Yanmar 4JH45 Operation Manual
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Yanmar 4JH45 Operation Manual

Marine engines
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OPERATION MANUAL

MARINE ENGINES

4JH45
4JH57
4JH80
4JH110
http://yanmar.com
0AJHC-EN0010

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Summary of Contents for Yanmar 4JH45

  • Page 1: Marine Engines

    OPERATION MANUAL MARINE ENGINES 4JH45 4JH57 4JH80 4JH110 http://yanmar.com 0AJHC-EN0010...
  • Page 2 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. OPERATION MANUAL...

  • Page 3: Table Of Contents

    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...........
  • Page 4 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...........
  • Page 5 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............
  • Page 6 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 ..........

  • Page 7: Introduction

    • Make sure this manual is transferred to manufacture. subsequent owners. This manual should To help you enjoy your Yanmar JH series be considered a permanent part of the engine for many years to come, please engine and remain with it.

  • Page 8: Record Of Ownership

    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:___________________________________________________________ JH Series Operation Manual...

  • Page 9: Safety

    SAFETY Yanmar considers safety of great DANGER importance and recommends that anyone that comes into close contact with its Indicates a hazardous situation which, products, such as those who install, if not avoided, will result in death or operate, maintain or service Yanmar serious injury.

  • Page 10: Safety Precautions

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. Store any containers containing fuel or • Consult authorized Yanmar Marine other flammable products in a dealer or distributor for additional well-ventilated area, away from any training.
  • Page 11 SAFETY 12/05 Exhaust Hazard WARNING Never block windows, vents Sever Hazard or other means of ventilation if the engine is Rotating parts can cause operating in an enclosed severe injury or death. area. All internal combustion engines Never wear jewelry, create carbon monoxide gas during unbuttoned cuffs, ties or operation and special precautions are...
  • Page 12 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...
  • Page 13 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...

  • Page 14: Location Of Safety Decals

    SAFETY 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 WARNING 056977-00X00 Figure 1 1–Part Number: 128377-07350 2–Part Number: 128990-07270 3–Part Number: 196630-12980 JH Series Operation Manual...
  • Page 15 SAFETY 12/05 4JH80/4JH110 Engines WARNING 128296-07300 056978-00X00 Figure 2 1–Part Number: 128377-07350 2–Part Number: 128990-07270 3–Part Number: 128296-07300 4–Part Number: 196630-12980 JH Series Operation Manual...
  • Page 16 SAFETY This Page Intentionally Left Blank JH Series Operation Manual...

  • Page 17: Product Overview

    The 4JH45, 4JH57 is 4-cylinder and shipyard and equipment manufacturers. naturally aspirated. The 4JH common rail series engines are The 4JH80, 4JH110 is 4-cylinder and designed to be operated at maximum turbocharged with an air cooler.

  • Page 18: New Engine Break-In

    • With the clutch in NEUTRAL, accelerate lifetime. from the low-speed position to the high-speed position briefly. A new Yanmar diesel engine must be operated at suitable speeds and power • Repeat this process five times. settings during the break-in period to make...

  • Page 19: Component Identification

    PRODUCT OVERVIEW 12/05 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 Left Side (Viewed from Flywheel) Flywheel) - 4JH45/4JH57 - 4JH45/4JH57...

  • Page 20: Right Side (Viewed From Flywheel) - 4Jh80/4Jh110

    PRODUCT OVERVIEW 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 Left Side (Viewed from Flywheel) Flywheel) - 4JH80/4JH110 - 4JH80/4JH110 056982-00X00 056981-00X00 Figure 3 Figure 4 1 –...

  • Page 21: Nameplates

    NAMEPLATES The marine gear nameplate (Figure 6) is attached to the marine gear. Check the The nameplates of Yanmar JH series marine gears model, gear ratio, oil used, engines are shown in Figure 5. Check the oil quantity and serial number.

  • Page 22: Function Of Major Components

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

  • Page 23: Electronic Control System

    Doing so may cause contact failure of than intended or in other ways than the connector pins, resulting in specified by Yanmar. Doing so could malfunction of the ECU. result in the violation of emission • Take care to prevent water from entering...

