Yanmar 4JH110 Operation Manual Download

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MARINE ENGINES

OPERATION MANUAL

4JH45

4JH57

4JH80

4JH110

http://yanmar.com

0AJHC-M00011

OPERATION MANUAL

4JH45 4JH57 4JH80 4JH110

English

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Summary of Contents for 4JH110

Page 1: ...TION MANUAL 4JH45 4JH57 4JH80 4JH110 http yanmar com 0AJHC M00011 OPERATION MANUAL 4JH45 4JH57 4JH80 4JH110 en English fr French pt Portuguese es Spanish da Danish de German el Greek fi Finnish it Italian nl Dutch no Norwegian sv Swedish ...

Page 2: ...publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any time without notice Yanmar and are registered trademark...

Page 3: ...OVERVIEW 11 YANMAR 4JH COMMON RAIL SERIES FEATURES AND APPLICATIONS 11 New Engine Break In 12 COMPONENT IDENTIFICATION 13 Right Side Viewed from Flywheel 4JH45 4JH57 13 Left Side Viewed from Flywheel 4JH45 4JH57 13 Right Side Viewed from Flywheel 4JH80 4JH110 14 Left Side Viewed from Flywheel 4JH80 4JH110 14 NAMEPLATES 15 FUNCTION OF MAJOR COMPONENTS 16 ELECTRONIC CONTROL SYSTEM 17 MAIN ELECTRONIC...

Page 4: ...l 42 Adding Engine Oil 43 MARINE GEAR OR SAIL DRIVE OIL 43 Marine Gear Oil Specifications 43 Sail Drive Oil Specifications 43 Checking Marine Gear Oil 44 Adding Marine Gear Oil 44 Checking and Adding Sail Drive Oil 44 ENGINE COOLANT 45 Engine Coolant Specifications 45 Coolant Closed Cooling System 45 Checking and Adding Coolant 46 ENGINE OPERATION 49 INTRODUCTION 49 SAFETY PRECAUTIONS 49 OPERATION...

Page 5: ...arted 63 WARM UP MODE SHIFT DISCONNECT 64 THROTTLE AND SHIFT CONTROL 65 Neutral 65 Forward 65 Reverse 65 Forward Reverse to Reverse Forward 65 ENGINE SPEED LIMIT MODE 66 CAUTIONS DURING OPERATION 66 SHUT DOWN THE ENGINE STOPPING 68 Normal Stopping 68 Emergency Stop 69 CONTROL THE BACKUP PANEL 70 CHECKING THE ENGINE AFTER OPERATION 71 PERIODIC MAINTENANCE 73 INTRODUCTION 73 SAFETY PRECAUTIONS 73 PR...

Page 6: ... of Operation 100 TROUBLESHOOTING 103 SAFETY PRECAUTIONS 103 TROUBLESHOOTING AFTER STARTING 103 TROUBLESHOOTING INFORMATION 104 TROUBLESHOOTING CHART 105 FAILSAFE DIAGNOSIS FUNCTIONAL SPECIFICATION CHART 110 LONG TERM STORAGE 115 PREPARE ENGINE FOR LONG TERM STORAGE 115 DRAIN SEAWATER COOLING SYSTEM 116 RETURNING THE ENGINE TO SERVICE 117 SPECIFICATIONS 119 PRINCIPAL ENGINE SPECIFICATIONS 119 4JH4...

Page 7: ... v 12 05 YANMAR CO LTD LIMITED EMISSION CONTROL SYSTEM WARRANTY USA ONLY 147 Your Warranty Rights and Obligations 148 Warranty Period 148 Warranty Coverage 149 Exclusions 149 Owner s Responsibility 149 Customer Assistance 149 Maintenance Log 150 ...

Page 8: ...TABLE OF CONTENTS vi JH Series Operation Manual This Page Intentionally Left Blank ...

Page 9: ...tices and maintenance procedures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized Yanmar Marine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part of the engine and remain with it Constant efforts are made to improve the qua...

Page 10: ...ture Engine Model __________________________________________________________ Engine Serial No _______________________________________________________ Date Purchased _________________________________________________________ Dealer _________________________________________________________________ Dealer Phone ___________________________________________________________ ...

Page 11: ... sure you order the new part and label at the same time DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation which can cau...

Page 12: ...gns and labels are additional reminders for safe operating and maintenance techniques Consult authorized Yanmar Marine dealer or distributor for additional training During Operation and Maintenance WARNING The safety messages that follow have WARNING level hazards Explosion Hazard While the engine is running or the battery is charging hydrogen gas is being produced and can be easily ignited Keep t...

Page 13: ...ipment including appropriate clothing gloves work shoes and eye and hearing protection as required by the task at hand Sudden Movement Hazard Never operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals Burn Hazard Some of the engine surfaces become very hot during operation and shortly after shutdown Keep hands and other bod...

Page 14: ...Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engine Consult authorized Yanmar Marine dealer or distributor if you need to operate the engine at high altitudes At high altitudes the engine will lose power run rough and produce exhaust gases that exceed the design specifications Always be environment...

Page 15: ...ine does not enter the exhaust of the non running engine s This water could cause seizure of the non running engine s Consult authorized Yanmar Marine dealer or distributor for a complete explanation of this condition If you have an installation with two or three engines and only one engine is operating it is important to limit the amount of throttle applied to the running engine If you observe bl...

Page 16: ...e 1 and Figure 2 show the location of safety decals on Yanmar 4JH45 57 and 4JH80 110 series marine engines 4JH45 4JH57 Engines Figure 1 1 Part Number 128296 07350 2 Part Number 128990 07270 3 Part Number 196630 12980 WARNING 128296 07350 128990 07270 1 2 3 056977 01X00 ...

Page 17: ... Operation Manual 9 12 05 4JH80 4JH110 Engines Figure 2 1 Part Number 128296 07350 2 Part Number 128990 07270 3 Part Number 120650 07060 4 Part Number 196630 12980 WARNING 128296 07350 128990 07270 1 2 4 3 056978 01X00 ...

Page 18: ...SAFETY 10 JH Series Operation Manual This Page Intentionally Left Blank ...

Page 19: ...ent attached to the engine should be easy to use and accessible for service To handle the drive equipment propulsion systems including the propeller and other inboard equipment always observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers The 4JH common rail series engines are designed to be operated at maximum throttle 1 for less ...

Page 20: ...ne oil will adhere to the piston rings when operating at low speeds for long periods this will interfere with proper movement of the rings and the engine oil consumption may increase Low idle speed does not allow break in of sliding parts If operating engine at low speed and light load you must race the engine to clean the carbon from the cylinders and fuel injection valve Perform this procedure i...

Page 21: ... Intake manifold 5 Fuel filter 6 Engine oil filler cap 7 Fuel supply pump 8 Engine oil filter 9 Engine oil cooler 10 Marine gear KM4A1 11 Shift lever 12 Marine gear oil dipstick Left Side Viewed from Flywheel 4JH45 4JH57 Figure 2 13 Coolant pump 14 Engine nameplate on rocker arm cover 15 Coolant filler cap 16 Coolant tank Heat exchanger 17 Exhaust water mixing elbow 18 Starter motor 19 Exhaust man...

Page 22: ... filter 7 Engine oil filler cap 8 Fuel supply pump 9 Engine oil filter 10 Engine oil cooler 11 Marine gear KMH4A 12 Marine gear oil dipstick 13 Shift lever Left Side Viewed from Flywheel 4JH80 4JH110 Figure 4 14 Coolant pump 15 Engine nameplate on rocker arm cover 16 Coolant filler cap 17 Coolant tank Heat exchanger 18 Exhaust water mixing elbow 19 Starter motor 20 Air cooler 21 Exhaust manifold 2...

