Yanmar 4JH45, 4JH110, 4JH57, 4JH80 Operation Manual

MARINE ENGINES

MARINE ENGINES

OPERATION MANUAL

4JH45
4JH57
4JH80
4JH110

http://yanmar.com

0AJHC-EN0010

OPERATION MANUAL

4JH45 4JH57 4JH80 4JH110

ڦMarine Operations Division

Quality Assurance Dept.

Overseas Office

ڦYanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Phone: [phone] Fax: [phone]

ڦYanmar Asia (Singapore) Corporation Pte Ltd. (YASC)

4 Tuas Lane, Singapore 638613
Phone: [phone] Fax: [phone]

5-3-1, Tsukaguchi-honmachi, Amagasaki

Hyogo, 661-0001, Japan

Phone: [phone] Fax: [phone]

ڦYanmar Engine (Shanghai). Co., Ltd.

10F, E-Block POLY PLAZA, No.18 Dongfang Road
Pudong Shanghai, CHINA P.R.C. 200120
Phone: [phone] Fax: [phone]

ڦYanmar America Corporation (YA)

101 International Parkway
Adairsville, GA 30103, U.S.A.
Phone: [phone] Fax: [phone]

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest
information available at the time of 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 trademarks of YANMAR CO., LTD. in
Japan, the United States and/or other countries.

All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means ­graphic, electronic, or mechanical, including photocopying, recording, taping, or
information storage and retrieval systems - without the written permission of
YANMAR CO., LTD.

MODEL

OPERATION MANUAL

CODE

All Rights Reserved, Copyright

4JH45, 4JH57, 4JH80, 4JH110

0AJHC-EN0010

1st edition: October 2013

OPERATION MANUAL

4JH45, 4JH57, 4JH80, 4JH110

Issued by: YANMAR CO., LTD. Marine Operations Division

Edited by: YANMAR TECHNICAL SERVICE CO., LTD.