  • Page 24: Main Electronic Control Components And Features

    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 target speed indication entered from the accelerator sensor, the controller adjusts the engine speed and power. Fuel pump (supply pump) The fuel pump supplies fuel to the common rail.

  • Page 25: Control Equipment

    PRODUCT OVERVIEW 12/05 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.
  • Page 26 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.
  • Page 27 PRODUCT OVERVIEW 12/05 Instrument Panel The formats for the instrument panel are shown below. 042563-01X00 Figure 10 1 – Alarm lamp 3 – LCD 4 – Switches (push-buttons) 2 – Tachometer Control panel switches All switches are push-buttons. Power switch Start switch Pushing this switch turns Pushing this switch...
  • Page 28 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.
  • Page 29 PRODUCT OVERVIEW 12/05 LCD control (hour meter, coolant temperature, display brightness, oil pressure, battery voltage) You can switch (scroll) between displays Figure 2 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.)
  • Page 30 PRODUCT OVERVIEW Setup screen access and control (Setting the temperature and pressure units and others) Use the buttons on the bottom of the LCD Figure 3 display to set the instrument panel. Press the left button to switch between displays. Press and hold both buttons until "SET UP"...
  • Page 31 PRODUCT OVERVIEW 12/05 Selecting the fuel tank level gauge (Usually set at boat builder) The display indicates "FUEL". Figure 4 (You can select to the next setting by pressing the left button.) Press the right button to select the type of the gauges.
  • Page 32 PRODUCT OVERVIEW Selection of the display setting The following indicators can be Figure 5 displayed on LCD by this setting. TH ON Throttle position TH POS TH OFF Ld ON Engine load ENG Ld Ld OFF FR ON Fuel flow rate FL RT L/h or Gal/h FR OFF...
  • Page 33 PRODUCT OVERVIEW 12/05 Scroll the LCD screen with the buttons. Figure 7 Fuel temperature These parameters are indicated if the display setting is set to "ON". Hour meter Throttle position Water temperature Engine load Backlight Fuel flow rate Engine oil pressure Intake air pressure Battery voltage Fuel temperature...
  • Page 34 Instrument panel (power switch) Power ON Immediately After 2 seconds After 4 seconds Before start After start Starter switch Alarm buzzer Charge lamp Coolant temperature lamp Engine lubricating oil pressure lamp LCD display Yanmar Full display Hour meter JH Series Operation Manual...

  • Page 35: Accessory Power Output

    PRODUCT OVERVIEW 12/05 Accessory power output The harness attached to the panel has a terminal where the signal that is synchronized to the panel power supply can be taken off. (Figure 17) (Refer to the Wiring Diagrams on page 117.) The maximum current of this output terminal is 3 A (Fuse capacity).

  • Page 36: Single-Lever Remote Control Handle

    PRODUCT OVERVIEW Single-Lever Remote Control Handle Figure 9 0004511 Figure 19 Note: Yanmar recommends the use of 0004504 a single-lever type for the remote Figure 18 control system. If only a Note: Direction of travel will vary two-lever type is available in the...

  • Page 37: Before You Operate

    BEFORE YOU OPERATE INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual Before performing any operations within describes the diesel fuel, engine oil and this section, review the Safety section on engine coolant specifications and how to page 3. replenish them. JH Series Operation Manual...

  • Page 38: Diesel Fuel

    Only use diesel fuels recommended by • In Europe, biodiesel fuels must comply Yanmar for the best engine performance, with the European Standard to prevent engine damage and to comply EN590-2009, EN14214.
  • Page 39 BEFORE YOU OPERATE 12/05 • Even biodiesel fuels that comply with a • Do not use Biocide. suitable standard as delivered will • Lubricity: Wear mark of WS1.4 should be require additional care and attention to Max. 0.016 in. (400 µm) at HFRR test. maintain the quality of the fuel in the equipment or other fuel tanks.
  • Page 40 BEFORE YOU OPERATE Handling of Diesel Fuel 2. Keep the fuel container stationary for several hours to allow any dirt or water WARNING to settle to the bottom of the container. Use a pump to extract the clear, filtered Fire and Explosion Hazard. fuel from the top of the container.

  • Page 41: Filling The Fuel Tank

    BEFORE YOU OPERATE 12/05 Fuel System 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 057347-00X00...

