Yanmar 3JH2 Series - Piston Head and Combustion Surface; Measurement of Piston Outside Diameter;Inspection; Replacing the Piston

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History of Revision3
Exterior Views3
Injection Pump3
Intake and Exhaust System3
Contents5
General/Contents6
Exterior Views 3JH2E7
Exterior Views 3JH2-TE8
Exterior Views 3JH25A/30A9
Sea Water Pump9
Exterior Views with KM3P1/KM35P110
Fresh Water Pump10
Specifications11
Lubrication System12
Marine Gear13
Applicability of Marine Gear and Reduction Ratio13
Engine Outline 3JH2-E (KBW10-E)15
Engine Outline 3JH2-BE (KM3A)16
Engine Outline 3JH2TE (KBW10-E)17
Engine Outline 3JH2-TB (KM3A)18
Engine Outline 3JH25A/30A19
Mixing Elbow19
Dimensions of Flywheel20
Performance Curves 3JH2-(B)E21
Performance Curves 3JH2-T(B)E22
Performance Curve 3JH25A23
Performance Curve 3JH30A24
Piping Diagrams 3JH2-(B)E25
Piping Diagrams 3JH2-TE26
Piping Diagrams 3JH2-TBE27
Piping Diagrams 3JH25A/30A28
Fuel Feed Pump28
Basic Engine Parts/Contents29
Cylinder Block30
Inspection of Parts30
Cleaning of Oil Holes30
Color Check Procedure30
Replacement of Cup Plugs31
Cylinder Bore Measurement32
Cylinder Head33
Inspecting the Cylinder Head34
Distortion of the Combustion Surface34
Checking for Cracks in the Combustion Surface34
Checking the Intake and Exhaust Valve Seats34
Valve Seat Correction Procedure35
Intakes/Exhaust Valves, Valve Guides35
Wearing and Corrosion of Valve Stem35
Inspection of Valve Seat Wear and Contact Surface36
Valve Sinking/Guide36
Checking Valve Springs37
Spring Tension Tester37
Assembling the Cylinder Head38
Measuring Top Clearance38
Intake and Exhaust Valave Arms38
Adjustment of Valve Head Clearance39
Pistons and Piston Pins40
ID Marks for Piston/Piston Pin40
Piston Head and Combustion Surface41
Measurement of Piston Outside Diameter/Inspection41
Replacing the Piston41
Measuring the Rings/Ring Gap42
Replacing the Piston Rings43
Inspecting the Connecting Rod44
Twist and Parallelism of the Large and Small Ends44
Checking Thrust Clearance44
Piston Pin Bushing45
Checking Crank Pin Bushing45
Measuring Crank Pin Oil Clearance45
Precautions on Replacement of Crank Pin Bushing45
Assembling Piston and Connecting Rod46
Crankshaft47
Color Check of Shaft47
Bending of the Crankshaft48
Measuring the Crank Pin and Journal48
Checking Side Clearance of the Crankshaft49
Inspecting the Main Bearing49
Measuring the Inner Diameter of Metal49
Checking the Camshaft Side Gap50
Camshaft Height50
Tappets51
Timing Gear53
Inspecting the Gears53
Gear Timing Marks54
Specifications of Flywheel55
Dimensions of Flywheel and Mounting Flange56
Ring Gear57
Position of Top Dead Center and Fuel Injection Timing57
Damper Disc and Cooling Fan58
Applicability of Cooling Fan58
Fuel Injection Equipment/Contents59
Fuel Injection Pump Service Data (Yanmar Type: YPES-3CL)60
Governor Exploded View62
Governor Disassembly63
Inspection/Assembling of Governor67
Governor Spring Spec. Table67
Fuel Injection Pump Exploded View71
Disassembly of Fuel Injection Pump72
Inspection of Fuel Injection Pump76
Reassembly of Fuel Injection Pump77
Adjustment of Fuel Injection Pump and Governor81
Preparations81
Adjustment of Top Clearance82
Adjusting of Injection Timing83
Plunger Pressure Type84
Delivery Valve Pressure Test84
Adjusting/Measuring/Adjustment of Injection Volume (Uniformoty of each Cylinder)84
Adjustment of Governor85
Adjusting Fuel/Rpm Limit Bolt85
Adjusting Idling85
Check Injection Volume When Starting86
Construction of Fuel Feed Pump87
