OPERATION MANUAL MARINE ENGINE JH 3JH40 4JH45 4JH57 4JH80 4JH110 English Greek Danish Cit) Italian German Norwegian Spanish Grid Dutch Cit) French Portuguese Cfi> Finnish Gy) Swedish YANMAR California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. \ y, 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 WAIN are registered trademarks of YANMAR POWER TECHNOLOGY CO., LTD. in Japan, the United States and/or other countries. All Rights Reserved: No part ofthis 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 POWER TECHNOLOGY CO., LTD. in case of exporting this product and providing the related technical material to non-residents in Japan or residents overseas, it is required to comply with the export and trade control laws and regulations of Japan and other relevant countries. Please be sure to follow the necessary procedure. MODEL 3JH40, 4JH45, 4JH57, 4JH&O, 4JH110 OPERATION MANUAL CODE OAJHC-MO0001E All Rights Reserved, Copyright YANMAR POWER TECHNOLOGY co., LTD. TABLE OF CONTENTS INTRODUCTION ......00......cccccccccceecceceeeeeceteeeseeeseeeeeteeeanes 1 RECORD OF OWNERSHIP ...000.....eceeeeeeeeeteeeeees 2 ST a i ce 3 SAFETY PRECAUTIONS .............0::::::cccceeeeeeeteeteetnees 4 General Information ............0..::::cccceceeeeeeeeeerneeteees 4 Before You Operate ............ccccccccccsssessssesesseeeeeeeeees 4 During Operation and Maintenance..................... 4 LOCATION OF SAFETY DECALS .............cceeeeeeee 8 PRODUCT OVERVIEW ......0......... ccc ceecceeceteeeeeeeteeeenene 11 YANMAR 3/4JH COMMON RAIL SERIES FEATURES AND APPLICATIONS ...........ccceeeeeeees 11 New Engine Break-in.............cccccceecceceeeeerteeneees 12 COMPONENT IDENTIFICATION .............::cceeeeeeeee 13 Right Side (Viewed from Flywheel) - 3JH40...... 13 Left Side (Viewed from Flywheel) - 3JH40........ 13 Right Side (Viewed from Flywheel) - ASHAS/4 IST oc cccee ccc ecsteeeeeesnteeteereeaes 14 Left Side (Viewed from Flywheel) - AJH4S/4IHD7 oe ccccceeeeeeeesteeeeeeesneereeeeeaes 14 Right Side (Viewed from Flywheel) - 4JH80/4JH110 eee cecseeeeeeeeesteereeeeeaes 15 Left Side (Viewed from Flywheel) - 4JH80/4JH110 eee cecseeeeeeeeesteereeeeeaes 15 NAMEPLATES .....0......cccccceccecesneeeeeecsnneeeeeeenneeeeeeeeaes 16 FUNCTION OF MAJOR COMPONENTS ..............- 17 ELECTRONIC CONTROL SYSTEM..............:::0e 18 MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES .............::0:::ceccececeeeeeeeeeeteeeenennaaeees 19 YANMAR JH Series Operation Manual TABLE OF CONTENTS CONTROL EQUIPMENT...............::cecceeeeeeseeetteeeees 20 Instrument Panel (Optional) ....................cccccee 20 Accessory Power Output...............c.cccccccceeeeeeeeees 32 Single-Lever Remote Control Handle ................ 33 VESSEL CONTROL SYSTEM (VC10)...........:::08 34 DiSPlAy ...........ecceceeeceeceececeeeeeeeeeeeeeeenceceeeeeeeneerenes 35 VESSEL CONTROL SYSTEM (VC20)............:0008 38 DS) 0): 40 BEFORE YOU OPERATE ..............00::cccccceceseesssteeeeeeees 45 INTRODUCTION 0.0.0... cceccccceccsteeeeecenteeeeeeenseeeeeeeeas 45 SAFETY PRECAUTIONS. ....00......cccccecccceeessteeeseeerteees 45 DIESEL FUEL... cccecceeeceesteeeeeseesseeeseeesaeeess 46 Diesel Fuel Specifications ..................ccccccccccceeees 46 Filling the Fuel Tank.................cccccccccceeeeeeeeeeeeenes 49 Bleeding the Fuel System. ................cccccccccceeeeees 50 Priming the Fuel SyStem................cccccceceeeeeeeeeees 51 StOTN]ik ©) | Re 51 Engine Oil Specifications ...............ccccccccceseeeees 51 Engine Oil ViSCoSity .................ccccccceceeeeeeeeeeeeneees 52 Checking the Engine Oil... ccc 52 ADDING ENGINE OIL.......... ccc ccccceeceeeeeesteeeees 53 MARINE GEAR OR SAIL DRIVE OIL ............ ee 53 Marine Gear Oil Specifications....................008 53 Sail Drive Oil Specifications ........... cee 53 Checking Marine Gear Oil... eee 54 Adding Marine Gear Oil.................cccccccceeeeeeeeeeees 54 Checking and Adding Sail Drive Oil................... 54 ENGINE COOLANT. .........00:ccccccceecceeeesseeeeeessnneeeeee 55 Engine Coolant Specifications ...................00. 55 Coolant (Closed Cooling System)..................008 55 Checking and Adding Coolant..............c eee 56 ENGINE OPERATION ............0....cccccccccccsseeeeeessteeeeeees 61 INTRODUCTION 0.0... ccecccccccseteeeeecsnneeeeeessteeeeeeenaas 61 SAFETY PRECAUTIONS. ....0......ccccccccccceesteeeeeeeeteeees 61 OPERATION (B25, C35-TYPE INSTRUMENT PANEL) ................ 