Yanmar 4JH2E User manual

SERVICE MANUAL
MARINE DIESEL ENGINE
2001.4
A0A1029-0104
4JH2E,4JH2-TE,
4JH2-HTE,4JH2-DTE

MllRINE DIESEi. EllSlllE
MODELS
4JH2E
4JH2·TE
4JH2-HTE
4JH2-DTE

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 ofcorrection !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
IApr. 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.

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 applicabilityto 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
awide range ofoperating
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 mainte-
nance, and as a text for engineering guidance.

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

Printed in Japan
AOAJ029-9002
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

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

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

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

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
(ForwardIReverse)
Marine gear Direction of rotation (Forward)
Clockwise
system Viewed from stam
Lubricating oil capacity Ia(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 I2.64/3.04 / 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

3.Performance Curve
------------------------------------ 4JH2 Series
2-2. Marine Gear
Model KBW20 I KBW21
Type
Multiple friction disc clutch
(Parallel drive)
Reduction ratio
2.17/ 2.62/ 3.28/12.17/ 2.62/
(Forward/ Reverse) 3.06. 3.06, 3.06 3.06. 3.06
Marine gear
system Reduction
of rotation (Forward)
Clockwise
Lubrication oil capacity
£(cu.in.)
0. 15/1.2 I 0. 15/1 .2
Effect/max.
Lubricating oil
Dexron, ATF
Weight
kg( lb.) 26
I
30
2-3. Applicability of Marine gear & Redection ratio
Engine Model
Marine Gear
Model
KM3P2
KBW20
KBW21
KM4A
Printed in Japan
AOAl029-9109SP
Reduction ratio
2.36
2.61
2.17
2.62
3.28
2.17
2.62
3.28
1.47
2.14
2.63
3.30 I
4JH2E
4JH2-TE
l.D Mark
s • x
G • x
s • •
G • •
GG
• •
s 0 0
G 0 0
GG
0 0
SS
• •
s • •
G • •
GG
• •
KM3P2
One clutch
(Parallel drive)
2.36/ 2.61
0.05/0.35
SAE 20/30.
15.5
KM4A
One clutch
(Angle drive)
1.47/ 2. 14/ 2.63/ 3.30/
1.471.2.
14, 2.63, 3.30
Bi-rotation
0.2/1.3
Same as Engine oil
28
e:standard combination
O:optional combination
x ·inapplicable
4JH2-HTE 4J H2-DTE 4J H2-UTE
x x x
x x x
x x x
x x x
x x x
• • •
• • •
x x x
• • •
• • •
• • •
• • •

Chapter 1 General
3. Construction
-----------------------------------4JH2-Series
3. Construction
ENGINE MODEL
Group
Part
Engine Proper
Culinder block
Cylinder liner
Timing gear case
Oil sump
Main bearings
Engine feet
lntake/E xhaust,
Cylinder head
Valve Drive
Intake/exhaust valves
Intake manifold
Exhaust manifold
Air cooler
Tarbocharger
Valve drive
Timing gear
Main Moving Parts Crankshaft
Flywheel
Pistons
Piston rings
Piston pin
Connecting rod
Crank pin bushings
Lube Oil System Lube oil pump
Oil filter
Oil cooler
Control valve
Cooling Water System Fresh water pump
Sea water pump
Thermostat
Fresh water cooler
Bilge Bilge pump
Fuel injection pump
Fuel Injection
Equipment
Fuel injection nozzles
Fuel feed pump
Fuel filter
Governor Governor
Remote Control Engine speed
Equipment & marine gearbox
Starting Equipment Electric starter
Generator
Marine Gearbox Clutch
Reduction gear
4JH2E 4JH2-TE 4JH2-HTE I 4JH2-DTE I 4JH2-UTE
Construction
Integrally-cast water jacket and crankcase
Dry sleeve
Cast aluminum
Cast aluminum,
oil pan
Hanger-type bearing supports
Cylinder block and Flywheel mounting side
Integrally-case type, jet cooling between valves,
Intake/exhaust valve seat inserts
Mushroom shaped, seat angle: Intake:
120°
Exhaust:
90°
Aluminum diecast integral
Water cooled integral with i,yater tank
Plate fin type I
Corrugated fin type
IHI RHB52 IHI RHB52HW exhaust gas turbo,
-
exhaust Water cooled type
gas turbo
Overhead valve push rod rocker arm system
Helical gear
Stamped forging
Cast iron static balance with ring gear
Cast aluminum, oval type
2
compression rings, 1 oil ring
Floating type
Forged steel
Aluminum bushings
Trochoid type
Full flow paper element cartridge type
Sea water cooled pipe type Sea water cooled multi-pipe type
Cylindrical type with external adjusting shims
V-pulley driven, centrifugal type
Gear driven, rubber impeller type
Wax pellet type
Multi-tube type integral with exhaust manifold
Electric
YANMAR YPES-4CL
Hole type
Diaphragm type
Paper element cartridge type
Centrifugal all-speed mechanical type
Single control lever type with push-pull cable
DC 12V, 1.4kW starter motor
12V, 55A with built-in IC regulator
Multiple friction disc clutch/cone clutch
Helical gear constant mesh type
1-6
I NP-VE4
I
Vane type
Printed in Japan
AOA1029-9109SP

