 1) Open the coolant (fresh water) tank cap and fill with water. (L) Engine capacity 4.5 2) Fill with water until the level in the coolant recovery tank is between the full and low marks. (L) Coolant recovery tank capacity (full) 0.
5. Inspection and Servicing of Basic Engine Parts 5. Inspection and Servicing of Basic Engine Parts 5.1 Cylinder Block The cylinder block is a thin-skinned, (low-weight), short skirt type with rationally placed ribs. The side walls are save shaped to maximize rigidity for strength and low noise. Cap plug 50 mm (Camshaft hole) Cap plug 30 mm Cap plug 30 mm Cap plug 12 mm (main gallery) 5.1.
5. Inspection and Servicing of Basic Engine Parts (6) Clean the surface with the cleaner. NOTE: Without fail, read the instructions for the color check kit before use. 5.1.4 Replacement of cup plugs Step No. 1 Description Procedure Tool of material used Screw driver or saw blade Thinner Clean and remove grease from the hole into which the cup plug is to be driven. (Remove scale and sealing material previously applied.) Remove foreign materials with a screw driver or saw blade.
5. Inspection and Servicing of Basic Engine Parts 5.1.5 Cylinder bore measurement Especially clean head surface, cylinder bores and oil holes, and check the below items after removing any carbon deposit and bonding agent. (a) Appearance inspection Check if there is any discoloration or crack. If crack is suspected, perform color check. Sufficiently clean the oil holes and check they are not clogged.
5. Inspection and Servicing of Basic Engine Parts 5.2 Cylinder Head The cylinder head is of 3-cylinder integral construction, mounted with 14 bolts. Special 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.
5. Inspection and Servicing of Basic Engine Parts 5.2.1 Inspecting the cylinder head The cylinder head is subjected to very severe operating conditions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts. (1) Distortion of the combustion surface Carefully check for cylinder head distortion as this leads to gasket damage and compression leaks. 1) Clean the cylinder head surface.
5. Inspection and Servicing of Basic Engine Parts 5.2.2 Valve seat correction procedure The most common method for correcting unevenness of the seat surface with a seat grinder is as follows: (1) Use a seat grinder to make the surface even. As the valve seat width will be enlarged, first use a 70° grinder, then grind the seat to the standard dimension with a 15° grinder. Seat grinder NOTE: When seat adjustment is necessary, be sure to check the valve and valve guide.
5. Inspection and Servicing of Basic Engine Parts 5.2.3 Intake/exhaust valves, valve guides (1) Wearing and corrosion of valve stem Replace the valve stem is excessively worn or corroded. 30 mm 60 mm mm Valve stem outside dia. Standard Limit Intake Ø7.955-Ø7.975 Ø7.90 Exhaust Ø7.955-Ø7.970 Ø7.90 (2) Inspection of valve seat wear and contact surface Inspect for valve seat scratches and excessive wear. Check to make sure the contact surface is normal.
5. Inspection and Servicing of Basic Engine Parts (4) Valve guide 1) Measuring inside diameter of valve guide. Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit. mm Valve guide inside dia. Clearance Standard Limit Intake Ø8.010-Ø8.025 Ø8.2 Exhaust Ø8.015-Ø8.030 Ø8.2 Intake 0.035-0.070 0.18 Exhaust 0.045-0.075 0.18 NOTE: The inside diameter standard dimensions assume a pressure fit.
5. Inspection and Servicing of Basic Engine Parts 5.2.4 Valve springs (1) Checking valve springs 1) Check the spring for scratches or corrosion. 2) Measure the free length of the spring. Free length (Valve spring) 3) Measure inclination. Inclination B Square gauge A (Valve spring) 4) Measure spring tension. Valve spring Unit Standard Limit Free length A mm 44.4 43.0 Inclination B mm – 1.1 N/mm (kgf/mm) 26.6/35.4 (2.71/3.
5. Inspection and Servicing of Basic Engine Parts 6) Spring retainer and spring cotter Inspect the inside face of the spring retainer, the outside surface of the spring cotter, the contact area of the spring cotter inside surface and the notch in the head of the valve stem. Replace the spring retainer and spring cotter when the contact area is less than 70%, or when the spring cotter has been recessed because of wear. (1) Clean out the cylinder head bolt holes.
5. Inspection and Servicing of Basic Engine Parts 5.2.7 Intake and exhaust rocker arms The wear of rocker arm and rocker arm bushing may change opening/closing timing of the valve, and may in turn affect the engine performance according to the extent of the change. (1) Rocker arm shaft and rocker arm bushing Measure the outer diameter of the shaft and the innerdiameter of the veering, and replace if wear exceeds the limit. mm Standard Limit Outside dia of intake and exhaust rocker arm shaft. 15.966-15.
