Yanmar 3JH3(B)(C)E, 4JH3(B)(C)E Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the 3JH3E, 3JH3BE, 3JH3CE, 4JH3E, 4JH3BE & 4JH3CE Yanmar Marine Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar 3JH3E
Yanmar 3JH3BE
Yanmar 3JH3CE
Yanmar 4JH3E
Yanmar 4JH3BE
Yanmar 4JH3CE


TABLE OF CONTENTS :

Chapter 1 GENERAL
Chapter 2 INSPECTION AND SERVICING OF BASIC ENGINE PARTS
Chapter 3 FUEL INJECTION EQUIPMENT
Chapter 4 INTAKE AND EXHAUST SYSTEM
Chapter 5 LUBRICATION SYSTEM
Chapter 6 COOLING WATER SYSTEM
Chapter 7 REDUCTION AND REVERSING GEAR
Chapter 8 REMOTE CONTROL (OPTIONAL)
Chapter 9 ELECTRICAL SYSTEM
Chapter 10 DISASSEMBLY AND REASSEMBLY
Chapter 11 TROUBLESHOOTING


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Code No. : HINSHI-H8009
Total Pages : 284


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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COVER
FOREWORD
INDEX
Chapter 1 GENERAL
1. Exterior Views
1-1 3JH3E
1-2 4JH3E
2. Specifications
2-1 3JHE,3JH3BE,3JH3CE
2-2 4JH3E,4JH3BE,4JH3CE
2-3 Sales condition,Marine gear
3. Engine Outline
3-1 3JH3E(with KM3P Marine gear)
3-2 3JH3BE(with KM3A Marine gear)
3-3 4JH3E(with KM3A Marine gear)
3-4 4JH3BE(with KM3A Marine gear)
4. Piping Diagrams
4-1 3,4JH3(B)(C)E
Chapter 2 INSPECTION AND SERVICING OF BASIC ENGINE PARTS
1. Cylinder Block
1-1 Inspection of parts
1-2 Cleaning of oil holes
1-3 Color check procedure
1-4 Replacement of cup plugs
1-5 Cylinder bore measuremant
2. Cylinder Head
2-1 Inspecting the cylinder head
2-2 Valve seat correction procedure
2-3 Intake/exhaust valves, valve guides
2-4 Valve springs
2-5 Assembling the cylinder head
2-6 Measuring top clearance
2-7 Intake and exhaust valve head clearance
2-8 Adjustment of valve head clearance
3. Piston and Piston Pins
3-1 Piston
3-2 Piston Pin
3-3 Piston rings
4. Connecting Rod
4-1 Inspecting the connection rod
4-2 Crank pin bushing
4-3 Piston pin bushing
4-4 Assembling piston and connecting rod
5. Crankshaft and Main Bearing
5-1 Crankshaft
5-2 Main bearing
6. Camshaft and Tappets
6-1 Camshaft
6-2 Tappets
7. Timing Gear
7-1 Inspecting the gears
7-2 Gear timing marks
8. Flywheel and Housing
8-1 Specifications of flywheel
8-2 Dimensions of flywheel and mounting flange
8-3 Ring gear
8-4 Position of top dead center and fuel injection timing
8-5 Damper disk and cooling fan
Chapter 3 FUEL INJECTION EQUIPMENT
1. Fuel Injection Pump Service Data
1-1 3JH3(B)(C)E
1-2 4JH3(B)(C)E
2. Governor
2-1 Cold start knob(For 4JH3(B)(C)E only)
2-2 Disassembly Reassembly and Inspection of Governor
2-3 Assembling governor
3. Disassembly, Reassembly and Inspection of Fuel Injection pump
3-1 Disassembly of fuel injection pump
3-2 Inspection of fuel injection pump
3-3 Reassembly of fuel injection pump
4. Adjustment of Fuel Injection Pump and Govemor
4-1 Preparations
4-2 Adjustment of top clearance
4-3 Adjusting of injection timing
4-4 Plunger pressure test
4-5 Delivery valve pressure test
4-6 Adjusting injection volume(uniformity of each cylinder)
4-7 Adjustment of govenar
5. Fuel Feed Pump
5-1 Construction of fuel feed pump
5-2 Fuel feed pump specifications
5-3 Disassembly and reassembly of fuel feed pump
5-4 Plunger pressure test
6. Fuel Injection Nozzle
6-1 Function of fuel injection nozzle
6-2 Fuel injection nozzle disasembly
6-3 Fuel injection nozzle inspection
6-4 Fuel injection nozzle reassembly