  • Page 42: Bleeding The Fuel System

    BEFORE YOU OPERATE Bleeding the Fuel System Bleeding the pre-filter The fuel system has an automatic air bleeding device that purges air from the fuel system. No manual air bleeding is required for normal operation. Bleeding must be done if any fuel system maintenance has been performed (replacement of fuel filter, etc.) or if the engine does not start after several...

  • Page 43: Priming The Fuel System

    • Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE Service Grade Viscosity Chart (Figure 5). • Yanmar does not recommend the use of engine oil “additives”. JH Series Operation Manual...

  • Page 44: Engine Oil Viscosity

    4 – Upper Limit 5 – Lower Limit 3. Engine oil should be replaced at the specified intervals, regardless if the Note: 4JH45/57 shown. Other models engine has been operated. are similar. Engine Oil Viscosity 1. Make sure the engine is level.

  • Page 45: Adding Engine Oil

    Refer to the Operation Manual of the sail drive for the procedure to fill or replace the sail drive oil. Never overfill the engine with engine oil. 4JH45, 4JH57 (SD60-5) 4JH80 (SD60-4): 3. Insert the dipstick fully to check the • API Service Categories CD or higher level.

  • Page 46: Checking Marine Gear Oil

    BEFORE YOU OPERATE Checking Marine Gear Oil 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)).

  • Page 47: Engine Coolant

    BEFORE YOU OPERATE 12/05 ENGINE COOLANT Coolant (Closed Cooling System) Engine Coolant Specifications Note: In the U.S., LLC is required for Always add LLC to soft water especially the warranty to be valid. when operating in cold weather. Never use •...

  • Page 48: Checking And Adding Coolant

    BEFORE YOU OPERATE 4JH80, 4JH110 Checking and Adding Coolant 4JH45, 4JH57 056988-00X00 Figure 10 056983-00X00 1 – Coolant drain cock (Turbocharger) Figure 8 2 – Turbocharger 3 – Coolant drain cock 1 – Coolant drain cock (Cylinderblock) (Cylinderblock) 4 – Marine gear oil cooler (KMH4A) 2 –...
  • Page 49 BEFORE YOU OPERATE 12/05 1. Ensure all drain cocks are closed. Note: The drain cocks are opened Never pour cold coolant into a hot before shipping from the factory. engine. Marine gear ZF25A does not have a drain cock on the clutch cooler.
  • Page 50 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. JH Series Operation Manual...

  • Page 51: Engine Operation

    ENGINE OPERATION INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual Before performing any operations within describes the diesel fuel, engine oil and this section, review the Safety section on engine coolant specifications and how to page 3. replenish them. It also describes the daily engine checkout.
  • Page 52 ENGINE OPERATION WARNING Fire and Explosion If any indicator illuminates during engine Hazard operation, stop the engine immediately. Determine the cause and repair the Never jump-start the problem before you continue to operate engine. Sparks caused by the engine. shorting the battery to the starter terminals may cause a fire or explosion.

  • Page 53: Starting The Engine

    3. Put remote control handle in premature engine wear and damage. NEUTRAL. • Consult your authorized Yanmar Marine Note: Safety equipment should make it engine dealer or distributor if the engine impossible to start the engine in...

  • Page 54: If The Engine Fails To Start

    ENGINE OPERATION If the Engine Fails to Start Air Bleeding the Fuel System After Starting Failure Before pushing the start switch again, be sure to confirm that the engine has If the engine does not start after several stopped completely. If an attempt to restart attempts, there may be air in the fuel is made while the engine is running, the system.

  • Page 55: After The Engine Has Started

    81 or Troubleshooting Chart on page 83 • Quickly shift to the FORWARD . If necessary, consult authorized position then back to the NEUTRAL Yanmar dealer or distributor. position. • Observe whether the boat moves in the direction you expect.

  • Page 56: Switching To Trolling (Kmh4A Only)

    ENGINE OPERATION Shifting the marine gear while operating at high speed or not pushing the handle fully into position (partial engagement) will result in damage to marine gear parts and abnormal wear. 1. Before using the marine gear, be sure to move the throttle handle to a low idle position (less than 1000 min ).

