Yanmar 4JH2 Series (4JH2E, TE, HTE, DTE, UTE) Marine Diesel Engine Service & Repair Manual

SERVICE MANUAL MARINE DIESEL ENGINE 2001.4 A0A1029-0104 4JH2E,4JH2-TE, 4JH2-HTE,4JH2-DTE Downloaded from www.Manualslib.com manuals search engine

MllRINE DIESEi. EllSlllE MODELS 4JH2E 4JH2·TE 4JH2-HTE 4JH2-DTE Downloaded from www.Manualslib.com manuals search engine

I Publication No. I AOA1029-0104 History of Revision Manual Name Service Manual for Marine Diesel Engine Engine Model : 4JH2E/ 4JH2-TE/-HTE/-DTE/-UTE Number of Date of Reason for Outline of correction ! correction item Corrected 1--r_e_~_s1_·o_n__.~re-~_·s_io_n__.~c-o_rr_ec~ti-on~-'-~~--~--~~~~~~~~'~-N_o_.(page) by --1 I : 1st I Apr. 2001 I . I •lightening I I ! , torque bolis i & nuts I I Printed in Japan AOA1019..0!34 •Crankshaft V-pulley bolt tightening torque. •Injection timing changed. I 1-4, 10~-31 •Added tightening torque of bolts and nuts j 10-32 for general use. I •Added the tightening torque of nut for the 8-3 remote control cable connection of clutch I shifting lever. (for KBW20/21} •Added the standard V-pulley (material : i casting iron) bolt tightening torque. I i Quality I Assurance 1' Dept. Downloaded from www.Manualslib.com manuals search engine

Printed in Japan AOA/029-9002 FOREWORD This service manual has been compiled for engineers engaged 1n sales, service, inspection and maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized in this manual while items which should already be common knowledge are omitted. One characteristic of a marine diesel engine is that its performance in a vessel is governed by its applicability to the vessel's hull construction and its steering system. Engine installation, fitting out and propeller selection have a substantial effect on the performance of the engine and the vessel. Moreover, when the engine runs unevenly or when trouble occurs, it is essential to check a wide range of operating conditions- such as installation on the hull and suitability of the ship's piping and propeller - and not just the engine itself. To get maximum performance from this engine, you should com- pletely understand its functions, construction and capabilities, as well as proper use and servicing. Use this manual as a handy reference in daily inspection and maintenance, and as a text for engineering guidance. Downloaded from www.Manualslib.com manuals search engine

MODELS 4JH2E 4JH2-TE CHAPTER 1 GENERAL 1. Exterior Views 2. Specifications . 3. Construction. 4. Performance Curves . 5. Engine Cross Section .. 6. Dimensions. 7. Piping Diagrarns .. CHAPTER 2 BASIC ENGINE PARTS 1. Cylinder Block 2. Cylinder Liners. 3. Cylinder Head .. 4. Piston and Piston Pins. 5. Connecting Rod. 6. Crankshaft and Main Bearing 7. Camshaft and Tappets. 8. Timing Gear 9. Flywheel and Hou.sing CHAPTER 3 FUEL INJECTION EQUIPMENT 1. Fuel Injection Pump Service Data .. 2. Governor ...... . 3. Disassembly, Reassembly and Inspection of Fuel Injection Pump .. 4. Adjustment of Fuel Injection Pu1np and Governor .. 5. Fue! Feed Pump. 6. Fuel Injection Nozzle . 7. Troubleshooting. 8. Tools. 9. Fuel Filter . 10. Fue! Tank (Optional) CHAPTER 4 INTAKE ANO EXHAUST SYSTEM 1. Intake and Exhaust System ............ . 2. Turbocharger .............. . 3. Mixing Elbow . . . ................ _ CHAPTER 5 LUBRICATION SYSTEM 1. Lubrication System .. 2. Lube Oil Pump .. 3. Lube Oil Filter . 4. Oil Pressure Control Valve. 5. Lube Oil Cooler .. 6. Piston Cooling Nozzle. . ... 7. Rotary Waste Oil Pump (Optional) CHAPTER 6 COOLING WATER SYSTEM l. Cooling Water System. 2. Sea Water Pump. 3. Fresh Water Pump 4. Heat Excharger 5. Pressure Cap and Sub Tank 6. Thermostat. 7. Kingston Cock (Optiona!) 8. Sea Water Filter (Optional) . . 9. Bilge Pump and Bilge Strainer (Optional) Printed in Japan AOA1029-9002 .1-1 . lA .1-6 . 1-7 . 1-11 . .1-12 . 1-21 .2 1 .2·4 .. .2-6 .2-13 .2-17 .2-20 .2-23 .2-26 .2-28 .. 3-1 .3-2 .3-13 . .3-23 .3-29 .3-31 .3-35 .337 .3-39 .3-40 4-1 4-4 4-18 .5-1 .5-3 .5-6 .5-8 . .5-9 . .5· 11 .5 12 .6-1 .64 .6-7 .6·10 .6-12 .614 .6-16 .6-17 .6-18 4JH2-HTE 4JH2-DTE CHAPTER 7 REDUCTION ANO REVERSING GEAR Marine gear model KBliV 20 and 21 1 Construction . 2 Installation 3. Operation and Maintenance. 4 Inspection and Servicing. 5. Disassembly . 6. Reassembly 7. Special Tools Marine gc3r model KM·1A. (Angle drive) 1 Construction. 2. Shifting Device 3 Inspection arid Servicing . 4. Spcci31 Tools 5. Disassembly . 6. Reassembly Marine gear model KM3P2 1. Construction. 2. Shifting Device .. 3. Inspection and Servicing . 4. Disassembly . 5. Reassembly CHAPTER 8 REMOTE CONTROL 1. Remote Control System 2. Remote Contra! Installation. 3. Remote Control Inspection 4. Remote Control Adjustment CHAPTER 9 ELECTRICAL SYSTEM 7 1 7 6 7 7 7-8 7.13 7.1 7 7-23 7-24 . 7-28 7-33 . 7-43 . ?·45 . 7.53 . .. 7-62 . . 7-68 . 7-73 . 7-80 . 7-85 .8-1 .8 2 .8 5 .8-6 1. Electrical System.. . ..... 9-1 2. Battery . . . . . . .9.7 3. Starter Motor . . . . . ..... 9-10 4. Alternator . . . . . .9-26 5. Instrument Panel and Wiring Codes . .9-36 6. Warning Devices. . . . . . .9-39 7. Air Heater (Optional). . .9-42 8. Electric Type Engine Stop Device {Optional). ..... 9-43 9. Tachometer . . ........ 9-45 10. Alternator 12V /80 A (Optional) . · ..... · · .q.43 CHAPTER 10 DISASSEMBLY ANO REASSEMBLY 1. Disassembly and Reassembly Precautions ....... 10-1 2. Disassembly and Reassembly Tools. . .10-2 3. Disassembly and Reassembly . . 10-9 4. Bolt/nut Tightening Torque.. .10-32 5. Test Running . . . . . . . . . . . . 10-33 Ref. 4JH/4JH2E PARTS DEFERING Downloaded from www.Manualslib.com manuals search engine