TABLE OF

CONTENTS

INTRODUCTION .............................................................. 1

RECORD OF OWNERSHIP ...................................... 2

SAFETY ........................................................................... 3

SAFETY PRECAUTIONS .......................................... 4

General Information ............................................. 4

Before You Operate............................................. 4

During Operation and Maintenance..................... 4

LOCATION OF SAFETY DECALS ............................ 8

PRODUCT 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

Page

NAMEPLATES ......................................................... 15

FUNCTION OF MAJOR COMPONENTS ................ 16

ELECTRONIC CONTROL SYSTEM........................ 17

MAIN ELECTRONIC CONTROL COMPONENTS

AND FEATURES ..................................................... 18

JH Series Operation Manual i

TABLE OF CONTENTS

CONTROL EQUIPMENT.......................................... 19

Instrument Panel (Optional) ............................... 19

Accessory power output ..................................... 29

Single-Lever Remote Control Handle ................ 30

BEFORE YOU OPERATE .............................................. 31

INTRODUCTION ...................................................... 31

SAFETY PRECAUTIONS......................................... 31

DIESEL FUEL........................................................... 32

Diesel Fuel Specifications .................................. 32

Filling the Fuel Tank........................................... 35

Bleeding the Fuel System .................................. 36

Priming the Fuel System .................................... 37

ENGINE OIL ............................................................. 37

Engine Oil Specifications .................................. 37

Engine Oil Viscosity ........................................... 38

Checking the Engine Oil..................................... 38

Adding Engine Oil .............................................. 39

MARINE GEAR OR SAIL DRIVE OIL ...................... 39

Marine Gear Oil Specifications........................... 39

Sail Drive Oil Specifications ............................... 39

Checking Marine Gear Oil .................................. 40

Adding Marine Gear Oil...................................... 40

Checking and Adding Sail Drive Oil ................... 40

ENGINE COOLANT ................................................. 41

Engine Coolant Specifications ........................... 41

Coolant (Closed Cooling System) ...................... 41

Checking and Adding Coolant............................ 42

ENGINE OPERATION .................................................... 45

INTRODUCTION ...................................................... 45

SAFETY PRECAUTIONS......................................... 45

STARTING THE ENGINE ........................................ 47

If the Engine Fails to Start.................................. 48

Starting at Low Temperatures............................ 48

After the Engine has Started .............................. 49

REMOTE CONTROL HANDLE OPERATION .......... 49

Acceleration and Deceleration ........................... 49

Shifting the Engine ............................................. 49

Switching to Trolling (KMH4A Only)................... 50

CAUTIONS DURING OPERATION.......................... 51

ii JH Series Operation Manual

12/05

TABLE OF CONTENTS

SHUTTING DOWN THE ENGINE ........................... 52

Normal Shutdown .............................................. 52

Emergency Shutdown ....................................... 53

CHECKING THE ENGINE AFTER OPERATION .... 54

PERIODIC MAINTENANCE........................................... 55

INTRODUCTION...................................................... 55

SAFETY PRECAUTIONS ........................................ 55

PRECAUTIONS ....................................................... 57

The Importance of Periodic Maintenance .......... 57

Performing Periodic Maintenance ..................... 57

The Importance of Daily Checks ....................... 57

Keep a Log of Engine Hours and Daily Checks 57

Yanmar Replacement Parts .............................. 57

Tools Required .................................................. 57

Ask Your Authorized Yanmar Marine Dealer or

Distributor for Help............................................. 57

PERIODIC MAINTENANCE SCHEDULE ................ 60

PERIODIC MAINTENANCE PROCEDURES .......... 62

Daily Checks...................................................... 62

After Initial 50 Hours of Operation ..................... 63

Every 50 Hours of Operation ............................. 69

Every 250 Hours of Operation ........................... 71

Every 500 Hours of Operation ........................... 77

Every 1000 Hours of Operation ......................... 78

TROUBLESHOOTING ................................................... 81

SAFETY PRECAUTIONS ........................................ 81

TROUBLESHOOTING AFTER STARTING ............. 81

TROUBLESHOOTING INFORMATION ................... 82

TROUBLESHOOTING CHART................................ 83

FAILSAFE DIAGNOSIS FUNCTIONAL

SPECIFICATION CHART ........................................ 88

LONG-TERM STORAGE ............................................... 91

PREPARE ENGINE FOR LONG-TERM STORAGE 91

DRAIN SEAWATER COOLING SYSTEM ............... 92

RETURNING THE ENGINE TO SERVICE .............. 93

JH Series Operation Manual iii

TABLE OF CONTENTS

SPECIFICATIONS .......................................................... 95

PRINCIPAL ENGINE SPECIFICATIONS................. 95

4JH45 Engine..................................................... 96

4JH57 Engine..................................................... 97

4JH45, 4JH57 Marine Gear or Sail Drive........... 98

4JH80 Engine..................................................... 99

4JH110 Engine................................................. 100

4JH80, 4JH110 Marine Gear or Sail Drive....... 101

SYSTEM DIAGRAMS................................................... 103

PIPING DIAGRAMS ............................................... 103

WIRING DIAGRAMS .............................................. 117

iv JH Series Operation Manual

INTRODUCTION

Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and
from cruisers to mega yachts. In marine
leisure boating, the worldwide reputation of
Yanmar Marine is second to none. We
design our engines to respect nature. This
means quieter engines, with minimal
vibrations, cleaner than ever. All of our
engines meet applicable regulations,
including emissions, at the time of
manufacture.

To help you enjoy your Yanmar JH series
engine for many years to come, please
follow these recommendations:

• Read and understand this Operation
Manual before you operate the machine
to ensure that you follow safe operating
practices 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
quality and performance of Yanmar
products, so some details included in
this Operation Manual may differ slightly
from your engine. If you have any
questions about these differences,
please consult your authorized Yanmar
Marine dealer or distributor.