Page 23: ...rm cover Figure 5 The marine gear nameplate Figure 6 is attached to the marine gear Check the marine gears model gear ratio oil used oil quantity and serial number Figure 6 The sail drive nameplate Figure 7 is attached to the sail drive Check the sail drive model and serial number Figure 7 129670 07201 Continuous power kW Speed of prop shaft Gear Model ｍｉｎ１ Fuel stop power kW MFG DATE ｍｉｎ１ｍ...

Page 24: ...eat exchanger The seawater also cools the engine marine gear oil and intake air depending on model through the cooler s in an open circuit Coolant pump The centrifugal water pump circulates coolant inside the engine The circulating pump is driven by a V ribbed belt Seawater Pump Pumps seawater from outside vessel to the engine The seawater pump is gear driven and has a replaceable rubber impeller ...

Page 25: ...to an abrupt and unexpected increase in engine speed Replacing the ECU involves migrating the fuel injection data to the existing ECU to the new unit Be sure to consult your local Yanmar dealer before replacing the ECU Failure to migrate the fuel injection data before replacing the ECU will void the engine warranty NOTICE Do not plug or unplug the ECU for a period of at least 6 seconds after power...

Page 26: ... Injectors the high pressure fuel from the rail to the engine combustion room after receiving a signal from the ECU in the most appropriate injection timing injection volume injection ratio number of injection and spray condition Accelerator sensor Installed in the ECU box Unlike mechanical governors the common rail fuel injection system has no governor lever The accelerator sensor serves as the g...

Page 27: ...connected by control cables to the engine control lever and marine gear Instrument Panel Optional Equipment and Functions The instrument panel is located in the cockpit The following instruments enable you to start or stop the engine and to monitor its condition during operation B25 Type Figure 8 C35 Type Figure 9 1 Alarm lamp 2 Tachometer 3 LCD 4 Switches push buttons 5 Coolant temperature gauge ...

Page 28: ...5 C35 Type panels have a digital LCD screen inside the tachometer C35 Type panels have an electric gauge with a needle Instrument Function Tachometer Shows engine rotation speed Hour meter Shows number of operating hours Can be used as a guide for periodic maintenance checks The hour meter is located at the bottom of the tachometer Coolant Temperature Gauge Shows the coolant temperature Engine Oil...

Page 29: ...amp 2 Tachometer 3 LCD 4 Switches push buttons Control panel switches All switches are push buttons 042563 01X00 4 2 1 3 Start switch Pushing this switch operates the starter and starts the engine Stop switch Pushing this switch stops the engine 042564 00X00 042565 00X00 Power switch Pushing this switch turns on or off the power 042567 00X00 ...

Page 30: ...ound Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure Check the load and troubleshoot the cooling system Engine Oil Low Pressure Indicator and Alarm When the engine oil pressure falls below normal the oil pressure sensor will send a signal to the indicator causing it to light and the alarm to sound Stop operation to avoid damage to the engine Check...

Page 31: ...on continuously and the digits of the LCD start flashing In this condition press the right button to decrease the brightness and the left button to increase the brightness The brightness changes in 6 steps of 20 To set the desired brightness do not touch the buttons for 3 seconds Note Continuously pressing means holding the button for approx 2 seconds Next press the right button to show the pressu...

Page 32: ...e and pressure display Setting the temperature and pressure units The display says UNIT Next press the right button to select Metric units C BAR The display says METRIC Press the left button to switch to Imperial units F PSI The display says ENGL Press the right button to select and go back to the UNIT screen Press the left button and go to the next screen FUEL Confirm that the display indicates F...

Page 33: ...ght button to select the type of the gauges Change the type by pressing the left button Press the right button to select the type Press the left button and go to the next screen dISPLAY There are four types of fuel level gauge setting The type of level gauge can be changed by scrolling and selecting the setting with the buttons Figure 4 Figure 13 Type F3 180 F240 3 F70 3 CAN 057181 00EN00 4 1 2 3 ...

Page 34: ... Setting of the next indicator Repeat the same procedure to set other indicators When RETURN is indicated on the screen press the right button to exit the dISPLAY mode Press the right button when EXIT is shown on the screen to exit the setup mode All LCD light up for a while then the screen returns to hour meter Figure 5 Figure 14 Figure 6 Figure 15 TH POS TH ON Throttle position TH OFF ENG Ld Ld ...

Page 35: ...tons Figure 7 Figure 16 057189 00EN00 Fuel temperature Hour meter Water temperature Backlight Engine oil pressure Battery voltage Hour meter Throttle position Engine load Fuel flow rate Intake air pressure Fuel temperature These parameters are indicated if the display setting is set to ON ...

Page 36: ...our meter is displayed After Engine Start After engine start make sure that the warning devices operate correctly and according to After start in the below table All alarm lamps turn off The above check tells you whether the electric circuit for the alarm lamps and alarm buzzer operate correctly If they do not operate correctly inspection and repair are required Consult your dealer or distributor ...

Page 37: ...ynchronized to the panel power supply can be taken off Figure 17 Refer to the Wiring Diagrams on page 141 The maximum current of this output terminal is 3 A Fuse capacity Do not use a current higher than 3 A For the content of the output terminal refer to the Wiring Diagrams on page 141 Figure 8 Figure 17 043801 01EN00 F1A 3 AMP Fuse Buzzer ACC Output ...

Page 38: ... handle controls the direction of the boat ahead or astern and also acts as an accelerator by increasing engine speed as the lever is pushed further in FORWARD or REVERSE directions When the handle is pulled out Figure 19 1 the engine speed can be controlled without engaging the clutch The clutch remains in NEUTRAL no load position Turn the knob Figure 19 2 counterclockwise to move the handle or c...

Page 39: ... this system is not utilized in specific accordance with the instructions in this manual or the system is modified in any way Yanmar will not be responsible for any warranty failures in the operation of the system or the vessel utilizing the system Yanmar has designed the Vessel Control System VC10 in conjunction with the 4JH common rail series The system has many functions that must be configured...

Page 40: ...t If the system does not function normally contact your authorized Yanmar Marine dealer or distributor and ask for diagnostics Diag Codes Screen Figure 13 Figure 23 Alarm Indicator Functions The alarm indicators and buzzer are activated when sensors detect an abnormality during engine operation The alarm indicators are off during normal operation but are activated as follows when an abnormality ar...

Page 41: ... indication function is displayed Display the related setting screen of the relevant icon If there are multiple items execute with the ENTER button after selecting with the buttons Adjusting Brightness Press the button Display the brightness adjustment screen and adjust brightness with the buttons Switching Night Mode Press the button Switch to the night mode indication Setting Complete Hold the E...

Page 42: ...itch Emergency Stop Switch Use this switch only in an emergency NOTICE Under normal circumstances do not use the Emergency stop switch to stop the engine The engine shuts down suddenly when the Emergency stop switch is pressed After the engine has stopped press the Emergency stop switch to release the emergency stop Eng START STOP switch Check Eng indicator Emergency stop switch Power switch 03762...

Page 43: ...TRODUCTION This section of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them SAFETY PRECAUTIONS Before performing any operations within this section review the Safety section on page 3 ...

Page 44: ...diesel fuels must meet the minimum specifications for the country in which they are used In Europe biodiesel fuels must comply with the European Standard EN590 2009 EN14214 In the United States biodiesel fuels must comply with the American Standard ASTM D 6751 Grade S15 D7467 Grade B7 S15 Biodiesel should be purchased only from recognized and authorized diesel fuel suppliers Precautions and concer...