63 Starting the Engine...............::cccccceeeeseesteeeeeeeees 63 If the Engine Fails to Start... 64 Starting at Low Temperatures..........0....::cceee 64 After the Engine has Started ................:::0 65 JH Series Operation Manual YANMAR TABLE OF CONTENTS REMOTE CONTROL HANDLE OPERATION ......... 65 Acceleration and Deceleration..................cc000008 65 Shifting the Engine ..................ccccceceseeeeeeeeeeeeneees 65 Switching to Trolling (KMH4A Only) ................. 66 CAUTIONS DURING OPERATION ..........cceeeeeee 67 SHUTTING DOWN THE ENGINE .............000:ceeceee 69 Normal Shutdown uu... cccccccccceccsesseeeseseeeeerenees 69 Engine Auxiliary Stop Switch .............. ccs 70 Auxiliary Stop Switch (Option: It is recommended that this switch is installed in an easily accessible location.)......... 71 CHECKING THE ENGINE AFTER OPERATION .... 71 OPERATION (VC10: VESSEL CONTROL SYSTEM) ..............005 72 Starting the Engine ................cccccccccecceeeeeeeeeeeeeees 72 Station Protect .............:ccceceeeeeeceeeeeeeeeeeeeeeeeteeee 74 Sys on by ID, Start by ID... ee eeeeee eens 74 Owner ID Change..............c:ccccccesesseeseeeeeeeesesenenes 74 If the Engine Fails to Start 0.0... ceeeeeeeeees 75 Starting at Low Temperatures .................000:008 75 After the Engine has Started ................ccccceeeceees 75 WARM UP MODE (SHIFT DISCONNECT) ............. 76 THROTTLE AND SHIFT CONTROL.............000:eees 77 CT 77 a]: ke 77 Ao) 77 Forward (Reverse) to Reverse (Forward).......... 77 ENGINE SPEED LIMIT MODE ..........0....:cccccceccceees 78 CAUTIONS DURING OPERATION ..........cceeeeeee 78 SHUT-DOWN THE ENGINE (STOPPING).............. 80 Normal Stopping ..........ccccccccccceceseeeseseeeeeeeererees 80 Normal Stopping (for folding / feathering propeller) ..................... 81 EMe@rgency Stop ........ccccccccccsessesssseeeesseseereeeees 83 CONTROL THE BACKUP PANEL.............:0cceeeeee 84 CHECKING THE ENGINE AFTER OPERATION .... 85 OPERATION (VC20: VESSEL CONTROL SYSTEM) ..............005 86 Starting the Engine ................cccccccccecceeeeeeeeeeeeeees 86 Station Protect .............:cceceeeeeeceeeeeeeeeeeeeeeeeeeeee 88 Sys on by ID, Start by ID... cece cee eees 88 Owner ID Change..............c:ccccccesesseeseeeeeeeesesenenes 88 YANMAR E-kKCy .......0..:cccccecceccecsteeeeeeessteeeeeseeaes 89 If the Engine Fails to Start ........ eee 93 Starting at Low Temperatures .................000:008 93 After the Engine has Started ................ccccceeeceees 93 WR MAGA JH Series Operation Manual TABLE OF CONTENTS WARM UP MODE (SHIFT DISCONNECT).............. 94 THROTTLE AND SHIFT CONTROL ............0:::::00e 95 Neutral... cccceccsessssesesecececeeeeeeeeeeeeeeneesnananes 95 ae) A: 10 rn 95 REVEISE 0... cccecccceceseseeeeeeseeeeeseseseeeeeeeceseseseneeetenenes 95 Forward (Reverse) to Reverse (Forward) .......... 95 ENGINE SPEED LIMIT MODE.............00::ccccceeeeeeees 96 CAUTIONS DURING OPERATION ...........:::::ceeeeees 96 SHUT-DOWN THE ENGINE (STOPPING) .............. 98 Normal Stopping ...............cccccccsesssecseeeeeeeeeseeeeenes 98 Normal Stopping (for folding / feathering propeller).................. 99 Emergency Stop.............ccccccccsscseeeeeeeeeeeeeneeeeeees 101 CONTROL THE BACKUP PANEL ..............::::008 102 CHECKING THE ENGINE AFTER OPERATION... 103 PERIODIC MAINTENANCE ..................ccccecceceeeessteeees 105 INTRODUCTION 0.00... cceccceccseeeeeesesteeeeesssnneeeeenss 105 SAFETY PRECAUTIONS. ..............cccecceccesssteeeeeenees 105 PRECAUTIONG........0..::cccccecsccceceeesteeeeseessteeeeseeeeaees 107 The Importance of Periodic Maintenance ........ 107 Performing Periodic Maintenance.................... 107 The Importance of Daily Checks..................... 107 Keep a Log of Engine Hours and Daily Checks... 107 YANMAR Replacement Parts .................c008 107 TOOIS REQUIFE 0.0... ec cec cece cesses eeeeeeseseeeeeeeneees 107 Consult Your Authorized YANMAR Marine Dealer or Distributor for Help ................ccee 107 Tightening Fastener ..........ccccceeeseeseeeeeneeeees 108 EPA MAINTENANCE REQUIREMENTS ............... 110 EPA Requirements for USA and Other Applicable Countries ...............ccccccccscceseeeeeeeeeees 110 Environmental Condition for operation and MAINTENANCE. ....... ccc cece ceeeseeseeeeseeeeeeeeeeeeeeenenenes 111 Inspection and Maintenance ...................cccc 112 Installation of Exhaust Sampling Port.............. 112 PERIODIC MAINTENANCE SCHEDULE .............. 