6-5 Adjusting fuel injection nozzle
7. Trouble shooting of fuel injection pump
7-1 Troubleshooting of fuel injection pump
7-2 Major faults and troubleshooting
8. Tools
9. Fuel Filter
9-1 Fuel filter specifications
9-2 Fuel filter inspection
10. Fuel Tank
11.Troubleshooting
Chapter 4 INTAKE AND EXHAUST SYSTEM
1. Intake System
2. Exhaust System
2-1 Construction
2-2 Mixing elbow inspection
Chapter 5 LUBRICATION SYSTEM
1. Lubrication System
2. Lube Oil Pump
2-1 Lube oil pump construction
2-2 Specifications of lube oil pump
2-3 Lube oil pump disassembly
2-4 Lube oil pump inspection
2-5 Oil pressure regulating valve construction
3. Lube Oil Filter
3-1 Lube oil filter construction
3-2 Lube oil filter replacement
4. Lube Oil Cooler
4-1 Lube oil cooler construction
4-2 Inspecting the lube oil cooler
5. Rotary Waste Oil Pump (Optional)
5-1 Construction
5-2 Inspecting the waste oil pump
Chapter 6 COOLING WATER SYSTEM
1. Cooling Water System
2. Sea Water Pump
2-1 Specifications of sea water pump
2-2 Sea water pump disassembly
2-3 sea water pump Inspection
2-4 Sea water pump reassenbly
2-5 Current characeristics
3. Fresh Water Pump
3-1 Fresh water pump construction
3-2 Specifications of fresh water pump
3-3 Fresh water pump disassembly
3-4 Fresh water pump inspection
4. Heat Exchaniger
4-1 Heat exchanger construction
4-2 Specifications of heat exchanger
4-3 Disasembly and reassenbly of the heat exchanger
4-4 Heat exchanger inspection
5. Pressure Cap and Sub Tank
5-1 Pressure cap construction
5-2 Pressure cap pressure control
5-3 Pressure cap inspection
5-4 Funktion of the sub tank
5-5 Specifications of sub tank
5-6 Mounting the sub tank
5-7 Precautions on usage of the sub tank
6. Thermostat
6-1 Funktion of thermostat
6-2 Thermostat construction
6-3 Characteristics of thermostat
6-4 Thermostat inspection
6-5 Testing the thermostat
7. Bilge Pump and Bilge Strainer (Optional)
7-1 Introductin
7-2 Description
7-3 Cautions
Chapter 7 REDUCTION AND REVERSING GEAR
Marine Gear Models [KM3A]
1. Construction
1-1 Construction
1-2 Specifications
1-3 Power transmission system
1-4 Drawing
1-5 Sectional view
2. Shifting Device
2-1 Construction of shifting mechanism
2-2 Forward and reverse clutch operation
2-3 Engagement and disengagement of clutch
2-4 Clutch shifting force
2-5 Adjustment of shifting device
2-6 Adjustment of the remoto control head
2-7 Cautions
3. Inspection and Servicing
3-1 Clutch case
3-2 Bearing
3-3 Gear
3-4 Forward and reverse large gears
3-5 Drive cone
3-6 Trust collar
3-7 Cup spring
3-8 Oil seal of out put shaft
3-9 Input shaft
3-10 Out put shaft
3-11 Intermediate shaft
3-12 Shifting device
3-13 Damper disk
3-14 Shim adjustment for output and input shafts
3-15 Torque limiter
4. Disassembly
4-1 Dismanting the clutch
4-2 Removal of the output shaft
4-3 Removal of the ointermediate shaft
4-4 Dismanting the shifting device
5. Reassembly
5-1 Reassembly of output shaft
5-2 Reassembly of the clutch
5-3 Reassembly of the shiating device
Marine Gear Models [KM3P4]
1. Construction
1-1 Construction
1-2 Specifications
1-3 Power transmission system
1-4 Drawing
1-5 Spectional view
2. Shifting Device
2-1 Construction of shifting mechanism
2-2 Forward and reverse clutch operation
2-3 Engagement and disengagement of clutch
2-4 Clutch shifting force
2-5 Adjustment of the remoto control head