Page 45: ... the warranty coverage of your engine Additional Technical Fuel Requirements The fuel cetane number should be 45 or higher The sulfur content must not exceed 0 5 by volume Less than 0 05 is preferred Especially in U S A and Canada Ultra Low sulfur fuel 15 ppm must be used Never mix kerosene used engine oil or residual fuels with the diesel fuel Water and sediment in the fuel should not exceed 0 05...

Page 46: ...ricity buildup which could cause sparks and ignite fuel vapors 1 Water and dust in the fuel may cause engine failure When fuel is stored be sure that the inside of the storage container is clean and dry and that the fuel is stored away from dirt or rain Figure 1 2 Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container Use a pump to ...

Page 47: ...el fuel Dispose of waste properly To fill the fuel tank WARNING Fire and Explosion Hazard Operate bilge ventilation blowers for a minimum of 5 minutes to purge fumes from engine compartment after refueling Never operate bilge blower while refueling Doing so can pump explosive fumes into the engine compartment and result in an explosion 1 Clean the area around the fuel cap 2 Remove the fuel cap fro...

Page 48: ...changing the fuel filter and draining the fuel filter water separator or replacing a fuel system component WARNING Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions Failure to comply could result in death or serious injury Exposure Hazard Always wear safety glasses when bleeding the fuel system Bleeding the pre filter Figure 4 1 Priming Pump 2 Air Bleed Scre...

Page 49: ... not meet or exceed the following guidelines or specifications may cause seizure of parts abnormal wear and shorten engine life Service Categories Use an engine oil that meets or exceeds the following guidelines and classifications API Service Categories CD CF CF 4 CI and CI 4 SAE Viscosity 10W 30 15W 40 Engine oil 10W 30 and 15W 40 can be used throughout the year NOTICE Be sure the engine oil eng...

Page 50: ... 15W 40 are the recommended oil viscosities If you operate your equipment at temperatures outside the limits shown consult your authorized Yanmar dealer or distributor for special lubricants or starting aids Checking the Engine Oil Figure 6 1 Engine oil filler port cap On the rocker arm cover 2 Engine oil filler port cap On the gearcase 3 Dipstick 4 Upper Limit 5 Lower Limit Note 4JH45 57 shown Ot...

Page 51: ...ly to check the level NOTICE Always keep the oil level between upper and lower lines on the oil cap dipstick 4 Hand tighten the filler port cap securely MARINE GEAR OR SAIL DRIVE OIL Marine Gear Oil Specifications Use marine gear oil that meets or exceeds the following guidelines and classifications KM35P KM35A2 KM4A1 KM4A2 KMH4A API Service Categories CD or higher SAE Viscosity 20 or 30 ZF30M ZF2...

Page 52: ...ure 7 5 Remove dipstick The oil level should be between upper Figure 7 3 and lower Figure 7 4 lines on the dipstick 6 Screw in the dipstick Adding Marine Gear Oil 1 Make sure the engine is level 2 Remove the filler cap Figure 7 1 at the top of the housing 3 Fill with oil to the upper limit on the dipstick Figure 7 3 See Marine Gear Oil Specifications on page 43 NOTICE Never overfill the marine gea...

Page 53: ...ICE Always add LLC to soft water especially when operating in cold weather Never use hard water Water should be clean and free from sludge or particles Without LLC cooling performance will decrease due to scale and rust in the coolant system Water alone may freeze and form ice it expands approximately 9 in volume Use the proper amount of coolant concentrate for the ambient temperature as specified...

Page 54: ...olant tank Heat exchanger 7 Seawater pump Drain from pump cover 4JH80 4JH110 Figure 10 1 Turbocharger 2 Coolant drain cock Cylinderblock 3 Marine gear oil cooler KMH4A 4 Seawater drain cock Marine gear oil cooler Figure 2 Figure 11 5 Coolant pump 6 Coolant tank Heat exchanger 7 Coolant drain cock Coolant tank Heat exchanger 8 Seawater drain cock Air cooler 9 Air cooler 10 Seawater pump Drain from ...

Page 55: ...ller Port Notches 4 Coolant Tank 3 Pour coolant slowly into coolant tank Figure 12 4 to avoid air bubbles Fill until coolant overflows from the filler port NOTICE Never pour cold coolant into a hot engine 4 Align filler cap tabs Figure 12 1 with filler port notches Figure 12 3 and tighten filler cap Figure 12 2 firmly NOTICE Alwaystightencoolanttankcapsecurely after checking coolant tank Steam can...

Page 56: ...y Failure to do so will cause water leakage 8 Check the rubber hose Figure 13 1 connecting the reservoir to coolant tank heat exchanger Replace if damaged Note If the coolant runs low too often or the coolant level in coolant tank drops without any change in the level in the reservoir there may be water or air leaks in the cooling system Consult authorized Yanmar dealer or distributor Reservoir Ca...

Page 57: ... of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them It also describes the daily engine checkout SAFETY PRECAUTIONS Before performing any operations within this section review the Safety section on page 3 ...

Page 58: ...repair the problem before you continue to operate the engine If the vessel is equipped with a water lift water lock muffler excessive cranking could cause seawater to enter the cylinders and damage the engine If the engine does not start after cranking for 10 seconds close the thru hull water intake valve to avoid filling the muffler with water Crank for 10 seconds at a time until the engine start...

Page 59: ...YPE INSTRUMENT PANEL Starting the Engine 1 Open the seacock if equipped 2 Open the fuel tank cock 3 Put remote control handle in NEUTRAL Note Safety equipment should make it impossible to start the engine in any other position than NEUTRAL Figure 1 Figure 1 4 Turn on the battery switch for engine and engine control system Do not turn off the battery switch during engine operation Also turn it off ...

Page 60: ...conds close the thru hull water intake valve to avoid filling the muffler with water Crank for 10 seconds at a time until the engine starts When the engine does start stop the engine immediately and turn off the power switch Be sure to re open the seacock and restart the engine Operate the engine normally Air Bleeding the Fuel System After Starting Failure If the engine does not start after severa...

Page 61: ...stop the engine immediately Identify the cause and repair NOTICE The engine will seize if it is operated when seawater discharge is too small or if load is applied without any warming up operation For troubleshooting assistance see Troubleshooting After Starting on page 103 or Troubleshooting Chart on page 105 If necessary consult authorized Yanmar dealer or distributor REMOTE CONTROL HANDLE OPERA...

Page 62: ...hould only be shifted with the engine at idle When sailing set the remote control handle in NEUTRAL Not doing so WILL introduce slippage or any damage and void your warranty In case that the marine gear can not be shifted by remote control handle for some reason such as broken cable remove the cable from shift lever on the marine gear and shift manually by turning the lever Switching to Trolling K...

Page 63: ...continuous rated output engine speed Operate the engine at about 100 min 1 lower than the full throttle engine speed Note If the engine is in the first 50 hours of operation see New Engine Break In on page 12 Always be on the lookout for problems during engine operation Pay particular attention to the following Is sufficient seawater being discharged from the exhaust and seawater outlet pipe If th...

Page 64: ...gine room periodically for any problems Is there sufficient diesel fuel in the diesel fuel tank Replenish diesel fuel before leaving the dock to avoid running out of fuel during operation When operating the engine at low speed for long periods of time race the engine once every 2 hours NOTICE Racing the engine With the gear in NEUTRAL accelerate from the low speed position to the high speed positi...