113 Inspection and Maintenance of Emission-Related Parts...............ccccccccceeeeeneeeees 115 PERIODIC MAINTENANCE PROCEDUREG......... 116 Daily CHECKS 0.00.0... ccc ccccceeeeseseeeeeeeeeeceeeeeeeeenenenes 116 After Initial 50 Hours of Operation................. 117 Every 50 Hours of Operation...................cc008 123 Every 250 Hours of Operation...................00 125 Every 500 Hours of Operation...................00 132 Every 1000 Hours of Operation..................0. 133 JH Series Operation Manual VYVANAIAR TABLE OF CONTENTS TROUBLESHOOTING......... ccc cccceeen eee ee ee ne ees 135 SAFETY PRECAUTIONS1.0.0.0... cccccccecessssessseeneees 135 TROUBLESHOOTING AFTER STARTING............ 135 TROUBLESHOOTING INFORMATION ............... 136 TROUBLESHOOTING CHART..........0ccccceceeeeeeeees 137 FAILSAFE DIAGNOSIS FUNCTIONAL SPECIFICATION CHART ............:cccccssesssssssesesenenes 142 LONG-TERM STORAGE .................0.00cccccccceeeeeeeeeeeneees 147 PREPARE ENGINE FOR LONG-TERM 8 O) Ca 147 DRAIN SEAWATER COOLING SYSTEM ............. 148 RETURNING THE ENGINE TO SERVICE ............ 150 SPECIFICATIONS 0.0... ccc cccceeeeeeaeaeeeeee nen ene 151 PRINCIPAL ENGINE SPECIFICATIONS .............. 151 BJH40 Engine ......... cc ccccsessesesesecseeeeeeesesenenes 152 3JH40 Marine Gear or Sail Drive..................... 153 AJH45 Engine .............c ccc ccccccccccccceeeeeeeeeeeeaeenenes 154 AJH57 Engine .............ccccccccccccccccceeeeeeeeeeeeaeenenes 155 4JH45, 4JH57 Marine Gear or Sail Drive ........ 156 AJH80 Engine .............cccccccccccccccccceeeeeeeeeenanenenes 157 4JH110 Engine .000.0... cc eeccececneceeeeeeeeeeees 158 4JH80, 4JH110 Marine Gear or Sail Drive ...... 159 SYSTEM DIAGRAMS oo... ccc cece eee ee eee ee nena 161 PIPING DIAGRAMS .........ccccccccccccceseeeeeeeeeenenenenenes 161 WARRANTY USA ONLY .................:cccccccsssssssseseseserenes 185 YANMAR POWER TECHNOLOGY CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY......... ec ccccccccceeteeeeeeeneaes 185 YANMAR EMISSION CONTROL SYSTEM WARRANTY STATEMENT....................:00:ccccccsseeeeeeeeees 187 YOUR WARRANTY RIGHTS AND OBLIGATIONS. ........0:ccccccecsceecessesseeeeesessteeeeseeesaees 187 YANMAR’s warranty Coverage: ..............6cceee 187 Warranted Parts: .00..........:ccccccceeeeeececeeeeeeeeeeees 188 EXCIUSIONS: .........2ccceeeeeeeeeeceeceeeeeeeeeeeeteeteetenneeees 188 Owners Warranty Responsibilities:..........0..... 189 Customer ASSiStanCe?...........0.:ccceeceeeeettteeteee 189 Maintenance Log .........ccccccccecessseseseeeeeeeereneees 190 WR MAGA JH Series Operation Manual TABLE OF CONTENTS This Page Intentionally Left Blank JH Series Operation Manual VYVANAIAR INTRODUCTION Welcome to the world of YANMAR Marine! Read and understand this Operation YANMAR Marine offers engines, drive Manual before you operate the machine systems and accessories for all types of to ensure that you follow safe operating boats, from runabouts to sailboats, and practices and maintenance procedures. from cruisers to mega yachts. In marine Keep this Operation Manual in a leisure boating, the worldwide reputation of convenient place for easy access. YANMAR Marine is second to none. We design our engines to respect nature. If this Operation Manual is lost or This means quieter engines, with minimal damaged, order a new one from your vibrations, cleaner than ever. All of our authorized YANMAR Marine dealer or engines meet applicable regulations, distributor. including emissions, at the time of 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. follow these recommendations: 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. 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. VELMA JH Series Operation Manual INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact YANMAR for service, parts or documentation. Engine Model: Engine Serial No.: Date Purchased: Dealer: Dealer Phone: To Register Your YANMAR Engine 1. Visit https:/Awww.yanmar.com/marine/service/register-your-engine/ or our website: https:/Awww.yanmar.com/marine 2. Login to the YANMAR Marine Support Portal and register your engine. To Get Multi Language Operation Manual 1. Scan the following two dimensional code. 2. Select your engine series. 3. Select your engine. 4. Select the language you want, and get the Operation Manual. 