  • Page 57: Cautions During Operation

    ENGINE OPERATION 12/05 CAUTIONS DURING • Are there abnormal vibrations or noise? OPERATION Excessive vibration may cause damage to the engine, marine gear, hull and Engine trouble can arise if the engine is onboard equipment. In addition, it operated for a long time under overloaded causes able passenger and crew conditions with the control handle in the full discomfort.

  • Page 58: Shutting Down The Engine

    5 minutes. engine at near maximum engine speed while underway. This will generate higher exhaust temperatures, which will For maximum engine life, Yanmar help clean out hard carbon deposits, recommends that when shutting the maintaining engine performance and engine down, you allow the engine to prolonging the life of the engine.

  • Page 59: Emergency Shutdown

    ENGINE OPERATION 12/05 Emergency Shutdown Continue to hold the stop switch in until the engine is completely stopped. If the Never use the emergency stop switch for a switch is released before the engine normal engine shutdown. Use this switch has completely stopped, it may restart.

  • Page 60: Checking The Engine After Operation

    ENGINE OPERATION 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 tank. See Filling the Fuel Tank on page 35. • Close seawater cock(s). •...

  • Page 61: Periodic Maintenance

    PERIODIC MAINTENANCE INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual Before performing any maintenance describes the procedures for proper care procedures within this section, read the and maintenance of the engine. following safety information and review the Safety section on page 3. WARNING Crush Hazard If the engine needs to be...
  • Page 62 Any • When welding is completed, alterations to this engine may void its reconnect the alternator and engine warranty. Be sure to use Yanmar genuine control unit prior to reconnecting the replacement parts. batteries. Entanglement Hazard...

  • Page 63: Precautions

    Yanmar Replacement Parts operating in an enclosed area. All internal combustion engines create Yanmar recommends that you use carbon monoxide gas during operation. genuine Yanmar parts when replacement Accumulation of this gas within an parts are needed.

  • Page 64: Tightening Fasteners

    PERIODIC MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the engine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. NOTICE The tightening torque in the Standard Torque Chart should be applied only to the bolts with a “7”...
  • Page 65 PERIODIC MAINTENANCE 12/05 Main Bolts and Nuts Lubricating Oil Thread Diameter Application Name Torque N·m (ft-lb) x Pitch (thread portion and seat surface) Head bolt M10 x 1.25 Apply oil 88.2 ± 2.9 (65.1 ± 2.1) +4.9/0 +3.6/0 Connecting rod bolt M9 x 1.0 Apply oil 44.1...

  • Page 66: Periodic Maintenance Schedule

    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...
  • Page 67 PERIODIC MAINTENANCE 12/05 : Check or Clean : Replace ●: Consult your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval Daily Every 50 Every 250 Every 500 Every 1000 See Daily hours or hours or 1 hours or 2...

  • Page 68: Periodic Maintenance Procedures

    Daily Checks cracks, abrasions, and damaged or corroded connectors. Before you head out for the day, make sure the Yanmar engine is in good 7. Check hoses for cracks, abrasions, and operating condition. damaged, loose or corroded clamps. 8. Check the fuel filter/water separator for NOTICE presence of water and contaminants.

  • Page 69: After Initial 50 Hours Of Operation

    PERIODIC MAINTENANCE 12/05 Checking and Refilling Marine Gear After Initial 50 Hours of Operation Refer to the Operation Manual for the marine gear. Perform the following maintenance after the initial 50 hours of operation. Checking the Battery Electrolyte Level • Draining the Fuel Tank •...
  • Page 70 057148-00X00 It is easiest and most arailable to drain the Figure 2 engine oil after operation while the engine Note: 4JH45/4JH57 shown. is still warm. 4. Install a new filter element and tighten WARNING by hand until the seal touches the housing.
  • Page 71 PERIODIC MAINTENANCE 12/05 (c) Hold the filter in place with the coil NOTICE spring (Figure 3, (3)) and insert into the case. Install a new O-ring Be careful not to get any oil on the (Figure 3, (4)) in the side cover. V-ribbed belt.
  • Page 72 2. Check that the belt fits properly in the engine damage. Consult authorized ribbed grooves. Yanmar Marine dealer or distributor to adjust the intake/exhaust valve clearance. JH Series Operation Manual...
  • Page 73 PERIODIC MAINTENANCE 12/05 Checking and Adjusting Remote Adjusting Clutch Remote Control Cable Control Cables KM35P Adjusting Engine Speed Remote Control Cable Ensure the control lever in the ECU box side moves to the high-speed stop position and low-speed stop position when the remote control lever is moved to HIGH and then to LOW.
  • Page 74 This is considered normal maintenance and the adjustment requires specialized knowledge and techniques. Consult your authorized Yanmar Marine dealer or distributor. Check for any unusual noise and vibration in the engine/boat hull, while increasing and decreasing the engine speed gradually.

