Barrus 4JH57 Manual
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Barrus 4JH57 Manual

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ORIGINAL INSTRUCTION
4JH57 BARNES ENGINE MANUAL
For the following engine models*:
4JH57 Barnes
4JH57 Barnes 180
4JH57 Barnes 24 120
Addendum to the Yanmar Marine Engines Manual Owners Handbook
*Standard Model, there may be a number of optional extras, or alternative components, that
might be fitted to an engine that are not shown in this book.
RDG603A29 – Issue 4

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  • Page 1 ORIGINAL INSTRUCTION 4JH57 BARNES ENGINE MANUAL For the following engine models*: 4JH57 Barnes 4JH57 Barnes 180 4JH57 Barnes 24 120 Addendum to the Yanmar Marine Engines Manual Owners Handbook *Standard Model, there may be a number of optional extras, or alternative components, that might be fitted to an engine that are not shown in this book.
  • Page 2 SAFETY E.P. Barrus is concerned for your safety. We use safety statements throughout the manual to call your attention to the potential hazards associated with the operation of your engine. Follow the precautions listed throughout the manual before operation, during operation and during servicing/maintenance procedures for your safety, the safety of others and to protect the performance of your engine.
  • Page 3 Engine Details Engine Number: Please enter your engine serial number in the space provided above. Please quote the engine identification number during any enquiry or when ordering spare parts. Information about the engine serial number and its location on the engine can be found in SECTION 2 of the manual.
  • Page 4 A TRANSFER OF TITLE OCCURS, IT MUST ALWAYS BE HANDED OVER TO THE NEW OWNER. Thank you for purchasing this 4JH57 Barnes Engine from E.P.Barrus. This manual has been compiled to help you to operate your engine and its associated parts with safety and pleasure.
  • Page 5 Routine maintenance outlined in the Owner’s Manual must be performed using genuine parts in order to maintain warranty coverage. If the customer performs maintenance, Barrus reserves the right to make future warranty coverage possible only with proof of proper maintenance.
  • Page 6 with the recommended operation/duty cycle section of the Owner’s Manual, accident, submersion, improper installation (proper installation specification and techniques are set forth in the Operations and First time running sections in this manual), use of an accessory or part not manufactured or sold by us, or alteration or removal of parts. Expenses related to crane-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other types of accidental or consequential damages are not covered by this warranty.

  • Page 7: Table Of Contents

    SECTION 2 – Engine Identification............. 11 SECTION 3 – Component Identification ............. 12 4JH57 Barnes ..................12 4JH57 Barnes 180 ................13 4JH57 Barnes 24 120 ................14 Engine Mounts ..................15 SECTION 4 – Installation ................16 Calorifier ....................16 SECTION 5 –...

  • Page 8: Section 1 - Safety Precautions

    SECTION 1 – Safety Precautions 1. General NOTICE: NEVER PERMIT ANYONE TO OPERATE THE ENGINE WITHOUT PROPER TRAINING. It is the responsibility of the installer/operator to ensure that the finished installation complies with CE Marking, the relevant Health & Safety requirements and the recreational craft directive before commissioning.

  • Page 9: Exhaust System

    The engine and its accessories are not intended to be put into operation until they are integrated into the boat as a whole. No person should be in the engine compartment and the engine cover or deck hatches should be closed whilst the engine is running. 4.
  • Page 10 WARNING: BURN HAZARD! BATTERIES CONTAIN SULPHURIC ACID. NEVER ALLOW BATTERY FLUID TO COME IN CONTACT WITH SKIN, EYES OR CLOTHING. SEVERE BURNS COULD RESULT. MAKE SURE THE CORRECT PERSONAL PROTECTION EQUIPMENT IS WORN. • Batteries can produce explosive gases; keep sparks and flames away from the battery. NO SMOKING •...

  • Page 11: Section 2 - Engine Identification

    SECTION 2 – Engine Identification The engine serial number can be found engraved into the brass plate on the top of the engine rocker cover and stamped to the crankcase next to the starter motor. An example of the engine identification plate is shown below (Figure 1): Description Engine Model Serial Number...

  • Page 12: Section 3 - Component Identification

    125 Amp 12 Volt Alternator 120 Amp 24 Volt Alternator Calorifiers Water Pump Oil Cooler Figure 2: 4JH57 Barnes Left Side (Viewed from front) Description* Oil Filter Fuel Filter Figure 3: 4JH57 Barnes Right Side (Viewed from rear) *Note: There are a number of optional extras that may be fitted to an engine that are not shown here.

