Yanmar 3JH4E Wartungshandbuch

3JH4(B)(C)(M)EM9961-03E090Service Manual

3. Precautions for Service Work(1) Precautions for SafetyRead the safety precautions given at the beginning of this manual carefully and always mind

4. Disassembly and Reassembly84(8) Mounting the gear case flangeApply the liquid gasket to the gear case flange and mount the gear case flange and lu

4. Disassembly and Reassembly852) Coat the outside of the piston and the inside of theconnecting rod crank pin metal with engine oil andinsert the pi

4. Disassembly and Reassembly86(11) Mounting the idling gear1) Mount the idling gear so that the oil hole of the idlegear shaft faces up.NOTE:The idl

4. Disassembly and Reassembly87(14) Mounting the lube oil inlet pipeMount the lube oil inlet pipe on the bottom of the cylinder block, using new gask

4. Disassembly and Reassembly88(19) Mounting the marine gearbox1) Mount the fan and damper disk to the flywheel.2) Align the damper disk with the inp

4. Disassembly and Reassembly89(22) Mounting the fuel injection pump1) Lightly fit the fuel injection pump on the gear caseflange. (After adjusting i

4. Disassembly and Reassembly90(25) Mounting the intake manifoldThoroughly clean the inside of the intake manifold, and mount the gasket packing and

4. Disassembly and Reassembly91(30) Mounting the cooling water pipes (seawater / fresh water)1) Mount the seawater pipes with the hose clips(seawater

4. Disassembly and Reassembly92(38) Filling with lube oilFill the engine with lube oil from the supply port on top of the gear case and fill the mari

5. Inspection and Servicing of Basic Engine Parts935. Inspection and Servicing of Basic Engine Parts5.1 Cylinder BlockThe cylinder block is a thin-s

CONTENTS1. GENERAL ... 11.1 Exter

5. Inspection and Servicing of Basic Engine Parts94(6) Clean the surface with the cleaner.NOTE: Without fail, read the instructions for the color che

5. Inspection and Servicing of Basic Engine Parts955.1.5 Cylinder bore measurementEspecially clean head surface, cylinder bores and oilholes, and che

5. Inspection and Servicing of Basic Engine Parts965.2 Cylinder HeadThe cylinder head is of 3-cylinder integral construction, mounted with 14 bolts.

5. Inspection and Servicing of Basic Engine Parts975.2.1 Inspecting the cylinder headThe cylinder head is subjected to very severe operating conditio

5. Inspection and Servicing of Basic Engine Parts985.2.2 Valve seat correction procedureThe most common method for correcting unevennessof the seat s

5. Inspection and Servicing of Basic Engine Parts995.2.3 Intake/exhaust valves, valve guides(1) Wearing and corrosion of valve stemReplace the valve

5. Inspection and Servicing of Basic Engine Parts100(4) Valve guide1) Measuring inside diameter of valve guide.Measure the inside diameter of the val

5. Inspection and Servicing of Basic Engine Parts1015.2.4 Valve springs(1) Checking valve springs1) Check the spring for scratches or corrosion.2) Me

5. Inspection and Servicing of Basic Engine Parts1026) Spring retainer and spring cotterInspect the inside face of the spring retainer, theoutside su

5. Inspection and Servicing of Basic Engine Parts1035.2.7 Intake and exhaust rocker armsThe wear of rocker arm and rocker arm bushing maychange openi

4.2.2 Special Handtools ... 6

5. Inspection and Servicing of Basic Engine Parts1045.3 Piston and Piston PinsPistons are made of a special light alloy with superiorthermal expansio

5. Inspection and Servicing of Basic Engine Parts105(3) Removing the piston pinA floating type piston pin is used in this engine. The piston pin can

5. Inspection and Servicing of Basic Engine Parts106(1) Measuring the rings.Measure the thickness and width of the rings, and thering-to-groove clear

5. Inspection and Servicing of Basic Engine Parts1073) After fitting the piston ring, make sure it moveseasily and smoothly.4) Stagger the piston rin

5. Inspection and Servicing of Basic Engine Parts1085.4 Connecting RodThe connecting rod is made of high-strength forgedcarbon steel.The large end wi

5. Inspection and Servicing of Basic Engine Parts109(2) Checking the side clearance of a connectingrodFit the respective crank pins to the connecting