Chapter I General
.:,4;_. ,;.Pe:,rfi~o;;,;rm;.;a;;;,n;;;,ce;_;;C,;;;u"'.;.e;.;s _________________________ 41H2 Series
4-1. 4JH2E
E
°'
-""
~
"'
::J
0-
~
0
I-
<!>
c 1
·a,
c 1
w 1
..... 4
::l
0.
..... 3
8 2
,
'
1
0
9
c
0
0
0
0
"\.
"\.
r-..
Specific Fuei Consumption
" {at
propeller P~"!_er_c;ur~e)_
'~
~
,.....
-~
I ' Engine
Torque
I I
{DIN6270B rating w/o Ma'.in_~~
I I
.__ ~
: Dl~-S:?7~B rating output without Marine gear,
>--
DIN 6270B rating output with
/
Marine gear
--: t::O--
v
!...-:
I;::="
~\)(~
/
~~
#( ..,,.v
~
'?o
''"( ,,,v
'?(o?"v,....
L---
V"
--
L'1!
/
0
18 20 22 24 26 28 30 32 34 36 (X 102)
Printed in Japan
A0Al029-9002
Speed of Crank Shaft : rpm
1-7
.i:::
2
2
2
~
3
-
1
1
250~
40'-
30~
20·
10§
oo--o
9oe
80~
c::
0
u
u
;;::
·-·
u
d)
0.
Cl)

Chapter I General
4. Performance Curves
,;,;_:..::;:.:::.::::;:.:...:.:;.:.:: _________________________ 4JH2 Series
4-2. 4JH2-TE
-·~
"'
:J
rr
~
0
r
.,
c
o;
c
w
5
'.
1
1
1
1
1
1
7
3
"
,,
1
c
0
I
~
" "
I
)"
/
I/
Specific Fuel Consumption
!"-..
(at propeller power curve}
t--...
~
I I
v f-.::[ I I
I I
t--...
. I
Engine Torque
(DIN6270B rating'w/o Marine gear}
o • , r f I
6
0
DIN6270B rating output without Marine gear,
"
c
+-' 4
;:l
0.
+-' 3
8 2
0
0
0
0
0
/ d...
I
OIN6270B ratirg output
C/
:.--
/
with
Marine gear -
....-:
/ /
-~
, /
/,-
c::,(""' I/ ; I
~
~"'( / I
w
'(0
~'"'( '/
'((o<f' / ~
v
l/
---
L--'
18 20 22 24 26 28 30 32 34 36(X10"")
Speed of Crank Shaft : rpm
1-8
~
:;
~·
..i::
50 P-.
40~
30~
20·
10 §
oo-.:::
soe-
so 1;l
')
'-
?
~
,
-
,
-
1
1
c:
0
u
u
:B
u
<!)
0.
Cl)
Printed in Japan
AOAJ029-9002

Chapter 1 General
4. Perfortnance Curves
~;_:;;:.:.;.;;.::,:.:..=.:.:.:------------------------- 4JH2 Series
4-3. 4JH2-HTE
E
"'
_,,_
"'
1
::J
rr
~
1
0
f-
1
.;,
c 1
°'
c
w
8
7
'1.
6
..,..
~
,_, 5
;:I
0.
"::i 4
0 3
!'-..
Specific Fuel Consumption
r--.
(at propeller power curve)
r--
7 v -I
~r--1---
5 I
l/ Engine to(que
1--...
5 v
(OIN6270B rating w/o Marif\e gear I
A
--r-- r ' •
I
0 OIN6270B rating output witho'ut Marine geark
!"-.
~~
0 v
.....--
i--- v
L---
(
DIN6270B rating output / v- /
with Marine gear
,..,...
/
,::;
/ /
0
~
1 .. ~
/
/
0
hv
(,.:§ /
,?-
,.,,. .. ( v
¥'?0
0
~ .. ( /
'?(o<f ,v
/
0 /
~
v
7'
,
I
I
2
10
18 20 22 24 26 28 30 32 34 36(X10:i.)
Printed in Japan
AOAJ029-9002
Speed of Crank Shaft : rpm
1-9
..c:
,
...
,_
~
30"-
..,.
20::::
....
~
10 ~
~ 00
90§
80-.;::
1
1
1
0.
708
g
c:
0
u
_g
:?::::
0
(\)
0.
Cl]