JH Series Operation Manual 1

• The specifications and components
(instrument panel, fuel tank, etc.)
described in this manual may differ from
ones installed on your vessel. Please
refer to the manual provided by the
manufacturer of these components.

• Refer to the Yanmar Limited Warranty
Handbook for a complete warranty
description.

INTRODUCTION

RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar for
service, parts or literature.

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

Date Purchased:_________________________________________________________

Dealer:_________________________________________________________________

Dealer Phone:___________________________________________________________

2 JH Series Operation Manual

SAFETY

DANGER

WARNING

CAUTION

NOTICE

Yanmar considers safety of great
importance and recommends that anyone
that comes into close contact with its
products, such as those who install,
operate, maintain or service Yanmar
products, exercise care, common sense
and comply with the safety information in
this manual and on the machine’s safety
decals. Keep the labels from becoming
dirty or torn and replace them if they are
lost or damaged. Also, if you need to
replace a part that has a label attached to
it, make sure you order the new part and
label at the same time.

This safety alert symbol
appears with most safety
statements. It means
attention, become alert,

A

your safety is involved!
Please read and abide by
the message that follows
the safety alert symbol.

Indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.

Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.

Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.

Indicates a situation which can cause
damage to the machine, personal property
and/or the environment, or cause the
equipment to operate improperly.

JH Series Operation Manual 3

SAFETY

DANGER

WARNING

SAFETY PRECAUTIONS

General Information

There is no substitute for common sense
and careful practices. Improper practices
or carelessness can cause burns, cuts,
mutilation, asphyxiation, other bodily injury
or death. This information contains general
safety precautions and guidelines that
must be followed to reduce risk to personal
safety. Special safety precautions are
listed in specific procedures. Read and
understand all of the safety precautions
before operation or performing repairs or
maintenance.

Before You Operate

The safety messages that follow have
DANGER level hazards.

During Operation and
Maintenance

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 the area

around the battery
well-ventilated and keep sparks, open
flames and any other form of ignition
out of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosive
under certain conditions.

Never permit anyone to install
or operate the engine without
proper training.

Read and understand this
Operation Manual before you operate or
service the engine to ensure that you
follow safe operating practices and
maintenance procedures.

• Safety signs and labels are additional

reminders for safe operating and
maintenance techniques.

• Consult authorized Yanmar Marine

dealer or distributor for additional
training.

Never use a shop rag to catch the fuel.

Wipe up all spills immediately.

Never refuel with the engine running.

Fire Hazard

Undersized wiring systems
can cause an electrical fire.

Store any containers containing fuel or
other flammable products in a
well-ventilated area, away from any
combustibles or source of ignition.

Store any equipment in a designated
area away from moving parts.

Never use the engine compartment for
storage.

4 JH Series Operation Manual

12/05

WARNING

Sever Hazard

Rotating parts can cause
severe injury or death.
Never wear jewelry,
unbuttoned cuffs, ties or

loose-fitting clothing and
always tie long hair back when working
near moving/rotating parts such as the
flywheel or PTO shaft. Keep hands, feet
and tools away from all moving parts.

Alcohol and Drug Hazard

Never operate the engine
while under the influence of
alcohol or drugs, or when
feeling ill.

SAFETY

Exhaust Hazard

Never block windows, vents
or other means of
ventilation if the engine is

operating in an enclosed
area. All internal combustion engines
create carbon monoxide gas during
operation and special precautions are
required to avoid carbon monoxide
poisoning.

Exposure Hazard

Always wear personal
protective equipment
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 body

parts away from hot engine surfaces.

JH Series Operation Manual 5

SAFETY

CAUTION

NOTICE

The safety messages that follow have
CAUTION level hazards.

Poor Lighting Hazard

Ensure that the work area is adequately
illuminated. Always install wire cages
on portable safety lamps.

Too l Ha z ar d

Always use tools appropriate for the
task at hand and use the correct size
tool for loosening or tightening
machine parts.