  • Page 75: Every 50 Hours Of Operation

    PERIODIC MAINTENANCE 12/05 Figure 4 Every 50 Hours of Operation Perform the following procedures every 50 hours thereafter or monthly, whichever comes first. • Draining Fuel Filter/Water Separator • Checking Battery Electrolyte Level (Serviceable Batteries Only) Draining Fuel Filter/Water Separator WARNING 056904-01X00 Figure 11...
  • Page 76 PERIODIC MAINTENANCE Note: If there is a large quantity of NOTICE water and sediment in the fuel filter/water separator, also drain Never operate with insufficient battery the fuel tank See Draining the electrolyte. Operating with insufficient Fuel Tank on page 63. electrolyte will destroy the battery.

  • Page 77: Every 250 Hours Of Operation

    PERIODIC MAINTENANCE 12/05 Every 250 Hours of Operation Perform the following maintenance every 250 hours or 1 year of operation, whichever comes first. • Draining the Fuel Tank U P P E R L E V E L L O W E R L E V E L •...
  • Page 78 PERIODIC MAINTENANCE Replacing the Fuel Filter Element 1. Close the fuel tank drain cock. 2. Loosen the clamp screw and remove WARNING the fire-resistant cover, which is installed to the lower part of the fuel Fire and Explosion Hazard. pre-filter / water separator to protect the When removing any fuel system water alarm switch.
  • Page 79 5. Bleed the fuel system. See Bleeding operation, replace the mechanical seal. the Fuel System on page 38. Dispose Consult authorized Yanmar Marine of waste properly. dealer or distributor. 6. Check for fuel leaks. Replacing the Seawater Pump Impeller...
  • Page 80 PERIODIC MAINTENANCE 0004510 Figure 15 There are two types of special service tools for removing the impeller: 0004567 Figure 17 Puller A (standard) Part No. 129671-92110 0004501 Figure 16 Puller A Jack Screw B 0004568 M18x1.5 M10x40 mm length Figure 18 1.
  • Page 81 PERIODIC MAINTENANCE 12/05 Changing the Coolant Figure 54JH45, 4JH57 CAUTION 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. Change the coolant every year.
  • Page 82 2. Clean dirt and scale out of the exhaust and seawater passages. 3. If the mixing elbow is damaged, repair 056989-00X00 or replace. Consult authorized Yanmar Figure 22 Marine dealer or distributor. 4. Inspect the gasket and replace if 6 – Coolant pump 7 –...

  • Page 83: Every 500 Hours Of Operation

    This should be done only by a trained and Replacing the Exhaust/Water Mixing qualified technician. Consult authorized Elbow Yanmar Marine dealer or distributor. Replace the mixing elbow with a new one Adjusting the Alternator V-ribbed every 500 hours or 2 years, whichever belt Tension comes first, even if no damage is found.

  • Page 84: Every 1000 Hours Of Operation

    • Cleaning and Checking the Seawater • Heat Exchanger Passages • Pressure Cap • Checking Diaphragm Assembly Consult authorized Yanmar Marine dealer (4JH45/4JH57 Only) or distributor. • Replacing the Alternator V-ribbed belt Checking Diaphragm Assembly • Adjusting Intake/Exhaust Valve...
  • Page 85 Replacing the Alternator V-ribbed belt See Checking and Adjusting the Alternator V-ribbed belt Tension on page 65. 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.
  • Page 86 PERIODIC MAINTENANCE This Page Intentionally Left Blank JH Series Operation Manual...

  • Page 87: Troubleshooting

    TROUBLESHOOTING SAFETY TROUBLESHOOTING PRECAUTIONS AFTER STARTING Before performing any troubleshooting Just after the engine has started, check the procedures within this section, review the following items at a low engine speed: Safety section on page Is sufficient water being discharged If a problem occurs, stop the engine from the seawater outlet pipe? immediately.