Page 65: ...ch After the engine has stopped push the power switch off NOTICE Continue to hold the stop switch in until the engine is completely stopped If the switch is released before the engine has completely stopped it may restart If the engine does not shut down see Emergency Shutdown on page 58 5 Wait 6 seconds or more before turning the battery switch off for secure system settle down NOTICE Do not turn...

Page 66: ... ambient temperature is below 0 C 32 F Emergency Shutdown NOTICE Never use the emergency stop switch for a normal engine shutdown Use this switch only when stopping the engine suddenly in an emergency Figure 2 Figure 5 1 Pressing the Emergency Stop switch on the ECU cover will stop the engine immediately 2 EMG STP will be shown on the LCD of the instrument panel 3 After the engine has stopped pres...

Page 67: ...mediately You can restart the engine but an alarm may be set up when the power switch is turned on Unless you are in an emergency situation in order to release above alarm turn off the power switch and wait 6 seconds before turning the power switch on again CHECKING THE ENGINE AFTER OPERATION Check that the power switch is off and that the battery switch if equipped is turned to off Fill the fuel ...

Page 68: ...ngine START STOP switch be sure to turn the Power switch ON Figure 5 Figure 8 5 If the Sys on by ID has been set enter the password into the display 6 Press the control head SEL switch Waituntilthedisplayshowstheengine data The display is shown 7 If the Start by ID has been set enter the password into the display The Start by ID has been set the engine can be started in 10 seconds after entering t...

Page 69: ... control head SEL lamp For Multi Station the SEL lamp will flash and for Single Station the SEL lamp will come on 2 Pressing the Engine START STOP switch when the SEL lamp is flashing allows the station to be selected as the engine is started 3 The engine will not start or stop if the Power switch is OFF The Power switch must be ON at all times when the engine is running 4 Do not press the engine ...

Page 70: ... is turned off the selected Sys on by ID and Start by ID cannot be disabled and it is required to enter the Owner ID at each time After entering the ID and verification if you don t operate for 10 seconds the entry becomes invalid and it is required to enter the Owner ID again Owner ID Change The ID used in Sys on by ID and Start by ID can be set and changed as follows If you select Owner ID chang...

Page 71: ...power switch Be sure to re open the seacock and restart the engine Operate the engine normally Air Bleeding the Fuel System After Starting Failure If the engine does not start after several attempts there may be air in the fuel system If air is in the fuel system fuel cannot reach the fuel supply pump Bleed the air out of the system See Bleeding the Fuel System on page 40 Starting at Low Temperatu...

Page 72: ...OTICE The engine will seize if it is operated when seawater discharge is too small or if load is applied without any warming up operation WARM UP MODE SHIFT DISCONNECT 1 Move the remote control handle to the N Neutral position The NEUTRAL lamp will come on 2 Press the NTRL switch of the selected station control head 3 The NEUTRAL lamp will come on and the NEUTRAL lamp will flash 4 Move the remote ...

Page 73: ...or reverse position Forward Move the handle toward F forward to the forward side notch position The engine will remain idling Moving the handle forward further will increase the engine speed Reverse Move the handle toward R reverse to the reverse side notch position The engine will remain idling Pulling the handle back further will increase the engine speed Forward Reverse to Reverse Forward Movin...

Page 74: ...ION NOTICE Engine trouble can arise if the engine is operated for a long time under overloaded conditions with the control handle in the full throttle position maximum engine speed position exceeding the continuous rated output engine speed Operate the engine at about 100 min 1 lower than the full throttle engine speed Note If the engine is in the first 50 hours of operation see New Engine Break I...

Page 75: ... engine room periodically for any problems Is there sufficient diesel fuel in the diesel fuel tank Replenish diesel fuel before leaving the dock to avoid running out of fuel during operation When operating the engine at low speed for long periods of time race the engine once every 2 hours NOTICE Racing the engine With the gear in NEUTRAL accelerate from the low speed position to the high speed pos...

Page 76: ... switch when the engine is stopped The engine will restart 5 Wait 6 seconds or more before turning the battery switch off for secure system settle down NOTICE Do not turn the buttery switch off before turning the power switch off or immediately after turning off the power switch Turning the battery switch off before secure system settle down may cause alarm to be set at the next activation by turn...

Page 77: ... Emergency Stop screen will be shown on the display and the buzzer will sound 3 After the engine has stopped press the Emergency Stop switch to release the emergency stop After releasing it may take sometime to restart Note 1 The Emergency Stop switch should only be used in emergencies Use the Engine START STOP switch to stop the engine normally 2 The engine cannot be started while the Emergency S...

Page 78: ... position 2 Press the power switch to the ON position on the backup panel The lamp will come and control by the backup panel is enabled 3 The engine can be started or stopped with the START STOP switch 4 Adjust the engine speed using the sub throttle control volume anti clockwise lower engine speed clockwise raise engine speed When controlling the throttle first move it fully anti clockwise NOTICE...

Page 79: ...he battery switch if equipped is turned to off Fill the fuel tank See Filling the Fuel Tank on page 39 Close seawater cock s If there is a risk of freezing check that the cooling system contains enough coolant See Engine Coolant Specifications on page 45 If there is a risk of freezing drain the seawater system See Drain Seawater Cooling System on page 116 At temperatures below 0 C 32 F drain seawa...

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Page 81: ...tion and review the Safety section on page 3 WARNING Crush Hazard If the engine needs to be transported for repair have a helper assist you attach it to a hoist and load it on a truck The engine lifting eyes are engineered to lift the weight of the marine engine only Always use the engine lifting eyes when lifting the engine Additional equipment is necessary to lift the marine engine and marine ge...

Page 82: ...engine Someone may accidentally start the engine and not realize you are servicing it Shock Hazard Always turn off the battery switch if equipped or disconnect the negative battery cable before servicing the equipment Always keep the electrical connectors and terminals clean Check the electrical harnesses for cracks abrasions and damaged or corroded connectors Never use undersized wiring for the e...

Page 83: ...re performed on a regular basis Make it a habit to perform daily checks before the start of each operating day See Daily Checks on page 84 Keep a Log of Engine Hours and Daily Checks Keep a log of the number of hours the engine is run each day and a log of the daily checks performed Also note the date type of repair e g replaced alternator and parts used for any service needed between the periodic...

Page 84: ...bolts that are not listed Apply 80 torque when tightened to aluminum alloy When lock adhesive is applied decide separately When seal washer applied torque is 34 5 N m 25 1 3 7 ft lb Bolt Diameter x Pitch mm M6x1 0 M8x1 25 M10x1 5 M12x1 75 M14x1 5 M16x1 5 Tightening Torque N m 10 8 1 0 25 5 3 0 49 5 0 88 2 10 0 140 0 10 0 230 0 10 0 ft lb 8 0 0 7 18 8 2 2 36 2 3 7 65 1 7 4 103 7 2 170 7 2 Taper Plu...

Page 85: ...8 1 1 Rocker arm cover nut M8 x 1 25 Without oil 13 5 0 5 10 0 0 4 Supply pump gear nut M18 x 1 5 Without oil 80 0 5 0 59 0 3 7 Retainer bolt for Flywheel speed sensor M6 x 1 0 Without oil 8 0 2 0 5 9 1 5 Retainer bolt for Cam shaft speed sensor M6 x 1 0 Without oil 8 0 0 5 5 9 0 4 Retainer nut for Lubricating Oil Cooler M20 x 1 5 Without oil 78 5 4 9 57 9 3 6 High pressure pipe nut Injector M12 x...

