YANMAR SERVICE MANUAL MARINE DIESEL ENGINE move. 4JH3-TE/HTE/DTE aS 3 YANMAR DIESEL ENGINE CO.LTD.Publication No. | HINSHI H110-009 History of Revision Page No. 1 Manual Name Service Manual for Marine Diesel Engine Engine Model: | _4JH3-TE, HTE, DTE SE a ee eden: Outline of correction ere ee ‘@New edition Aug. 1998 HINSHI W009Foreword This book describes the procedures for servicing the 4JH3 series marine diesel engine. Use this manual to help you service the engine accurately, quickly and safely. The descriptions in this manual are for the standard engine. Therefore, the specifications or components of your engine may vary, depending on the exact engine installed in the ship. For more specific details, also refer to the service manual for the ship. Note that modifications may be made in the specifications or parts in order to improve the engine. Any such changes which affect the contents of this manual will be noted by issuing a modification report each time a change is made. For details about the marine gear, see the service manual for it (HINSHI-H10-01 1). a 4 ‘ These products have been developed, Oo) qionet, designed, and manufactured in the facil- = ts ities certified by the Standards for Quality conten Content, Systems of ISO 9001. ‘wi-coss ISO 9001 Certified Segoe INSET H09K9CONTENS 1. To Perform Service Safely peeeeeereernee 1.1. Warning Symbols-+ sesseerenen 1.2 Safety Precautions~ 1.3 Location of Product Safety Labels, 2. General Description « 2.1. Principal Particulars : 2.2 Appearance and Names of Parts, 2.3 Cross-sectional Drawing: 2.4 Piping Diagram ~~~ 2.5 Performance Curves ° 2.6 Front Power Take-off 2.7 Fuel Oil ~~ 2.8 Lube Oil ~~ 2.9 Cooling Water 3. Overhaul 3.1. Operating Cautions 3.2 Overhaul Preparations 3.3 Overhaul 3.3.1 Cylinder Head =~ (1) Combustion surface (2) Valve seat ~~ - (8) Suction/exhaust vaive and valve guide ~ (4) Valve spring " (6) Valve arm and push rod (6) Installing the cylinder head ~ 3.3.2 Piston ~~ (1) Piston (2) Piston pin (3) Piston ring 3.3.3 Cylinder Block: 3.3.4 Connesting Rod ~ (1) Connecting rod (2) Crank pin metal ~ (3) Piston pin bushing ~~~ (4) Assembling piston and connecting rod - 3.3.5 Crankshaft and Main Bearing (1) Crankshaft +++ (2) Main bearing 8.36 Camshaft and Tappet (1) Camshatt == (2) Tappet « 3.3.7 Gear Train - (1) Check on gears «~~ (2) Idler gear ~~~ 2-8~2-10 QAI BAZ MINSiNL Hs00083.3.8 Lubrication System (1) Lubricating oil path diagram « (2) Lubricating oil pump =~ (3) Pressure regulating valve and lubricating oi (4) Lubricating oil cooler 5 (6) Piston cooling oil nozzle. ~ 3.3.9 Cooling Water System * (1) Cooling water system (2) Sea water pump --*+"~ (3) Servicing standards for sea water pump ~ (4) Fresh water pump and thermostat (6) Fresh water cooler ~~ 3.3.10 Fuel System ~ (1) Fuel Injection Pump (2) Fuel Injection Nozzle -------------reerene -3-38~3-40 (8) Procedures for adjusting the injaction timing “3-40 3.3.11 Electrical Equipment + B-AI~3-46 (1) Wiring Diagram B.41~3-44 3-45 3-46 + 3-47~3-60 F 347 3-48~3-50, 4-1~4-9 a (2) Starter (3) Alternator 3.3.12 Turbocharger (1) Patticulars and structure (2) Checking and servicing procedures ~~~ 4, Troubleshooting --"----~ 4.1 Does not Start or Difficult to Start 4.2. Unsmooth Revolution « 4.3 Sudden Engine Stop 4.4 Poor Exhaust Gas Color 455 Insufficient Output. ~~ 4.6 Uneven Cylinder Outputs 4.7 Knocking ~ 4.8 Trouble with Breakdown 4.9 Other Malfunctions ~~~ 5. Periodic Checking List------ 6. Tool and Measuring Instrument (1) Tookssesseeee (2) Measuring instrument =~ 7. Service Specifications +s sseeeestreeeteeeees 7.1. Engine adjusting standards ++ 7.2 Service standards 8. Instrument Panel (Option) -- seeeeseeeee Bed SBD HINSHI HID0091. To Perform Service Safely 1.1 Warning Symbols @Most accidents are caused by neglecting basic safety rules and precautions. To prevent this type of accident, always follow safe working practices. Please read this manual carefully before starting repair or maintenances in order to gain a full understanding of the safety precautions and the appropriate inspection and maintenance proce- dures. Do not attempt to perform repairs or maintenance it you don't have sufficient background knowl- ‘edge, or it may result in an accident. @'tis impossible to cover every possible danger when making repairs or performing maintenance. Therefore, you must always exercise sufficient general consideration for safety, in addition to the specific matters marked with 4 CAUTION, both in this manual and on the product. Especially when performing a repair or maintenance procedure not described in this manual, ask for some advice from a person who has experience in that area. @ The warning symbols used in this manual and their meanings are as follows: DANGER- indicates an imminently hazardous BA DANGER | Suaton vic, int avoided, WILL rest n death or serious injury. WARNING- indicates a potentially hazardous WARNING situation which, if not avoided, COULD result in death or serious injury. CAUTION-indicates a potentially hazardous CAUTION situation which, if not avoided, may result in injury. @ Any issue marked with a [NOTICE] in this manual contains especially important information about servicing the engine. If the advice not followed, the product's performance and quality may not be guaranteed. HINSHE H100001.2 Safety Precautions (e sure to follow the cautions below for your own safety.) (1) Service Shop (Place) AAWARNING) © Well-ventilated work area Jobs such as running the engine, welding and polishing the paint with S sandpaper should be done in a well-ventilated workplace. [Otherwise] Itcan be very dangerous to inhale poisonous gas or dust. © Sufficiently wide and flat place ‘The floor space in a service shop where inspections or maintenance are performed should be wide enough and completely flat, without any pits or holes. [Otherwise] An accident may occur. Clean and orderly work area No dust, mud, oil or parts should be left on the floor. [Otherwise] You may slip, trip or fal © Bright and safely lighted workplace The workplace should be well lit. When performing a job in a position that is dark or difficult to see, use a portable work lamp. The bulb must be covered with a wire or plastic cage. [Otherwise] if the light does not have a cage, the bulb may be broken and can cause a fire. ACAUTION ) Workplace must have a fire extinguisher. Keep a first-aid kit and a fire extinguisher close at hand, in case of injury or fire HINSHT Hogg(2) Work Clothing A CAUTION) © Clothing for safe operation Wear a helmet, protective clothing, safety shoes and other safety devices according to the job being performed. Make sure to wear close-fitting work clothes. [otherwise] ‘A serious accident can happen if you get caught in a machine. () Tools to Be Used ® Appropriate lifting and supporting devices Never try to work on the engine if it is only supported with wooden blocks or by a jack. To lift and support the engine, be sure to use a crane with a sufficient lifting capacity or use a fixed jack designed for the job. [otherwise] A serious accident may occur. | (Avwarnina) @ Use appropriate tools. Use the right tools for the job to be done. Always use the correct size } ( ) tool to loosen or tighten parts. wy & [Otherwise] A serious injury or engine damage may occur. (4) Use Genuine Parts, and Lubricants. ‘AXCAUTION ) © Always use genuine parts. BS [otherwise] The engine lite may be shortened or an accident may occur. (6) Tightening Nuts and Bolts © Always tighten each part to the specified torque if i given in the manual. & © {Otherwise} YU, Loose or falling parts may cause damage or injuries. HINSHT 110.008(6) Handling the Engine Parts zt © Be very careful of hot parts. Do not touch the engine when itis running or immediately atter it has stopped. [otherwise] ‘You may be badly burned. EA © Be careful around rotating parts