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4JH2E
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Yanmar 4JH2E Service Manual
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Service manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
History of Revision
Table of Contents
General/Table of Contents
Exterior Views 4JH2E
Exterior Views 4JH2E-TE
Exterior Views 4JH2E-HTE/DTE/UTE
Marine Gear
Applicability of Marine Gear and Reduction Ratio
Construction
4JH2E Performance Curves
4JH2E-TE Performance Curves
4JH2E-HTE Performance Curves
4JH2E-DT (B) E Performance Curves
4JH2E-UTE Performance Curves
Engine Cross Section
4JH2E X KM3P2 Dimensions
4JH2E X KBW20 Dimensions
4JH2E X KBW21 Dimensions
4JH2E-TE X KM4A Dimensions
4JH2E-TE X KBW20 Dimensions
4JH2E-HTE X KM4A Dimensions
4JH2E X KM4A Dimensions
4JH2E-DTE X KM4A Dimensions
4JH2E-DTE X KBW21 Dimensions
4JH2E-UTE X KW4A Dimensions
4JH2E-UTE X KBW21 Dimensions
Piping Diagram 4JH2E
Piping Diagram 4JH2E-TE
Piping Diagram 4JH2E-HTE/DTE/UTE
Inspection Ans Servicing of Basic Engine Parts/Table of Contents
Cylinder Block
Inspection of Parts
Cleaning of Oil Holes
Color Check Procedure
Replacement of Cup Plugs
Cylinder Bore Measurement
Cylinder Head
Inspecting the Cylinder Head
Distortion of the Combustion Surface
Checking for Cracks in the Combustion Surface
Checking the Intake and Exhaust Valve Seats
Valve Seat Correction Procedure
Wearing and Corrosion of Valve Stem
Inspection of Valve Seat Wear and Contact Surface
Valve Sinking/Guide
Checking Valve Springs
Assembling the Cylinder Head
Measuring Top Clearance
Intake and Exhaust Valve Arms
Adjustment of Valve Head Clearance
Piston and Piston Pins
ID Mark for Piston
Over Size Piston and Ring COMP
Piston Head and Combustion Surface
Measurement of Piston Outside Diameter/Inspection
Replacing the Piston
Piston Rings
Measuring the Rings
Measuring Piston Ring Gap
Replacing the Piston Rings
Inspecting the Connecting Rod
Twist and Parallelism of the Large and Small Ends
Checking Thrust Clearance
Checking Crank Pin Bushing
Measuring Crank Pin Oil Clearance
Precautions on Replacement of Crank Pin Bushing
Piston Pin Bushing
Assembling Piston and Connecting Rod
Crankshaft
Color Check of Shaft
Bending of the Crankshaft
Measuring the Crank Pin and Journal
Checking Side Clearance of the Crankshaft
Inspecting the Main Bearing
Measuring the Inner Diameter of Metal
Camshaft
Tappets
Timing Gear
Inspecting the Gears
Gear Timing Marks
Specifications of Flywheel
Dimensions of Flywheel and Mounting Flange
Ring Gear
Position of Top Dead Center and Fuel Injection Timing
Damper Disc and Cooling Fan
Applicability of Cooling Fan
Fuel Injection Equipment/Table of Contents
Fuel Injection Pump Service Data
Governor
Boost Compensator
Diassembly, Reassembly and Inspection of Governor
Governor Disassembly
Inspection of Governor
Assembling Governor
Disassembly, Reassembly and Inspection of Fuel Injection Pump
Disassembly of Fuel Injection Pump
Inspection of Fuel Injection Pump
Reassembly of Fuel Injection Pump
Adjustment of Fuel Injection Pump and Governor
Adjustment of Top Clearance
Adjusting of Injection Timing
Plunger Pressure Test
Delivery Valve Pressure Test
Measuring/Adjustment of Injection Volume
Adjusting Fuel/Rpm Limit Bolt
Adjusting Idling
Check Injection Volume When Starting
Construction of Fuel Feed Pump
