Yanmar 4JH2-TE - 3. Starter Motor; CHAPTER 10 DISASSEMBLY AND REASSEMBLY; 1. Disassembly and Reassembly Precautions

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History of Revision3
Table of Contents5
General/Table of Contents6
Exterior Views 4JH2E7
Exterior Views 4JH2E-TE8
Exterior Views 4JH2E-HTE/DTE/UTE9
Marine Gear10
Applicability of Marine Gear and Reduction Ratio10
Construction12
4JH2E Performance Curves13
4JH2E-TE Performance Curves14
4JH2E-HTE Performance Curves15
4JH2E-DT (B) E Performance Curves16
4JH2E-UTE Performance Curves17
Engine Cross Section18
4JH2E X KM3P2 Dimensions19
4JH2E X KBW20 Dimensions20
4JH2E X KBW21 Dimensions21
4JH2E-TE X KM4A Dimensions22
4JH2E-TE X KBW20 Dimensions23
4JH2E-HTE X KM4A Dimensions24
4JH2E X KM4A Dimensions25
4JH2E-DTE X KM4A Dimensions26
4JH2E-DTE X KBW21 Dimensions27
4JH2E-UTE X KW4A Dimensions28
4JH2E-UTE X KBW21 Dimensions29
Piping Diagram 4JH2E30
Piping Diagram 4JH2E-TE31
Piping Diagram 4JH2E-HTE/DTE/UTE32
Inspection Ans Servicing of Basic Engine Parts/Table of Contents33
Cylinder Block34
Inspection of Parts34
Cleaning of Oil Holes34
Color Check Procedure34
Replacement of Cup Plugs35
Cylinder Bore Measurement36
Cylinder Head39
Inspecting the Cylinder Head40
Distortion of the Combustion Surface40
Checking for Cracks in the Combustion Surface40
Checking the Intake and Exhaust Valve Seats40
Valve Seat Correction Procedure41
Wearing and Corrosion of Valve Stem41
Inspection of Valve Seat Wear and Contact Surface42
Valve Sinking/Guide42
Checking Valve Springs43
Assembling the Cylinder Head44
Measuring Top Clearance44
Intake and Exhaust Valve Arms44
Adjustment of Valve Head Clearance45
Piston and Piston Pins46
ID Mark for Piston46
Over Size Piston and Ring COMP46
Piston Head and Combustion Surface47
Measurement of Piston Outside Diameter/Inspection47
Replacing the Piston47
Piston Rings48
Measuring the Rings48
Measuring Piston Ring Gap48
Replacing the Piston Rings49
Inspecting the Connecting Rod50
Twist and Parallelism of the Large and Small Ends50
Checking Thrust Clearance50
Checking Crank Pin Bushing51
Measuring Crank Pin Oil Clearance51
Precautions on Replacement of Crank Pin Bushing51
Piston Pin Bushing51
Assembling Piston and Connecting Rod52
Crankshaft53
Color Check of Shaft53
Bending of the Crankshaft54
Measuring the Crank Pin and Journal54
Checking Side Clearance of the Crankshaft55
Inspecting the Main Bearing55
Measuring the Inner Diameter of Metal55
Camshaft56
Tappets57
Timing Gear59
Inspecting the Gears59
Gear Timing Marks60
Specifications of Flywheel61
Dimensions of Flywheel and Mounting Flange62
Ring Gear63
Position of Top Dead Center and Fuel Injection Timing63
Damper Disc and Cooling Fan64
Applicability of Cooling Fan64
Fuel Injection Equipment/Table of Contents65
Fuel Injection Pump Service Data66
Governor67
Boost Compensator67
Diassembly, Reassembly and Inspection of Governor69
Governor Disassembly70
Inspection of Governor74
Assembling Governor74
Disassembly, Reassembly and Inspection of Fuel Injection Pump78
Disassembly of Fuel Injection Pump79
Inspection of Fuel Injection Pump83
Reassembly of Fuel Injection Pump84
Adjustment of Fuel Injection Pump and Governor88
Adjustment of Top Clearance89
Adjusting of Injection Timing90
Plunger Pressure Test91
Delivery Valve Pressure Test91
Measuring/Adjustment of Injection Volume91
Adjusting Fuel/Rpm Limit Bolt92
Adjusting Idling92