2 JH Series Operation Manual VYANMAR SAFETY YANMAR considers safety of great importance and recommends that anyone A DANGER 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. 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 Indicates a hazardous situation which, dirty or torn and replace themif they are if not avoided, could result in death or lost or damaged. Also, if you need to serious injury. replace a part that has a label attached to it, make sure you order the new part and A CAUTION label at the same time. Indicates a hazardous situation which, if not avoided, could result in minor or This safety alert symbol moderate injury. appears with most safety statements. It means attention, become alert, NOTICE your safety is involved! Indicates a situation which can cause Please read and abide by damage to the machine, personal property the message that follows and/or the environment, or cause the the safety alert symbol. equipment to operate improperly. WR MAGA JH Series Operation Manual SAFETY SAFETY PRECAUTIONS During Operation and Maintenance General Information There is no substitute for common sense and careful practices. Improper practices The safety messages that follow have or carelessness can cause burns, cuts, WARNING level hazards. mutilation, asphyxiation, other bodily injury or death. This information contains general Explosion Hazard safety precautions and guidelines that While the engine is running must be followed to reduce risk to personal or the battery is charging, safety. Special safety precautions are hydrogen gas is being listed in specific procedures. Read and produced and can be easily understand all of the safety precautions ignited. Keep the area before operation or performing repairs or around the battery maintenance. well-ventilated and keep sparks, open flames and any other form of ignition Before You Operate out of the area. A DANGER Fire and Explosion Hazard The safety messages that follow have Diesel fuel is flammable and explosive DANGER level hazards. under certain conditions. Never permit anyone to install or operate the engine without Never use a shop rag to catch the fuel. proper training. Wipe up all spills immediately. *« Read and understand this Operation Manual before you operate or service Never refuel with the engine running. the engine to ensure that you follow safe operating practices and Fire Hazard maintenance procedures. Undersized wiring systems * Safety signs and labels are additional VAY can cause an electrical fire. Never use improper reminders for safe operating and capacity of fuses. maintenance techniques. ¢ Consult authorized YANMAR Marine Store any containers containing fuel or dealer or distributor for additional other flammable products ina training. 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. JH Series Operation Manual YANMAR SAFETY Sever Hazard Exhaust Hazard Rotating parts can cause : @» Never block windows, vents be severe injury or death. or other means of & Never wear jewelry, g ventilation if the engine is unbuttoned cuffs, ties or operating in an enclosed loose-fitting clothing and area. All internal combustion engines always tie long hair back when working create carbon monoxide gas during near moving/rotating parts such as the operation and special precautions are flywheel or PTO shaft. Keep hands, feet required to avoid carbon monoxide and tools away from all moving parts. poisoning. Alcohol and Drug Hazard Never operate the engine while under the influence of alcohol or drugs, or when feeling ill. Exposure Hazard &. @ @ Always wear personal € z protective equipment e JF «a 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 4d@, during operation and ee §=~shortly after shutdown. Keep hands and other body parts away from hot engine surfaces. YANMAH JH Series Operation Manual SAFETY A CAUTION NOTICE The safety messages that follow have The safety messages that follow have CAUTION level hazards. NOTICE level hazards. Poor Lighting Hazard It is important to perform daily checks as listed in the Operation Manual. Ensure that the work area is adequately Periodic maintenance prevents unexpected illuminated. Always install wire cages downtime, reduces the number of accidents on portable safety lamps. due to poor engine performance and helps extend the life of the engine. Tool Hazard Always use tools appropriate for the Consult authorized YANMAR Marine task at hand and use the correct