5. Inspection and Servicing of Basic Engine Parts110• Other procedure of measuring crank pin oil clearance1) Use the press gauge (Plastic gauge) form

5. Inspection and Servicing of Basic Engine Parts1115.4.3 Piston pin bushing(1) Measuring piston pin clearance.Excessive piston pin bushing wear may

5. Inspection and Servicing of Basic Engine Parts1125.5 Crankshaft and Main BearingThe crank pin and crank journal have been inductionhardened for su

5. Inspection and Servicing of Basic Engine Parts113(3) Measuring the crank pin and journalMeasure the outside diameter, roundness and taper ateach c

5.7 Timing Gear ...1195.7.1 Ins

5. Inspection and Servicing of Basic Engine Parts114(4) Checking the side gap of a crankshaftAfter assembling the crankshaft, tighten the mainbearing

5. Inspection and Servicing of Basic Engine Parts1155.5.2 Main bearing(1) Inspecting the main bearingCheck for flaking, seizure or burning of the con

5. Inspection and Servicing of Basic Engine Parts1165.6 Camshaft and Tappets5.6.1 CamshaftThe camshaft is normalized and the cam and bearingsurfaces

5. Inspection and Servicing of Basic Engine Parts117(3) Camshaft and bearing hole measurementMeasure the camshaft outside diameter with amicrometer.

5. Inspection and Servicing of Basic Engine Parts1185.6.2 Tappets(1) The tappets are offset to rotate duringoperation and thereby prevent unevenweari

5. Inspection and Servicing of Basic Engine Parts1195.7 Timing GearThe timing gear is helical type for minimum noise and specially treated for high d

5. Inspection and Servicing of Basic Engine Parts1205.8 Flywheel and HousingThe function of the flywheel is through inertia, to rotate the crankshaft

5. Inspection and Servicing of Basic Engine Parts1215.8.2 Damper disc and cooling fanTorsional rigidity 219 kgf•m/radMax. angle of torsion7.3 x 10-2

6. FUEL INJECTION EQUIPMENT1226. FUEL INJECTION EQUIPMENT6.1 Fuel Injection Pump/GovernorRefer to the JH3E manual of separate volume for the disasse

6. FUEL INJECTION EQUIPMENT1236.1.2 Fuel injection pump service data(1) 3JH4(B)(C)EPart code (Back No.) - 729271-51450 (TM02)Adjustment SPEC - ENG SP

8.2.3 Lube oil pump disassembly and reassembly ... 1428.2.4 Lube oil pum

6. FUEL INJECTION EQUIPMENT124(2) Adjusting fuel limit bolt at rated load1) Adjust the fuel limit bolt to bring the rack positionto the specified val

6. FUEL INJECTION EQUIPMENT1256.1.3 Fuel injection pump structure(1) ComponentControl rackTappetPlunger springDelivery valveBarrelPlungerCamshaftPump

6. FUEL INJECTION EQUIPMENT126(2) Section of a fuel injection pump/ governor for 3JH4(B)(C)E

6. FUEL INJECTION EQUIPMENT1276.1.4 Removing a fuel injection pumpThe procedure to remove a fuel injection pump from the gear case is shown.[NOTICE]B

6. FUEL INJECTION EQUIPMENT1286.1.7 Troubleshooting of fuel injection pumpComplete repair means not only replacing defective parts, but finding and e

6. FUEL INJECTION EQUIPMENT129Fault Cause Remedy2. Engine starts, but immediately stops.(1) Fuel pipe is clogged.(2) Fuel filter is clogged.(3) Impro

6. FUEL INJECTION EQUIPMENT130Fault Cause Remedy7. Loud knocking. (1) Injection timing is too fast or too slow.(2) Injection from nozzle is improper

6. FUEL INJECTION EQUIPMENT1316.1.9 ToolsName of tool Shape and size ApplicationPump mounting scalefor Yanmar tester 158090-51010for Bosch (tester) 1

6. FUEL INJECTION EQUIPMENT132Name of tool Shape and size ApplicationRack indicator158090-51500Rack lock screw158090-51010Dummy nut158090-51520Nozzle