Flying Object Hazard

Always wear eye protection when
servicing the engine or when using
compressed air or high-pressure water.
Dust, flying debris, compressed air,
pressurized water or steam may injure
your eyes.

Coolant Hazard

Wear eye protection and
rubber gloves when you

handle engine coolant. If
contact with the eyes or skin should
occur, flush eyes and wash immediately
with clean water.

The safety messages that follow have
NOTICE level hazards.

It is important to perform daily checks as
listed in the Operation Manual. 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 environmentally
responsible.

Follow the guidelines of the

EPA or other governmental
agencies for the proper disposal of
hazardous materials such as engine oil,
diesel fuel and engine coolant. Consult the
local authorities or reclamation facility.

Never dispose of hazardous materials by
dumping them into a sewer, on the ground,
or into ground water or waterways.

If a Yanmar Marine Engine is installed at
an angle that exceeds the specifications
stated in the Yanmar Marine Installation
Manuals, engine oil may enter the
combustion chamber causing excessive
engine speed, white exhaust smoke and
serious engine damage. This applies to
engines that run continuously or those that
run for short periods of time.

6 JH Series Operation Manual

12/05

NOTICE

If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the
non-running engine(s) should be closed.
This will prevent water from being forced
past the seawater pump and eventually
finding its way into the engine. The result
of water entering the engine could cause
seizure or other serious problems.

If you have an installation with two or three
engines, and only one engine is operating,
please note that if the propeller shaft
thru-hull (stuffing box) is lubricated by
engine water pressure and the engines are
interconnected, care must be taken that
water from the running engine 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.

SAFETY

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 black smoke or movement of the
throttle does not increase engine speed,
you are overloading the engine that is
running. Immediately throttle back to
approximately 2/3 throttle or to a setting
where the engine performs normally.
Failure to do so may cause the running
engine to overheat or cause excess
carbon buildup which may shorten the
engine’s life.

Never turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electrical
system will result.

JH Series Operation Manual 7

SAFETY

WARNING

056977-00X00

LOCATION OF SAFETY DECALS

Figure 1, and Figure 2 show the location of safety decals on Yanmar 4JH45/57 and

4JH80/110 series marine engines.

4JH45/4JH57 Engines

1

2

3

Figure 1

1–Part Number: 128377-07350
2–Part Number: 128990-07270

3–Part Number: 196630-12980

8 JH Series Operation Manual

12/05

WARNING

128296-07300

3

056978-00X00

SAFETY

4JH80/4JH110 Engines

12

Figure 2

1–Part Number: 128377-07350
2–Part Number: 128990-07270

3–Part Number: 128296-07300
4–Part Number: 196630-12980

4

JH Series Operation Manual 9

SAFETY

This Page Intentionally Left Blank

10 JH Series Operation Manual

PRODUCT OVERVIEW

YANMAR 4JH COMMON
RAIL SERIES FEATURES
AND APPLICATIONS

The 4JH common rail series are
four-stroke diesel engines equipped with
direct injection common rail system and
with liquid coolant systems.

The 4JH45, 4JH57 is 4-cylinder and
naturally aspirated.

The 4JH80, 4JH110 is 4-cylinder and
turbocharged with an air cooler.

The engines are equipped with a marine
gear or sail drive unit.

These engines are designed for pleasure
craft use.

It is recommended that new vessels be
propped so the engines can operate at 50
to 100 min
engine speed to allow for some added
weight and hull resistance.

Failure to do so can lead to reduced vessel
performance, lead to increased smoke
levels and cause permanent damage to
your engine.

-1

above the fuel stop power

The engine must be installed correctly with
coolant lines, exhaust gas lines and
electrical wiring. Any auxiliary equipment
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 (3000 to 3200 min
5% of total engine time (30 minutes out of
every 10 hours) and cruising speed (2800

-1

min

or less).