Page 86: ... requirements for the EPA Unless these requirements are met the exhaust gas emissions will not be within the limits specified by the EPA See Conditions to Ensure Compliance with EPA Emission Standards on page 79 Clean or replace the air cleaner element if the air intake restriction exceeds the referenced specifications EPA Requirements The EPA emission regulation is applicable only in the USA and ...

Page 87: ...or lower The diesel fuel should be ASTM D975 No 1 D S15 or No 2 D S15 or equivalent minimum of cetane No 45 The lubricating oil should be API Service Categories CD CF CF 4 CI and CI 4 Be sure to perform inspections as outlined in Periodic Maintenance Procedures on page 84 and keep a record of the results Pay particular attention to these important points Replacing the engine oil Replacing the engi...

Page 88: ...ns are allowed The instructions for the proper installation and location of the required sample port in addition to those specified above in the quoted federal regulation are as follows 1 The connection should be located as far downstream as reasonably practicable from any sharp bend of 30 degrees or more in the exhaust pipe to help ensure that a well mixed exhaust flow sample may be taken 2 The r...

Page 89: ...ngine s life and may affect the warranty coverage on your engine Consult authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a Check or Clean Replace Consult your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval Daily SeeDaily Checks on page 84 Every 50 hours or monthly which ever comes first Every 250 hours or 1 yea...

Page 90: ...lectrical System Check the alarm and indicators Check the electrolyte level in the battery Adjust the tension of the alternator V ribbed belt or replace V ribbed belt Initial 50 Check the wiring connectors Engine Cylinder Head and Block Check for leakage of fuel engine oil and engine coolant After starting Tighten all major nuts and bolts Adjust intake exhaust valve clearance Initial 50 Miscellane...

Page 91: ...e engines Inspection and Maintenance of EPA Emission Related Parts for CI Marine Engines Note The inspection and maintenance items shown above are to be performed at your Yanmar Marine dealer or distributor Parts Interval Clean fuel injectors 1500 hours Check fuel injectors 3000 hours Check turbocharger adjustment if equipped Check electronic engine control unit and its associated sensors and actu...

Page 92: ...treatment Never check for a fuel leak with your hands Always use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair any damage 3 Check for engine coolant leaks 4 Check for damaged or missing parts 5 Check for loose missing or damaged fasteners 6 Check the electrical harnesses for cracks abrasions and damaged or corroded connectors 7 Check hoses for cracks ...

Page 93: ...he Alarm Indicators When operating the start switch on the instrument panel check that there is no alarm message on the display and the alarm indicators work normally See Control Equipment on page 19 Preparing Fuel Oil and Coolant in Reserve Prepare sufficient fuel for the days operation Always store engine oil and coolant in reserve for at least one refill onboard to be ready for emergencies Perf...

Page 94: ...the oil For easier draining remove the engine oil fill cap Dispose of used oil properly NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick and the surrounding area before removing the dipstick Always be environmentally responsible 3 Remove the engine oil filter Figure 2 with a filter wrench turn counterclockwise Figure 2 Note 4JH45 4JH57 shown 4 Install a new...

Page 95: ...the filter in place with the coil spring Figure 3 3 and insert into the case Install a new O ring Figure 3 4 in the side cover d Install side cover and tighten side cover bolts 3 Fill marine gear with clean marine gear oil See Marine Gear Oil Specifications on page 43 4 Perform a trial run and check for oil leaks 5 Approximately 10 minutes after stopping the engine remove the oil dipstick and chec...

Page 96: ...wear frayed cords etc If any defects are found replace the V ribbed belt 2 Check that the belt fits properly in the ribbed grooves NOTICE Confirm by hand that the belt has not slipped out of the grooves on the bottom of the pulley Checks on the rib side of the belt are considered acceptable If the belt has chunks missing from the ribs it should be replaced Figure 1 Figure 5 Figure 2 Figure 6 Inspe...

Page 97: ...sen the adjustment screw Figure 7 7 for the remote control cable and adjust 2 Adjust the low speed stop position Figure 7 6 first and then adjust the high speed stop position Figure 7 2 with the adjustment screw on the remote control lever Figure 7 4 Adjusting Marine Gear Remote Control Cable KM35P Figure 8 KMH4A Figure 9 1 Ensure that the remote control lever Figure 8 2 or Figure 9 2 moves to the...

Page 98: ...ng Figure 10 1 and adjust the position of the cable Adjusting Propeller Shaft Alignment The flexible engine mounts are compressed slightly during initial engine operation and may cause misalignment between the engine and the propeller shaft After the first 50 hours of operation the alignment should be checked and readjusted if necessary This is considered normal maintenance and the adjustment requ...

Page 99: ...y fuel system component Figure 4 Figure 11 1 Filter element 2 Drain plug 3 Cover fire resistant 4 Clamp screw NOTICE If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator two to three turns coun...

Page 100: ...es and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment NOTICE Never turn off the battery switch if equipped or short the battery cables during operation Damage to the electric system will result NOTICE Never operate with insufficient battery electrolyte Operating with insufficient electrolyte will destroy the battery Battery fluid ...

Page 101: ...e Engine Oil Filter Element Changing the Marine Gear Oil and Replacing Marine Gear Oil Filter Element If Equipped Checking or Replacing the Seawater Impeller Changing the Coolant Cleaning the Intake Silencer Air Cleaner Element Cleaning the Exhaust Water Mixing Elbow Wash the Turbocharger blower If Equipped Adjusting the Alternator V ribbed belt Tension Checking the Wiring Connectors Tightening Al...

Page 102: ...is installed to the lower part of the fuel pre filter water separator to protect the water alarm switch 3 Attach a tube to the drain plug 4 Loosen the drain plug and drain the fuel from the drain plug 5 Disconnect the electrical connectors and remove the alarm switch with a spanner wrench 6 Remove the filter element with a filter wrench 7 Clean the filter element mounting surface Install new filte...

Page 103: ...Gear Oil and Replacing the Marine Gear Oil Filter Element if equipped See Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter If Equipped on page 87 Checking or Replacing Seawater Pump Impeller 1 Loosen side cover bolts and remove the side cover 2 Inspect the inside of the seawater pump with a flashlight If any of the following are found disassembly and maintenance are required I...

Page 104: ... 2 Install puller Figure 16 A in the impeller 3 Turn the jack screw Figure 16 B clockwise to remove the impeller from the pump body Figure 17 Figure 18 Note When replacing a used impeller with a new one the impeller must have an M18x1 5 thread Figure 17 1 Turn the M18 screw side of the impeller to the cover side and install Figure 18 Puller A Jack Screw B M18x1 5 M10x40 mm length 0004510 1 0004501...

Page 105: ...r mix different types and or colors of coolants Discard old coolant in an approved manner according to environmental laws Note If Long Life coolant is used replace coolant every 2 years Figure 54JH45 4JH57 Figure 19 1 Coolant drain cock Cylinderblock 2 Marine gear oil cooler KM4A1 3 Seawater drain cock Marine gear oil cooler Figure 20 4 Coolant pump 5 Coolant tank Heat exchanger 6 Coolant drain co...

Page 106: ...e properly 3 Close all the drain cocks 4 Fill coolant tank and reservoir with appropriate coolant See Engine Coolant Specifications on page 45 and Checking and Adding Coolant on page 46 Cleaning the Intake Silencer Air Cleaner Element 1 Disassemble the intake silencer air cleaner 2 Remove element Clean element and housing with a neutral detergent 3 Dry completely and reassemble Cleaning the Exhaus...