6. FUEL INJECTION EQUIPMENT1336.2 Fuel Feed PumpThe fuel feed pump pumps fuel from the fuel tank,passes it through the fuel filter element, and suppl

9.6.3 Characteristics of thermostat ... 1579.6.4

6. FUEL INJECTION EQUIPMENT1346.2.3 Disassembly and reassembly of fuel feed pump(1) Disassembly1) Remove the fuel feed pump mounting nut, and take th

6. FUEL INJECTION EQUIPMENT135(4) Valve contact/mountingClean the valve seat and valve with air to remove anyforeign matter.(5) Inspect the diaphragm

6. FUEL INJECTION EQUIPMENT1366.3 Fuel FilterThe fuel filter is installed between the fuel feed pumpand fuel injection pump, and removes dirt/foreign

6. FUEL INJECTION EQUIPMENT1376.4 Fuel TankA triangular 30 liter fuel tank with a 2000mm (78.7402 in.) rubber fuel hose to fit all models is availabl

7. INTAKE AND EXHAUST SYSTEM1387. INTAKE AND EXHAUST SYSTEM7.1 Intake SystemAir enters in the intake silencer mounted at the end ofthe intake manifo

7. INTAKE AND EXHAUST SYSTEM139[NOTICE]1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, andtroubles occur.

7. INTAKE AND EXHAUST SYSTEM1407.2 Exhaust System7.2.1 ConstructionThere are two types of mixing elbows, the L-type and the U-type. The mixing elbow

8. LUBRICATION SYSTEM1418. LUBRICATION SYSTEM8.1 Lubrication SystemThe lube oil in the oil pan is pumped up through the intake filter and intake pipi

8. LUBRICATION SYSTEM1428.2 Lube Oil Pump8.2.1 Lube oil pump constructionThe trochoid type lube oil pump is mounted in the gearcase, and the inner ro

8. LUBRICATION SYSTEM1438.2.4 Lube oil pump inspection(1) Outside clearance of outer rotorInsert a gap gage between a outer rotor and a pump body,and

12.6 Instrument Panel ...18512.6.1 B-type

8. LUBRICATION SYSTEM1448.3 Lube Oil Filter8.3.1 Lube oil filter constructionThe lube oil filter is a full-flow paper element type.mounted to the sid

8. LUBRICATION SYSTEM1458.5 Rotary Waste Oil Pump (Optional)A rotary waste oil pump to pump out waste oil isavailable as an option.Rotary waste oil p

9. Cooling Water System1469. Cooling Water System9.1 Cooling Water SystemThe cooling water system is of the indirect seawater cooled, fresh water cir

9. Cooling Water System147Fresh water lineSeawater line(Fresh water pipe)Water temperature senderWater temperature switchExhaust manifoldHeat exchang

9. Cooling Water System1489.2 Seawater PumpThe seawater pump is driven by a gear. The two kinds of seawater pumps are prepared. The standardone is mo

9. Cooling Water System1499.2.2 Seawater pump disassemblyRefer to 2.2.4.(5).(1) Remove the rubber hose from the seawater pump outlet and then the sea

9. Cooling Water System1509.3 Fresh Water Pump9.3.1 Fresh water pump constructionThe fresh water pump is of the centrifugal (volute) type, and circu

9. Cooling Water System1519.3.2 Specifications of fresh water pump9.3.3 Fresh water pump disassembly(1) Do not disassemble the fresh water pump. It i

9. Cooling Water System152Measuring clearance between impeller and pump body.Measuring clearance between impeller and pump bodybracket.mmStandard Lim

9. Cooling Water System1539.4 Heat Exchanger9.4.1 Heat exchanger constructionThe heat exchanger cools the hot fresh water, that hascooled the inside

1. GENERAL11. GENERAL1.1 Exterior Views(1) 3JH4E<Note> This illustration shows the 3JH4E with Yanmar marine gear (Model:KM35P).Engine name plat

9. Cooling Water System1549.5 Pressure cap and coolant recovery tank9.5.1 Pressure cap constructionThe pressure cap mounted on the fresh water filler

9. Cooling Water System1559.5.4 Replacing filler neck1) Take out the copper tube inside the filler neck with striking a circumference with a driver a

9. Cooling Water System1569.5.5 Function of the coolant recovery tankThe pressure valve opens to discharge steam when thesteam pressure in the fresh