Check Injection Volume When Starting93
Construction of Fuel Feed Pump94
Fuel Feed Pump Specifications94
Disassembly and Reassembly of Fuel Feed Pump95
Fuel Feed Pump Inspection95
Functioning of Fuel Injection Nozzle96
Fuel Injection Nozzle Disassembly/Inspection97
Fuel Injection Nozzle Reassembly98
Nozzle Inspection98
Adjusting Opening Pressure99
Injection Test99
Troubleshooting of Fuel Injection Pump100
Major Faults and Troubleshooting100
Tools102
Fuel Filter Specifications104
Fuel Tank105
Fuel Supply System (4JH2-UTE)106
Air Bleeding in the Fuel System107
Check the Fuel Injection Timing108
Removal and Installation of Injection Pump108
Fuel Injection Pump Outline109
VE Type Injection Pump Construction109
Fuel System (4JH2-UTE)110
Injection Pump Construction and Operation (4JH2-UTE)111
Cross-Sectional View of VE Type Injection Pump111
Fuel Delivery111
Speed Governing112
Cutaway View of Fuel/Speed Delivery112
Injection Timing Control113
Feed Pump113
Regulating Valve114
Plunger Operation115
Suction/Delivery Stroke116
End of Injection117
Equalizing Stroke117
Reverse Rotation Prevention118
Injection Quantity Control118
Plunger Strokes for Cylinders a and B118
Plunger's Effective Stroke118
Delivery/Damping Valve119
Governing Mechanism (4JH2-UTE)121
Variable Speed Governor Construction and Operation121
Variable Speed Governor Lever Assembly122
Engine Starting123
Idling Operation124
Full-Load and No-Load Maximum Speed Control125
Combination Governor Construction/Lever Assembly127
Partial Load Operation130
Combination Governor Characteristics131
Control Lever Shaft Assembly131
Variable Speed Governor and Combination Governor134
Governor Equipped with Negative Torque Control Device135
Negative Torque Control Characteristic136
Full-Load Maximum Speed Operation140
Negative Torque Control Stroke Operation141
No-Load Maximum Speed Operation142
Standard Type Timer (Speed Timer)143
Servo Valve Timer144
When Advance Angle Is "0"(Low Pump Chamber Pressure)145
When Pump Chamber Pressure Has Increased145
Stable Condition (Balanced)145
When Pump Chamber Pressure Has Decreased146
Maximum Advance Position146
Load Timer147
Magnet Valve148
Feed Pump Assembly149
Roller Height149
Distributor Head Inspection149
Timer Movement Inspection150
Visual Inspection of Timer Lock Pin150
Drive Shaft Key Way and Pin Groove151
Plunger Position Adjustment151
Measurement of Plunger Spring Set Length152
Governor Shaft Installation152
Testing Governor Lever Action152
Flyweight Assembly Clearance153
Starting Stroke "MS" Adjustment153
Governor Spring Installation (Variable Governor)155
Testing Governor Lever Assembly Movement156
Air-Tightness Test156
Handling of O-Rings156
Test Bench Adjustment of VE Pump157
Standard Type VE Pump158
VE Pump Special Specifications159
Troubleshooting160
Fuel Injectin Pump Test Data163
Specification163
Intake and Exhaust System/Table of Contents164
4JHE Engine Intake/Exhaust System165
4JHE-TE Engine Intake System166
Air Cooler for Models 4JH2-HTE/DTE/UTE167
Air Cooler Specifications167
Turbocharger Specifications/Construction168
Interchangeability of Turbochargers169
Turbocharger Model Name Plate169
Interchangeability of Turbocharger Components170
Components Parts no170
Preparation for Disassembly171
Inspection Prior to Disassembly172
Disassembly172
Preparations for Reassembly172
Reassembly173
Turbocharger Washing174
Disassembly/Reassembly Precautions174