The laws of some countries may require
hull and engine inspections, depending on
the use, size and cruising area of the boat.
The installation, fitting and surveying of
this engine all require specialized
knowledge and engineering skills. See
Yanmars local subsidiary in your region or
your authorized Yanmar Marine dealer or
distributor.

-1

) for less than

JH Series Operation Manual 11

PRODUCT OVERVIEW

NOTICE

New Engine Break-In

As with all reciprocating engines, the way
your engine is operated during its first 50
hours of operation plays a very significant
role in determining how long it will last and
how well the engine will perform over its
lifetime.

A new Yanmar diesel engine must be
operated at suitable speeds and power
settings during the break-in period to make
the sliding parts, such as piston rings,
break-in properly and to stabilize engine
combustion.

During the break-in period, the engine
coolant temperature gauge should be
monitored; temperature should be
between 71° and 87°C (160° and 190°F).

During the first 10 hours of operation, the
engine should be run at maximum engine
speed minus 400 to 500 min
(approximately 60 to 70% of load) most of
the time. This will ensure the sliding parts
break in properly. During this period, avoid
operating at maximum engine speed and
load to avoid damaging or scoring sliding
parts.

Do not operate at WOT (wide open
throttle) for more than a minute at a time
during the first 10 hours of operation.

-1

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 in open waters:

• With the clutch in NEUTRAL, accelerate

from the low-speed position to the
high-speed position briefly.

• Repeat this process five times.

Once past the initial 10 hours until 50
hours, the engine should be used over its
full operating range, with special emphasis
on running at relatively high power
settings. This is not the time for an
extended cruise at idle or low speed. The
boat should be run at maximum speed
minus 400 min

-1

most of the time
(approximately 70% load), with a 10
minute run at maximum minus 200 min

-1

(approximately 80% load) every
30 minutes and a 4 to 5 minute period of
operation at WOT (wide open throttle)
once each 30 minutes. During this period,
be sure not to operate your engine at low
speed and light load for more than
30 minutes. If operating engine at low
speed and light load by necessity, just after
the low idle operation, be sure to race the
engine.

To complete engine break-in, perform After
Initial 50 Hours of Operation maintenance
procedures. After Initial 50 Hours of
Operation on page 63.

Do not operate the engine at low idle or at
low speed and light load for more than
30 minutes at a time. Since unburned fuel
and engine 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.

12 JH Series Operation Manual

12/05

789101112

13 14 15 16 17

1819202122

056980-00X00

PRODUCT OVERVIEW

COMPONENT IDENTIFICATION

Figure 1 and Figure 2 illustrate a typical version of a 4JH45/4JH57 engine. Your engine

may have different equipment from that illustrated.

Right Side (Viewed from
Flywheel) - 4JH45/4JH57

Figure 1

123 4 56

056979-00X00

Left Side (Viewed from Flywheel)

- 4JH45/4JH57

Figure 1

1 – Intake silencer
2 – Common rail

3 – Engine oil dipstick
4 – 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

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 manifold
20–Alternator
21–Seawater pump
22 – Belt cover

JH Series Operation Manual 13

PRODUCT OVERVIEW

12 3 4 5 67

891013 1112

056981-00X00

14 15 16 17 18

192022 212324

056982-00X00

Figure 3 and Figure 4 illustrate a typical version of a 4JH80/4JH110 engine. Your engine
may have different equipment from that illustrated.

Right Side (Viewed from
Flywheel) - 4JH80/4JH110

Left Side (Viewed from Flywheel)

- 4JH80/4JH110

Figure 3

1 – Turbocharger
2 – Intake silencer

3 – Common rail
4 – Engine oil dipstick
5 – Intake manifold
6 – Fuel 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

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
22–Seawater pump
23–Alternator
24 – Belt cover

14 JH Series Operation Manual

12/05

129670-07201

Continuous power kW

Speed of prop.shaft

Gear Model

ｍｉｎ

-１

Fuel stop power kW

MFG.DATE

ｍｉｎ

-１

/

/

ｍｉｎ

-１

Model

ENG.No.