9. Cooling Water System1579.6 Thermostat9.6.1 Functioning of thermostatThe thermostat opens and closes a valve according to changes in the temperatur

9. Cooling Water System1589.7 Bilge Pump and Bilge Strainer (Optional)9.7.1 Introduction(1) General Introduction(2) ExteriorName Bilge pumpTime 10 mi

9. Cooling Water System1599.7.2 Description(1) Characteristics1) Discharge at lift : 0 m discharge capacity : 20 liters/min. or greater.2) Automatic

9. Cooling Water System160(7) The pump cannot be used to drain off rain water or large amounts of flood water. Thepump can be run continuously for a

9. Cooling Water System161(4) Attaching the delivery nozzle (outlet)• Make a fixing hole of Ø21 or less for attaching thenozzle. The hose attached at

9. Cooling Water System1629.7.5 Cautions for AssemblingObserve the following cautions for handling.• Do not use gasoline or solvents.1) gasoline 2) e

9. Cooling Water System1639.7.6 TroubleshootingRefer to the following countermeasures for difficulties that arise.Problem Cause Countermeasure1. Pump

1. GENERAL21.2 Specifications(1) 3JH3E, 3JH3BE, 3JH3CE, 3JH4MEOfficial engine model name unit 3JH4ECompany internal model name- 3JH4E 3JH4BE 3JH4CE 3

10. Reduction and Reversing Gear16410. Reduction and Reversing GearMarine gear KM35P and KM35A are applied to the 3JH4E series engines.Refer to chapt

11. REMOTE CONTROL (OPTIONAL)16511. REMOTE CONTROL (OPTIONAL)11.1 Remote Control system11.1.1 Construction of remote control systemThe remote control

11. REMOTE CONTROL (OPTIONAL)166(2) Remote control cableUse only Super Responsive Morse Control CablesThese are designed specifically for use with Mo

11. REMOTE CONTROL (OPTIONAL)16711.2 Remote Control Installation(1) Speed controlClampRemote control cableCable bracketCable jointRemote control brac

11. REMOTE CONTROL (OPTIONAL)168(2) Clutch control(3) Engine stopUsually, to stop the engine, the stop button of aninstrument panel is pushed, and th

11. REMOTE CONTROL (OPTIONAL)16911.3 Remote Control Inspection(1) When the control lever movement does notcoincide with operation of the engine, chec

11. REMOTE CONTROL (OPTIONAL)17011.4 Remote Control Adjustment(1) Shift lever adjustmentMove the lever several times-the movement of the clutch lever

12. Electrical System17112. Electrical System12.1 Electrical SystemNeutral safety switch2 place expression (optional)Sail driveFlywheel housingStarti

12. Electrical System17212.1.1 Wiring diagram(1) For B-type instrument panel(Color coding) R Red B BlackW WhiteL Blue RB Red / Black LB Blue / Black Y

12. Electrical System173(2) For C-type instrument panel(Color coding) R Red B BlackW WhiteL Blue RB Red / Black LB Blue / Black YW Yellow / White YB Y

1. GENERAL3(Note)1. Rating condition : ISO 3046-1, 86652. 1HP (metric horse power) ≒ 0.7355 kW3. Fuel condition : Density at 15°C = 0.842* Fuel tempe

12. Electrical System17412.2 BatteryRefer to 2.2.3(2) for electrolyte level and battery charge. Also refer to the service manual of the 3/4 JH3E serie

12. Electrical System17512.3 Starting MotorA starting motor turns the ring gear installed on a engine flywheel by the pinion while overcomingresistanc

12. Electrical System17612.3.3 Structure(1) Disassembly drawingMagnetic switchInternal gearBracketPinionGear housingArmatureYokeRear cover

12. Electrical System177(2) StructureWhen the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. The pinionengages

12. Electrical System17812.4 Alternator Standard, 12V/60AThe alternator serves to keep the battery constantly charged. It is installed on the cylinder

12. Electrical System17912.4.2 Structure(1) Disassembly drawing(2) Structure(12V60A alternator)PulleyFront bracketRotorStatorFanBall bearingRear brack

12. Electrical System18012.4.3 Wiring diagram[NOTICE]1) Don't do mis-connecting and short-circuit of each terminal.2) Don't remove a battery