  • Page 88: Troubleshooting Information

    If the engine does not operate properly, refer to the Troubleshooting Chart on page Check the engine room daily for any leaks 83 or consult authorized Yanmar Marine or loose connections. dealer or distributor. Is there sufficient fuel in the fuel tank?

  • Page 89: Troubleshooting Chart

    TROUBLESHOOTING 12/05 TROUBLESHOOTING CHART Symptom Probable Cause Measure Indicators light on the Shift to low speed operation immediately, and check which indicator has come on. Stop the instrument panel and alarm engine and inspect. If no abnormality is identified and there is no problem with operation, return sounds during operation to port at lowest speed and request repairs.
  • Page 90 TROUBLESHOOTING Symptom Probable Cause Measure Engine is not running smoothly Operation failure of injection Nozzle operation failure Replace valve Broken fuel valve spring Replace Uneven fuel injection quantities Clogged fuel filter Replace Faulty operation of regulator valve Replace Air trapped in fuel injection system Bleed air from system and prime system Faulty operation of fuel supply pump Repair...
  • Page 91 TROUBLESHOOTING 12/05 Symptom Probable Cause Measure Insufficient fuel injection Oil leak from fuel injection pipe joint Tighten Clogged fuel filter Replace Clogged fuel pipe Clean Failure of fuel supply pump Repair Insufficient injection by fuel Clogged injection hole Replace injection nozzle Faulty valve seat Replace Sticking nozzle...
  • Page 92 TROUBLESHOOTING Symptom Probable Cause Measure Breakdown of turbo-charger (If equipped) Drop in intake pressure Dirty air filter Clean Leak from intake piping Repair Leak of exhaust gas Repair High intake air temperature Complete thermal insulation of exhaust pipe Ensure intake air path is unrestricted from outside air Clean air filter Drop in air pressure in engine room Ensure intake air path is unrestricted from outside air...
  • Page 93 Symptom Probable Cause Measure Reference • Water in sail drive seal Rubber sail drive seal broken. Consult authorized Yanmar indicator comes on Marine dealer or distributor. Indicators Do Not Go On: • The tachometer does not No electrical current available.

  • Page 94: Failsafe Diagnosis Functional Specification Chart

    TROUBLESHOOTING FAILSAFE DIAGNOSIS FUNCTIONAL SPECIFICATION CHART Failsafe Actions Level 1 (LV1): Reduce engine speed to 2400 min or less Level 2 (LV2): Reduce engine speed to 1600 min or less Level 3 (LV3): Reduce engine speed to 1000 min Level 4 (LV4): Reduce engine speed to low idle Failsafe Action With DTC Description...
  • Page 95 TROUBLESHOOTING 12/05 Failsafe Action With DTC Description Level Level Level Level Note Stop CHK ENG P0237 Boost Pressure Sensor Error - Low Range Engine is still operational. Suspicious Broken sensor or CHK ENG P0238 Boost pressure Sensor Error - High Range wire ...
  • Page 96 TROUBLESHOOTING Failsafe Action With DTC Description Level Level Level Level Note Stop CHK ENG P1608 522588 12 ECU Error - Actuator Supply1 ECU internal failure  Voltage High Range CHK ENG P1609 522590 12 ECU Error - Sensor Supply1 ECU internal failure Voltage bT VOLT P160C Battery Voltage Too High...

  • Page 97: Long-Term Storage

    6 months. If it remains unused for longer than this, please consult your authorized 1. Wipe off any dust or oil from the outside Yanmar Marine dealer or distributor. of engine. Before performing any storage procedures 2. Drain water from fuel filters.

  • Page 98: Drain Seawater Cooling System

    LONG-TERM STORAGE DRAIN SEAWATER Figure 34JH80, 4JH110 COOLING SYSTEM Figure 14JH45, 4JH57 056988-00X00 Figure 3 1 – Coolant drain cock (Turbocharger) 056983-00X00 2 – Turbocharger Figure 1 3 – Coolant drain cock (Cylinderblock) 1 – Coolant drain cock 4 – Marine gear oil cooler (KMH4A) (Cylinderblock) 5 –...