size dealer or distributor if you need to operate tool for loosening or tightening the engine at high altitudes. At high machine parts. altitudes the engine will lose power, run rough and produce exhaust gases that exceed the design specifications. Flying Object Hazard Always wear eye protection when Always be environmentally servicing the engine or when using ly responsible. compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. a0 Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as Coolant Hazard engine oil, diesel fuel and engine coolant. Wear eye protection and Consult the local authorities or reclamation - i] rubber gloves when you facility. handle engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately Never dispose of hazardous materials by with clean water. dumping them into a sewer, on the ground, or into ground water or waterways. If aYANMAR 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. JH Series Operation Manual VYANMAH SAFETY NOTICE If you have an installation with two orthree 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 orthree 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 ofthis condition. If you have an installation with two orthree 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. YANMAR JH Series Operation Manual SAFETY LOCATION OF SAFETY DECALS Figure 571, Fig show theengloca ure 2 and110Figserureies3 mar tion of safety decals on YANMAR 3JH40, 4JH45/ and 4JH80/ ine ines. 3JH40 Engine 2 3 4 gN = + | CAUTION: Overcranliftking WARNING engine with water muffler can cause damage. OME FRBG GUTS e Fa, MEARS LSTe $B Et.H Y. ollever renove the a 3 g 3 x é 2 Fa ro oo = 6 Ee @| fe i ena @ Rotating parts. @ Can cause injury. \ 428298-07350 J 108118-02% Figure 1 4 — Part Number: 428296-07350 2 — Part Number: 428171-07 150 3 — Par t Num ber : 428 990 -07 270 JH Series Operation Manual YWANMAR SAFE!!! ines 4JH45/45SH57 Eng king a CAUTneIOwiN th: Ovwaerteerranit engi can cause damage. : c rouffier AGA TA-O7 ASO en eiee @ Rotatiusnge painrt s. Se @ Can ca428296-07 jury. npagt7-& 3X atiion Manual ot JH Series Oper PRODUCT OVERVIEW YANMAR 3/4JH COMMON The engine must be installed correctly with coolant lines, exhaust gas lines and RAIL SERIES FEATURES electrical wiring. Any auxiliary equipment AND APPLICATIONS attached to the engine should be easy to use and accessible for service. To handle The 3/4JH common rail series are the drive equipment, propulsion systems four-stroke diesel engines equipped with (including the propeller) and other inboard direct injection common rail system and equipment, always observe the with liquid coolant systems. instructions and cautions given in the The 3JH40 is 3-cylinder and naturally operation manuals supplied by the aspirated. shipyard and equipment manufacturers. The 4JH45, 4JH57 are 4-cylinder and The 3/4JH common rail series engines are naturally aspirated. designed to be operated at maximum throttle’! for less than 5% of total engine The 4JH80, 4JH110 are 4-cylinder and time (30 minutes out of every 10 hours) turbocharged with an air cooler. and cruising speed*2. The engines are equipped with a marine The laws of some countries may require gear or sail drive unit. hull and engine inspections, depending on These engines are designed for the use, size and cruising area ofthe boat. recreational craft use. The installation, fitting and surveying of this engine all require specialized Failure to do so can lead to reduced vessel knowledge and engineering skills. performance, lead to increased smoke See YANMARs local subsidiary in your levels and cause permanent damage to region or your authorized YANMAR Marine your engine. dealer or distributor. “1 maximum throttle: fuel stop power engine speed “2 cruising speed: fuel stop power engine speed -200 mirr! or less YANMAR JH Series Operation Manual 11 PRODUCT OVERVIEW New Engine Break-In If operating engine at low speed and light load, you must race the engine to clean the As with all reciprocating engines, the way carbon from the cylinders and fuel injection your engine is operated during its first 50 valve. hours of operation plays a very significant role in determining how long it will last and Perform this procedure in open waters: how well the engine will perform over its « With the clutch in NEUTRAL, accelerate lifetime. from the low-speed position to the Anew YANMAR diesel engine must be high-speed position briefly. operated at suitable