12. Electrical System18112.4.5 Inspection(1) V belt inspection1) Inspect the matter whether there are not crack,stickiness and wear on the belt visual

12. Electrical System18212.5 Alternator 12V/80A (Optional)12.5.1 SpecificationsYanmar code 119573-77201Model of alternator LR180-03C (HITACHI)Model of

12. Electrical System18312.5.2 StructureDisassembly drawing and StructureFanFront coverBearing retainerStatorBrush regulator assyDiodeCondenserRotorBa

M9961-03E090

1. GENERAL41.3 Engine Outline(1) 3JH4E (with KM35P marine gear)4- 10.5 100 50+0.0250 32PC 786 7.54DETAIL OF COUPLINGSCALE 1:33-M10 X 1.5DE

12. Electrical System18412.5.3 Wiring diagram [NOTICE]1) Don't do mis-connecting and short-circuit of each terminal.2) Don't remove a batter

12. Electrical System18512.6 Instrument PanelThe new type instrument panels are applied for 3JH4E series engines. The features are compactness,waterpr

12. Electrical System18612.7 Warning Devices12.7.1 Oil pressure alarmIf the engine oil pressure is below 0.01-0.03MPa (0.1-0.3kgf/cm2, 1.42-4.26 lb/in

12. Electrical System18712.7.2 Sender unit for lube oil pressure gaugeThe sender unit for the lube oil pressure gauge has amounting seat for mounting

12. Electrical System18812.7.3 Cooling water temperature alarmA water temperature lamp and water temperature gauge, backed up by an alarm in the instr

12. Electrical System18912.8 Air Heater (Optional)An air heater is available for warming intake air when starting in cold areas in winter. The air hea

12. Electrical System19012.9 Electric Engine Stopping Device (Optional)The electric engine stop device is fitted to the governor.The device is operate

13. SERVICE STANDARDS19113. SERVICE STANDARDS13.1 Engine TuningNo. Inspection item Standard LimitReferencepage1Intake/exhaust valve clearancemm0.15-0

13. SERVICE STANDARDS19213.2 Engine Body13.2.1 Cylinder head(1) Cylinder head(2) Intake/exhaust valve and guide(3) Valve spring(4) Rocker arm and sha

13. SERVICE STANDARDS19313.2.2 Camshaft and gear train (1) Camshaft(2) Idle gear shaft and bushing(3) Backlash of each gearmmInspection item Standard

1. GENERAL5(2) 3JH4BE(with KM35A Marine gear)+0.02506 7.5DETAIL OF COUPLINGSCALE 1:33-M10 X 1.5DEPTH 14 / 20DIRECTION OF ROTATIONDETAIL OF PULLEYSCAL

13. SERVICE STANDARDS19413.2.3 Cylinder block(1) Cylinder block(2) Crankshaft(3) Thrust bearing(4) Piston and ring1) PistonmmInspection item Standard

13. SERVICE STANDARDS1952) Piston ring(5) Connecting rod(6) TappetmmInspection item Standard limit Reference pageTop r in gRing groove width 2.060-2

13. SERVICE STANDARDS19613.3 Lubricating Oil System (Trochoid Pump)(1) Outside clearance of outer rotor(2) Side clearance of outer rotor(3) Inside cl

14. TIGHTENING TORQUE FOR BOLTS AND NUTS19714. TIGHTENING TORQUE FOR BOLTS AND NUTS14.1 Main Bolt and Nut14.2 Standard Bolts and Nuts (without lube o

January, 2004Printed in JapanYANMAR CO,. LTD.MARINE FACTORYENGINE PRODUCT OPERATIONS DIVISION5-3-1, TSUKAGUCHI HONMACHI, AMAGASAKI-SHI, HYOGO 661,JAPA

1. GENERAL6(3) 3JH4CE (with SD40 sail drive)538.6517.6243.6194.1210395431.46052107210(266.4)(202.5)(202.5)97353837214347(112.5)(185)1036.4641.4420480

1.General71.4 Piping Diagrams(1) 3JH4(B) ENote: The following piping diagram is for the 3JH4E model.OverflowFuel oil inletFuel feed pumpLubricating oi