Fuel Feed Pump Specifications87
Disassembly/Reassembly/Inspection of Fuel Feed Pump88
Functioning of Fuel Injection Nozzle89
Fuel Injection Nozzle Disassembly/Inspection90
Washing90
Fuel Injection Nozzle Reassembly91
Nozzle Inspection91
Adjusting Fuel Injection Nozzle92
Adjusting Opening Pressure92
Injection Test92
Troubleshooting of Fuel Injection Pump93
Major Faults and Troubleshooting93
Tools95
Fuel Filter Specifications/Inspection97
Fuel Tank98
Intake and Exhaust System/Contents99
JHE Engine Intake/Exhaust System100
3JH25A/30A Intake/Exhaust System101
3JH-TE Engine Intake System102
Turbocharger Specifications/Construction103
Interchangeability of Turbochargers104
Turbocharger Model Name Plate104
Interchangeability of Turbochargers Components105
Turbocharger Preparation for Disassembly106
Inspection Prior to Disassembly107
Disassembly107
Preparation for Reassembly107
Reassembly108
Turbocharger Inspection and Maintenance109
Disassembly/Reassembly Precautions109
Inspection Procedure111
Periodic Inspection112
Turbocharger Troubleshooting115
Excessive/White Exhaust Smoke115
Excessive Oil Consumption115
Decrease in (Engine) Output115
Turbocharger Blower Washing Procedure116
Poor (Slow) Turbochrger Responsiveness116
Abnormal Noise or Vibration116
Mixing Elbow Construction/Inspection117
Lubrication System/Contents118
Lubrication System119
3JH2-TE Lubrication Points120
3JH25A/30A Lubrication Points121
Lube Oil Pump Construction122
Specifications of Lube Oil Pump123
Lube Oil Pump Disassembly/Inspection124
Lube Oil Filter Construction125
3JH25A/30A Lube Oil Filter Construction126
Cylinderblock126
Lube Oil Filter Replacement127
Oil Pressure Control Valve Construction/Replacement128
Vibration Preventing Damper128
Lube Oil Cooler Construction/Inspection129
Piston Cooloing Nozzle Construction/Inspection (Only 3JH2TE)130
Rotary Waste Oil Pump Construction/Inspection131
Cooling Water System/Contents132
Cooling Water System133
Fresh Water Line (4JH2E&4JH2-TE)134
Sea Water Line (3JH2E&3JH2-TE)135
Sea Water Line (3JH25A/30A)136
Heat Exchanger136
Sea Water Pump Construction137
Specifications of Sea Water Pump137
Sea Water Pump Disassembly/Inspection137
Sea Water Pump Reassembly139
Fresh Water Pump Construction140
Specifications of Fresh Water Pump141
Fresh Water Pump Disassmebly/Inspection141
Heat Exchanger Construction143
Specifications of Heat Exchanger144
Disassembly and Reassembly of the Heat Exchanger144
Heat Exchanger Inspection144
Pressure Cap Construction/Inspection145
Pressure Cap Pressure Control145
Function of the Sub Tank145
Sub Tank Construction146
Specifications of Sub Tank146
Mounting the Sub Tank146
Precautions on Usage of the Sub Tank146
Functioning of Thermostat147
Thermostat Construction147
Characteristics of Thermostat147
Thermostat Inspection148
Testing the Thermostat148
Kingston Cock Construction/Inspection149
Kingston Cock Handling Precautions149
Sea Water Filter Construction150
Bilge Pump and Bilge Strainer Construction151
Bilge Pump Specifications151
Performance of Pump (in Pure Water)151
Reduction and Reversing Gear/Contents152
Marine Gear Models KM3A for Engine Models 3JH2BE/3JHE-TBE153
Gear Construction153
Gear Specifications154
Power Transmission System155
Arrangement of Shafts and Gears155
Reduction Ration155
Power Transmission Routine (Forward/Reverse)156
Power Transmission Drawing157
Power Transmission Sectional View158
Construction of Shifting Mechanism159
Forward and Reverse Clutch Operation160
Engagement and Disengagement of Clutch160
Clutch Shifting Force161
