Yanmar Marine Engine Manual (EN)

COVER

Printed in Japan A0A1015-0302 Printed in Japan A0A1015-0302 Publication No. A0A1015 History of Revision Page No 1 Manual Name Service Manual for Marine Diesel Engine Engine Model : 3JH2 series Number of revision Date of revision Reason for correction Outline of correction Correction item No. (page) Corrected by 1st Apr. 2001 ●Crank shaft V-pulley bolt tightening torque ●Clutch lever control cable connectlion. ●Added the standard V-pulley (material: casting iron) tightening torque and general use nuts & bolts tightening torque. ●Added the tightening torque of nut for the remote control cable connec- tion of clutch shifting lever. ●Injection timing changed.

10-32 8-3 1-3, 10-31 Quality Assurance Dept. 2nd Feb. 2003 ●Add the model 3JH25A & 3JH30A ● Added the Exterior Views ● Added the Specifieations ● Added the Engine Outiine ● Added the Pertomance Curves ● Added the Piping Diagrams ● Added the Fuel Injection Pump Sewice Data ● Added the Intake and Exhaust System figure ● Added the Lubrieation System figure ● Added the Lube Oil Filter figure ● Added theSea water line flgure ● Added the Marine Gear Models KM3P1,KM3P3,KM35P1 ● Added the Wiring diagrams 1-2-1, 1-2-2 1-3-1, 1-4-1 1-8-1 1-11-1, 1-11-2 1-14-1 3-1-1 4-1-1 5-2-1 5-6-1 6-3-1 7-29~7-56 9-4-1 Quality Assurance Dept.

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CONTENTS

CONTENTS CHAPTER 1 GENERAL 1.Exterior Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.Engine Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 4.Performance Curves . . . . . . . . . . . . . . . . . . . . . . . 1-10 5.Piping Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 CHAPTER 7 REDUCTION AND REVERSING GEAR KM3A 1.Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 2.Shifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 3.Inspection And Servicing . . . . . . . . . . . . . . . . . . . .

7-12 4.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 5.Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 CHAPTER 2 BASIC ENGINE PARTS 1.CylinderBlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 3.Piston and Piston Pins . . . . . . . . . . . . . . . . . . . . . . 2-11 4.Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 5.Crankshaft and Main Bearing . . . . . . . . . . . . . . . . 2-18 6.Camshaft and Tappets. . . . . . . . . . . . . . . . . . . . . . 2-21 7.Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 2-24 8.Flywheel and Housing . . . . . . . . . . . . . . . . . . . . . . 2-26 KM3P1,KM3P3,KM35P1 1.Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 2.Shifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 3.Inspection And Servicing . . . . . . . . . . . . . . . . . . . . 7-40 4.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 5.Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53 CHAPTER 8 REMOTE CONTROL 1.Remote Control System . . . . . . . . . . . . . . . . . . . . . . 8-1 2.Remote Control Installation . . . . . . . . . . . . . . . . . . . 8-2 3.Remote Control Inspection . . . . . . . . . . .

. . . . . . . . 8-5 4.Remote Control ADJUSTMENT. . . . . . . . . . . . . . . . 8-6 5.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 CHAPTER 3 FUEL INJECTION EQUIPMENT 1.Fuel Injection Pump Service Data . . . . . . . . . . . . . . 3-1 2.Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3. Disassembly Reassembly and Inspection of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 4. Adjustment of Fuel Injection Pump and Governor . . 3-21 5.Fuel Feed Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 6.FuelInjection Nozzle . . . . . . . . . . . . . . . . . . . . . . . 3-29 7.Troubleshooting . . .

. . . . . . . . . . . . . . . . . . . . . . . . 3-33 8.Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 9.Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 10.Fuel Tank (Optional). . . . . . . . . . . . . . . . . . . . . . . . 3-38 CHAPTER 9 ELECTRICAL SYSTEM 1.Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 2.Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 3.Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 4.Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 5.Instrument Panel . . . . . . . . . . . . . . . . . .

. . . . . . . . 9-34 6.Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36 7.Air Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . 9-39 8.Electric Type Engine Stop Device (Optional) . . . . . 9-40 9.Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42 10.AIternator 12V/80A(Optional) . . . . . . . . . . . . . . . . . 9-45 CHAPTER 4 INTAKE AND EXHAUST SYSTEM 1.Intake and Exhaust System . . . . . . . . . . . . . . . . . . 4-1 2.Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 3.Mixing Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 CHAPTER 5 LUBRICATION SYSTEM 1. Lubrication System . . . .

. . . . . . . . . . . . . . . . . . . . . 5-1 2.Lube Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 3.Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 4.Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . 5-8 5.Lube Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 6.Piston Cooling Nozzle . . . . . . . . . . . . . . . . . . . . . . 5-10 7.Rotary Waste Oil Pump (Optional). . . . . . . . . . . . . 5-11 CHAPTER 10 DISASSEMBLY AND REASSEMBLY 1.Disassembly and Reassembly Precautions . . . . . . 10-1 2.Disassembly and Reassembly Tools . . . . . . . . . . . 10-2 3.Disassembly and Reassembly . . . . . . . . . . . .

. . . . 10-9 4.Bolt/nut Tightening Torque. . . . . . . . . . . . . . . . . . 10-32 5.Test Running . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 CHAPTER 6 COOLING WATER SYSTEM 1.Cooling Water System . . . . . . . . . . . . . . . . . . . . . . 6-1 2.Sea Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 3.Fresh Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 4.Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 5.Pressure Cap and Sub Tank . . . . . . . . . . . . . . . . . 6-12 6.Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 7.Kingston Cock (Optional) . . . . . . . . . . . . . . . . . . .

6-16 8.Sea Water Filter (Optional) . . . . . . . . . . . . . . . . . . 6-17 9.Bilge Pump and Bilge Strainer (Optional) . . . . . . . 6-18 Printed in Japan A0A1015-0302 Printed in Japan A0A1015-0302

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