1.General8(2) 3JH4CE (with sail drive SD40)OverflowFuel oil inletFuel feed pumpLubricating oil filter (cartridge type)Lubricating oil coolerMixing elb

1.general91.5 Exhaust Gas Emission RegulationThe EPA and ARB (,California Air Resources Board)Off-road Compression Ignition engines regulations1.5.1 E

1.General101.5.2 Exhaust Gas RegulationsThis engine conforms to the EPA exhaust gas regulations (19kW and under 37kW).Note1. The transit smoke (ACC/LU

1.general11(5) Quality guarantee period for exhaust emission related partsFor exhaust emission related parts, follow the inspections outlined in the &

2. Inspection and Adjustment122. Inspection and Adjustment2.1 Periodic Maintenance ScheduleThe engine periodic inspection timing is hard to determine

2. Inspection and Adjustment13*1 For EPA requirements see also 1.5 in chapter 1.*2 Whichever comes first { : User-maintenance Å : Parts replacement

Printed in JapanM9961-03E090Publication No. M9961-03E090History of RevisionManual Name Service Manual for Marine Diesel EngineEngine Model: 3JH4(B)(C)

2. Inspection and Adjustment142.2 Periodic Inspection and Maintenance Procedure2.2.1 Check before startingBe sure to check the following points befor

2. Inspection and Adjustment152) Checking marine gear lube oil levela) Check the lube oil level of the marine gear with adipstick.b) When the level i

2. Inspection and Adjustment16IMPORTANT:If the cooling water runs short quickly or when the coolant tank runs short of water with the coolantrecovery

2. Inspection and Adjustment17(7) Check the leakage of water, lube oil and fuel.Brfore and after starting the engine, check the leakage of cooling wa

2. Inspection and Adjustment183) Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manuallyturning it clock

2. Inspection and Adjustment192) If necessary, adjust the V-belt tension (deflection).To adjust the V-belt tension, loosen the set bolt forthe belt a

2. Inspection and Adjustment20c) Valve clearance measurementInsert a thickness gage between the rocker armand valve cap, and record the measured valv

2. Inspection and Adjustment21(6) Check and adjust the remote control operationThe various control levers on the engine side are connected to the rem

2. Inspection and Adjustment222.2.3 Inspection every 50 hours or monthlyBe sure to check the following points every 50 hours or monthly, whichever co

2. Inspection and Adjustment23Fuel System Air bleeding Procedures1) Check the fuel level in the fuel tank. Replenish ifInsufficient.2) Loosen the air

FOREWORDThis service manual has been complied for engineers engaged in sales, service, inspection andmaintenance. Accordingly, descriptions of the con

2. Inspection and Adjustment24Battery structure(1) Electrolyte level• Check the level of fluid in the battery.When the amount of fluid nears the lowe

2. Inspection and Adjustment25(b) Measurement with hydrometerWhen using a hydrometer, the measured specificgravity must be corrected according to th

2. Inspection and Adjustment262.2.4 Inspection every 250 hours or one yearBe sure to check the following points every 250 hours or one year operatio

2. Inspection and Adjustment27(5) Check the impeller of the cooling water pump (seawater pump).1) Remove the seawater pump cover and take outthe O-r

2. Inspection and Adjustment282) Close the three water cocks for fresh water.3) Remove the filler cap of the fresh water cooler byturning the cap cou

2. Inspection and Adjustment297) Check the rubber hose connecting the coolantrecovery tank to the fresh water cooler. Be sure thehose is securely con

2. Inspection and Adjustment30(9) Check the wiring connectors.Check whether each connection part doesn't have looseness.Neutral safety switch2 p

2. Inspection and Adjustment312.2.5 Inspection every 1,000 hours or four yearsBe sure to check the following points every 1,000 hours or four years o

2. Inspection and Adjustment32(2) Check the injection spray condition of a fuel nozzleWear protective glasses when testing injection from the fuel in

2. Inspection and Adjustment33[Informative: Fuel injection valve structure]2) Spray pattern inspectionAfter adjustment to the specified valve opening

FOR SAFTY1. SAFETY LABELS• Most accidents are caused by negligence of basic safety rules and precautions. For accidentprevention, it is important to a

2. Inspection and Adjustment34b) Spray and injection states• Operate the nozzle tester lever at a rate of onceor twice a second and check no abnormal