Chapter 1 General
4. Performance Curves
-------------------------------------- 4JH2 Series
4-4. 4JH2-DT (B) E
....
" Specific
Fue1 Consumption
.......
-{at propetfer
power curve}
E
_v
~
,._
-v Engine
Torque
'~
/
(DIN6270B rating w/o Marine gear)
;,,
20
~
"
19
:>
O'
18
0
I-
17
"
c:
·c,
16
c:
w
90
DIN5270B rating output without Marine gear
"-
I
,_
::>
0..
80
70
60
5 50
0
40
30
20
-
DIN6270B rating ou~ut
with Marine gear (K 4A)
~
~
,,.
18
20
....._
--
--
/ /
I--... / / v
......_
"/
/
/'.
/ ~,,, /
/;-
ci'
..,< /
o"' /
'"
~,,, /
~ ..
«'o /
/
v
/
/
J
22 24
26 28 30
32 34
Speed of crankshaft: rpm
1-10
-
......
BB
/
85
36 (X 102)
.t:
•
ll.
I
.....
"'
230 z
0
;:::
ll.
220
210
200
::;:
::>
"'
z
190 0
u
180 _,
170
w
::>
u.
u
u:
u
w
Q..
"'
Printed in Japan
AOA1029-9002

3.Performance Curve
------------------------------------ 4JH2 Series
3-13.4JH2-UTE
E
'
Ji
..........
f----J----J-+--+-+-+-P~c--J--+ Specific Fuel Consumption
i"... (at propeller power output)
~ 24
cr
~
0
f--
Q)
c:
Ol
c:
w
CL
I
f--
=>
CL
f--
=>
0
22
20
18
100
[___....-- En• ine :;:ore ue ..........._,.._
f----J----J---b...-:f:_+-+--+ (DIN 62708 rating W/O marine gear;H--P..d--f---1
l/i I
,
~ I / .,,,'-+---+-+--+-----1--1
50 f---_j._.4<1:.._+--+-+-l---l--l---l---l--l-...JL-
1/ 0$-Q-+-+--+-+--+-+--<
I'./' I/ «
f---f-----1-+---+-+--+-+---+-+--l---,i"- Qo~-1---+---+--+---+-+--+---+
I / ,e<
40 f---+-----1-+---+-+---+-+--e-+--,!L-
1
/..o~~-1---+---+--+---+--+--+--+--'
I/ ~
I/
301---1--+--+---l--+-+-+,.L+--1~1--t---l--+-+---l--+-+---l---1--1
v
190
180
170
160
.t:
'
Q_
I
--
Ol
z
0
f--
CL
::;:
::::>
(/)
z
0
u
..J
w
::::>
LL
u
LL
u
w
CL
(/)
20 L__l_l__L___[,L::.L__j__j__j__j__j__l__j__j___J___j__J___j___j____[_j
18 20 22 24 26 28 30 32 34 36 (X 10')
Printed in Japan
AOAI029-9205SP
Speed of Crank Shaft: rpm
NOTE
Output, torque and specific fuel consumption are measured at the propeller shaft (The
engine flywheel output is approx. 3% higher)
1-10-1

:>.
£:'.
~
~
"'
"'
~
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"'
;·
~
"
~
n " "
"'
"'
~
"'"
•
•
~
"
"
~
'
!,
..
1. Cylinder block
2. Cy~nder liner
3. Oil pan
"· TlminO gear case
5. Crankshall
6. Main beal'ino bushing
7. Mam beannq cap
8. Crank !1831'
9. Crankshalt Y·pulley
10. Connecting roQ
"
"
"
..
"
"
~
n
11. Crank PIO bushino
12. Piston
13. Piston pin
u. Piston nng
15. Piston cooling noz.zle
16. Idle gear
17. Camshatl
18. Tappe!
19. Push rod
20. Cylil"lder head
~
M " "
21. Cylindet head tx>ll
22. Vatwe rOCket arm
23. Valve rocket arm shall
24. Va.Ne rOCkl!W arm shalt support
25. Intake valve
26. Exhaust Y3Ne
27. Valve spring
28. Breather
29. Intake silencer
JO. Intake manifold
n ro " 5
JI. Exhausl mantlotd
:12. Turoocharger
JJ. M1xino elbow
J.4. Fuel injl:t<;hon pomp
35. Fuel pressure pipe
J6. fuel lnie<:llon noule
37. Lubrical1r1g Oii lnlel pipe
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