Printed in Japan AOAJ 029-9002 CHAPTER 1 GENERAL 1. Exterior Views . . . . . ....... . 1-1 2. Specifications.. . . . . . . . . . . . . . . . .. 1-4 3. Construction. . . . . . . . . . . . ........... 1·6 4. Performance Curves . . . .............. . 1-7 5. Engine Cross Section .............. . 1-11 6. Dimensions.. . . . . . . . . .......... . 1-12 7. Piping Diagrams ......................... 1-21 Downloaded from www.Manualslib.com manuals search engine

Chapter I General I. Exterior Views 4JH Series ,;,__~~~~~~~~~~~~~~~~~~~~~ 1. Exterior Views 1·1 4JH2E lntal<e manifold Breather pipe Shilt lever Fresh water drain cock Alternator Sea water pump Printed in Japan AOA1029-9002 011 pressure sender Filler cap (fresh waler) Starter motor Heat exchanger 1-1 Dipstick Governor Fuel filter Fresh water pump Fuel injection pump Regulator lever Fuel feed pump / I ) , , I' Oil filter Exhaust manifold Mixing elbow Dipstick (marine gearbox) Output shaft Marine gearbox Downloaded from www.Manualslib.com manuals search engine

Chapter I General I. Exterior Views ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~4/H Series 1·2 4JH2-TE Intake manifold Breather pipe Intake silencer Fresh water drain cock Filler cap (fresh water) Heat exchanger Exhaust manifold O> O> Alternator -- __ Qi Sea water pump Starter motor 1-2 Dipstick Governor Fuel filter Fresh water pump Fuel injection pump Fuel feed pump Oil fitter Oil pressure sender Turbocharger Sea water drain cock Marine gearbox Output shaft Printed in Japan AOAI029-9002 Downloaded from www.Manualslib.com manuals search engine

Chapter 1 General 1. Exterior Views 1-3 4JH2-HTE 4JH2-DTE 4JH2-UTE Printed in Japan AOAJ029-9I09SP Heat exchanger (fresh water cooler) Pressure cap (water feed port) Air cooler Starting motor Cooling water pump (seawater) Exhaust manifold Exhaust manifold water drain plug Lube oil filler port Fuel injection valve Air intake manifold Air intake silencer Oil dipstick Fuel oil injection pump Clutch oil cooler Lube oil cooler Lube oil filter Fuel feed pump 1-3 4JH2-Series Downloaded from www.Manualslib.com manuals search engine

Chapter 1 General _2_. _s_p_e_c_ifi_c_a_t_io_n_s _____________________________ 3JH2 Series 2-2 Marine Gear Model KBW10E Type Multiple friction disc cluth (Parallel drive) Reduction ration 2.14/2.50 I 2.45/2.50 (Forward I Reverse) Marine gear Direction of rotation (Forward) Clockwise system Viewed from stam Lubricating oil capacity I a (cu ·n) 0.210.7 (12.204/42.714) Effect/ max. .1 • Lubricating oil Waight / kg (ib.) 17.5 (38.588) 2-3 Applicability of Marine gear & Reduction ratio Engine model Marine gear Model Reduction ratio 1.0 Merk 2.14 s KBW10E 2.45 G 2.83 GG 2.33 s KM3A 2.64 G 3.21 GG 1-4 KM3A Cone clutch (Angle drive) 2.33/3.04 I 2.64/3.04 / 3.21/3.04 Clockwise 0.05/0.35 (3.051/21.357) 3JH2E • • • • • • 13 (28.665) e : Standerd combination 0 : Optional combination X : Inapplicable 3JH2-TE • • x • • x Printed in Japan AOAJOJS-0104 Downloaded from www.Manualslib.com manuals search engine

Yanmar 4JH2 Series (4JH2E, TE, HTE, DTE, UTE) Marine Diesel Engine Service & Repair Manual

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