  • Page 99: Returning The Engine To Service

    LONG-TERM STORAGE 12/05 RETURNING THE ENGINE Note: The drain cocks are opened before shipping from the factory. TO SERVICE Marine gear ZF25A does not have a drain cock on the clutch 1. Replace the oil and the oil filter before cooler.
  • Page 100 LONG-TERM STORAGE This Page Intentionally Left Blank JH Series Operation Manual...

  • Page 101: Specifications

    SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS JH Series Operation Manual...

  • Page 102: 4Jh45 Engine

    SPECIFICATIONS 4JH45 Engine Specification 4JH45 Marine Gear Model KM35P ZF30M KM35A2 KM4A1 SD60 Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders Bore x Stroke 88 mm x 90 mm (3.46 in. x 3.54 in.) Displacement 2.190 L (133.6 cu in.)

  • Page 103: 4Jh57 Engine

    SPECIFICATIONS 12/05 4JH57 Engine Specification 4JH57 Marine Gear Model KM35P ZF30M KM35A2 KM4A1 SD60 Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders Bore x Stroke 88 mm x 90 mm (3.46 in. x 3.54 in.) Displacement 2.190 L (133.6 cu in.) Continuous power...

  • Page 104: 4Jh45, 4Jh57 Marine Gear Or Sail Drive

    SPECIFICATIONS 4JH45, 4JH57 Marine Gear or Sail Drive SD60-5 Model KM35P ZF30M KM35A2 KM4A1 (coupled at boat builder) Type Mechanical Mechanical Mechanical Mechanical Mechanical multiple cone clutch wet maliple cone clutch wet cone friction disc clutch disk clutch clutch Reduction Ratio (forward/reverse) 2.36 / 3.16...

  • Page 105: 4Jh80 Engine

    SPECIFICATIONS 12/05 4JH80 Engine Specification 4JH80 Marine Gear Model ZF30M KM4A2 KMH4A ZF25A SD60 Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Turbocharged with air cooler Number of Cylinders Bore x Stroke 84 mm x 90 mm (3.31 in.

  • Page 106: 4Jh110 Engine

    SPECIFICATIONS 4JH110 Engine Specification 4JH110 Marine Gear Model ZF30M KM4A2 KMH4A ZF25A Bobtail Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Turbocharged with air cooler Number of Cylinders Bore x Stroke 84 mm x 90 mm (3.31 in. x 3.54 in.) Displacement 1.995 L (121.7 cu in.) Continuous power...

  • Page 107: 4Jh80, 4Jh110 Marine Gear Or Sail Drive

    SPECIFICATIONS 12/05 4JH80, 4JH110 Marine Gear or Sail Drive SD60-4 Model ZF30M KM4A2 KMH4A ZF25A (coupled at boat builder) Type Mechanical Mechanical Hydraulic wet multiple disk Mechanical multiple wet maliple wet cone clutch friction disc clutch disk clutch clutch Reduction Ratio (forward/reverse) 2.15 / 2.64 1.47 / 1.47 2.04 / 2.04...
  • Page 108 SPECIFICATIONS This Page Intentionally Left Blank JH Series Operation Manual...

