Yanmar 4JH3BE - Chapter 1: General

MODELS
3JH3(B)(C)E49 4JH3(B)(C)E
Chapter 1 GENERAL
1. Exterior Views···················································1-1
2. Specifications ···················································1-3
3. Engine Outling ················································1-6
4. Piping Diagrams ·············································1-10
Chapter 2 INSPECTION AND SERVICING OF
BASIC ENGINE PARTS
1. Cylinder Block···················································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
Chapter 3 FUEL INJECTION EQUIPMENT
1. Fuel injection Pump Service Data ...... · ... ·· ... · · ... ·· · ·3-1
2. Governor · · .. · .. · .. · .. · · · · .. · .. ·· ·· .. · .. · ·· · · · · · · · ···· .. · · · · · · .. · ·3-4
3. Disassembly, Reassembly and Inspection of
Fuel injection pump .......................................... 3.14
4. Adjustment of Fuel Injection Pump and Governor ···3-24
5. Fuel Feed Pump ............................................. 3.30
6. Fuel injection Nozzle ············ ........................... 3.32
7. Troubleshooting ······ ....................................... 3.35
8. Tools ............................................................ 3.35
9. Fuel Filter · ....... ·· · · · · · · ...... · · ........ · · ..... · .. · · ·· · · · .. ·· ·3-40
10.Fuel Tank ...................................................... 3.41
11.Troubleshooting ···················· ......................... 3.42
Chapter 4 INTAKE AND EXHAUST SYSTEM
1. lntank System ........ · .... ·········· ... ······ ..... ·-· ..... · ..... 4.1
2. Exhaust System .... · · ............. · ... · · · ... ·· ... · ·· ·· ·· .. · .... 4.2
Chapter 5 LUBRICATION SYSTEM
1. Lubrication System ........ · · ·· · · ........ · ·· · · · ... ·· ... · · · ·· ·5-1
2. Lube Oil Pump ................ · ............ · .... · · · · · ....... · ·5-2
3. Lube Oil Filter · · ... ·· · · · ... · .. · · · · · · .......... · .... · · ... ·· · ·· ... ·5-6
4. Lube Oil Cooler .................................. · · .......... · ·5-8
5. Rotary Waste Oil Pump (Optional) · · · · ·· · · ·· ·· ·· .......... 5.9
Chapter 6 COOLING WATER SYSTEM
1. Cooling Water System .......... · ·· .. · · ...................... 5.1
2. Sea Water Pump ............................................. 5.3
3. Fresh Water Pump···································· ......... 5.5
4. Heat Exchanrger .. · ...... · .. · ...... · · .... · .. · · ... · · ... ·· · ·· ··6-8
5. Pressure Cap and Sub Tank .............................. 5.10
6. Thermostat · · · · · · · · .. · · ·· .. ·· ·· · · · .. · .. · .. · · .... · ·· · · ·· · ·· · · · ·6-12
7. Bilge pump and Bilge Strainer (Optional) ............ 5.14
Printed in Japan
HINSHI-H8009
Chapter 7 REDUCTION AND REVERSING GEAR
Marine Gear Models [KM3A]
1. Construction ................................................... 7.1
2. Shifting Device · ...... · ··· ·· · ·· ··· · ·· .. · ·· · · ...... · · · ... ·· · · · · · 7-7
3. Inspection and Servicing ................ ······ ... · ....... ··· 7-12
4. Disassembly ································· ............... 7.20
5. Reassembly ................................................... 7.25
Marine Gear Models [KM3P)
1. Construction ······· ......................................... 7.29
2. Shifting Device ................................................ 7.35
3. Inspection and Servicing····· ..... ········ ..... ···· ....... ·· 7-40
4. Disassembly ................................................ 7.45
5. Reassembly .. ·· · ..... · .............. · .................. ·· · ··· · 7-53
Chapter 8 REMOTE CONTROL (OPTIONAL)
1. Remote Control System .................................... 5.1
2. Remote Control Installation ................................. 8-2
3. Remote Control Inspection ................................. 5.4
4. Remote Control Adjust ment ..... ·· · ·· · ··· ··· ... ·· ·· · .... ·8-5
Chapter 9 ELECTRICAL SYSTEM
1. Electrical System ....... ·· .... · ......... · ............ · · ...... ·9-1
2. Battery ............................................................ 9.5
3. Starter Motor .. ·· · ..... · ·· · ........... · · .... · ...... · · · · .... ·· ... 9.5
4. Alternator Standard, 12V/55A ······························9-22
5. Alternator 12V/80A (OPTIONAL) ........................... 9.30
6. Instrument Panel .................... ·· · ............... · · · · · .. 9.40
7. Warning Devices ............................................. 9.42
8. Air Heater (Optional) · ·· ·· ·· · ·· ... · ·· ·· · ·· · ................. 9.45
9. Electric type Engine Stopping Device (Optional) ······9-46
10.Tachometer ··········· ........................................ 9.45
Chapter 10 DISASSEMBLY AND REASSEMBLY
1. Disassembly and Reassembly Precautions···· .... ····10-1
2. Disassembly and Reassembly Tools .................. 10-2
3. Disassembly and Reassembly·· .. ········· .............. 10-14
4. Table of Standard Measurements for Maintenance ···10-35
5. Tightening torque ........... ·· ··· ... · ·· ·· · ......... ··· ·· ... 10-40
6. Test Running ................................................ 10-41
Chapter 11 TROUBLESHOOTING
1. Troubleshooting ............................................. 11-1