Page 107: ...ctors Consult authorized Yanmar Marine dealer or distributor Tightening All Major Nuts and Bolts See Tightening Fasteners on page 76 or consult authorized Yanmar Marine dealer or distributor Perform the following maintenance every 500 hours or 2 years of operation whichever comes first Replacing the Exhaust Water Mixing Elbow Replacing Rubber Hoses Replacing the Exhaust Water Mixing Elbow Replace ...

Page 108: ...n if it is not damaged See Checking or Replacing Seawater Pump Impeller on page 95 Cleaning and Checking the Seawater Passages After prolonged use clean the seawater passages to remove trash scale rust and other contaminants that collect in the seawater passages This can cause declining cooling performance The following items need to be inspected Heat Exchanger Pressure Cap Consult authorized Yanm...

Page 109: ...ternator V ribbed belt Tension on page 87 Adjusting Intake Exhaust Valve Clearance Consult authorized Yanmar Marine dealer or distributor Checking the Remote Control Cable Operation Consult authorized Yanmar Marine dealer or distributor Adjusting the Propeller Shaft Alignment Consult authorized Yanmar Marine dealer or distributor ...

Page 110: ...PERIODIC MAINTENANCE 102 JH Series Operation Manual This Page Intentionally Left Blank ...

Page 111: ...ipe If the discharge is low stop the engine immediately Identify the cause and repair Is the smoke color normal The continuous emission of black exhaust smoke indicates engine overloading This shortens the engines life and should be avoided Are there abnormal vibrations or noise Depending on the hull structure engine and hull resonance may suddenly increase at certain engine speed ranges causing h...

Page 112: ...Periodically operate the engine near maximum speed while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintain engine performance and prolong the life of the engine TROUBLESHOOTING INFORMATION If the engine does not operate properly refer to the Troubleshooting Chart on page 105 or consult authorized Yanmar Marine dealer or distributor Supp...

Page 113: ...cable between battery and starter Increase the cable size or shorten Insufficient battery charge Charge No fuel injection Incomplete priming of fuel system Carry out sufficient priming Clogged fuel inlet filter Replace Fuel level in fuel tank is low Add fuel Closed cock of fuel tank Open cock Clogged fuel pipe Clean Failure of fuel supply pump Repair or replace Failure of fuel injector Faulty valv...

Page 114: ...r from drain cock and fuel pipe conduct priming Fuel cock closed Inspect and repair as necessary Clogged fuel filter Replace Broken fuel pipe Replace Failure of fuel supply pump Replace Other Moving parts seized Disassemble and repair or replace Controller defects system error Inspect DTC and conduct servicing Abnormal smoke color Failure of fuel injector Clogged injection nozzle Replace Sticking ...

Page 115: ... charger failure If equipped Clogged air filter Clean Dirty compressor side Clean Clogged turbine nozzle Clean Damaged bearing Replace Other Improper fuel Replace with correct fuel Clogged exhaust duct Clean Seized or overheated moving parts Disassemble and conduct servicing Insufficient seawater Inspect seawater pump Insufficient feed of engine oil Disassemble and clean engine oil pump and filter...

Page 116: ... deposit on turbine and compressor Clean Entrapment of foreign matter at turbine entrance Repair or replace Rapid change in load surging Stabilize the load or replace turbine nozzle Quick contamination of engine oil Gas trapped in bearing housing Repair Clogged seal air path Clean Damaged seal ring Replace Clogged pressure balance path Clean Pulsation of intake air pressure Uneven cylinder combust...

Page 117: ... authorized Yanmar Marine dealer or distributor One of the indicators does not go out Sensor switch is faulty Consult authorized Yanmar Marine dealer or distributor Battery low charge indicator does not go out during operation V ribbed belt is loose or broken Replace V ribbed belt or adjust tension See Checking and Adjusting the Alternator V ribbed belt Tension on page 87 Battery is defective Chec...

Page 118: ...R AC2 ERR P0223 P0222 91 28 4 4 Main Analog Throttle Sensor 1 Error Low Range Main Analog Throttle Sensor 2 Error Low Range Both signal of the dual throttle sensor are out of limit AC1 ERR AC2 ERR P0123 P0122 91 28 3 3 Main Analog Throttle Sensor 1 Error High Range Main Analog Throttle Sensor 2 Error High Range CHK ENG P0168 174 0 Fuel Temperature Too High Suspicious insufficient fuel in the fuel ...

Page 119: ...t Circuit FUEL P1151 522329 0 Water In Fuel Condition CHK ENG P1192 100 4 Oil Pressure Switch Open Circuit Suspicious Broken sensor or wire poor connection OIL PRS P1198 100 1 Oil Pressure Too Low CHK ENG P1262 651 3 Injector 1 Short Circuit Suspicious Broken injector or wire poor connection CHK ENG P1265 652 3 Injector 2 Short Circuit CHK ENG P1268 653 3 Injector 3 Short Circuit CHK ENG P1271 654...

Page 120: ...CHK ENG P1648 523462 13 Injector 1 QR Code Data Error Input failure of the injector correction value CHK ENG P1649 523463 13 Injector 2 QR Code Data Error CHK ENG P1650 523464 13 Injector 3 QR Code Data Error CHK ENG P1651 523465 13 Injector 4 QR Code Data Error CHK ENG P1665 523468 9 Rail Pressure Error After Pressure Limit Valve Open CHK ENG P1666 523469 0 Rail Pressure Limit Valve Open Exceed S...

Page 121: ...CU TO HELM ECU Station change comes to be unavailable U404 523761 9 CAN COM ERROR DRIVE ECU TO HELM ECU Shift change comes to be unavailable U1201 523762 9 CAN COM ERROR HELM ECU TO HELM ECU Station change comes to be unavailable U1202 523763 9 CAN COM ERROR HELM LOCAL Station change Synch Operation Warmup operation and Engine speed limit mode come to be unavailable B1001 523543 4 NEUTRAL SW ACTIV...

Page 122: ...TROUBLESHOOTING 114 JH Series Operation Manual This Page Intentionally Left Blank ...

Page 123: ...f seawater is left inside of the engine it may freeze and damage parts of the cooling system when the ambient temperature is below 0 C 32 F PREPARE ENGINE FOR LONG TERM STORAGE Note If the engine is close to a periodic maintenance interval perform those maintenance procedures before putting the engine into long term storage 1 Wipe off any dust or oil from the outside of engine 2 Drain water from f...

Page 124: ...Coolant tank Heat exchanger 7 Seawater pump Drain from pump cover Figure 34JH80 4JH110 Figure 3 1 Turbocharger 2 Coolant drain cock Cylinderblock 3 Marine gear oil cooler KMH4A 4 Seawater drain cock Marine gear oil cooler Figure 4 Figure 4 5 Coolant pump 6 Coolant tank Heat exchanger 7 Coolant drain cock Coolant tank Heat exchanger 8 Seawater drain cock Air cooler 9 Air cooler 10 Seawater pump Dra...

Page 125: ... drain Open the seawater drain cock on the air cooler 4JH80 4JH110 only and drain If no water drains use a stiff brush to remove any debris 2 Remove four bolts attaching the side cover of the seawater pump Remove the cover and drain the seawater 3 Install cover and tighten bolts 4 Close all the drain cocks RETURNING THE ENGINE TO SERVICE 1 Replace the oil and the oil filter before running the engi...

Page 126: ...LONG TERM STORAGE 118 JH Series Operation Manual This Page Intentionally Left Blank ...

Page 127: ...JH Series Operation Manual 119 SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS ...