5. Inspection and Servicing of Basic Engine Parts 5.3 Piston and Piston Pins Pistons are made of a special light alloy with superior thermal expansion characteristics, and the top of the piston forms a swirl type toroidal combustion chamber. 1st compression ring IMPORTANT: Piston shape differs among engine models. If any incorrect piston is installed, combustion performance will drop.
5. Inspection and Servicing of Basic Engine Parts (3) Removing the piston pin A floating type piston pin is used in this engine. The piston pin can be pressed into the piston pin hole at room temperature (Coat with oil to make it slide easily). 5.3.2 Piston pin Measure the outer diameter and replace the pin if it is excessively worn. 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.
5. Inspection and Servicing of Basic Engine Parts (1) Measuring the rings. Measure the thickness and width of the rings, and the ring-to-groove clearance after installation. Replace if wear exceed the limit. mm Standard First piston ring Second piston ring Oil ring Limit Groove width 2.060-2.075 2.170 Ring width 1.970-1.990 1.950 Clearance 0.070-0.105 0.200 Groove width 2.025-2.040 2.140 Ring width 1.970-1.990 1.950 Clearance 0.035-0.070 0.190 Groove width 4.015-4.030 4.
5. Inspection and Servicing of Basic Engine Parts 3) After fitting the piston ring, make sure it moves easily and smoothly. 4) Stagger the piston rings at 120° intervals, making sure none of them line up with the piston. 1st piston ring 12 2st piston ring 0 Direction of piston pin 120 Direction of side pressure 1st piston ring Oil ring Oil ring 1st piston ring 0 12 120 120 2nd piston ring 2st piston ring 120 Oil ring 5) The oil ring is provided with a coil expander.
5. Inspection and Servicing of Basic Engine Parts 5.4 Connecting Rod Piston pin bushing The connecting rod is made of high-strength forged carbon steel. The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing. Connecting rod Crank pin metal Connecting rod (bid end cap) Connecting rod bolt 5.4.
5. Inspection and Servicing of Basic Engine Parts (2) Checking the side clearance of a connecting rod Fit the respective crank pins to the connecting rod and check to make sure that the side clearance in the crankshaft direction is correct. Connecting rod side clearance Standard Limit 0.20-0.40 0.55 Crankshaft Thickness gage (Connecting rod side gap) 5.4.2 Crank pin metal (1) Checking crank pin metal Check for flaking, melting or seizure on the contact surface of the crank pin metal.
5. Inspection and Servicing of Basic Engine Parts • Other procedure of measuring crank pin oil clearance 1) Use the press gauge (Plastic gauge) for measuring the oil clearance of the crank pin. 2) Mount the connecting rod on the crank pin (tighten to specified torque). 3) Remove the connecting rod and measure the broken plastic gauge with measuring paper. Plastic gauge (3) Precautions on replacement of crank pin metal 1) Wash the crank pin metal.
5. Inspection and Servicing of Basic Engine Parts 5.4.3 Piston pin bushing (1) Measuring piston pin clearance. Excessive piston pin bushing wear may result in damage to the piston pin or the piston itself. Measure the piston pin bushing inside diameter and the piston pin outside diameter. Calculate the oil clearance from the measured values. (Refer to 5.3.2 for the piston pin.) mm Standard Limit Piston pin bushing inside dia 26.025-26.038 26.068 Oil clearance 0.025-0.043 0.
5. Inspection and Servicing of Basic Engine Parts 5.5 Crankshaft and Main Bearing The crank pin and crank journal have been induction hardened for superior durability, and the crankshaft is provided with for balance weights for optional balance. The crankshaft main veering is of the hanger type. The upper metal (cylinder block side) is provided with an oil groove. There is no oil groove on the lower metal Main bearing (bearing cap side).
5. Inspection and Servicing of Basic Engine Parts (3) Measuring the crank pin and journal Measure the outside diameter, roundness and taper at each crank pin and journal. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Replace if the defect is excessive. mm Item Limit (Diameter) Roundness Taper 0.01 To look for the oil clearance of crank pin, measure the inside diameter of crank pin metal. (Refer to 5.4.2(2).
5. Inspection and Servicing of Basic Engine Parts (4) Checking the side gap of a crankshaft After assembling the crankshaft, tighten the main bearing cap to the specified toque, and move the crankshaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance. Replace the thrust bearing if it is worn beyond the limit. mm Crankshaft side gap Standard Limit 0.14-0.22 0.30 (Side gap measurement 1) Other measurement method can also be effective.
5. Inspection and Servicing of Basic Engine Parts (1) Inspecting the main bearing Check for flaking, seizure or burning of the contact surface and replace if necessary. Wheel side 5.5.2 Main bearing Block side main bearing metals Cap side main bearing metals (2) Measuring the inner diameter of metal Gear side Tighten the cap to the specified torque and measure the inner diameter of the metal.