Keep your clothing and tools well away from any rotating parts. [otherwise] You or the tools may be caught and you may be seriously injured. ee © Electrical shorts Disconnect the terminal © at the battery before servicing the engine. {Otherwise} ‘A short in the wires may cause a fire to break out. © Battery charging Do not allow any open flame near the battery while itis charging. [otherwise] When charging, the battery produces highly flammable gas and an explosion may occur. © Battery acid The battery is filled with dilute sulfuric acid. Take special care to avoid getting it on your clothing or skin. [Otherwise] The battery acid will eat through fabric and can give you a serious. chemical bum. HINSHI i000(@) Waste Disposal (8) Safety Label AXCAUTION ) ® Observe the following instructions with regard to waste disposal. [otherwise] The environment may be polluted. Waste liquids such as engine oil and cooling water must be dis- charged into a container. Any spills on the ground must be wiped up right away. Do not discharge any waste fluids into the sewerage, a river or the ocean. Harmful wastes such as oils, fuels, solvents, filter elements and batteries must be treated according to the applicable laws and reg- ulations. Ask a qualified waste collection company for more infor- mation. AXCAUTION ) © Pay attention to the safety label warning on the product. The safety label (caution plate) is placed on the product to improve safe operation. If the safety label is missing or illegible, be sure to replace it with a new one. TINSHT Mo.0091.3 Location of Product Safety Labels To insure safe operation, product safety labels roduet Satay Labels, Pais Code Nombers have been attached. Their location is shown in [@ Tose 0750) the diagram below. Keep the labels from becom- | ~ ing dirty or torn and replace them if they are lost or ® oat damaged. Also replace labels when parts are | @ 128296-07300 replaced, ordering them in the same way as for ® 196630-12980 the parts. ean Fro TERE zurren, 1-66) HINSHEGeneral Description AJHS Series 2. General Description 2.1. Principal Particulars © 4JH3-TE “4JH3-TE (Printed on name plate) eeeeea 40H3-TE 4JHS-TBE ‘JHS-THE Use ~__ Pleasure boat | Type Vertical water-cooled 4-cycle diesel engine Number of ojnders BoraXstoke mm 4 # 84x20 Displacement a 1.995 = Aspiration system Turbocharger Cont ating output _KAhp}/tpm 0,7{69)/3700 Max. output keihpyrom 159.0(72)73800 ~ High ing (om) 4900425 : Low idling (om) 700 + 25 Combustion system Direct injection Starting system Electric stating Cooling system ‘Constant high temperature fresh water cooling Lubrication system Totaly enclosed and forced lubrication system with rochold pump Model Kewei Maa KMHAA a ie Technic wa rie dak ach | Mechanical we cone dutch | Hydra wel mall dk ch gear Inpacsoueccewrepuaiddve | 7 Down angle dive 8° Down ange erive Reduction ratio $:2.17/3.08 SSAATNAT §: 2142.14 $: 2.04/2.04 (headiAstern) | _ G:2.62/0.06 C2696 66330050 | _ G:2'45/2.45 yscton gi gtaten | Crankshat_ | ______ Counterclockwise Sc} Propeller shait Clockwise Bosh-distributor type Model VE(ZEXEL) Fuel injection pump iz Pinhole injection nozzle YDLLAP (6 - 0.23 X 180" ) Fuel injection valve Turbocharger RHBS2(IHI) Water cooling and forced lubrication system : Starter OC12V- 1.4KW Elec. devices __ [Alternator DC12V - 55A(option:80A) | sea txgne | Ol pan 65 (7) 580") capacity aot | Total 777°) | 7.0 (0°) (eked angle) ‘Clutch oil 12 | 13 20 Cooling water | Fresh water tank 60 capacity 2 | subtank 08. Dimensions (LXWXH) ___-mm| —_898XS60X635 888 X565X635 886X565X635 Dry weight kg 249 247 250 Engine installation style On the flexible rubber engine mount Recommended battery capacity 12V - BOA(SHR) or greater ae | Recommended engine room ventilator 42m? / min. or greater Peereeee| a- TINSHI H10.0002 General Description | aS Series © 4JH3-HTE 4IHS-HTE(Printed on name plate) coe —TanenTe | WHeHTBE | WHO-HTHE Use Pleasure boat | Type Vertical water-cooled 4-cycle diesel engine Number of elders BoxeXstioke mmm 4 $84X90 | Displacement t 1.995 A Aspiration system “Turbocharger, intercooler Cont rating ovipat__ KW hom 67.7(92)/3700 Max. output wtaayirpm | 70,6(96)/3800 : | High iating (em) 4,800 = 25 Low iding (em) _ 700+ 25 ‘Combustion system Direct injection Starting system Cooling system Electric starting Constant high temperature fresh water cooling Lubrication system Totally enclosed and forced lubrication system with trochoid pump [Model ewer | KM4A KMH¢A th ‘octarcal wel mutgle 6sk cic | Mechanical wet cone clutch | Hycrautic we! mufpe disk dutch Marine gear ype Inputiagput eonrtic peal drive | 7” Down angle crive Down angle drive Reduction ratio $:2.17/3.06 SSAATNAT $:2.14/2.14 S: 2.04/2.04 (AneaciAstern) G: 216213.06 6260263 66330090 | G:2.48/2.45 Ditection of rotation | Crankshaft Counterciockwise (iuhen viewed from Stein side} Propeller shatt Clockwise Fuel injection pump Bosh-cistributor type Model VE(ZEXEL) Fuel injection valve Pinhole injection nozzle YOLLAP(5-0.26X 150") ‘Turbocharger RHBS2(IHI) Water cooling and forced lubrication system Starter Dotev-1.4KW Elec. devices Alternator DO12V - SSA(option:80A) Oitpan 65 (7" 5.8 (0" Lube oil Engoe | CAPE eo capacity — # | | Total 777) 7.0 (0°) {raked angle) Clutch ot 12 1.3 20 Cooling water | Freshwater tank 7 ote capacity ‘Subtank 0.8 mensions (LXWXH) mm 886581 X660 Dry weight kg 260 Engine installation style ‘On the flexible rubber engine mount Recommended battery capacity 12V - 80A (SHR) or greater Recommended engine room ventilator 16n¥/ min. or greater INSHT 1100002, General Description AJH3 Series © 4JH3-DTE ‘4JH3-DTHE(Printed on name plate) Engine Model 4JH3-DTHE, Use Pleasure boat Type Vertical water-cooled 4-cycle diesel engine Number o yinders-BoreXtroke mn 4 $84XS0 Displacement 2 1.995 Aspiration system Turbocharger, intercooler Cont. rating output —_kWihp}irpm 85.31 16)/9700 Max. output kwthp}rpm 88.3{120}/9800 High iting rpm) 4,300 ++ 25. Low idiing (rpm) | é 700 + 25 Combustion system —___ Direct injection Starting system Electric starting i Cooling system Constant high temperature fresh water cooling Lubrication system Totally enclosed and forced lubrication system with trochoid pump Model KMHAA Marine gear ‘| TYP Hycraulic wet multiple disk lich 8” Oown angle dive eduction ratio $2,087.04 (ahead Aston) 6:2452.45 Beaton of olan | Crankshaft Counterclockwise Propeller shaft | Clockewise Fuel injection pump Sosh-distibutor type Model VE(ZEXEL) Fuel injection valve Pinhole injection nozzle YOLLAP(G-0.26%150°) Turbocharger FRHBS2{IHI) Water oooling and forced lubrication system Slater Doi2v- 1.4kW Etec. devices ‘Aterator DG12V - S5A(option:#0A) Toa 580" Lube oil Engine | TO BEE eee eeeee crete eeee One eee eer ree ere eeeeeet capacty igen 7010") (ee %naie) - hic 20 cooing water | shat tank 72 capacity | suptank os Dimensions (LXxWXH) mm 866x561 X660 Dry weight 'g 260 Engine installation style (On the flexible rubber engine mount Recommended battery capacity 12V - BOA (SHR) or greater Recommended engine room ventiator 20m?! min. or greater2 General Peseription its ies 2.2 Appearance and Names of Parts @ Operation Side (Right side as viewed from the propeller.) Contains the main parts necessary for operation Oil cooler (engine) Fuel il fiter Engine plate Fai israel a Trawling lever 7 Lube cit titer (Option) pipstick (clutchy é Dipstick (engine) Fuel injection pump | Non-Operation ae Filler cap. Fresh wate cooler Alternator Intercooler Turbocharger V-belt Clutch lever Seawater pump Starter Oil cooler (clutch) INOTE} ‘The 4JH3-DTE engine (with KMH4A clutch) is used as the example for the above diagram. ‘The 4JH3-TE Series is not equipped with an intercooler (indicated by mark in the diagram), 2-4 HINSHI 110.0002. General Description 4JH3 Series 2.3 Cross-sectional Drawing 2 g 8 s 8 & £ 3 — < = i S & g z The 4JH3-DTE engi as the