Adjustment of Shifting Device161
Measurement and Adjustment of Clearance162
Inspect for the Following Points (Every 2-3 Months)162
Adjustment of the Remote Control Head, Marine Gear Box Control Side163
Inspection and Servicing164
Clutch Case/Bearing/Gear164
Forward and Reverse Large Gears164
Drive Cone164
Lapping Procedure for Drive Cone165
Thrust Collar Construction166
Cup Spring167
Oil Seal of Output Shaft167
Input/Output Shaft167
Intermediate Shaft168
Shifter168
Shift Lever Shaft and Location Pin168
Damper Disc169
Shim Adjustment for Output and Input Shafts169
Shifter Spring and Stopper Bolt169
Side Cover and Oil Seal169
Torque Limiter171
Dismantling the Clutch172
Removal of the Output Shaft174
Removal of the Intermediate Shaft176
Dismantling the Shifting Device176
Reassembly of the Output Shaft177
Reassembly of the Clutch178
Reassembly of the Shifting Device180
Marine Gear Models KM3P1, KM3P3, KM35P1 for Engine Models 3JH25A/30A Construction181
Marine Gear Models KM3P1, KM3P3, KM35P1 for Engine Models 3JH25A/30A Specifications182
Remoto Control/Contents209
Construction of Remote Control System210
Remote Control Device Components210
Speed Control211
Clutch Control212
Engine Stop213
Remote Control Inspection214
Remote Control Adjustment215
Electrical System/Contents216
System Diagram of Electric Parts (B2-Type)217
System Diagram of Electric Parts (C-Type)218
Wiring Diagram for B-Type Instrument Panel219
Wiring Diagram for C-Type Instrument Panel220
Wiring Diagram for 3JH25A/30A221
Battery221
Battery Construction/Inspection222
Battery Capacity and Battery Cables222
Checking the Electrolyte223
Voltage Test223
Washing the Battery223
Charging Methods/Procedure/Precautions224
Battery Storage Precautions224
The Reduction Starters225
The Engagement Mechanism226
Troubleshooting the Starter System227
Starter Motor Disassembly228
Check the Diameter of the Commutator232
Continuity/Insulation Test for the Armature Coil232
Check for Surface Distortion on the Armature and the Commutator232
Check the Surface of the Commutator233
Check the Depth of Insulating Material from the Commutator Surface233
Continuity/Insulation Test for the Field Coil233
Brushes234
Brush Holder234
Magnetic Switch234
Continuity Test for the Shunt Coil234
Continuity Test for the Series Coil/Contact-Points235
Inspection of the Pinion235
Pinion Sliding Test235
Inspection of the Ball Bearings236
Starter Motor Reassembly237
Kind of Grease237
Reassembly of the Nagnetic Switch238
Operation Specifications Check239
The No-Load Test239
Sterter Motor Specifications240
Alternator Standard Features/Specifications/Characteristics241
Alternator Construction242
Handling Precautions243
IC Regulator243
Charge Lamp243
Alternator Circuit Diagram243
Disassembling the Alternator244
Alternator Inspection and Adjustment245
Diode245
Inspecting the Slip Ring Surface245
Rotor Coil Continuity Test245
Brush/Brush Wear246
Rotor Coil Insulation Test246
Check the Rear Side Ball Bearing246
Stator Coil Continuity/Insulation Test246
Reassembling the Alternator247
Performance Test248
Alternator Troubleshooting249
Charging Failure249
Overcharging250
Charge Lamp Failure250
B2-Type Instrument Panel with Wiring251
C-Type Instrument Panel251
Extension Codes252
Warning Devices253
Oil Pressure Alarm/Inspection253
Cooling Water Temperature Alarm254
Sender Unit for Lube Oil Pressure Gauge254
Sender Unit for Cooling Water Temperature Gauge255
Air Heater256
Electric Type Engine Stopping Device257
Solenoid257
Relay258
Wire Harness of Engine Stop258