5. Inspection and Servicing of Basic Engine Parts 5.6 Camshaft and Tappets 5.6.1 Camshaft The camshaft is normalized and the cam and bearing surfaces are surface hardened and ground. The cams have a curve that minimized the repeated shocks on the valve seats and maximizes valve seat life.
5. Inspection and Servicing of Basic Engine Parts (3) Camshaft and bearing hole measurement Measure the camshaft outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the measured camshaft outside diameter from the inside diameter of the camshaft bearing or bushing. The camshaft bushing at gear case side is measured with a cylinder gage after insertion to the cylinder. Replace if they exceed the limit or are damaged. mm Place Gear side Item Standard Limit Bushing I.
5. Inspection and Servicing of Basic Engine Parts 5.6.2 Tappets (1) The tappets are offset to rotate during operation and thereby prevent uneven wearing. Check the contact of each tappet and replace if excessively or unevenly worn. NOTE: When removing tappets, be sure to keep them separate for each cylinder and intake/exhaust valve. Abnormal contact surface Normal contact surface (Tappet) (2) Measure the outer diameter of the tappet, and replace if worn beyond the limit.
5. Inspection and Servicing of Basic Engine Parts 5.7 Timing Gear The timing gear is helical type for minimum noise and specially treated for high durability. 5.7.1 Inspecting the gears (1) Inspect the gears and replace if the teeth are damaged or worn. (2) Measure the backlash of all gears that mesh, and replace the meshing gears as a set if wear exceeds the limit.
5. Inspection and Servicing of Basic Engine Parts 5.8 Flywheel and Housing The function of the flywheel is through inertia, to rotate the crankshaft in a uniform and smooth manner by absorbing the turning force created during the combustion stroke of the engine, and by compensating for the decrease in turning force during the other strokes.
5. Inspection and Servicing of Basic Engine Parts 5.8.2 Damper disc and cooling fan Cooling fan Damper disc Flywheel 16 Flywheel side 2 19.5 Torsional rigidity 219 kgf•m/rad Max. angle of torsion 7.3 x 10-2 rad Stopper torque 20.8 kgf•m 121 6 7.1 189.928 190.000 44 169.8 170.2 47 61.5 Spline SAE 20/40 146 or less 6- 8.70 8.
6. FUEL INJECTION EQUIPMENT 6. FUEL INJECTION EQUIPMENT 6.1 Fuel Injection Pump/Governor Refer to the JH3E manual of separate volume for the disassembly and assembly, adjustment procedure of a fuel injection pump. 6.1.
6. FUEL INJECTION EQUIPMENT 6.1.2 Fuel injection pump service data (1) 3JH4(B)(C)E Part code (Back No.) - Adjustment SPEC - ENG SPEC SERVICE STD Item Fuel valve (Valve pressure) - VBG(220) (170) Nozzle type (ID mark) - 159P185VAD1 DN-12SD12 mm Ø 1.6 x 360 Ø2 x 600 min-1 200 - mm3/st 45 ± 5.0 - min-1 1500 - mm3/st 32.5 ± 0.
6. FUEL INJECTION EQUIPMENT 1) Adjust the fuel limit bolt to bring the rack position to the specified value (R0) with the governor control lever towards the fuel increase position, while keeping the pump at rated speed N0. 2) Measure fuel injection volume at rack position (R0). 3) If the injection volume is at the specified value, tighten the fuel limit bolt lock nut at that position. Note : The figure in the blank ( ) is the indicator. At starting 0.
6. FUEL INJECTION EQUIPMENT 6.1.
6.
6. FUEL INJECTION EQUIPMENT 6.1.4 Removing a fuel injection pump The procedure to remove a fuel injection pump from the gear case is shown. [NOTICE] Be sure to remove a flange and a fuel injection pump drive gear as a pair without loosening the flange bolts. Fuel injection pump Flange 1) Remove fuel injection pipes, fuel pipes and a remote control wire. Block the entrance with tape Fuel injection drive gear so that trash may not enter the fuel injection pipes Flange bolt and the fuel injection pump.
6. FUEL INJECTION EQUIPMENT 6.1.7 Troubleshooting of fuel injection pump Complete repair means not only replacing defective parts, but finding and eliminating the cause of the trouble as well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system. If the pump is removed prematurely, the true cause of the trouble may never be known Before removing the pump from the engine, at least go through the basic check points given here.
6. FUEL INJECTION EQUIPMENT Fault 2. Engine starts, but immediately stops. Cause (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 3. Engine’s (1) Knocking sounds caused by improper (too Defective output is fast) injection timing. injection timing (2) Engine overheats or emits large amount of insufficient.