example. NOTE) HINsitl 10.0092. General Description 2.4 Piping Diagram © 4JH3-TE, “97x09 4 Gre NAME 45X19 BH om RUBBER HOSE 47x09 8H EG STEEL PIPE FUEL on FUTER (caRTADOE Tee) 5 cizort_| COPPER PIE z (UNION) SCREW JOINT ws. ou PUMP 3 FLANGE JOINT zg EYE JOINT, _FRESH WATER TEMPERATURE SWITCH - INSERTION JOINT DAILL HOLE ears BH COOLING FRESH WATER COOLNG SEA WATERING == | waon pene Tet on Pens #8 COOLING WATER PUMP (FRESH WATER! | i DETAIL OF PART @) vot WATER convecron ee “ez wen cowecnow ouner HOT WATER CONNECTION INLET #28612 C120" AJH3 Series 7X13 RH FUEL IWJEGTION FUMP UB_OlL FIER (CARTRIDGE TYPE) PRESSURE CONTROL VALVE eae DETAIL OF PART ©) eisxir6 sts sis xa6 SIS 95x13 AH FUEL INIECTON PIPE #6.95 X 12.175. STS FUEL INJECTION NOZZLE. Ol PRESSURE SWITCH PISTON COOLING Ol JET $25.4 xt03 RH i ot couer 4 #8X107 STS SLUTCH LUB OL cooLER SS #28 X14 RH DETAIL OF PART ©) Cat HINSH reo 928 XtaBH ‘COOLING WATER PUMP_ISEA WATER) 26.4%t49 RH SA WATER NLET NOTE, 1 DIMENSION OF STEELPIPE: OUTER DIA_xTHICKNESS OIMENSION OF AUBBER PIPE INNER DIA_XTHIGKNESS i TURBO CHARGER #179x123 SGP al MIXING ELBLE FRESH WATER COLLER #254163 AH #25.4x 103 RH UB, OL INLET FILTER \ $254 t43 RH INTERCOOLER #7 X13_-RH #25 xt18 C1201T MAIN BEARING 475x125 RH 475x125 BH #25.4x149 RH For KMH4A Marine gear2, General Description © 4JHS-HTE,DTE rae NAME aK RUBBER HOSE ae STEEL PIPE COPPER PIPE (UNION) SOREW JOINT | FLANGE JOINT EYE JOINT INSERTION JOINT ORILL HOLE COOLING FRESH WATER PING (COOLING SEA WATER PIPING LUB. Ol PIPING: FUEL_OIL PIPING AJH3 Series 47X13 AH 47X13 RH "FUELIMECTION PUMP 8X13 BH OVERFLOW #7X13 BH FUEL OIL FILTER (CARTRIOGE TYPE} UB. Ot FILTER (CARTRIDGE TYPE) presse conTaO. wae « ws or g vee #15X116 STS Oasis SIs Fe waren PERATURE so fxs ot FUEL IECTION PIPE #6.35 X 12.175 STS 4 SSeS EEE © e27xta RY DETAIL OF PART ©) FUEL_BWECTION NOZZLE ff (OWL PRESSURE swWiTCH oe COOLING OL vET_ HOT WATER CONNECTION INLET pears RH a cara, Oi. COUR “ COOLNG WATER FUN (FRESH WATER a gexto7 sts Hs Cure WB on egoLen { $28.6 X12_C1201T al || “una ovanoen Hor wares conNeSTON outer I DETAIL OF TOON PAN 4173x123 SGP ‘THERMOSTAT MOXING ELBLE yams #28X16 RH i DETAIL OF PART DETAIL OF PART G HINSHE W008 =~ ‘SEA WATER OUTLET 4254x169 RH FRESH WATER COLLER #25.4Xt43 RH #25.4Xt69 PH 125.4% 163 BH #17 X19 BH 254X163 FH WB, OIL INLET FILTER SEA WATER INLET MAIN BEARING 78x125 AH Nore a 1_ DIMENSION OF STEELPIPE : OUTER DIA. XTHICKNESS DIMENSION OF RUBBER PIPE. INNER. DIA. XTHICKNES 2. FUEL RUBBER PIPES ARE SATISFIED MITHT THE SPEGIFICATION OF MANUFACTUER (NO_KH-500-0) (MARKED 1) For KM4A and KBW21 Marine gear2 General Poseripton gts Series 2.5 Performance Curves © 4JH3-TE (Max.output : 53.0kW/3800rpm with marine gear) kWh ‘SPECIFIC FUEL CONSUMPTION hon 200 oe 190 180 240 Max. output 170 a 160 Nem ENGINE TORQUE kgm 20 180 te 160 Max. output a 140 ae 120 i: 100 fe Kw OUTPUT hp a—. i Max. output wio 80 marine gear 70 Max. output with 60 aot marine gear 50 Or Propelier power curve — 40 30 zob 20 ye00 2000 2200 2400 2600 2800 3000 3200 9400 3600 3800 4000 ‘SPEED OF CRANKSHAFT: rpm iysttt 10-008General Description ——— 4JH13 Series © 4JH3-HTE (Max.output : 70.6kW/3800rpm with marine gear) ane ‘SPECIFIC FUEL CONSUMPTION giheh 180 ole 175, 290 F 170 165, fee M: itout 160 lax. ou 210 F ee 155, 150 Nem ENGINE TORQUE kgf-m 2 240 F 5 220 F Max. output —f 2 200 21 19 180 F 7 160 6 kw OUTPUT to 110 ry 70 Max. output wo a marine geat ie F oe Max, cutout with 20 matin eat roe 70 60 ah “A propelier power curve 50 ae 40 20 20 20 4800 2000 2200 2400 2600 2800 3000 200 9400 3600 3800 4000 ‘SPEED OF CRANKSHAFT: rpm HINSHL 110.0092. General Description AJH3 Serics © 4JH3-DTE (Max.output : 88.3kW/3800rpm with marine gear) o/kWeh SPECIFIC FUEL CONSUMPTION giherh 180 240 170 Max. output 200 160 150 200 140 Nem ENGINE TORQUE kalem 30 200 28 260 f. 26 240 Max. output 28 220 200 L 20 kw OUTPUT re 100 140 ‘ 120 fax. output wio sor marine gear 110 60 [_ ttax. output with marine gear en | Propeller power curve —} 60 ele peller po 40 20 20 1800 2000 2200 2400 2600 2800 9000 3200 3400 3600 9800 4000, ‘SPEED OF CRANKSHAFT: rpm. 2-10 HINSH M0.0092, General Description JH3 Series 2.6 Front Power Take-off (1) Allowable Output @4JH3-TE, HTE, DTE 20 ls a Dat ype pul prpelor aot den E's T t T t + t + i 5 D— ype ouput with arving propeller | > T T 5 | ‘A type output O° 10 EE T a bt | aw : Leer Ott * hl 8 i z t 4 2 { . 3000 3800 ENGINE SPEED (rpm) a-n HINSHT H1G0«82 General Description ag eres (2) Power takeoff method —— Schematic drawing Remarks o 2 W 5 iz) ° Ht pe 3 Mateja $450 : ty. use boty SCM (ls 1034 7 att couplit 129693 ' + < | Shattcouing (i) z equivalent) and spring washers. & 7 3 | Torque to 3.8 Kgfm (37.3N+m) 2 =Ikn | T3do0p Lateral | ahp Man 7 takeott | Fi 3 Upwars | : Pee Inallowable Upward Unatiowabi s | Cenown inthe gure) = Dive the belt without external | (DCerrection equation for per- 44mm or less bearing miesible takeot! horsepower Pulley outside diameter = 200 (hP) at L in excess of 44 mm_ mm or less eit cov 182 be gy | Pulley GD°= 0.2 Kam ortess | panoey ‘Shaft counting ne = Type XP 7 (WL excoede 44 mm, caleulate 3 the horsepower using the LL: Both ends ofthe shat e tquation shown Ia tho right coupling tothe pulley § column) soove canter (ram) 8 hpo : Allowable output inthe é sagram of page 2-11 The driven machine must be 3 installed on the support which 2The total weight othe support 2 textonds trom the engine side. ‘and driven machine must be 2 | W the takeott horsepower is 4 10 kg or less. If itis exceed 5 © | hp or tess (lateral takeoff}, a ‘ed, the rubber cushions must 3 Yanmar tension cluten (VC 5 | Oring pulley be changed 3 type) may be used in place of | (arangedloaly) 3 the support above - - : i The bearings at both a ends are supported Takeoff | 23hp (4JH3(C)E) through a unis I joint. Tahp (HSTE-HTE,oTe} | B | hough a universal jo & a 2 3 _ g ‘The working machine is condition | A universal joint (120698-| _| directly coupled through ondiion 21700) must be used | a unversal it | z a} joa! | | dee 2-12 NSH H1e0092. General Description — 1H3 Series 2.7 Fuel Oil -INOTICE) (1) Selection of Fuel Oil ‘When other than the specified fuel oil is used, the engine will not perform Use the following diesel fuels and select fuels of a to full capacity and parts may be higher quality for best engine performance. damaged [Diesel fuel standard for various countries} *1s0.8217 DMA ‘Sample for recommended fuel oll ASTM D975 Grade No.1-D or No.2-D Standardfor | ls ASTM ©JISK2204 Grade No: fue! of 2204 D975 Pour point (Temperature) No.3 or special-No.3 BS 2869 —_Part-1 class-At or A2 At low temperatures, fuel oil becomes difficult to ignite and will not flow easily, making starting difficult, Select fuel oil of a cetane of 45 or greater to insure ignitability, and use the outside temperature as a guide for selecting the proper grade to insure fluidity. Pump up only tual above the down halt, leaving dreg accumulated on the bottom. 