2. Inspection and Adjustment35(4) Clean & check the water passagesWhen it is used for a long time, cleaning of the cooling water passages is peri

2. Inspection and Adjustment364) Pressure cap inspectionDo not open the pressure cap while the engine is running or right afterstopping because high

2. Inspection and Adjustment37(7) Retighten all major nuts and bolts.Retighten the major nuts and bolts bellow by the standard tightening torques. (S

2. Inspection and Adjustment382.3 Adjusting the no-load maximum or minimum speed1) After warming the engine up, gradually raise thespeed and set it a

2. Inspection and Adjustment392.5 Thermostat inspection(1) Put the thermostat in a beaker with freshwater, and heat it on an electric stove. Thetherm

2. Inspection and Adjustment402.6 Adjusting OperationPerform the adjusting operation for an engine as follows after the maintenance job:2.6.1 Prelimi

2. Inspection and Adjustment412.6.3 Check Points and Precautions During RunningStep Item Instructions Precautions1 Checks before operation1) Make su

2. Inspection and Adjustment422.7 Long storageObserve the following instructions when the engine is to be stored for a long period without operation:

3. Troubleshooting433. Troubleshooting3.1 Preparation before troubleshootingIf the signs of a trouble appear, it is important to lecture on the count

2. Safety Precautions(1) SERVICE AREA• Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to oneshealth. Running

3. Troubleshooting443.2 Quick Reference Chart for TroubleshootingIt is important to thoroughly under stand each system and the function of all of the

3. Troubleshooting45TROUBLE AND TROUBLESHOOTING(I-1) Add fuel oil and prime.Chart 1THE ENGINE SUDDENLY STOPS.CountermeasureCause and EffectCountermea

3. Troubleshooting46Trouble and TroubleshootingTROUBLE AND TROUBLESHOOTINGCountermeasureChart 3POOR EXHAUST COLOR(I-1) Check, repair or replace.(I-

3. Troubleshooting47TROUBLE AND TROUBLESHOOTINGCause and EffectCountermeasure(IV-1) Replace.(IV-2) Clean.(IV-3) Replenish oil and check. Replace

3. Troubleshooting48TROUBLE AND TROUBLESHOOTINGCause and EffectCountermeasure(III-1) Replace.(III-2) Adjust.(III-3) Clean.(III-4) Disassemble, wa

3. Troubleshooting49(3) Sticking of valve needle(4) Faulty injection sprayTROUBLE AND TROUBLESHOOTINGCause and EffectCountermeasure(III-1) Adjust

3. Troubleshooting50TROUBLE AND TROUBLESHOOTINGCause and EffectCountermeasure(V-1) Replace plunger and barrel as a unit.(V-2) Replace.(V-3) Disas

3. Troubleshooting51TROUBLE AND TROUBLESHOOTINGCause and EffectCountermeasure(IV-1) Lap valves.(IV-2) Adjust.(IV-3) Replace.(IV-4) Replace.(IV-5)

3. Troubleshooting52TROUBLE AND TROUBLESHOOTINGCause and EffectCountermeasure(IV-1) Adjust the amount of returning water or check the co

3. Troubleshooting533.3 Troubleshooting (Concerning engine and fuel injectionequipment)Malfunctions Causes RemediesThe engine does not operate1. Fu

(2) WORK - WEAR (GARMENTS)• Safe Work ClothingAppropriate safety wear (gloves, special shoes/boots, eye/ear protection,head gear, harness', cloth

3. Troubleshooting54Malfunctions Causes RemediesThe engine exhaust contains smoke and the engine “knocks”1. The injection timing is incorrect2. The n

3. Troubleshooting55Malfunctions Causes Remedies4. The nozzle or the nozzle holder is not functioning properlyThe engine cannot reach its maximum spe

3. Troubleshooting563.4 Troubleshooting by measuring Compression PressureCompression pressure drop is one of major causes of increasing blowby gas (l

3. Troubleshooting57(3) Engine speed and compression pressure (for reference)(4) Measured value and troubleshootingWhen the measured compression pres

4. Disassembly and Reassembly584. Disassembly and Reassembly4.1 Disassembly and Reassembly Precautions(1) Disassembly• Take sufficient time to accura