6. FUEL INJECTION EQUIPMENT Fault Remedy (1) Injection timing is too fast or too slow. (2) Injection from nozzle is improper. Fuel drips after each injection. (3) Injection nozzle starting pressure is too high (4) Uneven injection. (5) Engine overheats, or insufficient compression. Adjust Adjust When exhaust smoke is black: (1) (2) (3) (4) 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. 7. Loud knocking.
6. FUEL INJECTION EQUIPMENT 6.1.
6.
6. FUEL INJECTION EQUIPMENT 6.2 Fuel Feed Pump The fuel feed pump pumps fuel from the fuel tank, passes it through the fuel filter element, and supplies it to the fuel injection pump. The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft. It is provided with a manual priming lever so that fuel can be supplied when the engine is stopped. From fuel tank To fuel filter (water separator) Packing Fuel feed pump 6.2.
6. FUEL INJECTION EQUIPMENT 6.2.3 Disassembly and reassembly of fuel feed pump (1) Disassembly 1) Remove the fuel feed pump mounting nut, and take the fuel feed pump off the fuel injection pump. 2) Clean the fuel feed pump assembly with fuel oil. 3) After checking the orientation of the arrow on the cover, make match marks on the upper body and cover, remove the small screw, and disassemble the cover, upper body and lower body.
6. FUEL INJECTION EQUIPMENT (4) Valve contact/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.
6. FUEL INJECTION EQUIPMENT 6.3 Fuel Filter The fuel filter is installed between the fuel feed pump and fuel injection pump, and removes dirt/foreign matter from the fuel pumped from the fuel tank. The fuel filter element must be changed periodiically. The fuel pumped by the fuel feed pump goes around the element, is fed through the pores in the filter and discharged from the center of the cover. Dirt and foreign matter in the fuel are deposited in the element.
6. FUEL INJECTION EQUIPMENT 6.4 Fuel Tank A triangular 30 liter fuel tank with a 2000mm (78.7402 in.) rubber fuel hose to fit all 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 Cock Drain cock Rubber hose 82 0 47 Clamp 15 230 176 30 36 49 PF 1/2 362 477.4 94 87 190 22.
7. INTAKE AND EXHAUST SYSTEM 7. INTAKE AND EXHAUST SYSTEM 7.1 Intake System Air enters in the intake silencer mounted at the end of the intake manifold, is fed to the intake manifold and then on to each cylinder. Exhaust gas goes into exhaust manifold (in the fresh water tank) mounted on the cylinder head outlet. After cooling, the exhaust gas enters the mixing elbow, which is directly connected with the exhaust manifold, and is discharged from the ship along with seawater.
7. INTAKE AND EXHAUST SYSTEM [NOTICE] 1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring, much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.
7. INTAKE AND EXHAUST SYSTEM 7.2 Exhaust System 7.2.1 Construction There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. Refer to the exterior diagrams included here. [Example assembly diagram: L-type mixing elbow.] U-type Mixing elbow Seawater Seawater L-type mixing elbow Gasket Exhaust manifold Exhaust manifold 7.2.2 3Mixing elbow inspection (1) Clean dirt and scale out of the gas and cooling water lines.
8. LUBRICATION SYSTEM 8. LUBRICATION SYSTEM 8.1 Lubrication System The lube oil in the oil pan is pumped up through the intake filter and intake piping by the lube oil pump, through the holes in the cylinder block and on to the lube oil pump, through the holes in the cylinder block and on to the discharge filter. The lube oil, which flows from the holes in the cylinder block through the bracket to the oil element, is filtered after the oil cooler. It is fed to main gallery in the cylinder block.
8. LUBRICATION SYSTEM 8.2 Lube Oil Pump 8.2.1 Lube oil pump construction The trochoid type lube oil pump is mounted in the gear case, and the inner rotor is driven by the crankshaft. The lube oil flows from the intake filter mounted on the bottom of the cylinder block through the holes in the cylinder block and engine plate, and out from the holes in the engine plate and cylinder block to the discharge filter. The lube oil pump is fitted with a control valve, which controls the discharge pressure at 0.
8. LUBRICATION SYSTEM 8.2.4 Lube oil pump inspection (1) Outside clearance of outer rotor Outer rotor Insert a gap gage between a outer rotor and a pump body, Gear case and measure the clearance. Outside clearance mm Standard Limit 0.12-0.21 0.30 (Outer diameter clearance) (2) Side clearance of outer rotor When measuring a side clearance, put a right-angle gage to the pump body, insert a gap gage and measure the clearance. Side clearance mm Standard Limit 0.02-0.07 0.
8. LUBRICATION SYSTEM 8.3 Lube Oil Filter 8.3.1 Lube oil filter construction The lube oil filter is a full-flow paper element type. Cylinder block mounted to the side of the cylinder body with the filter bracket. The cartridge type filter is easy to remove. r ate To prevent seizure in the event of the filter clogging up, w sh a bypass circuit is provided in the oil filter.