75% or greater] Grade No.2 | Grade No.2-D -20°C or greater] Grade No.3_| Grade No.1-D -B0°C or greater | Grade No.3-Sp. [Cetane fuel numbe | 45 or greater | 40 or greater (2) Handling of Fuel Oil Keep the fuel oil in a clean container. Store the container in a place away from rain and dirt as water and dust mixed in with the fuel cause engine failure © Keep the fuel container stationery for sev- eral hours to allow any dirt or water to settle to the bottom. Use a pump to extract the clear, filtered fuel from the top of the container for use. (3) Fuel Piping CUSTOMER Install the fuel pipe from the fuel tank to the fuel Fuol tank pump in accordance with the diagram to the = right. Be sure to attach a drain cock to the fuel tank to enable dirt and water which have settled Drain cock] Suction head - Sem or greater at the bottom of the tank to be drained off Ceereern The oil/water separator (optional) is placed at the center section of the line. HINSHI Toone2. General Description AJH3 Series [NOTICE] Using other than the specified lube oil will lead to seizure of parts inside the engine and gear device, abnormal wear, and shorten engine life. It will also effect the starting ability and 2-8 Lube oil (1) Selection of Engine Lube Oil Use the following lube oil *API Classification-~ “CD (Standards of America Petroleum Institute) *SAE Viscosity +--+ 15W40 ewer oui (Standards of Society of Automotive Engineering) (2) Selection of Marine Gear Oil Refer to the operation manual for the marine gear for the selection of the proper lube oil. (3) Handling the Lube Oil ‘When handling and storing lube oil, be careful not to allow dust and water to enter the lube oil. Clean around the filler port betore refilling. © Do not mix lube oils of different types or brands. Mixing may reduce the lubricating performance. Different oils are used for the engine and the marine drive unit. Be careful to use the correct oil for each one and store in separate clearly labeled containers. 2-9 Cooling Water © Always use soft water (tap water) for the fresh water. Never use dirty water or hard water. Impurities in the cooling water cause scale and rust to build up in the cooling system reducing cooling efficiency and causing the engine to overheat. ‘© During the cold season, add antifreeze to the cooling water to prevent freezing. Failure to add antifreeze will result in damage to various parts in the cooling water system. © Consult your Yanmar dealer or distributor on the use of antifreeze, anti-rust, and detergents. [NOTICE] © Refer to the instructions accompanying the antifreeze for the proper mixing ratio. ‘Select the ratio for the lowest temperature of the cold season. If the mixture is too thick, the cooling efficiency will be reduced. Do not mix different brands of antifreeze or anti-rust. Mixing reduces cooling efficiency and leads to parts damage. When the amount of cooling water is too low, refill with fresh water only. 4@) HINsHT FIo-0093 Overhaul 4JH3 Series 3. Overhaul 3.1 Operating Cautions (1) Safe operation To operate this equipment safely, read the safety precautions at the beginning of this manual carefully. (2) Checking the engine history Preparations are necessary to overhaul these engines accurately and efficiently. Check the engine history by looking through the customer's service records. (2.1) When was the last time the engine was overhauled? (2.2) How long has the engine been used since the previous overhaul was performed? (2.3) What problems were found the last time the engine was overhauled? What measures were taken to deal with them? (2.4) What replacement parts are expected to be used during this overhaul? (2.5) Are there records or check lists that will be necessary for this overhaul? (3) Preparation for disassembly (3.1) Assemble the general tools, specialized tools, measuring instruments, lubricants, disposable parts, replacement parts, etc. (3.2) When complicated components are disassembled, put ID marks or alignment-marks on the parts removed so that they can be reassembled correctly and efficiently. (4) Cautions during disassembly (4.1) When each partis removed, examine the conditions of the area where the part was installed and check both for deformation, damage, rough suriaces or flaws. (4.2) Lay out the parts in the order you remove them. Divide them into parts which need to be replaced and parts which will be reused. (4.3) Wash and clean the parts to be reused thoroughly, (6) Checking and measuring {5.1) Check and measure any part which will be reused, as necessary. Check to determine if it is reusable. (©) Assembling (6.1) Assemble the parts in the correct order by performing the steps according to the specified criteria (tightening torque, adjustment values, etc.). On specified important bolts and nuts, apply oil before tightening them. (6.2) Be sure to use genuine replacement parts. (6.3) Anew oil seal, O-ring and packing must be used. (6.4) In some places where packing is used, apply seal packing as necessary. Apply oil or grease to sliding surfaces. Grease the lip of oil seals before they are installed. (7) Adjusting and checking (7.1) Adjust to the specified service tolerances using a gauge and tester. HINSHI moo003_Overhaw) FHS Series 3.2 Overhaul Preparations Before overhauling the engine, make the following preparations. @Seoure the engine on a strong flat workbench ‘The engine must be secured tightly. Otherwise the engine could fall during the overhaul, caus- ing serious injury or damage to parts. @Drain the engine cooling water, lubricating oil and fuel oil @Clean any dirt, oil, or dust off the engine with compressed air or by steam cleaning it [NOTICE] Take care to keep dust out of the engine when cleaning it. When compressed air or steam is used, make sure to wear eye protection, Loose material may be blown into your eyes. [NOTICE] ‘© Replace any part which is found to be defective during a check or measurement. Also, replace any part whose measured value is out of the specified standard value or limits. ‘* Even when the measured value of a part is with the specified reference value or limit, place the part if you expect it to wear out before the next overhaul. HINSHL HID0083. Overhaul AJH3 Series 3.3 Overhaul 3.3.1 Cylinder Head (1) Combustion surface @ Inspect the warpage of combustion surface a) Clean the cylinder head. b) With a straightedge put in four places on each side and opposite two places respectively, | measure a clearance between the straightedge and combustion surface using a filler gauge. (re) Fier gat (Measuring warpage of combustion surface) Straightedoe ——— Standard Limit Head distortion | 0.05 or less 0.15 @Check on the combustion surface Remove the fuel valve, intake and exhaust valve. Clean the combustion surface and check it for discoloration, deformation or crack. (2) Valve seat @Remove the intake and exhaust valve. Check the seat surface and seat width. If the seat is too wide or if the seat surface is considerably rough, correct the seat surface using a seat grinder. (om) Valve seat width | Standard Limit Intake 20 25 Exhaust 13 18 @if the valve seat is wider than the standard, grind the seat surface using a 70° grinder first and then finish the seat width to the specitied size using a 15° grinder. ‘Angle @ Intake 30° Valve seat -— Exhaust 40" (Correcting angle of valve seat cutter) {NOTICE} If correcting the valve seat is needed, be sure to check a clearance between the valve stem and vaive guide. If the clearance exceeds the limit, replace the valve or valve guide first and then correct the seat. HINSISE H1o.0093. Overhaul 4JHS Series @knead a valve compound with oil and lap the valve and valve seat using it. @Tap it with oil only and finish. {NOTICE} © After correcting the valve seat, fully clean the valve and cylinder head with fuel oil until a ainda residual lapping compound or abrasive is iecoiroeting ta vaios oval removed completely. ‘For slightly poor smoothness, the steps @ and @ will do. (Lapping valve and valve seat) ®Replacing the valve seat ‘Grind of tin. If the valve seat cannot be corrected due to great (gana gue sine cot) wear or eccentric wear, replace the valve seat fing ameter) © Pulling out valve seat Grind off the valve head of a intake/exhaust | valve in use or out of service to a size smaller than the outside diameter of the valve seat. Grind off the end of valve stem until its out- Going otto a size eraler side diameter is the same as the diameter Lecter ep minral where the cotter is fitted. ine rave seat (Replacing the valve seat) Weld three places of the valve head of the intake/exhaust valve to the valve seat. ce 1 Tap the end of the intake/exhaust valve stem Weld he valve tree and tap out the valve seat. places othe See © Inserting a valve seat ™ Put a valve seat in liquid nitrogen to cool it fully. Alternatively, put dry ice in a container filled with ether or alcoho! and put the valve _[Replacing the valve seat) seat in the container. Heat the periphery of the valve seat insertion position on the cylinder head to 80 to 100°C using a dryer. ™ Securely insert the fully cooled valve seat into (Valve seat insertion) the cylinder head using a new intake/ exhaust valve by tapping the valve head of the intake/exhaust valve. ™ Let the entire cylinder head stand until it cools uniformly to the surrounding temperature. \ Valve seat an4 HENSHT H10.