2-6 Adjustment of the remoto control head
2-7 Cautions
3. Inspection and Servicing
3-1 Clutch case
3-2 Bearing
3-3 Gear
3-4 Forward and reverse large gears
3-5 Drive cone
3-6 Thrust collar
3-7 Cup spring and spring retainer
3-8 Oil seal of output shaft
3-9 Input shaft
3-10 Output shaft
3-11 Intermediate shaft
3-12 Shifting device
3-13 Damper disk
3-14 Shim adjustment for output and input shafts
3-15 Torque limiter
4. Disassembly
4-1 Dismantling the clutch
4-2 Removal of the output shaft
4-3 Removal of the intermediate shaft
4-4 Dismanting the shifting device
5. Reassembly
5-1 Reassembly of output shaft
5-2 Reassembly of the clutch
5-3 Reassembly of the shiating device
Chapter 8 REMOTE CONTROL (OPTIONAL)
1. Remote Control System
1-1 Construction of remoto control system
1-2 Remoto control device components
2. Remote Control Installation
2-1 Speed control
2-2 Clutch control
2-3 Engine stop
3. Remote Control Inspection
4. Remote Control Adjustment
Chapter 9 ELECTRICAL SYSTEM
1. Electrical System
1-1 System diagram of electric parts(B-type)
1-2 Wiring diagram
2. Battery
2-1 Construction
2-2 Battery capacity and battery cables
2-3 Inspection
2-4 Charging
2-5 Battery storage precautions
3. Starter Motor
3-1 Specifications
3-2 The planatary gear starter system
3-3 Removal
3-4 Trouble mooting the starter system
3-5 Disassembly
3-6 Inspection and Repair
3-7 Reasembly
3-8 Operation Specifications Check
4. Alternator Standard, 12V/55A
4-1 Features
4-2 Specifications
4-3 Characteristics
4-4 Construction
4-5 Aiternator functioning
4-6 Handling precautions
4-7 Disassemblling the alternator
4-8 Inspection and adjustment
4-9 Reassembling the alternator
4-10 Performance test
5. Alternator 12V/80A (OPTIONAL)
5-1 Features
5-2 Specifications
5-3 Characteristics
5-4 Construction
5-5 Alternator functioning
5-6 Handling precautions
5-7 Disassembling the alternator
5-8 Inspection and adjustment
5-9 Reassembling the alternator
5-10 Performance test
5-11 Troubleshooting
6. Instrument Panel
6-1 B2-type instrument panel with wiring
6-2 C-type instrument panel
6-3 Extension codes
7. Waming Devices
7-1 Oil pressure alarm
7-2 Cooling water temperature alarm
7-3 Sender unit for lube oil pressure gauge
7-4 Sender unit Oor the cooling water temperature gauge
8. Air Heater (Optional)
9. Electric type Engine Stopping Device (Optional)
9-1 Solenoid
9-2 Relay
9-3 Wire harness of engine stop
10. Tachometer
10-1 Construction of tachometer
10-2 Specifications and dimensions of tachometer
10-3 Measurement of sensor unit characteristics
Chapter 10 DISASSEMBLY AND REASSEMBLY
1. Disassembly and Reassembly Precautions
2. Disassembly and Reassembly Tools
2-1 General handtools
2-2 Special Handtools
2-3 Measuring Instruments
2-4 Other material
2-5 Measuring Instruments
3. Disassembly and Reassembly
3-1 Disassembly
3-2 Reassembly
4. Table of Standard Measurements for Maintenance
4-1 Cylinder head
4-2 Cylinder block
4-3 Valve equipment
4-4 Piston
4-5 Piston ring
4-6 Connecting rod
4-7 Cam shaft
4-8 Crank shaft
4-9 Side clearance and backlash
4-10 Miscellaneous
5. Tightening torque
5-1 Main Bolt and Nut
5-2 Standard Bolts and Nuts(without lubricant)
6. Test running
6-1 Preliminary Precautions
6-2 Check Points and Precautions During Running
Chapter 11 TROUBLESHOOTING
1. Troubleshooting
BACK COVER

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