8. LUBRICATION SYSTEM 8.5 Rotary Waste Oil Pump (Optional) A rotary waste oil pump to pump out waste oil is available as an option. Oil inlet pipe Outside dia. 16 mm Rotary waste oil pump Delivery capacity pen one revolution Delivery pressure Suction head Part No. 0.057 L 0.15 MPa (1.
9. Cooling Water System 9. Cooling Water System 9.1 Cooling Water System The cooling water system is of the indirect seawater cooled, fresh water circulation type. The cylinders, cylinder heads and exhaust manifold are cooled with fresh water, and fresh water cooler (heat exchanger) use seawater. Seawater pumped in from the sea by the seawater pump goes to the heat exchanger, where it cools the fresh water. Then it is sent to the mixing elbow and is discharged from the ship with the exhaust gas.
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9. Cooling Water System 9.2 Seawater Pump The seawater pump is driven by a gear. The two kinds of seawater pumps are prepared. The standard one is mounted on the gear case and the other (optional) is mounted on the gear case flange. (Option) Seawater pump Pump drive gear Pump drive gear Gear case flange Gear case Gear case Seawater pump 9.2.1 Specifications of seawater pump (1) Performance Flow Min. 3800 L/h at pin = -5 kPa (-0.05 bar) pout = 95 kPa (0.
9. Cooling Water System 9.2.2 Seawater pump disassembly Refer to 2.2.4.(5). (1) Remove the rubber hose from the seawater pump outlet and then the seawater pump assembly from the gear case. (2) Remove the seawater pump cover and take out the O-ring, impeller and wear plate, (3) Remove the mechanical seal side stop ring. (4) Insert pliers from the drive gear long hole and remove the stop ring that holds the bearings.
9. Cooling Water System 9.3 Fresh Water Pump 9.3.1 Fresh water pump construction The fresh water pump is of the centrifugal (volute) type, and circulates water from the fresh water tank to the cylinders and cylinder head. The fresh water pump consists of the pump body, impeller, pump shaft, bearing unit and mechanical seal. The V pulley on the end of the pump shaft is driven by a V belt from the crankshaft.
9. Cooling Water System 9.3.2 Specifications of fresh water pump Pulley ratio (crank shaft/pump shaft) Ø120/Ø120 Pump shaft speed(Max) 4020 min-1 Delivery capacity Total head 70 L/min 4m 9.3.3 Fresh water pump disassembly (1) Do not disassemble the fresh water pump. It is difficult to disassemble and, once disassembled, even more difficult to reassemble. Replace the pump as an assembly in the event of trouble.
9. Cooling Water System Measuring clearance between impeller and pump body. Thickness gauge Measuring clearance between impeller and pump body bracket. Straightedge mm Standard Limit Clearance between impeller and body 0.3-1.1 1.
9. Cooling Water System 9.4 Heat Exchanger 9.4.1 Heat exchanger construction The heat exchanger cools the hot fresh water, that has cooled the inside of the engine, with seawater. The cooler core consists of many small diameter tubes, baffle plates and tube cover. The seawater flows through the maze formed by the baffle plates. There is a reservoir below the cooler core, which serves as the fresh water tank. There is an exhaust gas passageway in the reservoir, which forms a water cooled exhaust manifold.
9. Cooling Water System 9.5 Pressure cap and coolant recovery tank 9.5.1 Pressure cap construction The pressure cap mounted on the fresh water filler neck incorporates a pressure control valve. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating. The top seal of the cap seals the top of the filler neck, and the pressure valve seals the lock seat. 9.5.
9. Cooling Water System 9.5.4 Replacing filler neck 1) Take out the copper tube inside the filler neck with striking a circumference with a driver and so on. When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it. 2) Clean both of new filler neck and the insertion part of fresh water cooler with T7471 type activation spray or equivalent.
9. Cooling Water System Coolant recovery tank mm 30 8 20.5 25 65 70 130 FULL 60 LOW 35 The pressure valve opens to discharge steam when the steam pressure in the fresh water tank exceeds 82-109 kPa (0.84-1.11 kgf/cm2). This consumes water. The coolant recovery tank maintains the water level by preventing this discharge of water. The steam discharged into the coolant recovery tank condenses into watch, and the water level in the tank rises.
9. Cooling Water System 9.6 Thermostat 9.6.1 Functioning of thermostat The thermostat opens and closes a valve according to changes in the temperature of the fresh water inside the engine, controlling the volume of water flowing to the heat exchanger from the cylinder head, and in turn maintaining the temperature of the fresh water in the engine at a constant level.