¢093. Overhaul (3) Intake/exhaust valve and valve guide valve stem and valve guide Replace a worn-out valve stem or valve guide. Install a valve stem with oil applied to it. 4JH3 Series Measuring position (tteasuring the valve stem diameter) tne SEE ere eee Standard Standard cil dearance| Maxi Gearance Limit 0,025, ise am Siem dente : =n inate te 522 | gcss~o0ss | 02 valve | vaive guide inside diameter +0010 +04 - = 0.030 Siem dame =a Eshaus to 28 | cows-o0rs | 02 - valve | valve guide inside diam tual +04 @vValve sinking ‘Over long periods of use and repeated the lapping combustion efficiency may drop. Measure the valve sinking and replace the valve and valve seat if the valve sinking exceeds the limit. (Measuring the valve sinking) Dapth gauge (oom) intakelexhaust valve | Standard Limit Valve sinking o4tot | 15 Margine thickness 12 | 07 @Replacing the valve guide © Pull out the valve guide from the cylinder head using a puller tool. ‘© Put dry ice in a container filled with ether or alcohol. Put the valve guide in the container to cool it. Tap the valve guide in to the cylinder head using a valve guide inserting tool. © Check the inside diameter. Finish it to the stan- dard. inside diameter as necessary using a reamer, Check the amount of protrusion from the oylin- der head. ‘Amount of protrusion 14,7~15.0 mm nas A Caution Do not touch a cooled valve guide with bare hands. Damage to the skin may result. ‘Walve sinking) ‘Replacing the valve guide) Oy | oe Valve sinking Y Inseting too! EENSITE H.008Overhaul @Replacing the valve stem seal Any disassembled intake/exhaust valve must be replaced with a new valve stem seal. Take care not to confuse the intake with exhaust side. ‘© Apply engine oil to the valve stem seal lip. ‘©To install the valve stem seal, push it in using an inserting tool. (4) Valve spring Check the valve spring. Any valve spring in excess of the limit must be replaced. @Check the appearance for flaw or corrosion. @Measure the free length. @Measure the inclination. @Measure the spring tension using a spring tension tester. 4JH3 Series [ de Inseting tool Valve stom seal VaNe guide ylinder head tom ang eee ot ave sping) _| vawe spring | Standara | Limit 7 Free lenath ae oe (Measuring valve spring inclination) Inclination 19 22 | Teraon | Kinet (wren compressed 1 mm) | Ke=3.6t Kot (5) Rocker arm and push rod The rocker arm opens or closes a valve. The engine performance such as the output depends on the valve timing Rocker arm shaft and rocker arm bushing Measure the rocker arm shaft diameter and rocker arm bushing inside diameter. Any rocker arm shaft or rocker arm bushing in excess of the limit must be replaced. {Measuring rocker arm bushing inside diameter) ae Stone fa ceiramares| wetgre | as] it clearance 0.016~0.052 0.18 ' {Measuring rocker arm shaft diameter) = HINSHL M0003. Overhaul @Check on the rocker arm and valve stem cap Check the contacting surface between the rocker arm and the valve stem cap and the contacting part between the valve clearance adjusting screw and the push rod for wearing and flaking. Replace itif worn or flaked. @Checking the push rod for damage or bending, Push rod Standard Limit Bending TIR 0.03 0.06 @Adjustment of valve clearance When the engine is cold, make sdjusting valve clearance at the compression top dead center. (T_D.Cicompression) ht Valve clearance | 0.2 2005 (6) Installing the cylinder head To install the cylinder head, the clamping bolts must be tightened in the specified sequence using a torque wrench to prevent the head from being distorted. @The sequence of tightening is shown in the figure. @Apply engine oil to the threaded portions and the seat of head bolts, tighten them in two steps. Nom | Fest stop ‘Second step Tightening torque 5 9.3:0.9(91.4+0.94) HINSHE Hi JUS Series Adjusting screw Valve clearance Lock ut ‘Valve stem cap, (Valve stem cap) Feder ai6o Esieian (Checking the push rod bending) (Sequence of head bolt tightening)Overhaul 4JH3 Series See eee 3-3-2 Piston The piston is made of aluminum alloy casting with less thermal expansion and excellent cooling characteristics. ‘The ellipticity of the piston is so designed that the piston will smoothly contact the cylinder surface during operation to minimize the oil consumption. The piston ring consists of two compression rings and one oil ring. The piston cooling oil nozzle fixed to each cylinder injects lubricating oll for cooling. For the piston and cylinder block, a combination of size marks is used. (1) Piston Q:0K _X:NO (@PCombination of piston and cylinder block size marks Piston To optimize the oil clearance between the piston | Combination nM =a and cylinder block, a size mark (L, M, §) is shown el test eee (on the top face of a piston and on the top of the }_ | t | © | O | x | x cylinder block, respectively). The same marks. £8 ulxlololx must be used in combination. During disassem- | $5 bly, take care to use a proper combination of cylin- s{[x|x]olo ders. vm) @Cleaning the piston top and combustion surface T Mark “Standard Wearing Clean the carbon deposits off the piston top and ee se | Foo combustion surface. Take care not to damage the | 3 | Toe08 piston. Check the combustion surface fordam- | $ | wi 0.005 @Measurement of the piston diameter 2 | 0.005 ‘© Measure the piston diameter at the position of 22 js atts to 25 mm from the piston bottom in a direction at right angles to the piston pin hole, if the piston periphery and the ring groove are worn or damaged, replace them. com) 2 Piston pin i i Senaaa | Weare 1e piston pin is of floating type. During the replace- Pr ment of a piston, the piston PH can be pushed re the [pangs +9009) +005 piston pin hole at room temperature by hand. Poston pndiamete| 628 | _9 9,4 005 Oitelearance ‘o~o022| 0-10 HINSHEL H100083. Overhaul 4JH3 Series (3) Piston ring Measurement of piston ring thickness. For the ring thickness, measure the clearance cre- ated when the ring is pushed into the ring groove. Ifitis in excess of the limit, replace the ring (en) Ring shape Standard Umit 5 1 Groove +0.065 ] wiath +0.050 F018 | 2nd tng 2 cag | 0.870098 0.20 i ae Wisth my 0.10 & 4 Groove| | 0.035 . viding treatment ‘width | -Fo'020 Hees eee iting 4 ay 0oso.08s 020 wath my ~0.10 te 2 CI {Note) The top ring, which is @ Keystone ring, cannot be measured. ed a (Chrome plating on ‘ouler surface 3 ‘Chrome plating on outer surface Thickness (Measurement of ring width) INSHE tH106093. Overhaul @Measuring end gap of the piston ring Push a piston ring into the cylinder on the top part of the piston and measure the end gap of the ring using a thickness gauge. The position where it is inserted must be 30 mm or so away from the cylin- der bottom. (ren) End gap Standard Limit Allrings 02~0.4 18 @Replacing the piston ring In replacing the ring, carefully clean the groove. Install the piston ring so as to prevent it from stretching excessively using the piston ring expander with the ring end surface on which the maker mark is shown upward 3.3.3 Cylinder Block AJH3 Series ‘ylinder head sido End gap \ fuer Cylinder block. ‘ston tag 20 0F £0 Tnstalling piston ting) with maker mark upward il ring end (OAS seconding ATS sans Sb 8 oll joint (Measuring end gap of the piston ring) (Aligning ring end) For the cylinder bore of the cylinder block, a sleeveless structure (integration of a cylinder block and liner) is employed. Therefore, replacing the cylinder liners, which is performed for a conventional engine, cannot be conducted. Instead, the cylinder unit is so designed that it can be overhauled using an oversize piston with the cylinder reboring. @Check on the cylinder block Make a visual check for leakage of water or oil and crack in the external surface. Ifa crack is suspected, make a color check to locate the crack. If there is any unamendable damage, replace the cylinder block. © Completely clean each oil hole and check it for clogging. 