Page 128: ...terclockwise viewed from stern Propeller shaft ahead Clockwise viewed from stern Counterclo ckwise or clockwise Bi rotation Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Cooling Water Capacity coolant Engine 6 0 L 6 34 qt Reservoir 0 8 L 0 85 qt Lubricating Oil Capacity engine Rake angle at rake angle 7 at rake angle 0 Total 5 0 L 5 28 qt 5 5 L 5 8...

Page 129: ...Counterclockwise viewed from stern Propeller shaft ahead Clockwise viewed from stern Counterclo ckwise or clockwise Bi rotation Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Cooling Water Capacity coolant Engine 6 0 L 6 34 qt Reservoir 0 8 L 0 85 qt Lubricating Oil Capacity engine Rake angle at rake angle 7 at rake angle 0 Total 5 0 L 5 28 qt 5 5 L...

Page 130: ... reverse min 1 1232 921 1114 921 1353 1103 1078 1103 1246 950 1103 950 1983 1981 1360 1359 1106 1105 1304 1304 1167 1167 Lubrication System Splash Centrifugal pump Oil bath Lubricating Oil Capacity total 0 5 L 0 53 qt 1 1 L 1 16 qt 0 65 L 0 69 qt 2 3 L 2 43 qt 2 8 L 3 0 qt Long Reach 75 mm 3 0 L 3 2 qt Lubricating Oil Capacity effective 0 05 L 0 05 qt 0 2 L 0 21 qt 0 15 L 0 16 qt 0 2 L 0 21 qt Coo...

Page 131: ... viewed from stern Propeller shaft ahead Clockwise viewed from stern Counterclo ckwise or clockwise Bi rotation Clockwise or counterclockwise Bi rotation Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Cooling Water Capacity coolant Engine 7 2 L 7 61 qt Reservoir 0 8 L 0 85 qt Lubricating Oil Capacity engine Rake angle at rake angle 7 at rake angle 0...

Page 132: ...rclockwise viewed from stern Propeller shaft ahead Clockwise viewed from stern Counterclock wise or clockwise Bi rotation Clockwise or counterclockwise Bi rotation Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Cooling Water Capacity coolant Engine 7 2 L 7 61 qt Reservoir 0 8 L 0 85 qt Lubricating Oil Capacity engine Rake angle at rake angle 7 at ra...

Page 133: ...9 Propeller Speed forward reverse min 1 1444 1176 1150 1176 2115 2113 1451 1450 1180 1179 1520 1520 1263 1263 1607 1607 1250 1250 1391 1391 1245 1245 Lubrication System Splash Centrifugal pump Trochoid pump Oil bath Lubricating Oil Capacity total 1 1 L 1 16 qt 3 0 L 3 17 qt 2 0 L 2 11 qt 1 8 L 1 90 qt 2 8 L 3 0 qt Long Reach 75 mm 3 0 L 3 2 qt Lubricating Oil Capacity effective 0 2 L 0 21 qt 0 3 L...

Page 134: ...SPECIFICATIONS 126 JH Series Operation Manual This Page Intentionally Left Blank ...

Page 135: ...outer diameter x thickness Dimension of rubber pipe inner diameter x thickness Fuel rubber pipes marked satisfy EN ISO7840 Notation Description Screw Joint Union Flange Joint Eye Joint Insertion Joint Drilled Hole Coolant Piping Cooling Seawater Piping Lubricating Oil Piping Diesel Fuel Piping ...

Page 136: ...l 4JH45 4JH57 with KM35P or KM35A2 or SD60 Marine Gear Figure 1 1 3 7 8 5 6 9 10 12 13 11 14 A B C D 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 38 39 40 41 42 34 36 37 2 4 ø8 ø26 ø8 18 30 13 45 ø76 3 P P A C P P T B D 057225 00X00 ...

Page 137: ...g oil cooler 17 Fuel return pipe 18 9 x t3 5 Rubber hose 19 Oil pressure switch 20 Oil pressure sensor option 21 Fuel injector 22 Mixing elbow 23 25 4 x t4 3 Rubber hose 24 Heat exchanger 25 Main bearing 26 Lubrication oil inlet strainner 27 Seawater inlet 28 25 4 x t4 3 Rubber hose 29 Cooling water pump seawater 30 28 x t4 Rubber hose 31 28 x t4 Rubber hose 32 Hot water connection outlet 33 Coola...

Page 138: ...anual 4JH45 4JH57 with KM4A1 Marine Gear Figure 2 1 3 7 8 5 6 9 10 12 13 11 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 41 42 43 44 45 A B C D 37 39 40 2 4 ø8 ø26 ø8 18 30 13 45 ø76 3 P P A C P P T B D 057226 00X00 ...

Page 139: ... Rubber hose 19 Oil pressure switch 20 Oil pressure sensor option 21 Fuel injector 22 13 x t4 Rubber hose 23 Marine gear lubrication oil Cooler 24 Mixing elbow 25 25 4 x t4 3 Rubber hose 26 25 4 x t4 3 Rubber hose 27 Heat exchanger 28 Main bearing 29 Lubrication oil inlet strainner 30 Seawater inlet 31 25 4 x t4 3 Rubber hose 32 Cooling water pump seawater 33 28 x t4 Rubber hose 34 28 x t4 Rubber ...

Page 140: ...anual 4JH45 4JH57 with ZF30M Marine Gear Figure 3 1 3 7 8 5 6 9 10 12 13 11 14 15 16 17 18 19 20 21 23 22 24 25 26 27 28 29 30 31 32 33 34 35 37 40 41 42 43 44 A B C D E 36 38 39 2 4 ø8 ø26 ø8 18 30 13 45 ø76 3 P P A C P P T B D E 057227 00X00 ...

Page 141: ... 18 9 x t3 5 Rubber hose 19 Oil pressure switch 20 Oil pressure sensor option 21 Fuel injector 22 Seawater inlet 23 Marine gear lubrication oil Cooler 24 Mixing elbow 25 25 4 x t4 3 Rubber hose 26 25 4 x t4 3 Rubber hose 27 Heat exchanger 28 Main bearing 29 Lubrication oil inlet strainner 30 25 4 x t4 3 Rubber hose 31 Cooling water pump seawater 32 28 x t4 Rubber hose 33 28 x t4 Rubber hose 34 Hot...

Page 142: ...arine Gear Figure 4 056832 00X00 P P A A E B C D F P P T B E ø8 13 18 ø8 ø26 30 30 ø25 30 ø25 4 ø76 2 27 8 C F D 1 2 3 5 6 7 9 8 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 30 31 32 33 37 39 40 42 43 44 45 46 47 48 49 50 51 52 55 56 57 53 54 41 38 34 35 36 29 27 28 13 4 ...

Page 143: ...se 24 13 x t4 Rubber hose 25 8 x t1 STKM 26 Marine gear lubrication oil Cooler 27 To Oil pan 28 From Cylinder block 29 17 x t3 rubber hose 30 17 x t1 2 STKM 31 Turbo charger 32 Mixing elbow 33 25 4 x t4 3 Rubber hose 34 8 5 x t3 5 Rubber hose 35 25 4 x t4 3 Rubber hose 36 7 5 x t2 5 Rubber hose 37 Air cooler 38 Heat exchanger 39 Main bearing 40 Lubrication oil inlet strainner 41 To Camshaft 42 25 ...

Page 144: ...F25A Marine Gear Figure 5 061213 00X00 1 2 5 6 7 8 9 10 14 13 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 33 32 34 35 36 38 39 41 40 42 43 44 45 46 47 48 49 50 51 54 55 56 52 53 37 27 26 11 12 4 3 P P A F P P T B D C E E A F B C D ø8 18 30 ø25 4 ø8 13 ø26 30 30 ø25 27 8 ø76 2 ...