9. Cooling Water System 9.7 Bilge Pump and Bilge Strainer (Optional) 9.7.1 Introduction (1) General Introduction Name Bilge pump 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 (2) Exterior Motor assy Controller White Outlet Green Red Blue Strainer Red (+) Inlet Battery White (-) Pump dimensions Length 225 mm Yoke diameter Ø61 Assembly hole diameter Ø5.
9. Cooling Water System 9.7.2 Description (1) Characteristics 1) Discharge at lift : 0 m discharge capacity : 20 liters/min. or greater. 2) Automatic feeding height : 1 m or greater (Limit for automatic feeding height: new pump with inside parts wet, approx. 2 m) 3) Automatic feeding time : 2-5secs. (Limit for automatic feeding time: new pump with inside parts wet, approx. 1 sec.) 4) Automatic stopping : Air intake causes negative pressure triggering automatic stopping.
9. Cooling Water System (7) The pump cannot be used to drain off rain water or large amounts of flood water. The pump can be run continuously for a period of 10 minutes After this time it must shut off for a period of 2 hours before reusing. (8) Do not use the pump for showering. If the pump outlet is deformed for showering, the increase in water pressure will increase the load on the motor and cause motor seizure. (9) Fix the strainer so that it well not turn upside down or on its side.
9. Cooling Water System (4) Attaching the delivery nozzle (outlet) • Make a fixing hole of Ø21 or less for attaching the nozzle. The hose attached at the nozzle should be 1.8m or less and should reach without any strain, therefore care should be taken in deciding on the best position. • Fix the nozzle (outlet) in place and attach on the discharge side of the pump. Fixing hole 21 Hose Delivery nozzle (5) Attaching the hose • Attach the hose from the strainer to the pump inlet.
9. Cooling Water System 9.7.5 Cautions for Assembling Observe the following cautions for handling. • Do not use gasoline or solvents. 1) gasoline 2) ester 3) benzol 4) battery fluid 5) liquids at 70°C or greater or engine oil • Never run when there is no water in the bilge. Check to be sure that the strainer is in the water before turning on the switch. • Keep the cord terminal away from the water. Water inside the motor or switch may lead to damage.
9. Cooling Water System 9.7.6 Troubleshooting Refer to the following countermeasures for difficulties that arise. Problem 1. Pump does not turn Cause Countermeasure Faulty wiring Check the wiring between the motor and battery. Faulty battery Check to see if the specific gravity of the battery fluid is greater than 1.25. Recharge or replace the battery. Faulty starter switch Consult your local dealer. Faulty pump Consult your local dealer. Draws up air. Check hose connections.
10. Reduction and Reversing Gear 10. Reduction and Reversing Gear Marine gear KM35P and KM35A are applied to the 3JH4E series engines. Refer to chapter 7 in the service manual of 3JH3/4JH3 engines for inspection, disassembly and reassembly. Specifications Model KM35P KM35A For engine models 3JH4E 3JH4BE Clutch Reduction ratio Constant mesh gear with servo cone clutch (wet type) Forward 2.36 2.61 2.33 2.64 Reverse 3.16 3.16 3.04 3.
11. REMOTE CONTROL (OPTIONAL) 11. REMOTE CONTROL (OPTIONAL) 11.1 Remote Control system 11.1.1 Construction of remote control system The remote control permits one handed control of the engine speed changing from forward to reverse, and stopping. Fittings which allow for easy connection of the remote control cables with the fuel injection pump and transmission are provided with the remote control set.
11. REMOTE CONTROL (OPTIONAL) (2) Remote control cable Use only 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.
11. REMOTE CONTROL (OPTIONAL) 11.
11. REMOTE CONTROL (OPTIONAL) (2) Clutch control Lock nut Neutral S1 Cable clamp S2 Bolt Reverse Oil seal Forward Remote control head Washer Split pin Shift lever Pivot Note : ( ) Cable shift travel S1 = More than 36 mm (1.42") S2 = More than 36 mm (1.42") Bolt (M8 X 25) Clamp To engine speed Shims To marine gear Stopper bolt Bolt (M8 X 25) (KM35P marine gear) (3) Engine stop Usually, to stop the engine, the stop button of an instrument panel is pushed, and the engine is stopped.
11. REMOTE CONTROL (OPTIONAL) 11.3 Remote Control Inspection (1) When the control lever movement does not coincide with operation of the engine, check the cable end stop nut to see whither or not it is loose, and readjust/retighten when necessary. Neutral Reverse Forward Shim in Shim in Throttle Throttle Free throttle (2) Too many bends (turns) in the cable or bends at too extreme and angle will make it difficult to turn the handle.
11. REMOTE CONTROL (OPTIONAL) 11.4 Remote Control Adjustment (1) Shift lever adjustment Move the lever several times-the movement of the clutch lever on the engine from forward, neutral and reverse must coincide with the forward, neutral and reverse on the control lever. If they do not coincide, adjust the fittings as necessary (first engine side, then controller side). (2) Throttle lever adjustment Move the control lever all the way to full throttle several times, and then return.