3-10 MINSHE BoOCe3. Overhaul 4JH3 Series @Cylinder bore diameter and size mark © There are size marks L, M and S which show a cylinder bore diameter on the top of the cylinder, block. (mmm) Size mark] Reterencevaue | Limt L $0.03 | ~ | +002 | w | gee | $20? | toz oylnder |S | +901 ameter | Creulesty, —.0tarless | 0.08 ‘Cylindricity 0.01 or less 0.03 i ©The cylinder bore diameter must be measured at three places:10 mm from the cylinder top face, 20 mm from the cylinder bottom and the center. Circularity: Difference between the maximum and minimum in the same cross section Cylindricity: Difference between the maximum and minimum in the same direction @Honing Ifa cylinder suffers eccentric wear or flaw, per form the honing or boring For slight eccentric wear or flaw, the honing with a flex hone will do. For great eccentric wear, how- ever, the honing must be performed after the bor- ing {wake meremers ae {120 Grectone ofA and 6. (Measurement position of evlinder bre ciameter) © Preparations for honing Flex hone ‘ m Electric drill # ® Honing liquid (mixture of 50% of engine oil BOY Pp and 50% of fuel oil) / fo i * f Ghectic dei | f Uf eet me tue | f F ae J rex none = é JE Honing lui | (Preparation for honing) 3-1 HINSIIE 110.0093. Overhaul AJH3 Series ‘* Procedures for honing With a honing liquid applied to the fiex hone, insert the electric drill which rotates at 300 to 1200 rpm into the cylinder bore and move the flex hone upward or downward so that honing traces will be obtained at an angle of 30 to 40 degrees. (Honing trace) [NOTICE] (1) Avoid a high speed rotation in excess of 1200 rpm. Such a high speed rotation may cause damage. (2) The hone will cause damage to the cylinder if the hone is inserted or removed with it stopped. (3) The grinding amount per honing must be limited to 1/1000 mm or so. ® Cylinder overhaul (for reference) eytrde Back working tit (8 re (Ha=3H1) rng and honng cytes (He) THe =1 SRT Honing yee (0) treeatein tre Incease ate Increase nthe crease nthe Urea consumption Pacing e- Thermostat Ftesh water pur body id3. Overhaul anes (5) Fresh water cooler @Fresh water cooler ‘Sea water which flows in a tube cools the fresh water which flows outside the tube. A integrated fresh water tank is provided under the tube to cool the exhaust manifold. ‘Soa water outet ‘Sea water inlet Fresh water colar ‘Cooling tube Battle plato cooling pipe (vertow (o subtark) + Soa water inlet Sea water outlet Exhaust gas Fresh water tank Exhauel mantows Diain plug 4JH3-HTE, DTE Sea water if Fresh water 3-28 ENSHH H100093. Overhaul @Checking the fresh water path for water leakage Fill the fresh water tank and engine with fresh water and attach the cap tester to the water filer. ® Inclease the pressure to 0.9 kgf/cm? (0.09 Mpa) by captester and check that the pressure does not drop. PRTG Never remove the pressure cap while the ‘engine and freshwater tank are hot. Otherwise, you will be bumt by hot water and steam. @Checking the pressure cap Attach the pressure cap to the cap tester and measure the pressure cap valve opening pressure applying pressure to the pressure cap. If the mea- sured valve opening pressure is out of 0.9 0.15kg/cm*(0.09:£0.015Mpa). Replace the pres- sure cap. {NOTICE]. For the use of a cap tester, carefully read the instruction manual for the cap tester. INSEL mo.008 4JH3 Series Water filter Cap tester (Checking fresh water system for water leakage) Pressure cap (Checking the pressure cap)3. Overhaul —__— 4JH3 Series 3.3.10 Fuel System The fuel injection pump is VE typ (ZEXEL made). [NOTICE] The disassembly and adjustment of a fuel Make a request to ZEXEL service shop for them. Fuel injection pumo_| VE type Fueltedpump | Vane type (ulin) Timer | Hydraulic (oulvin) (1) Fuel injection pump. Particulars Mode! VEst2F Direction of rotation Clockwise (viewed from the dive side) Plunger diameter 12mm Governer type Allspeed Fuel feed type Vane - “Timer advancing angle | 2760010 1900 rpm (pump speed) Lubricating method Fuel ol ubrcating Fuel cut method 41) Magnetic valve (normal open) 2) With a manual stop lever Additional device Boost compensator ‘| Model notation NP - VE 4 / 12 F 1900 R_ NP1995 [Coco zion fan o uo ened om be vd) A cose «Couche Moxnum see ot goer cnt (2m coveror we rector wpe F Mechancal ip Pungerdarete (#) umber fens AE ype jon pump exe. 10 HINSHE H10.0093. Overhaul 4JH3 Series @Fuel path diagram Priming pump Overtiow pipe ‘Overflow valve Magnetic valve Injection | nozzle Regulating valve Plunger barrel Feed pump d) e) Fuel oil in the fuel tank is sucked by the feed pump built in the pump through the fuel filter (with a built-in water separator which is located at the bottom) and sent to the fuel inlet of the fuel injection pump. There is an air breathe bolt on the side of the collected water at the bottom of the fuel fiter. The fuel oil sent to the fuel inlet is pressurized by the feed pump and supplied to the pump chamber. The pressure of the fuel in the pump chamber is proportional to the pump speed. However, if the specified pressure is exceeded, the regulating valve will return excessive fuel to the suction side. The fuel in the pump chamber is sent to the plunger through the fuel passage located in the distributor head. The pressure of the fuel is then increased by the plunger and the fuel is sent to the nozzle holder under pressure through the fuel injection pipe. The overflow valve located on the top of the pump holds the fuel oil pressure in the pump chamber constant and returns excessive fuel to the fuel tank. ing pump, and a sensor for detecting BINSHI H1000G3 Overhaul ss Series @structure and working of injection pump Governor spring Fiywoight ting spring Full toad ‘adjusting scrow Controb over, Clive sat | Tension lever Gover lever assembly Magnetic valve Reguiating valve Plunger Outet port Drive shalt Delivery valve Control sleeve Feed pump Drive gear Plunger spring ross coupling! Cam disc Plunger a) The drive shaft directly receives the engine rotation by means of gears and transfers the rotation to the cam disc through the cross coupling. The positioning pin press-ftted to the cam disc is also inserted in the groove of the plunger flange, so that the plunger and cam disc rotate in the same The cam disc has a face cam to r by a specified cam lift on the roller of the roller holder assembly. eee rane Outlet port Drive shaft 3-32 INSEL H10.0003. Overhaul 4AJH3 Series b) There are two plunger springs having setting forces on the outside of the plunger. They return the plunger which is pushed up by the cam disc, in the descending process. That is, the plunger rotates by means of the drive shaft and reciprocates by means of the cam disc. When the fuel whose pressure is increased by the plunger is sent to the outlet port, the delivery valve opens to allow the fuel to be injected into the combustion chamber through the fuel injection nozzle. © Governor @The governor, which is located above the pump house, consists of a flyweight holder, governor lever assembly, etc. The flyweight holder holds four flyweights and governor sleeve and is supported by the governor shaft. The drive gear engages with the flyweight holder gear and speeds up the drive shaft rotation to rotate the flyweight holder