Lube Oil System174
Intake/Exhaust System174
Inspection Procedure176
Periodic Inspection177
Excessive Smoke/Oil Consumption180
White Exhaust Smoke180
Decrease in (Engine)Output180
Turbocharger Blower Washing Procedure181
Poor (Slow) Turbocharger Responsiveness (Starting)181
Abnormal Noise or Vibration181
Blower Washer Parts Cord181
Mixing Elbow Construction/Inspection182
Lubrication System/Table of Contents183
Lubrication System184
Lube Oil Pump Construction186
Specifications of Lube Oil Pump187
Lube Oil Pump Disassembly/Inspection188
Lube Oil Filter Construction189
Lube Oil Filter Replacement190
Oil Pressure Control Valve Construction/Replacement191
Vibration Preventing Damper191
Lube Oil Cooler Construction 4JH2E192
Inspecting the Lube Oil Cooler 4JH2E192
Inspecting the Lube Oil Cooler 4JH2E- TE/HTE/DTE/UTE193
Inspecting the Lube Oil Cooler 4JH2E-TE/HTE/DTE/UTE193
Piston Cooling Nozzle194
Rotary Waste Oil Pump Construction/Inspection195
Cooling Water System/Table of Contents196
Cooling Water System197
Fresh/Sea Water Line (4JH2E/-TE)198
Fresh/Sea Water Line (4JH2E-HTE/DTE/UTE)199
Specifications of Sea Water Pump200
Sea Water Pump Disassembly/Inspection200
Sea Water Pump Reassembly202
Fresh Water Pump Construction203
Specification of Fresh Water Pump204
Fresh Water Pump Disassembly/Inspection204
Heat Exchanger Construction206
Specifications of Heat Exchanger207
Disassembly and Reassembly of the Heat Exchanger207
Heat Exchanger Inspection207
Pressure Cap Construction/Inspection208
Pressure Cap Pressure Control208
Function of the Sub Tank208
Specifications/Mounting of Sub Tank209
Precautions on Usage of the Sub Tank209
Functioning of Thermostat210
Thermostat Construction210
Characteristics of Thermostat210
Thermostat Inspection211
Testing of Thermostat211
Kingston Cock Construction/Inspection212
Kingston Cock Handling Precautions212
Sea Water Filter213
Bilge Pump Specifications214
Performance of Pump (in Pure Water)214
Bilge Strainer214
Reduction and Reversing Gear/Table of Contents215
Marine Gear Model KBW20/21 Construction/Specifications216
Power Transmission System217
Reduction and Reverse Gear Drawing218
Reduction and Reverse Gear Cross Section (KBW20)219
Reduction and Reverse Gear Cross Section (KBW21)220
Installation Angle221
Clutch Operation Force (Reference Value)221
Lube Oil222
Precautions222
Side Cover222
Clutch Case/Bearing/Gear/Steel Plate Inspection and Servicing223
Friction/Pressure Plate Inspection and Servicing224
Driving Plate/Retainer/Plate Spring/Thrust Collar Inspection and Servicing225
Shift Ring/Fork/Lever Inspection and Servicing226
Output Shaft/Damper Disc Inspection and Servicing226
Input/Intermediate Shaft Inspection and Servicing227
Disassembling the Clutch and Accessories228
Disassembling the Input/Output Shaft229
Disassembling the Intermediate Shaft230
Disassembling the Operating System231
Reassembly Precautions232
Reassembling the Output Shaft232
Reassembling the Input/Intermediate Shaft235
Installing the Input and Output Shaft235
Reassembling and Installing the Operating System236
Installing the Output Shaft Coupling237
Special Tools238
Marine Gear Model KM4A Construction239
Specifications of Angle Drive Marine Gear240
KM4A Sectional View241
Arrangement of Shafts and Gear242
Reduction Ratio242
Construction of Shifting Mechanism243
Clutch Gear (A/B) Operation244
Engagement/Disengagement of Clutch244