12. Electrical System 12. Electrical System 12.1 Electrical System Alternator Neutral safety switch (Fitting to marine gear) Optional Optional Battery Battery switch C.W. temp. sensor Starter B terminal C.W. temp.
12. Electrical System 12.1.
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12. Electrical System 12.2 Battery Refer to 2.2.3(2) for electrolyte level and battery charge. Also refer to the service manual of the 3/4 JH3E series for other data regarding battery. (1) Battery capacity Since the battery has a minimum capacity of 12V, 80AH. it can be used for 80-120AH. Battery capacity minimum 12V-80AH standard 12V-100AH cold district 12V-120AH Full charged specific gravity 1.26 (2) Battery cable Wiring must be performed with the specified electric wire.
12. Electrical System 12.3 Starting Motor A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start. 12.3.1 Specifications YANMAR Part No. 129608-77010 HITACHI Model No. S114-817A 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.
12. Electrical System 12.3.
12. Electrical System (2) Structure When the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. The pinion engages with the ring gear of a engine, and the engine is started. Magnetic Switch Center Bracket (A) Torsion Spring Shift Lever Brush Gear Case Pinion Shaft Pinion Armature Planet Gear Center Bracket (P) Rear Cover Yoke Internal Gear 12.3.
12. Electrical System 12.4 Alternator Standard, 12V/60A The alternator serves to keep the battery constantly charged. It is installed on the cylinder block by a bracket, and is driven from the V-pulley at the end of the crankshaft by a V belt. The type of alternator used in this engine is ideal for high speed engines with a wide range of engine speeds. It contains diodes that convert AC to DC, and an IC regulator that keeps the generated voltage constant even when the engine speed changes. 12.4.
12. Electrical System 12.4.
12. Electrical System 12.4.3 Wiring diagram Condenser 2.2 BAT P F Rotor coil Diode Stator coil B S Key switch IG L 1 Charge lamp 12V3.4W L F P Battery E IC regulator E Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop. 12.4.
12. Electrical System 12.4.5 Inspection (1) V belt inspection 1) Inspect the matter whether there are not crack, stickiness and wear on the belt visually. Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set. 2) V belt tension : (Refer to 2.2.2.(4) in Chapter 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.
12. Electrical System 12.5 Alternator 12V/80A (Optional) 12.5.1 Specifications Yanmar code 119573-77201 Model of alternator LR180-03C (HITACHI) Model of IC regulator 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 5000 min-1 Rated speed 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.
12. Electrical System 12.5.
12. Electrical System 12.5.3 Wiring diagram P BAT Key switch R Diode Rotor coil SubDiode Condenser (3.2 F) R 50 L L Charge lamp 12V3.4W F E IC regulator Stator coil Battery E Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop. 12.5.
12. Electrical System 12.6 Instrument Panel The new type instrument panels are applied for 3JH4E series engines. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed with new panel is activated by alternator B terminal pulse. 12.6.
12. Electrical System 12.7 Warning Devices 12.7.1 Oil pressure alarm If the engine oil pressure is below 0.01-0.03MPa (0.10.3kgf/cm2, 1.42-4.26 lb/in.2), with the main switch in the ON position, the contacts of the oil pressure are closed by a spring and the lamp is illuminated through the lamp oil pressure switch ground circuit system. If the oil pressure is normal, the switch contacts are opened by the lubricating oil pressure and the lamp remains off.
12. Electrical System 12.7.2 Sender unit for lube oil pressure gauge The sender unit for the lube oil pressure gauge has a mounting seat for mounting on the lube oil filter bracket. Oil pressure is measured when the oil enters into the 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.
12. Electrical System 12.7.3 Cooling water temperature alarm A water temperature lamp and water temperature gauge, backed up by an alarm in the instrument panel, are used to monitor the temperature of the engine cooling water. A high thermal expansion material is set on the end of the water temperature unit. When the cooling water temperature reaches a specified high temperature, the contacts are closed, and an alarm lamp and buzzer are activated at the instrument panel.
12. Electrical System 12.8 Air Heater (Optional) An air heater is available for warming intake air when starting in 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. 79 60 Air heater Gasket 52 22 Relay 50 52.5 60 79 9 2-M6 x 1 terminal 4- 9 Intake manifold Wire harness Parts No. 129120-77501 Rated output 390W Rated current 35.
12. Electrical System 12.9 Electric Engine Stopping Device (Optional) Emergency stop button The electric 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.