/

kW

㻹㻻㻰㻱㻸
㻹㻲㻳㻚㻌㻺㻻㻚
㻳㻱㻭㻾㻌㻾㻭㼀㻵㻻
㻻㻵㻸㻌

177524-02903

196460-02120

/#&'+0'7

/1&'.

20

)'#44#6+1
/()01

1+.6;2'

PRODUCT OVERVIEW

NAMEPLATES

The nameplates of Yanmar JH series
engines are shown in Figure 5. Check the
engine’s model, output, min
number on the nameplate. Please replace
if damaged or lost.

The engine nameplate is attached to the
engine rocker arm cover.

-1

and serial

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 5

Figure 7

JH Series Operation Manual 15

PRODUCT OVERVIEW

FUNCTION OF MAJOR COMPONENTS

Name of Component Function

Fuel Filter The fuel filter removes contaminants and sediments from the diesel fuel. Periodic replacement

Fuel pre-filter
(Water separator)

Fuel Priming Pump This is a manual fuel pump. Pushing the knob on the top of the fuel pre-filter feeds the fuel.

Engine Oil Filler Port Filler port for engine oil.

Engine Oil Filter Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is distributed to

Marine Gear Filler Port Filler port for marine gear lube oil. Located on top of the marine gear case.

Cooling System There are two cooling systems: closed cooling with coolant and seawater. The engine is

Coolant pump The centrifugal water pump circulates coolant inside the engine. The circulating pump is

Seawater Pump Pumps seawater from outside vessel to the engine. The seawater pump is gear-driven and

Reservoir The pressure valve in the filler cap releases vapor and hot water overflow to the reservoir.

Oil Cooler - Engine A heat exchanger that cools high temperature engine oil using coolant.

Oil Cooler - Marine Gear
(Optional)

Turbocharger (if equipped) The turbocharger pressurizes the air coming into the engine. It is driven by a turbine that is

Air cooler (if equipped) This heat exchanger cools the pressurized charging air from the turbocharger with seawater

Intake Silencer (Air Cleaner) The intake silencer guards against dirt in the air and reduces the noise of air intake.

Nameplates Nameplates are provided on the engine and the marine gear and have the model, serial

Starter Starter motor for the engine. Powered by the battery.

Alternator Driven by belt and generates electricity and charges the battery.

Engine Oil Dipstick Gauge stick for checking the engine oil level.

of the fuel filter is necessary. See Periodic Maintenance Schedule on page 60 for the
replacement frequency.

The water separator removes contaminants, sediment and water from diesel fuel going to the
fuel filter. This is a required component of the fuel system and is standard equipment with
every engine. The water separator is installed between the fuel tank and the fuel feed pump.
Periodically drain the water from the water separator using the drain cock at the bottom of the
separator and replace the filter element.

This pump is also used to bleed air from the fuel system.

the engine’s moving parts. The filter is a cartridge type and the element should be replaced
periodically. See Changing the Engine Oil and Replacing the Engine Oil Filter Element on
page 73.

cooled by the closed cooling circuit. The closed circuit is cooled by seawater using a heat
exchanger. The seawater also cools the engine/marine gear oil and intake air (depending on
model) through the cooler(s) in an open circuit.

driven by a V-ribbed belt.

has a replaceable rubber impeller. Do not operate it without seawater, as this will damage the
impeller.

When the engine stops and the coolant cools, the pressure in coolant tank drops. The filler
cap vacuum valve then opens to send water back from the reservoir. This minimizes coolant
consumption. The closed cooling system coolant level can easily be checked and refilled in
this tank.

This heat exchanger cools the marine gear (KMH4A) oil using seawater.

energized by exhaust gases.

to increase the charging air quantity.

number and other data.

