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