13. SERVICE STANDARDS 13. SERVICE STANDARDS 13.1 Engine Tuning Standard Limit Reference page 0.15-0.25 - 2.2.2(5) Used part 8-10 - New part 6-8 - MPa (kgf/cm ) 21.1-22.1 (215-225) - 2.2.5(2) 4 Compression pressure (at 250 min-1) MPa (kgf/cm2) 3.63±0.1 (37±1) 2.94±0.1 (30±1) 3.4 5 Cooling water Capacity Engine (Liter) Coolant recovery tank 4.5 - 0.8 - 5.0±0.3 - 3JH4E with KM35A/ SD40 Liter (rake angle 0 degree) 5.5±0.3 - Marine gear KM35P Liter 0.
13. SERVICE STANDARDS 13.2 Engine Body 13.2.1 Cylinder head (1) Cylinder head Inspection item Standard Limit Reference page 0.05 or less 0.15 5.2.1(1) 0.30-0.50 0.8 5.2.3(3) Intake 120 - Exhaust 90 - Combustion surface distortion mm Valve sink Valve seat Intake mm Exhaust Seat angle Deg. 5.2.1(3) (2) Intake/exhaust valve and guide mm Inspection item Standard Limit Guide inside diameter 8.010-8.025 8.10 Valve stem outside diameter 7.955-7.975 7.90 Clearance 0.035-0.070 0.
13. SERVICE STANDARDS 13.2.2 Camshaft and gear train (1) Camshaft mm Inspection item Standard Limit Reference page 0.05-0.20 0.35 5.6.1(1) 0.02 or less 0.05 5.6.1(4) 38.600-38.800 38.350 5.6.1(2) Bushing inside diameter 44.990-45.055 45.130 Camshaft outside diameter 44.925-44.950 44.890 0.040-0.130 0.240 Bushing inside diameter 45.000-45.025 45.100 Camshaft outside diameter 44.910-44.935 44.875 0.065-0.115 0.225 Bushing inside diameter 45.000-45.025 45.
13. SERVICE STANDARDS 13.2.3 Cylinder block (1) Cylinder block mm Inspection item Cylinder inside diameter Standard Limit 88.000-88.030 88.200 0.01 or less 0.03 Roundness Cylinder bore Inclination Reference page 5.1.5 (2) Crankshaft mm Inspection item Standard Limit Reference page - 0.02 5.5.1(2) Pin outside diameter 47.952-47.962 47.902 Metal inside diameter 48.000-48.026 - Metal thickness 1.492-1.500 - Clearance 0.038-0.074 0.150 Journal outside diameter 49.952-49.962 49.
13. SERVICE STANDARDS 2) Piston ring mm Inspection item Top ring Second ring Oil ring Standard limit Ring groove width 2.060-2.075 2.170 Ring width 1.970-1.990 1.950 Side clearance 0.070-0.105 0.200 End clearance 0.200-0.400 0.490 Ring groove width 2.025-2.040 2.140 Ring width 1.970-1.990 1.950 Side clearance 0.035-0.070 0.190 End clearance 0.200-0.400 0.490 Ring groove width 4.015-4.030 4.130 Ring width 3.970-3.990 3.950 Side clearance 0.025-0.060 0.
13. SERVICE STANDARDS 13.3 Lubricating Oil System (Trochoid Pump) (1) Outside clearance of outer rotor mm Standard Limit Reference page 0.12-0.21 0.30 8.2.4(1) (2) Side clearance of outer rotor mm Standard Limit Reference page 0.02-0.07 0.12 8.2.4(2) (3) Inside clearance of inner rotor mm Item Inside clearance of inner rotor Width across flat clearance of inner rotor Parts Standard Gear boss diameter 53.05-53.15 Rotor diameter 53.45-53.55 Width across flat of Gear boss 49.45-49.
14. TIGHTENING TORQUE FOR BOLTS AND NUTS 14. TIGHTENING TORQUE FOR BOLTS AND NUTS 14.1 Main Bolt and Nut No Name Thread diameter x pitch (mm) Lubricating oil application (thread portion, and seat surface) Torque N•m(kgf-m) 1 Head bolt M10 x 1.25 Coat with lube oil 85.2-91.2 (8.69-9.30 ) 2 Rod bolt M9 x 1.0 Coat with lube oil 44.1-49.1 (4.50-5.01) 3 Flywheel retainer bolt M10 x 1.25 Coat with lube oil 83.3-88.3 (8.49-9.00) 4 Metal cap retainer bolt M12 x 1.
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 DIESEL AMERICA CORP. 101 INTERNATIONAL DRIVE ADAIRSVILLE, GA 30103, U.S.A. TEL : 1-770-877-6229 FAX : 1-770-877-9009 YANMAR ASIA (SINGAPORE) CORPORATION PTE LTD. 4 TUAS LANE, SINGAPORE 638613 TEL : 65-6861-3855 FAX : 65-6862-5195 YANMAR CO,. LTD.