Fuel Feed Pump Specifications
Disassembly and Reassembly of Fuel Feed Pump
Fuel Feed Pump Inspection
Functioning of Fuel Injection Nozzle
Fuel Injection Nozzle Disassembly/Inspection
Fuel Injection Nozzle Reassembly
Nozzle Inspection
Adjusting Opening Pressure
Injection Test
Troubleshooting of Fuel Injection Pump
Major Faults and Troubleshooting
Tools
Fuel Filter Specifications
Fuel Tank
Fuel Supply System (4JH2-UTE)
Air Bleeding in the Fuel System
Check the Fuel Injection Timing
Removal and Installation of Injection Pump
Fuel Injection Pump Outline
VE Type Injection Pump Construction
Fuel System (4JH2-UTE)
Injection Pump Construction and Operation (4JH2-UTE)
Cross-Sectional View of VE Type Injection Pump
Fuel Delivery
Speed Governing
Cutaway View of Fuel/Speed Delivery
Injection Timing Control
Feed Pump
Regulating Valve
Plunger Operation
Suction/Delivery Stroke
End of Injection
Equalizing Stroke
Reverse Rotation Prevention
Injection Quantity Control
Plunger Strokes for Cylinders a and B
Plunger's Effective Stroke
Delivery/Damping Valve
Governing Mechanism (4JH2-UTE)
Variable Speed Governor Construction and Operation
Variable Speed Governor Lever Assembly
Engine Starting
Idling Operation
Full-Load and No-Load Maximum Speed Control
Combination Governor Construction/Lever Assembly
Partial Load Operation
Combination Governor Characteristics
Control Lever Shaft Assembly
Variable Speed Governor and Combination Governor
Governor Equipped with Negative Torque Control Device
Negative Torque Control Characteristic
Full-Load Maximum Speed Operation
Negative Torque Control Stroke Operation
No-Load Maximum Speed Operation
Standard Type Timer (Speed Timer)
Servo Valve Timer
When Advance Angle Is "0"(Low Pump Chamber Pressure)
When Pump Chamber Pressure Has Increased
Stable Condition (Balanced)
When Pump Chamber Pressure Has Decreased
Maximum Advance Position
Load Timer
Magnet Valve
Feed Pump Assembly
Roller Height
Distributor Head Inspection
Timer Movement Inspection
Visual Inspection of Timer Lock Pin
Drive Shaft Key Way and Pin Groove
Plunger Position Adjustment
Measurement of Plunger Spring Set Length
Governor Shaft Installation
Testing Governor Lever Action
Flyweight Assembly Clearance
Starting Stroke "MS" Adjustment
Governor Spring Installation (Variable Governor)
Testing Governor Lever Assembly Movement
Air-Tightness Test
Handling of O-Rings
Test Bench Adjustment of VE Pump
Standard Type VE Pump
VE Pump Special Specifications
Troubleshooting
Fuel Injectin Pump Test Data
Specification
Intake and Exhaust System/Table of Contents
4JHE Engine Intake/Exhaust System
4JHE-TE Engine Intake System
Air Cooler for Models 4JH2-HTE/DTE/UTE
Air Cooler Specifications
Turbocharger Specifications/Construction
Interchangeability of Turbochargers
Turbocharger Model Name Plate
Interchangeability of Turbocharger Components
Components Parts no
Preparation for Disassembly
Inspection Prior to Disassembly
Disassembly
Preparations for Reassembly
Reassembly
Turbocharger Washing
Disassembly/Reassembly Precautions
Lube Oil System
Intake/Exhaust System
Inspection Procedure
Periodic Inspection
Excessive Smoke/Oil Consumption
White Exhaust Smoke
Decrease in (Engine)Output
Turbocharger Blower Washing Procedure
Poor (Slow) Turbocharger Responsiveness (Starting)
Abnormal Noise or Vibration
Blower Washer Parts Cord