Clutch Shifting Force245
Adjustment of Shifting Device245
Measurement and Adjustment of Clearance246
Inspect for the Following Points (Every 2-3 Months)246
Adjustment of the Remote Control Head Marine Gearbox Control Side247
Inspection and Servicing248
Clutch Case/Cover/Gear A/B248
Bearing248
Gear248
Lapping Procedure for Drive Cone250
Thrust Coller A/B for Clutch Shaft251
Cup Spring and Spring Retainer251
Input/Output Shaft252
Intermediate Shaft253
Shifter253
Shift Lever Shft and Location Pin253
Damper Disc254
Shifter Spring254
Stopper Bolt254
Side Cover and Oil Seal254
Shim Adjustment for Output and Input Shafts255
Disassembling the Clutch Shaft264
Disassembling the Shifting Device267
Reassembly of Clutch Shaft268
Reassembly of Input Shaft271
Reassembly of the Intermediate Shaft272
Reassembly of the Bearing Outer Races and Shims in the Clutch Case272
Reassembly of the Input Shaft273
Reassembly of the Mounting Flange273
Reassembly of the Oil Cooler274
Reassembly of the Clutch Case Cover274
Reassembly of the Shifting Device275
Reassembly of the Lube Oil Drain Plug and the Dipstick276
Marine Gear Models KM3P2 Construction277
Power Transmission Routine (Forward/Reverse)280
KM3P2 Sectional View282
Forward and Reverse Clutch Operation284
Engagement and Disengagement of Clutch284
Forward and Reverse Large Gears288
Drive Cone288
Thrust Collar289
Oil Seal of Output Shaft290
Torque Limiter294
Dismantling the Clutch295
Removal of Thr Output Shaft297
Removal of the Intermediate Shaft298
Dismantling the Shifting Device299
Reassembly of Output Shaft300
Reassembly of the Clutch301
Remote Control/Table of Contents304
Construction of Remote Control System305
Remote Control Device Components305
Remote Control Installation306
Speed Control306
Clutch Control307
Engine Stop308
Remote Control Inspection309
Remote Control Adjustment310
Electrical System/Table of Contents311
System Diagram of Electric Parts (B2-Type)312
System Diagram of Electric Parts (C/D/E-Type)313
Wiring Diagram (for B-Type Instrument Panel)314
Wiring Diagram (for C-Type Instrument Panel)315
Wiring Diagram (for D-Type Instrument Panel)316
Wiring Diagram (for E-Type Instrument Panel)317
Battery Construction/Capacity/Cable318
Visual Inspection318
Checking the Electrolyte319
Voltage Test319
Washing the Battery319
Battery Storage Precautions320
Charging Methods/Procedure/Precautions320
The Reductions Starters321
The Engagement Mechanism322
Troubleshooting the Starter System323
Starter System Disassembly324
Starter System Inspection and Repair328
The Field Coil329
Brushes330
Brush Holder330
Magnetic Switch330
Pinion Clutch331
Starter System Reassembly333
Reassembly of the Magnetic Switch334
Operation Specifications Check335
Appendix336
Alternator 12V/55A Features/Specifications/Characteristics337
Alternator Construction338
Alternator Functioning339
Disassembling the Alternator340
Inspection and Adjustment the Alternator341
Reassembling the Alternator343
Performance Test344
Charging Failure345
Overcharging346
Charge Lamp Failure346
B2-Type Instrument Panel with Wiring347
C-Type Instrument Panel347
D/E-Type Instrument Panel348
Extension Cord for B2/C/D/E-Type Instrument Panel349
Oil Pressure Alarm/Inspection350
Coling Water Temperature Alarm351
Sender Unit for Lube Pressure Gauge351
Sender Unit for the Cooling Water Temperature Gauge352
Air Heater353
Electric Type Engine Stopping Device354
Solenoid354