Page 145: ...3 Marine gear 24 8 x t1 STKM 25 Marine gear lubrication oil Cooler 26 To Oil pan 27 From Cylinder block 28 17 x t3 rubber hose 29 17 x t1 2 STKM 30 Turbo charger 31 Mixing elbow 32 25 x t4 5 Rubber hose 33 25 x t4 5 Rubber hose 34 8 5 x t3 5 Rubber hose 35 7 5 x t2 5 Rubber hose 36 Air cooler 37 Heat exchanger 38 Main bearing 39 Lubrication oil inlet strainner 40 To Camshaft 41 25 4 x t5 Rubber ho...

Page 146: ...M Marine Gear Figure 6 061214 00X00 1 3 2 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 23 24 27 28 29 30 31 32 26 39 51 52 33 34 35 36 37 38 40 41 42 43 44 45 46 47 48 49 50 53 54 55 25 11 8 9 10 P P A F P P T B D C E A E B C D F 30 ø25 30 ø26 ø8 18 30 ø25 4 27 8 ø76 2 ø8 13 ...

Page 147: ...il jet 23 8 x t1 STKM 24 Marine gear lubrication oil Cooler 25 To Oil pan 26 From Cylinder block 27 17 x t3 rubber hose 28 Turbo charger 29 Mixing elbow 30 25 x t4 5 Rubber hose 31 17 x t1 2 STKM 32 25 x t4 5 Rubber hose 33 8 5 x t3 5 Rubber hose 34 7 5 x t2 5 Rubber hose 35 Air cooler 36 Heat exchanger 37 Main bearing 38 Lubrication oil inlet strainner 39 To Camshaft 40 25 4 x t5 Rubber hose opti...

Page 148: ...SYSTEM DIAGRAMS 140 JH Series Operation Manual This Page Intentionally Left Blank ...

Page 149: ...W White G Green Gr Gray Y Yellow Br Brown O Orange Lg Light green P Pink V Purple Allowable Length by Cross Sectional Area of Battery Cable Section of Cable mm2 in 2 Allowable Length L 1 2 3 m ft 15 0 023 0 86 0 26 20 0 031 1 3 0 40 30 0 046 2 3 0 70 40 0 062 2 8 0 85 50 0 077 3 5 1 07 60 0 093 4 1 1 25 ...

Page 150: ...5 K84 G 0 85 A_GND K45 R 0 5 APS2 K83 L 0 85 WIFSW WDSBSW LOPSW STR RLY K86 O 0 5 K86 O 0 5 PINT PEGRL K28 W 0 85 K15 Br 0 5 5VS K46 W 0 85 K43 R 0 85 K66 L 0 85 CHGSW 5VS K39 W 0 5 B54 R 3 0 K19 Y 0 5 5VS K61 P 0 85 A_GND K62 B 0 85 K43 R 0 85 K62 B 0 85 K61 P 0 85 A_GND K45 R 0 5 Throttle sensor K60 B 0 5 Diode2 Oil pressure sensor option K24 R 0 5 OP K57 L 0 5 K38 L 0 85 5VS K29 G 0 85 K24 R 0 ...

Page 151: ...r 0 85 SHUDNSW A_GND 9 A07 WG 0 5 A25 Gr 0 5 A26 P 0 5 A54 O 0 5 A39 W 0 5 5 10 G14 Br 1 25 B01 R 3 0 K51 O 0 5 ECU K K67A L 0 85 6 11 7 A29 L 0 5 UB3 K90 O 0 5 EMGSW APP IP7 B65 R 1 25 Coolant temperature sensor K65 BY 0 5 K53A G 0 5 K75A Y 0 5 K89 WBr 0 5 K67 L 0 85 K01 R 2 0 VB VB K05 R 2 0 K03 R 2 0 VB Fuse box G11 B 0 85 G11 B 0 85 B60 R 3 0 B61 W 3 0 B67 O 0 85 G10 B 1 25 A K67A L 0 85 B63 W...

Page 152: ... 0 85 A_GND K45 R 0 5 APS2 K83 L 0 85 WIFSW WDSBSW LOPSW STR RLY K86 O 0 5 K86 O 0 5 PINT PEGRL K28 W 0 85 K15 Br 0 5 5VS K46 W 0 85 K43 R 0 85 K66 L 0 85 CHGSW 5VS K39 W 0 5 B54 R 3 0 K19 Y 0 5 5VS K61 P 0 85 A_GND K62 B 0 85 K43 R 0 85 K62 B 0 85 K61 P 0 85 A_GND K45 R 0 5 Throttle sensor K60 B 0 5 Diode2 Oil pressure sensor option K24 R 0 5 OP K57 L 0 5 K38 L 0 85 5VS K29 G 0 85 K24 R 0 5 PLO K...

Page 153: ... 0 5 UB3 K90 O 0 5 EMGSW APP IP7 B65 R 1 25 Coolant temperature sensor K65 BY 0 5 K53A G 0 5 K75A Y 0 5 K89 WBr 0 5 K67 L 0 85 K01 R 2 0 VB VB K05 R 2 0 K03 R 2 0 VB Fuse box G11 B 0 85 G11 B 0 85 B60 R 3 0 B61 W 3 0 B67 O 0 85 G10 B 1 25 A K67A L 0 85 B63 W 1 25 G00B B 1 25 G00C B 1 25 A6 G00A B 1 25 G12 B 0 5 G14 Br 1 25 G02 BY 1 25 K75B Y 0 5 K53B G 0 5 Diode1 B67 O 0 85 B60A R 0 85 Diode5 K32 ...

Page 154: ...SYSTEM DIAGRAMS 146 JH Series Operation Manual This Page Intentionally Left Blank ...

Page 155: ...YDXN2 19D4N ENGINE MODEL 4JH57 APPLICATION VARIABLE SPEED PROPULSION ENGINES USED EMISSION CONTROL SYSTEM DFI REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS WITH FIXED PITCH PROPELLERS 129675 07510 YANMAR CO LTD STANDARDS NOx HC 5 8g kW hr CO 5 0g kW hr PM 0 20g kW hr EMISSION CONTROL INFORMATION THIS MARINE ENGINE COMPLIES WITH U S EPAREGULATIONS FOR 2014 ULTRALOW SULFUR D...

Page 156: ...ission control system warranty period Where a warrantable emissions condition exists Yanmar will repair your engine at no charge to you for diagnosis parts and labor Warranty service or repair will be provided at authorized Yanmar Marine dealers or distributors It is recommended that any replacement parts used for maintenance repair or replacement of emission control systems are Yanmar parts The o...

Page 157: ... loss of time inconvenience loss of use of marine vessel engine or commercial loss Owner s Responsibility As the Yanmar Marine engine owner you are responsible for the performance of the required maintenance listed in your Operation Manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your marine engine but Yanmar cannot deny warranty solely for the...

Page 158: ...EPA WARRANTY USA ONLY 150 JH Series Operation Manual Maintenance Log Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature ...

Page 159: ...EPA WARRANTY USA ONLY JH Series Operation Manual 151 12 05 Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature ...

Page 160: ...l meet the exhaust emission requirements of Directive 94 25 EC as amended by Directive 2003 44 EC when installed in a recreational craft in accordance with the engine manufacturer s supplied instructions and that this these engine s must not be put into service until the recreational craft into which it is they are to be installed has been declared in conformity with the relevant provisions of the...

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