assembly. The governor lever assembly is supported by the pivot bolt in the pump housing and the ball pin located at the bottom of it is inserted in the control sleeve which slides on the outside surface of the plunger. @The governor spring located at the top of it is connected to the tension: lever with the retaining pin and the governor spring end face is connected to the control lever through the control lever shaft Control lever shaft Governor onto! fever Retaining pin Faywsignt bide gear Flyweight “Governar sleeve Control sleeve. The control lever is linked to the governor handle through the link to vary the setting force of the governor spring according to the inclined angle. A difference between the setting force of the governor spring and the centrifugal force of the flyweight corresponds to the control sleeve movement which increases or decreases the injection quantity. Timer ‘There is a built-in timer at the bottom of the injection pump. A timer spring having a setting force is installed on the low pressure side. The fuel pressure in the pump house is directly applied to the opposite side (high pressure side). The position of the timer piston varies according to the relation between this fuel pressure and timer spring force and the roller holder is rotated through the roller holder pin. When the piston moves in the direction where the timer spring is shrunk, a lead of angle takes place (the roller holder moves in the reverse direction of rotation) to advance the injection timing. Thal Roller holder | ler holder pin | oH | Low pressure Side the timer controls the injection timing according to the fuel oil pressure in the pump house. 3-33 HINSHI i000Overhaul HS Series @Boost compensator stopper (BCS : Boocon) Boost prossure inlet } B Adjusting pinata Boocon | Diaphragm Gonnecting pin Boocon lever “Tension lever {| {Supporting point A ai 2 Governor spring Flyweight Plunger | Gomval sleeve | a) The boost compensator stopper (abbreviated to “boocon") is a device which increases the injection quantity when the air quantity (turbocharging boost) supplied to the suction manifold is increased b) The boocon is installed on the top of the injection pump governor. There is a diaphragm in an upper part of the boocon and the boost pressure is applied to the upper part with this diaphragm as the boundary. A boocon spring with a setting force is installed under the diaphragm. An adjusting pin is directly connected to the diaphragm so that it will move in conjunction with the diaphragm. A specified amount of lubricant necessary for sliding is stored at the bottom of the adjusting pin. ¢) The tension lever in the injection pump is drawn to the right by the governor spring. This motion causes the boocon lever to rotate counterclockwise round the supporting point A to push the connecting pin against the taper of the adjusting pin. Therefore, when the adjusting pin moves downward or upward through the diaphragm, this movement is transferred to the connecting pin boocon lever tension lever, so that the control sleeve position (injection quantity) can be changed directly. d) For the boocon, the set value cannot be changed. (Note) The description above is given based on the service manual issued by the Service Department of ZEXEL. HnnNsHE H100093. Overhaul 4JH3 Series @®Adjustment of fuel injection pump ¢4JH3-TE,HTE Nozzle pe ZEXEL 105760-0060 (NP-DNOSD1510) 5 | Nozzle opening pressure 193kgHiom®(14MPa) | Fal inaction pipe (outside clameterXinsde dametrtongth) ~-$8X2.450mm Fuel oil feed pressure O.2kgt/em: (0.02MPa) Eraine moet | nat ump speed (pr) 4JH3TE | QHSHTE Item {mm*st) 400 — aes ae so | fas.ztas) | 2et6o) ~ 600 | weazas) | iste — Ful load injection quantity 900 7.445) | (61945) — mst 1350 | @2oras) | ietes) — oe 1600 (66.5245) (74.541.0) 6 a 1900 (66.0445) | (70.140) — 3 2160 7oias | eoees | —— 3 Start injection quantity _mmdist 100 (e520) _ 1050 — (080.4) oe Timer stroke mm z +P Be Stee 4 +800 | it |e Procsre in pump house to80 | wsttocy | torent ra] so iesotoeen | rire Pump code —— | 129671-s1900 | 129672-51800 | -——— (Note) A numeric in parentheses is a relerence value. The cisassembly and adjustment of a fuel injection pump need expertise and facilities. Make a request to ZEXEL service shop for them. NINSHT Hone3. Overhaul Fe 4JH3 Series © 4JH-DTE Nozzle type ZEXEL 105780-0060 (NP-DNOSD510) & | Nozzle opening pressure 139kgfem!(13MPa} § | Fue inecton pipe (etside ameter xinsie taneterterat) #6X2-450mm Fuel cil feed pressure (0.2kgtiom: (0.02MPa) !-———_ model Pump speed | Boost pressure Ununitormity (em) mmHg (Pa) et {enmss) tem —~ 400 ° (30.084) = 500 0 (348) —— 950 ° (49.4) — 1e0=10 950(008) | genet) se.6et — Ful cad injection quantity —— 50:10 samt | THY | ears. Taskt 6 3 50010 3 ited (66.7413) scsiatsiescsiadl a 500*10, oe 7 i 1900 60781) (e435) — = i 500-10 z aso | St i128 4 Idle injection quantity —mmvist | 908 0 potas 3 Start injection quantity mmct | 100 ° (@7.3:+20) = 1050 — oso. — Timor stroke mmist a : __ 1900 — 17 498 — Pressure in pump house te s2t04 atom (Mpa) (o.s1#0.04) Pump code — 129698.51901 — (Note) A numeric in parentheses is a reference value. The disassembly and adjustment of a fuel injection pump need expertise and facilities. Make a request to ZEXEL service shop for them. BINSHL 1100093. Overhaul 4JH13 Series @Fuel filter 4 © Particulars tem Unit | Specifications Fitraon | | Paper element Fiter bod) oe Paper soment | ¥ oat tor | ERSHOT |e 028 a HY prming | Dserare | erst 18 pume | stroke = | mm 8 ¢t | Alarm ’ eos Water [eapacty | strain | Manin | cae tag Element © Drain . AL Loosening the switch slackens the seal Leal erm [ICS brain groove at 23 mm between the switch and element to let water flow to the switch receiver for drainage from the drain groove. ‘@Handling of fuel system © Air vent of fuel filter Air vent location on fuel filter and priming Pump (Hand pump) ‘Water alarm switch (Fue! titer) priming pump (Hand pump) Air vent bolt (Nate) To ¢rain water trom the ful titer, up fateh) st he botlom at tNsHit 10.008Overhaul hE (2) Fuel injection nozzle 4JH3 Series Nozzle specifications Eni med 4JH3-TE | 4JH3-HTE,DTE ce Nozzle te YOuAP Hol angle 150" Nuria of raze holes ; ; Macias rm) 8.4020 5-025 Teton rezale opening es Ileton 220-5kglen (21 870. 49MPa) Stamp No 150295480 150266,A0 Pantcode 129671-89000 1 29652-63000 Fuel injection nozzle stamp notation Y DLL A - 150 P 244d Design symbol Nozzle size Hole angie Cl return pipe joint Nozzle holder “8S, Prossure adjusting shim Nozzle spring Nozele spring seat deve |e —— Nozzle case nut ena Nozzle valve TY Posing in — 9 Nozzle body COW 3-38 Nozzle setting angle on the cylinder head Size P Size S Symbol A: Yes No symbol : No {_____— type (DLL : Semi-tong nozzle) — Maker (YANMAR) | | Nozzle valve Nozzle body Nozzle hole Hote angle {Nozzle cross section) INSeH H0.009Overhaul AJH3 Series @Adjustment of fuel injection nozzle and injection test Tightening torque of nozzle case nut (width across flat of nut 15 mm) £50 a) Install the nozzle injection nozzle on a nozzle tester and adjust the injection nozzle opening pressure with the adjusting shim. Injection nozzle 2204 5kgH/om* ‘opening pressure (21.58:£0.49MPa) (NOTICE) injection test) ©0.1 mm increase or decrease in the adjust- ing shim thickness changes the pressure by 19 kgf/cm? (186.4 N/om) or so. b) Inject two or three times and increase the pressure gradually. Keep the pressure just before the injection nozzle opening pressure of 20 kgf/cm*(1.96MPa) is reached for five seconds and check that there is no drop of fuel oil from the injection nozzle. c) Operate the nozzle tester lever at the rate of once or twice a second to check that there is No trouble with the injection. { (Condition of spray) (Good) (Bad) rion nection rom ‘© Extreme difference in angle {9} ‘* Extrome difference in injection angie (@) ‘© Non-fine spray from the entive injection ‘© Dull injection 3-39 unsstit 11100083. Overhaul Installing the fuel injection nozzle © Take care not to excessively tighten the nut for the fuel injection nozzle. Tightening torque 0.7-~0.9kgi+m (6.87~8.82N-m) (No oil application) (3) Procedures for adjusting the injection timing a) Check the match marks of the gear case flange and fuel pump bracket. b) Match the match mark of the fuel pump bracket with that of the fuel pump mounting flange. 