  • Page 109: System Diagrams

    SYSTEM DIAGRAMS PIPING DIAGRAMS Notation Description Screw Joint (Union) Flange Joint Eye Joint Insertion Joint Drilled Hole Coolant Piping Cooling Seawater Piping Lubricating Oil Piping Diesel Fuel Piping Note: • Dimension of steel pipe: outer diameter x thickness. • Dimension of rubber pipe: inner diameter x thickness. •...
  • Page 110 SYSTEM DIAGRAMS 4JH45/4JH57 with KM35P or KM35A2 or SD60 Marine Gear Figure 1 JH Series Operation Manual...
  • Page 111 SYSTEM DIAGRAMS 12/05 1 – Fuel overflow 2 – * 7 x t4.5 Rubber hose 3 – Fuel inlet 4 – Fuel oil pre-filter 5 – * 7 x t4.5 Rubber hose 6 – Fuel filter (cartridge type) 7 – * 7.5 x t3 Rubber hose 8 –...
  • Page 112 SYSTEM DIAGRAMS 4JH45/4JH57 with KM4A1 Marine Gear Figure 2 JH Series Operation Manual...
  • Page 113 SYSTEM DIAGRAMS 12/05 1 – Fuel overflow 2 – * 7 x t4.5 Rubber hose 3 – Fuel inlet 4 – Fuel oil pre-filter 5 – * 7 x t4.5 Rubber hose 6 – Fuel filter (cartridge type) 7 – * 7.5 x t3 Rubber hose 8 –...
  • Page 114 SYSTEM DIAGRAMS 4JH45/4JH57 with ZF30M Marine Gear Figure 3 JH Series Operation Manual...
  • Page 115 SYSTEM DIAGRAMS 12/05 1 – Fuel overflow 2 – * 7 x t4.5 Rubber hose 3 – Fuel inlet 4 – Fuel oil pre-filter 5 – * 7 x t4.5 Rubber hose 6 – Fuel filter (cartridge type) 7 – * 7.5 x t3 Rubber hose 8 –...
  • Page 116 SYSTEM DIAGRAMS 4JH80/4JH110 with KM4A2 Marine Gear Figure 4 JH Series Operation Manual...
  • Page 117 SYSTEM DIAGRAMS 12/05 1 – Fuel overflow 46 – 28 x t4 Rubber hose 47 – 28 x t4 Rubber hose 2 – * 7 x t4.5 Rubber hose 48 – Hot water connection outlet 3 – Fuel inlet 49 – Coolant temperature sensor 4 –...
  • Page 118 SYSTEM DIAGRAMS 4JH80/4JH110 with KMH4A or ZF25A Marine Gear Figure 5 JH Series Operation Manual...
  • Page 119 SYSTEM DIAGRAMS 12/05 1 – Fuel overflow 46 – Hot water connection outlet 47 – Coolant temperature sensor 2 – * 7 x t4.5 Rubber hose 48 – Thermostat 3 – Fuel inlet 49 – Cooling Water Pump (coolant) 4 – Fuel oil pre-filter 50 –...
  • Page 120 SYSTEM DIAGRAMS 4JH80/4JH110 with ZF30M Marine Gear Figure 6 JH Series Operation Manual...
  • Page 121 SYSTEM DIAGRAMS 12/05 1 – Fuel overflow 46 – Hot water connection outlet 47 – Coolant temperature sensor 2 – * 7 x t4.5 Rubber hose 48 – Thermostat 3 – Fuel inlet 49 – Cooling Water Pump (coolant) 4 – Fuel oil pre-filter 50 –...
  • Page 122 SYSTEM DIAGRAMS This Page Intentionally Left Blank JH Series Operation Manual...

  • Page 123: Wiring Diagrams

    SYSTEM DIAGRAMS 12/05 WIRING DIAGRAMS Color Coding Black Blue White Green Gray Yellow Brown Orange Light green Pink Purple Allowable Length by Cross Sectional Area of Battery Cable Section of Cable Allowable Length (in. L = 1 + 2 + 3 m (ft) 15 (0.023) <...
  • Page 124 SYSTEM DIAGRAMS B52/R 3.0 K28/W 0.85 Starter relay K73/R 0.85 B54/R 3.0 Injector B75/L 0.85 responsibility Allowable Length by cross sectional area of battery cable Section of cable Allowable Length L=1+2+3(m) 40(mm < 2.8(m) 50(mm < 3.5(m) < 4.1(m) 60(mm Battery (Eng earth) G00/B 5.0...
  • Page 125 SYSTEM DIAGRAMS 12/05 Terminal adapter (164000-29000) Main panel (B20,C30) Fuel tank GAUGE level Start Stop Power Throttle sensor Accesory Power Accesory Relay box relay 5 6 7 8 6 5 4 K35/ R 0.85 K73/R 0.85 Fuse box B63/W 1.25 B60B/ B60C/ R 3.0...
  • Page 126 Name of engine manufacturer: Street: Town: Tsuruno-cho, Kitaku, Osaka-City Post Code: 530-8311 Country: Japan Name of Authorised Representative: Yanmar Co., Ltd. Marine Operations Division 5-3-1 Tsukaguchi Honmachi, Amagasaki, Hyogo Street: Town: Post Code: 661-0001 Country: Japan Société Nationale de Certification et d'Homologation...

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