  • Page 13: Jh57 Barnes 180

    Description* 180 Amp 24 Volt Alternator Calorifiers Water Pump Oil Cooler Figure 4: 4JH57 Barnes 180 Left Side (Viewed from front) Description* Oil Filter Fuel Filter Figure 5: 4JH57 Barnes 180 Right Side (Viewed from rear) *Note: There are a number of optional extras that may be fitted to an engine that are not shown here.

  • Page 14: Jh57 Barnes 24 120

    Description* 120 Amp 24 Volt Alternator Calorifiers Water Pump Oil Cooler Figure 6: 4JH57 Barnes 24 120 Left Side (Viewed from front) Description* Oil Filter Fuel Filter Figure 7: 4JH57 Barnes 24 120 Right Side (Viewed from rear) *Note: There are a number of optional extras that may be fitted to an engine that are not shown here.

  • Page 15: Engine Mounts

    4. Engine Mounts There are two different types of engine mounts fitted to the engine. The engine mounts fitted to the front and the rear of the engine have different numbers stamped on them. The front mounts have a 200 stamped on them and the rear mounts have a 150 stamped on them. The mounts should not be changed front to rear or rear to front as they are designed to carry different loads.

  • Page 16: Section 4 - Installation

    • The hose connections for the calorifier are for a 5/8” internal diameter hose. • The connections for the calorifier are shown on (Figure 9) Connections on Engine Inlet Outlet 4JH57 Barnes Figure 9: Calorifier Connections RDG603A29 – Issue 4 Page 16 of 24...

  • Page 17: Section 5 - Operation

    SECTION 5 – Operation NOTICE: REFER TO THE YANMAR MANUAL PRIOR TO STARTING THE ENGINE. 1. Starting the engine for the first time • Remove ignition key. • Ensure all oil and coolant levels are checked. • Ensure both the engine and domestic batteries are connected. All battery master switches must be turned on.

  • Page 18: Section 6 - Service Procedure

    SECTION 6 – Service Procedure NOTICE: REFER TO THE YANMAR MANUAL PRIOR TO CARRYING OUT ANY SERVICE OR MAINTENANCE WORK. WARNING: PRIOR TO CARRYING OUT ANY SERVICE OR MAINTENANCE WORK MAKE SURE THE RELEVANT PERSONAL PROTECTION EQUIPMENT IS WORN. 1. Engine Oil and Filter Change WARNING: BURN HAZARD! WAIT UNTIL THE ENGINE COOLS SLIGHTLY BEFORE YOU DRAIN THE ENGINE OIL.
  • Page 19 • Do not allow oil or contaminated parts to enter the inland water way system. RDG603A29 – Issue 4 Page 19 of 24...

  • Page 20: Section 7 - Wiring Diagrams

    SECTION 7 – Wiring Diagrams 1. 4JH57 Barnes Engine Loom RDG603A29 – Issue 4 Page 20 of 24...

  • Page 21: Jh57 Barnes Panel Loom

    2. 4JH57 Barnes Panel Loom RDG603A29 – Issue 4 Page 21 of 24...

  • Page 22: Section 8 - Technical Data

    Approximate Dry Weight of Engine (Including Hydraulic Pump)* Model Dry Weight (kg) 4JH57 Barnes 230kg * The dry weights stated are for the standard engine in each model range. If a different gearbox or additional alternators are ordered the weight will change accordingly.

  • Page 23: Section 9 - Additional Part Numbers

    SECTION 9 – Additional Part Numbers Part Number Description RDG909A21 Heat Exchanger RDG201A11 24V 120A Alternator RDG6076 Belt for 12V 125A Alternator RDG004A204 Belt for 24V 120A Alternator RDG201A15 24V 180A Alternator RDG102A21 Belt for 24V 180A Alternator Hydraulic Pump Drive Coupling (supplied by ARS Anglian Diesels Limited): Part Number Description 3C14897...

  • Page 24: Section 10 - Afterlife Recycling

    SECTION 10 – Afterlife Recycling When it becomes necessary to dispose of your engine. This may be possible at recycling centre; however, it will likely require careful disassembly first before disposal. For further information please contact your local recycling centres for disposal advice to see what they will accept for disposal.

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