speeds and power * Repeat this process five times. settings during the break-in period to make the sliding parts, such as piston rings, Once past the initial 10 hours until 50 break-in properly and to stabilize engine hours, the engine should be used over its combustion. full operating range, with special emphasis on running at relatively high power During the break-in period, the engine settings. This is not the time for an coolant temperature gauge should be extended cruise at idle or low speed. monitored; temperature should be The boat should be run at maximum speed between 71° and 87 °C (160° and 190 °F). minus 400 min-1 most of the time During the first 10 hours of operation, the (approximately 70% load), with a 10 engine should be run at maximum engine minute run at maximum minus 200 min-1 speed minus 400 to 500 min“ (approximately 80% load) every (approximately 60 to 70% of load) most of 30 minutes and a 4 to 5 minute period of the time. This will ensure the sliding parts operation at WOT (wide open throttle) break in properly. During this period, avoid once each 30 minutes. During this period, operating at maximum engine speed and be sure not to operate your engine at low load to avoid damaging or scoring sliding speed and light load for more than parts. 30 minutes. If operating engine at low speed and light load by necessity, just after the low idle operation, be sure to race the NOTICE engine. Do not operate at WOT (wide open To complete engine break-in, perform throttle) for more than a minute at a time After Initial 50 Hours of Operation during the first 10 hours of operation. maintenance procedures. After Initial 50 Hours of Operation on page 117. 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 ofthe rings and the engine oil consumption may increase. Low idle speed does not allow break-in of sliding parts. 12 JH Series Operation Manual YANMAR PRODUCT OVERVIEW COMPONENT IDENTIFICATION Figure 1 and Figure 2 illustrate a typical version ofa 3JH40 engine. Your engine may have different equipment from that illustrated. Right Side (Viewed from Left Side (Viewed from Flywheel) Flywheel) - 3JH40 - 3JH40 Figure 1 Figure 2 1 -Intake silencer 13-—Coolant pump 2 -ECU cover 14-—Engine nameplate (on rocker 3 —Engine oil dipstick arm cover) 4 -—Intake manifold 15-Coolant filler cap 5 —Fuel filter 16 —Coolant tank/Heat exchanger 6 -—Engine oil filler cap 17 -Exhaust/water mixing elbow 7 —Fuel supply pump 18 —Starter motor 8 —Engine oil filter 19-Exhaust manifold 9 —Engine oil cooler 20-Alternator 10-Marine gear (KM35P) 21-Seawater pump 11 - Marine gear oil dipstick 22—Belt cover 12-Shift lever YWRANRGAR su Series Operation Manual 13 PRODUCT OVERVIEW Figure 3 and Figure 4 illustrate a typical version ofa 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 12 11 10 9 7 22 «21 20 19 18 Figure 3 Figure 4 1 -Intake silencer 13-—Coolant pump 2 -ECU cover 14-—Engine nameplate (on rocker 3 —Engine oil dipstick arm cover) 4 -—Intake manifold 15-Coolant filler cap 5 —Fuel filter 16 —Coolant tank/Heat exchanger 6 -—Engine oil filler cap 17 -Exhaust/water mixing elbow 7 —Fuel supply pump 18 —Starter motor 8 —Engine oil filter 19-Exhaust manifold 9 —Engine oil cooler 20-Alternator 10-Marine gear (KM4A1) 21-Seawater pump 11 - Shift lever 22—-Belt cover 12-Marine gear oil dipstick 14 JH Series Operation Manual VWALNPAAR PRODUCT OVERVIEW Figure 5 and Figure 6 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 22 21 20 19 956981-04X 056982-04%00 Figure 5 Figure 6 1 -—Turbocharger 14-Coolant pump 2 —Intake silencer (Air cleaner) 15-—Engine nameplate (on rocker 3 -ECU cover arm cover) 4 -Engine oil dipstick 16-Coolant filler cap 5 -—Intake manifold 17 -—Coolant tank/Heat exchanger 6 —Fuel filter 18-—Exhaust/water mixing elbow 7 —Engine oil filler cap 19-Starter motor 8 —Fuel supply pump 20-Air cooler 9 —Engine oil filter 21-—Exhaust manifold 10-—Engine oil cooler 22-—Seawater pump 11 —Marine gear (KMH4A) 23 —Alternator 12-Marine gear oil dipstick 24-Belt cover 13-Shift lever WR MAGA JH Series Operation Manual 15 PRODUCT OVERVIEW NAMEPLATES The marine gear nameplate (Figure 8) is attached to the marine gear. Check the The nameplates of YANMAR 3/4JH marine gears model, gear ratio, oil used common rail series engines are shown in and serial number. Figure 7. Check the engine’s model, output, min-1 and serial number on the (p ~ nameplate. Please replace if damaged or MODEL