Construction of Tachometer259
Specifications and Dimensions of Tachometer259
Measrement of Sensor Unit Characteristics260
Alternator 12V/80A Features/Specifications/Characteristics262
Alternator 12V/80A Construction263
Alternator 12V/80A Functioning264
Disassembly and Reassembly/Contents272
Disassembly and Reassembly Precautions273
Disassembly and Reassembly Tools274
Special Handtools277
Measuring Instruments279
Supplementary Packing Agent280
Paint280
Yanmar Cleaner280
Neji Lock Super280
Disassembly Drain Cooling Water/Lube Oil281
Removing (Electrical) Wiring281
Removing the Fuel Oil Filter/Pipe282
Removing the Intake Silencer282
Removing the Mixing Elbow282
Removing the Turbine (3JH2-TE)282
Removing the Starting Motor284
Removing the Alternator284
Removing the Cooling Water Pipe284
Removing the Heat Exchanger (Exhaust Manifold, Fresh Water Tank Unit)284
Removing the Cooling Water Pipe/Sea Water Pump285
Removing the Lube Oil Filter285
Removing the High Pressure Fuel Pipe285
Removing the Intake Manifold285
Removing the Fresh Water Pump286
Removing the Fuel Injection Nozzles286
Removing the Valve Elbow Shaft Assembly286
Removing the Cylinder Head286
Removing the Crankshaft V-Pulley287
Removing the Marine Gearbox287
Removing the Lube Oil Cooler287
Removing the Flywheel287
Turning the Engine over288
Removing the Oil Pan288
Removing the Lube Oil Intake Pipe/Pump288
Removing the Gear Case288
Remove the Oil Injection Pump289
Removing the Idling Gear289
Removing the Pistons and Connecting Rods289
Removing the Flywheel Housing290
Removing the Main Bearing290
Removing the Crankshaft/Camshaft/Tappets290
Removing the Gear Case Flange290
Removing/Mounting the Piston Cooling Nozzle291
Mounting the Gear Case Flange291
Inserting the Tappets291
Mounting the Camshaft/Crankshaft292
Mounting the Main Bearing Metal with Engine Oil and Main Bearing Cap292
Mounting the Flywheel Housing293
Stand up the Cylinder Block293
Mounting the Piston and Connecting Rod293
Mounting the Idling Gear294
Mounting the Fuel Injection/Lube Oil Pump294
Mounting the Fuel Feed Pump Drive Gear and Automatic Advancing Timer294
Mounting the Gear Case295
Mounting the Lube Oil Intake Pipe295
Mounting the Oil Pan/Flywheel295
Mounting the Engine Mounting Feet and Turning the Engine Upright295
Mounting the Marine Gearbox296
Mounting the Crank V-Pulley296
Mounting the Cylinder Head296
Mounting the Valve Rocker Arm Shaft Assembly Pushrod297
Mounting the Fuel Injection Nozzle297
Mounting the Fresh Water Pump297
Mounting the Intake Manifold298
Mounting the High Pressure Fuel Pipe and Fuel Oil Return Pipe298
Mounting the Lube Oil Cooler/Filter298
Mounting the Lube Oil/Cooling (Sea) Water Pipe299
Mounting the Dipstic Guide299
Mounting the Sea Water Pump299
Mounting the Heat Exchanger (Exhaust Manifold, Fresh Water Tank Unit)299
Mounting the Alternator300
Mounting the Starting Motor300
Mounting the Turbine (Model 3JH-TE)300
Mounting the Mixing Elbow and the Turbocharger301
Mounting the Intake Silencer/Fuel Filter/Oil Pipe302
Electrical Wiring302
Installation in the Ship and Completion of the Piping and Wiring302
Filling with Lube Oil302
Filling with Cooling Water303
Check Fuel Injection Timing303
Bolt/Nut Tightening Torque304
Test Running305
Preliminary Precautions305
Check Points and Precautions During Running305
Parts Differing in Shape306

Yanmar 3JH2 Series - Piston Head and Combustion Surface; Measurement of Piston Outside Diameter;Inspection; Replacing the Piston

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