16 JH Series Operation Manual

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WARNING

NOTICE

PRODUCT OVERVIEW

ELECTRONIC CONTROL
SYSTEM

• The 4JH common rail series engines
use a high pressure common rail
system.

• The fuel is injected at extremely high
pressure.

• Never disassemble the fuel system
parts.

• Failure to comply may result in death
or serious injury.

• If a malfunction occurs, consult your
nearest Yanmar dealer or distributor.

• Never use the ECU for other purposes
than intended or in other ways than
specified by Yanmar. Doing so could
result in the violation of emission
control regulations and will void the
product warranty.

• Be sure to use the ECU in conjunction
with the engines whose models or
serial numbers are specified by
Yanmar.Other ECU/engine
combinations than specified will void
the engine warranty.

• Replacing the fuel injector involves
rewriting the fuel injection data in the
ECU. Be sure to consult your local
Yanmar dealer before replacing the fuel
injector. Failure to rewrite the fuel
injection data before replacing the fuel
injector will void the engine warranty.

• 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.

• Do not plug or unplug the ECU for a
period of at least 6 seconds after power
to the unit has been turned on or off.

•

Do not touch connector pins of the ECU with
bare hands.
Doing so may result in corrosion of the
connector pins and/or damage to the internal
circuits of the ECU due to static electricity.

• Do not force a measuring probe into the
female coupler.
Doing so may cause contact failure of
the connector pins, resulting in
malfunction of the ECU.

• Take care to prevent water from entering
the couplers when plugging or
unplugging the connector.
Water inside the couplers may cause
corrosion, resulting in malfunction of the
ECU.

• Avoid plugging/unplugging the connector
more than approx. 10 times.
Frequent plugging/unplugging of the
connector may cause contact failure of
the connector pins, resulting in
malfunction of the ECU.

• Do not use the ECU that has ever
suffered drop impact.

• Improper use or misuse of the ECU

may result in death or serious injury
due to an abrupt and unexpected
increase in engine speed.

JH Series Operation Manual 17

•

Always check the battery for proper charge.
Otherwise the electronically controlled
engines may fail to start.

PRODUCT OVERVIEW

MAIN ELECTRONIC CONTROL COMPONENTS AND
FEATURES

Component/feature Description

Controller By controlling the fuel injection timing, volume, pressure and number in accordance with the

Fuel pump (supply pump) The fuel pump supplies fuel to the common rail.

Common rail The common rail stores the compressed high-pressure fuel from the supply pump and

Fuel injector The Fuel Injectors the high-pressure fuel from the rail to the engine combustion room after

Accelerator sensor
(Installed in the ECU box)

Engine diagnosis tool Allows the operator to troubleshoot the cause of a problem based on detailed information

target speed indication entered from the accelerator sensor, the controller adjusts the engine
speed and power.

distributes fuel to the injector in each cylinder.

receiving a signal from the ECU in the most appropriate injection timing, injection volume,
injection ratio, number of injection and spray condition.

Unlike mechanical governors, the common rail fuel injection system has no governor lever.
The accelerator sensor serves as the governor lever to provide the speed command signal
(voltage signal) to the ECU for engine speed control.

regarding the problem occurring in the ECU. This tool can also be used for data maintenance
tasks including programming and mapping. See Troubleshooting on page 81

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042563-01X00

4

213

043796-01X00

4

213

5

6

PRODUCT OVERVIEW

CONTROL EQUIPMENT

The equipment in the control room makes remote control operation possible. It consists of
the instrument panel, which is connected to the engine by a wire harness, and the remote
control handle, which is 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.

B20-Type

Figure 8

C30-Type

1 – Alarm lamp
2–Tachometer

3–LCD

Figure 9

4 – Switches (push-buttons)
5 – Coolant temperature gauge
6 – Engine oil pressure gauge

JH Series Operation Manual 19

PRODUCT OVERVIEW

Meters

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 Pressure Gauge Shows the engine oil pressure. (If oil pressure sensor equippeed)

Panel Lights When the power switch is pushed, the gauges will illuminate for easier viewing.