Relay355
Wire Harness of Engine Stop355
Construction of Tachometer356
Specifications and Dimensions of Tachometer356
Measyrement of Sensor Unit Characteristics357
Alternator 12V/80A359
Alternator 12V/80A Construction360
Disassembly and Reassembly/Table of Contents369
Disassembly and Reassembly Precautions370
Disassembly and Reassembly Tools371
General Handtools371
Special Handtools374
Measuring Instruments376
Supplementary Paentcking Agent377
Paint377
Yanmar Cleaner377
Drain Cooling Water/Lube Oil378
Removing (Electrical) Wiring378
Removing the Fuel Oil Filter and Fuel Oil Pipe379
Removing the Intake Silencer379
Removing the Mixing Elbow379
Removing the Turbine379
Rermoving the Air Cooler380
Removing the Mixing Elbow and the Turbocharger380
Removing the Starting Motor/Alternator381
Removing the Cooling Water Pipe381
Removing the Heat Exchanger381
Removing the Sea Water Pump382
Removing the Lube Oil Filter382
Removing the High Pressure Fuel Pipe382
Removing the Intake Mainfold382
Removing the Fresh Water Pump383
Removing the Fuel Injection Nozzles383
Removing the Valve Elbow Shaft Assembly383
Removing the Cylinder Head383
Removing the Crankshaft V-Pulley384
Removing the Marine Gearbox384
Removing the Lube Oil Cooler384
Removing the Flywheel384
Turning the Engine over385
Removing the Oil Pan385
Removing the Lube Oil Pipe/Intake Pipe385
Removing the Gear Case385
Removing the Fuel Injection Pump386
Removing the Idling Gear386
Removing the Pistons and Connecting Rods386
Removing the Flywheel Housing387
Removing the Main Bearing/Tappets387
Removing the Crankshaft/Camshaft387
Removing/Mounting the Piston Cooling Nozzle388
Mounting the Gear Case Flange388
Inserting the Tappets388
Mounting the Camshaft/Crankshaft389
Mounting the Main Bearing Metal with Engine Oil, and Mounting the Main Bearing Cap389
Mounting the Flywheel Housing390
Stand up the Cylinder Block390
Mounting the Piston and Connecting Rod390
Mounting the Idling Gear391
Mounting the Fuel Injection/Lube Oil Pump391
Mounting the Fuel Feed Pump Drive Gear and Automatic Advancing Timer391
Mounting the Gear Case392
Mounting the Lube Oil Intake Pipe392
Mounting the Oil Pan/The Flywheel392
Mounting the Engine Mounting Feet and Turning the Engine Upright392
Mounting the Marine Gearbox393
Mounting the Crank V-Pulley393
Mounting the Cylinder Head393
Mounting the Valve Rocker Arm Shaft Assembly Pushrod394
Mounting the Fuel Injection Nozzle394
Mounting the Fresh Water Pump394
Monting the Intake Manifold395
Mounting the High Pressure Fuel Pipe and Fuel Oil Return Pipe395
Mounting the Lube Oil Cooler/Filter395
Mounting the Lube Oil Pipe/Dipstick Guide396
Mounting the Sea Water Pump396
Mounting the Cooling Water/Sea Water Pipe396
Mounting the Heat Exchanger396
Mounting the Alternator397
Mounting the Starting Motor397
Mounting the Turbine397
Mounting the Mixing Elbow398
Mounting the Intake Silencer399
Mounting the Fuel Filter and Fuel Oil Pipe399
Electrical Wiring399
Installation in the Ship and Completion of the Piping and Wiring399
Filling with Cooling Water400
Check Fuel Injection Timing400
Bolt/Nut Tightening Torque401
Test Running402
4JHE/4JH2E Parts Differing in Shape403

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Yanmar 4JH2-TE - 3. Starter Motor; CHAPTER 10 DISASSEMBLY AND REASSEMBLY; 1. Disassembly and Reassembly Precautions

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