4. Disassembly and Reassembly594.2 Disassembly and Reassembly ToolsThe following tools are required when disassembling and reassembling the engine.Pl

4. Disassembly and Reassembly60Name of tool Illustration RemarksCopper hammer Local supplyMallet Local supplyNippers Local supplyPliers Local supplyO

4. Disassembly and Reassembly61Name of tool Illustration RemarksLead rod Local supplyFile Local supply 1setRod spanner for hexagon socket head screws

4. Disassembly and Reassembly624.2.2 Special HandtoolsName of tool Illustration RemarksPiston pin insertion/extraction toolConnecting rod small end b

4. Disassembly and Reassembly63Name of tool Illustration RemarksPiston ring compressorPiston ring replacer (for removal / installation of piston ring

(5) FASTENER TORQUE• Torqueing FastenersAlways follow the torque values and procedures as designated in theservice manual. Incorrect values, procedure

4. Disassembly and Reassembly64Name of tool Illustration RemarksPress tool 1 for filler neck-Press tool 2 for filler neck copper tube-Stem seal inser

4. Disassembly and Reassembly654.2.3 Measuring InstrumentsName of tool Illustration RemarksVernier calipers 0.05mm0-150mmMicrometer 0.01mm0-25mm25-50

4. Disassembly and Reassembly664.2.4 Other materialItems Usual Contents Features and applicationLiquid gasket Three BondNo.1TB1101200g(1kg also avail

4. Disassembly and Reassembly67Items Usual Contents Features and applicationScale solvent Scale solvent 1 box(4 kg × 4 removers)• The scale solvent r

4. Disassembly and Reassembly68[Notice]It is recommended that the liquid gasket of Three Bond TB1212 should be used for service work.Before providing

4. Disassembly and Reassembly694.2.5 Measuring InstrumentsNo. Name of tool Use Illustration1 Dial gauge Measures shaft bending, distortions of leveln

4. Disassembly and Reassembly70No. Name of tool Use Illustration9 V Block Measures shaft distortion.10 Torque wrench Used to tighten bolts and nuts t

4. Disassembly and Reassembly71No. Name of tool Use Illustration16 Rotation gaugeContact type Measures rotation speed by placing at the indentation h

4. Disassembly and Reassembly724.3 Disassembly and Reassembly4.3.1 Disassembly• Preparation on a boatFor engines mounted in an engine room of a ship,

4. Disassembly and Reassembly73(3) Removing (electrical) wiringRemove the wiring from the engine. (Refer to 2.2.4(9) )(4) Removing the fuel filter &a

(8) FURTHER PRECAUTIONS• Fueling / RefuelingKeep sparks, open flames or any other form of ignition (match, cigarette,etc.) away when fueling/refuelin

4. Disassembly and Reassembly74(6) Removing the mixing elbow1) Remove the seawater rubber hose connecting to aheat exchanger- a mixing elbow.2) Remov

4. Disassembly and Reassembly75(9) Removing the cooling water pipe (seawater/ fresh water)1) Remove the seawater pipe (seawater pump-heat exchanger).

4. Disassembly and Reassembly76(12) Removing the lube oil filter and lube oil cooler1) Remove the fresh water pipe (cylinder block-lubeoil cooler, lu

4. Disassembly and Reassembly77(16) Removing the fuel injection nozzlesRemove the bolt for the fuel nozzle retainer, and pull out the fuel nozzle ret

4. Disassembly and Reassembly78(22) Turning the engine over1) Place a wood block of appropriate size on the floor,and stand up the engine on the flyw

4. Disassembly and Reassembly79(28) Removing the idle gearLoosen the three bolts holding the idle gear and pull outthe idle gear and shaft.(29) Remov

4. Disassembly and Reassembly80(31) Removing the gear case flange1) Remove the gear case flange from the cylinderblock.2) Remove the O-rings from the

4. Disassembly and Reassembly81(35) Removing the main bearing.1) Remove the main bearing bolts.2) Remove the main bearing cap and lower mainbearing m

4. Disassembly and Reassembly824.3.2 Reassembly(1) Clean all partsClean all parts using by the cloth and diesel oil(or cleaning agent) before reassem

4. Disassembly and Reassembly83(5) Mounting the main bearing capCoat the lower main bearing metal with engine oil, andmount it to the main bearing ca