Mixing Elbow Construction/Inspection
Lubrication System/Table of Contents
Lubrication System
Lube Oil Pump Construction
Specifications of Lube Oil Pump
Lube Oil Pump Disassembly/Inspection
Lube Oil Filter Construction
Lube Oil Filter Replacement
Oil Pressure Control Valve Construction/Replacement
Vibration Preventing Damper
Lube Oil Cooler Construction 4JH2E
Inspecting the Lube Oil Cooler 4JH2E
Inspecting the Lube Oil Cooler 4JH2E- TE/HTE/DTE/UTE
Inspecting the Lube Oil Cooler 4JH2E-TE/HTE/DTE/UTE
Piston Cooling Nozzle
Rotary Waste Oil Pump Construction/Inspection
Cooling Water System/Table of Contents
Cooling Water System
Fresh/Sea Water Line (4JH2E/-TE)
Fresh/Sea Water Line (4JH2E-HTE/DTE/UTE)
Specifications of Sea Water Pump
Sea Water Pump Disassembly/Inspection
Sea Water Pump Reassembly
Fresh Water Pump Construction
Specification of Fresh Water Pump
Fresh Water Pump Disassembly/Inspection
Heat Exchanger Construction
Specifications of Heat Exchanger
Disassembly and Reassembly of the Heat Exchanger
Heat Exchanger Inspection
Pressure Cap Construction/Inspection
Pressure Cap Pressure Control
Function of the Sub Tank
Specifications/Mounting of Sub Tank
Precautions on Usage of the Sub Tank
Functioning of Thermostat
Thermostat Construction
Characteristics of Thermostat
Thermostat Inspection
Testing of Thermostat
Kingston Cock Construction/Inspection
Kingston Cock Handling Precautions
Sea Water Filter
Bilge Pump Specifications
Performance of Pump (in Pure Water)
Bilge Strainer
Reduction and Reversing Gear/Table of Contents
Marine Gear Model KBW20/21 Construction/Specifications
Power Transmission System
Reduction and Reverse Gear Drawing
Reduction and Reverse Gear Cross Section (KBW20)
Reduction and Reverse Gear Cross Section (KBW21)
Installation Angle
Clutch Operation Force (Reference Value)
Lube Oil
Precautions
Side Cover
Clutch Case/Bearing/Gear/Steel Plate Inspection and Servicing
Friction/Pressure Plate Inspection and Servicing
Driving Plate/Retainer/Plate Spring/Thrust Collar Inspection and Servicing
Shift Ring/Fork/Lever Inspection and Servicing
Output Shaft/Damper Disc Inspection and Servicing
Input/Intermediate Shaft Inspection and Servicing
Disassembling the Clutch and Accessories
Disassembling the Input/Output Shaft
Disassembling the Intermediate Shaft
Disassembling the Operating System
Reassembly Precautions
Reassembling the Output Shaft
Reassembling the Input/Intermediate Shaft
Installing the Input and Output Shaft
Reassembling and Installing the Operating System
Installing the Output Shaft Coupling
Special Tools
Marine Gear Model KM4A Construction
Specifications of Angle Drive Marine Gear
KM4A Sectional View
Arrangement of Shafts and Gear
Reduction Ratio
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Exterior Views 4Jh2E-Hte/Dte/Ute
Download this manual
A0A1029-0104
SERVICE MANUAL
MARINE DIESEL ENGINE
4JH2E,4JH2-TE,
4JH2-HTE,4JH2-DTE
2001.4
Table of
Contents
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Table of Contents
Troubleshooting
Troubleshooting of fuel injection pump
100
Troubleshooting
160
Troubleshooting the starter system
323
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Summary of Contents for Yanmar 4JH2E
Page 1
A0A1029-0104 SERVICE MANUAL MARINE DIESEL ENGINE 4JH2E,4JH2-TE, 4JH2-HTE,4JH2-DTE 2001.4...
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