lost. MFG. NO. GEAR RATIO The engine nameplate is attached to the OIL engine rocker arm cover. ( = Model KANZAMI KOMYUKOKE RIFG GO., LD. MADE IN JAPAN 177524-02903 Gear Model Figure 8 Continuous power ki’ / min’ Speed of prop.shaft min The sail drive nameplate (Figure 9) is Fuel stop power kW / min attached to the sail drive. Check the sail ENG.No. drive model and serial number. MFG.DATE / (p ~ YANMAR MODEL VANMAR POWER TECHNOLOGY GG. LTD. GEAR RATIO MADE IN JAPAN 129670-07202 MFG.NO. P/N Figure 7 OIL TYPE VANMAR POWER TECHNOLGGY CO. LTO. MABE IN EU Figure 9 16 JH Series Operation Manual VYVANAIAR 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 113 for the replacement frequency. Fuel pre-filter The water separator removes contaminants, sediment and water from diesel fuel going to the (Water separator) 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 filter. Periodically drain the water from the water separator using the drain cock at the bottom ofthe separator and replace the filter element. Fuel Priming Pump This is a manual fuel pump. Pushing the knob on the top of the fuel pre-filter feeds the fuel. This pump is also used to bleed air from the fuel system. 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 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 127. 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 cooled by the closed cooling circuit. The closed circuit is cooled by seawater using a heat exchanger. The seawater also cools the 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. Do not operate it without seawater, as this will damage the impeller. Reservoir The pressure valve in the filler cap releases vapor and hot water overflow to the reservoir. 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. Oil Cooler - Engine A heat exchanger that cools high temperature engine oil using coolant. Oil Cooler - Marine Gear This heat exchanger cools the marine gear (KMH4A) oil using seawater. (Optional) Turbocharger (if equipped) The turbocharger pressurizes the air coming into the engine. It is driven by a turbine that is energized by exhaust gases. Air cooler (if equipped) This heat exchanger cools the pressurized charging air from the turbocharger with seawater to increase the charging air quantity. 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 number and other data. 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. YANMAR JH Series Operation Manual 17 PRODUCT OVERVIEW ELECTRONIC CONTROL SYSTEM * 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 The 3/4JH common rail series replacing the ECU. Failure to migrate engines use a high pressure common the fuel injection data before replacing rail system. the ECU will void the engine warranty. The fuel is injected at extremely high pressure. NOTICE Never disassemble the fuel system Do not plug or unplug the ECU for a parts. period of at least 6 seconds after power Failure to comply may result in death to the unit has been turned on or off. or serious injury. Do not touch connector pins of the ECU with If a malfunction occurs, consult your bare hands. nearest YANMAR dealer or Doing so may result in corrosion of the distributor. connector pins and/or damage to the internal circuits of the ECU due to static electricity. Do not force a measuring probe into the Never use the ECU for other purposes female coupler. than intended or in other ways than Doing so may cause contact failure of specified by YANMAR. Doing so could the connector pins, resulting in result in the violation of emission malfunction of the ECU. control regulations and will void the product warranty. Take care to prevent water from entering the couplers when plugging or Be sure to use the ECU in conjunction unplugging the connector. with the engines whose models or Water inside the couplers may cause serial numbers are specified by corrosion, resulting in malfunction of the YANMAR. Other ECU/engine ECU. combinations than specified will void the engine warranty. Avoid plugging/unplugging the connector more than approx. 10 times. Replacing the fuel injector involves Frequent plugging/unplugging of the rewriting the fuel injection data in the connector may cause contact failure of ECU. Be sure to consult your local the connector pins, resulting in YANMAR dealer before replacing the malfunction of the ECU. fuel injector. Failure to rewrite the fuel injection data before replacing the fuel Do not use the ECU that has ever injector will void the engine warranty. suffered drop impact. Improper use or misuse of the ECU Always check the battery for proper charge. may result in death or serious injury Otherwise the electronically controlled due to an abrupt and unexpected engines may fail to start. increase in engine speed. 