4JH3 Series y SS Fuel injection nozzle: Insulating protector Nozzle seat —_s Fuel injection timing 121" (6T.D.C}) Pump bracket rd (Reference) ‘Special tool for measuring the plunge’ litt as the injection timing. HINSH H10-0083._ Overhaul 3.3.11 Electrical Equipment (1) Wiring Diagram © 4JH3-TE, HTE, DTE (12V New 8 type) Color coding @).GW) AY fod Y ® [Black WI White ae Y [Yellow Fahd TTB eterna —] [rojusl 0 fv] 10 [Orange [s[ Cort green : Lb | Lightbive rm Br Brown) 7 u [ral P {Pink a) ey] raf con Gr] Gray Leaf Pupe Ortaca ——etusotccuper —=—etas oer We Starter Switch BACT 7 TOSSTP | PaAR [stow oFF_[O. ‘ON, ‘STAR Tacha wih Hour Mete charge Ej O1P OW Tero Sail Dive Exhavst Fuslenp. Instrument _panel =a HINSHI Mo0e from (Wiew fiom A~#) Wire Harness AJH3 Series 12v we | Procured By Customer [rteta< me mm | Batery pitets< me mw [@ 2 | (Cross sectional area) Eng. Stop ' Battery Switcn © Sobral ‘ (FE pune b..— See Air Heater samerretyi Gar cw Erg OiPessuo = aun ‘Swe Earth Bot AMernater (salt brve) (CWETemp Sencee) FuslFiter Switeh (Beest Sender Eng 0 Pressure Sensor3. Overhaul AJH3 Series 7 = vee | Procured By Customer 12V. © 4JH3-TE, HTE, DTE (New G type) A Gee $+243< a> om (Cross sectional area) unser Sep Eng Stop Eneies Boxer Hout Meter Sip Swi we 7) Starter gate swicr | crmge a frp OP . ae toa cea estuad Arata Ear eat Sal De Foote. Instrument pane! (No.2 station} Option OW. Temp Sender The Sensor (Gai Deve} Bune Burzer Stop Hari es Em.02 —Gwronp Teoh Win BW — Neer Mawr Meer Eng Ol Prassire Sencar Fue Fiter Switch Color coding aT Ra Starter Switch Gi) 8 [ Back Tao RCT 7 TST PT PEAR Charge WI White |GLOW fra vP Y [Yetow or 19. OW erp, [Bue On. se peccee Sai Ore G | Green Stati ole + Of Orange ras] ofa : ‘ Ita] Light green ratte | Wats Weiner 2pe fA Cel uightoive Fuetero. ! {option ‘ {Brown = a ele au Pul Purple aca| 6 ce Instrument panel Data of api enton®-8 © Vnw fon AA 3-42 BINSHD Hioo0e3. Overhaul © 4JH3-TE, HTE, DTE (12V B type) Color coding A] Re 3} Bed biepane few ¥ | Yelow. als] of i [Blue GT] Green O{ Orange Starter Switch a ra Ta} ight graen Sater Soe ai Lb | Lignt ve a SS ean Br [ Brown oe | Pink oer for [Gr] Gray. [START] Details of ecupler (Pol Pups ‘ow fon ea o. -a ‘ON or StARILOF—10H Details of coupler Wow Uheinaton Instrument panel purser 3-44 MESSI stone3. Overhaul (2) Starter 4JH3 Series For the starter disassembling and assembling procedures, refer to "Starter service manual”. Specifications and service standards. THNsnit 10.008 item Unit ‘NH3-TEHTEDTE Yanmar code 171008-77010 Model (Hitech) = 114-483 Nominal output kw 14 | Direction of rotation (viewed from the pinion side) Clockwise _, | Engagement method Magnetic shit 5 Terminal voltagotcurront vA 12/100 or less §| Noload g Startor speed tom 4300 oF more 3 Terminal vokage/curront vA 9.87200 ba Teed = lkgemiNem)) 6 Torque/starter speed bmi 0.45 (4.41)/1900 Clutch ype = Over running Pirion shit voltage v Borless Pinion OP/Number of tooth — DPtons Mass Zi mm | 5.0149.05) Brush Spring force kgtiN) 1.84~ 2.24 (18,05~21.95) us Standard height/limit height mm 15/12 Magne wichresstnce] —_Seres isha a 0.26/0.59 Outside ciamater Sirdatiot | mm | 30128 _, | rune | Dior teen asnonaxd minum danees| Sida | mm 0.05102 3 Under cut depth Siardardtimit | mm 0.5~0.8/0.2 | armature | Pinion side mm 886903 8 shaft 3 | bearing | @ | No.” | Rear cover side mm Ba6oe Pinion | Pinion gear side mm BB6004 shatt bearing No. | Rearsi¢e mm 86004 3-45Overhaul (3) Alternator 4JH3 Series ‘The alternator is a rotating-field type three-phase AC generator. The generated alternating current is converted to a direct current through full-wave rectification with diodes and stored in a battery. For the alternator disassembling and assembling procedures, refer to “Alternator service manual”. ‘Specifications and service standards Tem oe = | ‘Yanmar code - et 129772-77200 ‘Model (Hitachi) sara 155-208 : Nominal output : VIA “4265 Flea 9000 pe so00 Operating speed ‘pm 7000~3000 | Guput cureneted speed ‘oe 55000 § [Spenaio 05 i ‘Doo ries | Direction o tation (viewed irom the pully sie) = Ciockwise & | umber of pos /eartpoaiy = ‘Brnpatve-eanh Regulated voltage v 745403 Regulator ype = C a ypapulay aude darter Tam ra Putey Fue alo 2 Mass: #7 kg(N) 4.3(42.18) vecnua [ORS 3 358 Stator cot ( pas) 3 ar? $ Seng ore it ERS) £2" [Sandra niin ph om 16.080 3 anid oie anton ute darcier | mm 31.6506 3 ‘tip ring, i 5 [Fomouvin om 70863 Sa [Feta [Osetia ry 7ove203 Fear sda | Outside dameterosang_| ev 216101 50 3-46 HINSHI Hoos3. Overhaul 3.3.12 Tourbocharger (1) Particulars and structure 4JH3 Series Specifications @Components Model RHBS2W (IH) Spec. No. | S0GOIVPISNWTCWI97 Turbine Radial flow type. | Compressor | Centitugal ype | Lubricating | _ Engine system of | eoanng Ful toatng Cooling | Fresh water cooling | Dry Mass 2649 (95) @Sectional view and tightening torque ‘Components Turbine shat Thruet bushing @ | Ol rower Compressor sie sel ing (sah 5) | Compressor eee rg (a8) Turbine side seal ng Cooling water inlet Shai end nuetthand tvead) ‘Compressor impeller Seal pate ex Featng bearing Thrust bearing [Compressor housing [Compressor ede pate washor exagon bot wit Henge Turbine housing : [Thermal insulation plate Turbine side plate washer @ 0668 Gasiniet t+ AAS BBQ 4 oi ouet Cooling water outlet The mark # shows rnon-reusable par, HINSHIT M1000 Hexagon bot Bearing Rousing Retaining mg TORKT scrow bot TORXT screw bol a a he 4 Loci guid gasketOverhaul $$$ 4H 3 Series (2) Checking and servicing procedures @Senvice interval tom | ‘Check eyele Check on the conditions of turbine shat rotation Every 500 Fh ‘Check on play in the turbine shaft Every 1000 h Overnaul __ Every 4000 h @Checking Procedures a) Check on the conditions of turbine shaft rotation Check the conditions of turbine shaft rotation by listening to an abnormal sound during rotation. To make a check using a listening bar, strongly push the end of the bar against the turbocharger case and gradually increase the engine speed. In the event of trouble, a high-pitched sound will be produced every 2 to 3 seconds. When such a phenomenon occurs, the bearing or turbine shaft may be defective. Replace or overhaul the turbocharger. b) Check on play in the turbine shaft Dismount the turbocharger from the engine. Check end play and radial play in the turbine [ shaft as shown below. When the turbocharger is dismounted from the engine, be sure to block the oil inlet/outlet with gummed cloth tape. © End play in the turbine shaft End play Service standard : 0.03 100.08 mm ‘Wear limit: 0.09 mm J Move the turbine shalt in the axial direction Dial gauge Turbine housing 3-48 HINSHL H10.¢@3. Overhaul © Radial play in the turbine shaft 4JH3 Series Move the turbine 100.08 mm fee standard : 0.08 ] ‘Wear limit :0.17 mm ® Cautions about assembly a) Retaining ring & Install the abutment as shown in the figure. © Put the round ring surface on the metal side. b) Seal ring on the turbine side @ © Put the abutment on the oil inlet side. c) Seal ring on the compressor side @, @) © Insert the abutment as shown in the figure Ot inlet et as Viewed trom the compressor side shaft on the lett and right sides. simultaneously in the radial direction | Turbine housing This is applied to one abutment only that is located nearest the turbine side. Ot inlet => ‘Cutter groove wed from the turbine side “Abn here. \ Ail except the above one | 3-49 INSEL Hio.08