Note: The LCD on the instrument panel show hour meter, coolant temperature, display

brightness, oil pressure and battery voltage. See LCD control on page 23.
Other indicators in the LCD can be added by display setting. See Selection of
the display setting on page 26.

Coolant temperature and oil pressure display (option)

･B20, B30-Type panels have a digital LCD screen inside the tachometer.
･C30-Type panels have an electric gauge with a needle.

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213

042564-00X00

042565-00X00

042567-00X00

Instrument Panel

The formats for the instrument panel are shown below.

Figure 10

PRODUCT OVERVIEW

1 – Alarm lamp
2–Tachometer

Control panel switches

All switches are push-buttons.

Start switch

Pushing this switch
operates the starter and
starts the engine.

Stop switch

Pushing this switch stops
the engine.

3–LCD
4 – Switches (push-buttons)

Power switch

Pushing this switch turns
on or off the power.

JH Series Operation Manual 21

PRODUCT OVERVIEW

Indicators and Alarms (Optional)

When a sensor detects a problem during operation, the indicator on the instrument panel
will light and an alarm will sound. Indicators are located on the instrument panel and the
alarms are located on the back of the panel. Under normal operating conditions, the
indicators are off.

Battery Low Charge Indicator

When the alternator output is too low, the indicator will light. When
charging begins, the indicator will turn off.

Coolant High Temperature Indicator and Alarm

When coolant temperature reaches the maximum allowable temperature
(95°C [203°F] or higher), the indicator will light and the alarm will sound.
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 the oil level
and troubleshoot the lubrication system.

Water in Sail Drive Seal Indicator and Alarm

When water is detected between the seals of the sail drive, the indicator
will light and the alarm will sound.

Water in Fuel Filter Indicator and Alarm

When the water level in the fuel filter/water separator becomes too high,
the indicator will light and the alarm will sound. Drain the water from the
fuel filter/water separator. See Draining Fuel Filter/Water Separator on
page 69.

22 JH Series Operation Manual

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Scroll

Push and hold
(display will blink when
ready)

Scroll
100, 80, 60, 40, 20, 0
(value will be set after
3 seconds)

Imperial unitsMetric

Imperial unitsMetric

055130-00EN01

1 2 3

Engine hour ( >300 min-1)

Coolant temperature

Backlighting Brightness

Oil pressure

Battery voltage

LCD control
(hour meter, coolant temperature, display brightness, oil pressure, battery voltage)

You can switch (scroll) between displays
by pressing the buttons on the bottom as
the default setting.

• Switching screens by pressing the
right button (Pressing the left button
switches the screens in the opposite
direction.)

Press the power switch.

• After 4 seconds, the LCD shows the
hour meter.

Pressing the right button on the bottom of
the LCD shows the temperature display.
Select between Metric units (°C) and
Imperial units (°F) at the "System Units
screen" on the next page.

Pressing the right button again shows the
LCD brightness settings.
To set the brightness of the backlight:

PRODUCT OVERVIEW

Figure 2

Press the left button 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
pressure display. Select between Metric
units (BAR) and Imperial units (PSI) at the
"System Units screen" on the next page.

Press again to show the battery voltage.
Pressing the button once more, return the
display to the initial hour meter.
Return to hour meter

Return to hour meter

Figure 11

JH Series Operation Manual 23

PRODUCT OVERVIEW

057180-00EN00

1 2

14 2 3

Select

Scroll

Imperial Metric

Select

Scroll

Setup screen access and control
(Setting the temperature and pressure units and others)

Use the buttons on the bottom of the LCD
display to set the instrument panel.
Press the left button to switch between
displays.

Press and hold both buttons until "SET
UP" appears.

Press the left button to set the units for
the temperature 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".

Figure 3

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 "FUEL".
Pressing the right button displays the fuel
tank level setting screen.

Figure 12

24 JH Series Operation Manual