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)

--1

1st

IApr. 2001 I.

•lightening

I ! , torque bolis

i &

nuts

Printed in Japan

AOA1019..0!34

•Crankshaft

V-pulley bolt

tightening

torque.

•Injection timing changed. I

1-4,

10~-31

•Added

tightening

torque

bolts

and

nuts

10-32

for

general

use.

•Added

the

tightening

torque

nut

for

the

8-3

remote

control

cable

connection

clutch

shifting

lever.

(for

KBW20/21}

•Added

the

standard

V-pulley

(material

: i

casting

iron)

bolt

tightening

torque.

Quality I

Assurance

Dept.

Printed

Japan

AOA/029-9002

FOREWORD

This service manual has been compiled for engineers engaged

sales,

service, inspection and maintenance. Accordingly, descriptions of the

construction and functions of the engine are emphasized

this manual

while items which should already be common knowledge are omitted.

One characteristic of a marine diesel engine

that its performance

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

essential to check

awide range ofoperating

conditions-

such

installation

the hull and

suitability

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

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

GENERAL

Exterior

Views

Specifications

Construction.

Performance

Curves

Engine

Cross

Section

Dimensions.

Piping

Diagrarns

CHAPTER

BASIC

ENGINE

PARTS

Cylinder

Block

Cylinder

Liners.

Cylinder

Head

Piston

and

Piston

Pins.

Connecting

Rod.

Crankshaft

and

Main

Bearing

Camshaft

and

Tappets.

Timing

Gear

Flywheel

and Hou.sing

CHAPTER

FUEL

INJECTION

EQUIPMENT

Fuel

Injection

Pump

Service

Data

Governor

......

Disassembly,

Reassembly

and

Inspection

Fuel

Injection

Pump

Adjustment

Fuel

Injection

Pu1np

and

Governor

Fue!

Feed

Pump.

Fuel

Injection

Nozzle

Troubleshooting.

Tools.

Fuel

Filter

10. Fue!

Tank

(Optional)

CHAPTER

INTAKE

ANO

EXHAUST

SYSTEM

Intake

and

Exhaust

System

............

Turbocharger

..............

Mixing

Elbow

. . .

................

CHAPTER

LUBRICATION

SYSTEM

Lubrication

System

Lube

Oil

Pump

Lube

Oil

Filter

Oil

Pressure

Control

Valve.

Lube

Oil

Cooler

Piston

Cooling

Nozzle.

...

Rotary

Waste

Oil

Pump

(Optional)

CHAPTER

COOLING

WATER

SYSTEM

Cooling

Water

System.

Sea

Water

Pump.

Fresh

Water

Pump

Heat

Excharger

Pressure

Cap

and

Sub

Tank

Thermostat.

Kingston

Cock

(Optiona!)

Sea

Water

Filter

(Optional)

. .

Bilge

Pump

and

Bilge

Strainer

(Optional)

Printed in Japan

AOA1029-9002

.1-1

.1-6

.1-7

.1-11

. .1-12

1-21

.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·

.6-1

.64

.6-7

.6·10

.6-12

.614

.6-16

.6-17

.6-18

4JH2-HTE

4JH2-DTE

CHAPTER

REDUCTION

ANO

REVERSING

GEAR

Marine

gear

model

KBliV

and

Construction

Installation

Operation

and

Maintenance.

Inspection

and

Servicing.

Disassembly

Reassembly

Special

Tools

Marine

gc3r

model

KM·1A.

(Angle

drive)

Construction.

Shifting

Device

Inspection

arid

Servicing

Spcci31

Tools

Disassembly

Reassembly

Marine

gear

model

KM3P2

Construction.

Shifting

Device

Inspection

and

Servicing

Disassembly

Reassembly

CHAPTER

REMOTE

CONTROL

Remote

Control

System

Remote

Contra!

Installation.

Remote

Control

Inspection

Remote

Control

Adjustment

CHAPTER

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

.8-6

Electrical

System..

.....

9-1

Battery

. . . . . .

.9.7

Starter

Motor

. . . . .

.....

9-10

Alternator

. . . . .

.9-26

Instrument

Panel

and

Wiring

Codes

.9-36

Warning

Devices. . . . . .

.9-39

Air

Heater

(Optional).

. .9-42

Electric

Type

Engine

Stop

Device

{Optional).

.....

9-43

Tachometer

. .

........

9-45

10.

Alternator

12V

/80

(Optional)

. ·

.....

· · .q.43

CHAPTER

DISASSEMBLY

ANO

REASSEMBLY

Disassembly

and

Reassembly

Precautions

.......

10-1

Disassembly

and

Reassembly

Tools.

.10-2

Disassembly

and

Reassembly

. . 10-9

Bolt/nut

Tightening

Torque..

.10-32

Test

Running

. . . . . . . . . . . .

10-33

Ref.

4JH/4JH2E

PARTS

DEFERING

Printed

Japan

AOAJ029-9002

CHAPTER 1

GENERAL

Exterior

Views . . . . .

.......

1-1

Specifications..

. . . . . . . . . . . . . . .

1-4

3. Construction. . . . . . . . . . . .

...........

1·6

Performance

Curves . . .

..............

1-7

Engine Cross

Section

..............

1-11

Dimensions..

. . . . . . . .

..........

.1-12

7. Piping Diagrams

.........................

1-21

Chapter I General

I. Exterior Views

4JH

Series

,;,__~~~~~~~~~~~~~~~~~~~~~

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 ) , ,

Oil filter

Exhaust

manifold

Mixing

elbow

Dipstick

(marine gearbox)

Output

shaft

Marine

gearbox

Chapter I General

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

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

Japan

AOAI029-9002

Chapter 1 General

Exterior Views

1-3

4JH2-HTE

4JH2-DTE

4JH2-UTE

Printed

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.

•

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

2.33 s

KM3A 2.64 G

3.21

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

•

Printed in Japan

AOAJOJS-0104

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