18 JH Series Operation Manual YANMAHR 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. Common rail The common rail stores the compressed high-pressure fuel from the supply pump and distributes fuel to the injector in each cylinder. Fuel injector The Fuel 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 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. Engine diagnosis tool Allows the operator to troubleshoot the cause of a problem based on detailed information 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 135. YWRANRGAR su Series Operation Manual 19 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. B25-Type 042563-02x00 Figure 10 C35-Type 1 2 3 5 4 6 Figure 11 1 -Alarm lamp 4 -—Switches (push-buttons) 2 -—Tachometer 5 —Coolant temperature gauge 3 -LCD 6 —Engine oil pressure gauge 20 JH Series Operation Manual VYANMAR 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. 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 (hour meter, coolant temperature, display brightness, oil pressure, battery voltage, alarms) on page 24. Other indicators in the LCD can be added by display setting. See Selection of the display setting on page 28. Coolant temperature and oil pressure display * B25, C35-Type panels have a digital LCD screen inside the tachometer. * C35-Type panels have an electric gauge with a needle. YANMAHR JH Series Operation Manual 21 PRODUCT OVERVIEW Instrument Panel The formats for the instrument panel are shown below. ———— Pee xt000 Figure 12 1 —Alarm lamp 3 ~-LCD 2 — Tachometer 4 -Switches (push-buttons) Control panel switches All switches are push-buttons. Start switch Power switch Pushing this switch Pushing this switch turns operates the starter and | on or off the power. Starts the engine. Stop switch Pushing this switch stops the engine. STOP 942565 -C1X00 22 JH Series Operation Manual VYANMAH 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 i SS 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 filterAvater separator. See Draining Fuel Filter/Water Separator on page 123. VWRAINPGGAFE JH Series Operation Manual 23 PRODUCT OVERVIEW LCD control (hour meter, coolant temperature, display brightness, oil pressure, battery voltage, alarms) 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 ai Imperial units (°F) at the "System Units screen" on page 26. uff <> — WOME Metric Imperial units Pressing the right button again shows the LCD brightness settings. Backlighting Brightness To set the brightness of the backlight: bs Lo NN ing 100 | Press the left button continuously and the digits of the LCD start flashing. ————— PI In this condition, press the left button to increase the brightness. 2 3 Press the right button to decrease the Push and hold Scroll brightness. (The brightness changes in (display will blink when 100, 80, 60, 40, 20, 0 ready) (value will be set after 6 steps of 20%.) 3 seconds) To set the desired brightness, do not touch Vv the buttons for 3 seconds. Oil pressure Note: Continuously pressing means : 4 = i” Psi holding the button for approx. 2 4B Bho seconds. Metric Imperial units Next, press the right button to show the Vv pressure display. Select between Metric Battery voltage units (BAR) and Imperial units (PSI) at the WOLTS "System Units screen" on page 26. Press again to show the battery voltage. pededs . 055130-CCENO2 Figure 13 24 JH Series Operation Manual VYVANAIAR PRODUCT OVERVIEW Pressing the button once more, shows the engine alarms “ALARMS”. Vv Alarms Press and hold the left button, “WAIT” will display in the LCD about 1 second while DTC is being read. apeHLARMS Note: DTC means Diagnosis Trouble Code “NO dTC” or the number of DTC will show when DTC process is finished. Return to hour meter 2 | When “NO dTC’ is indicated on the —_— screen, press the left button and go to the next screen “RETURN”. v v No DTCs Number of DTCs 3 | Press and Scroll the left button for the number of DTCs to see all the applying trouble codes. ae NG dif "4 es a IE vy Se ee Look up the codes in the Failsafe Diagnosis Functional Specification Chart on page 142 and consult your 2 authorized YANMAR Marine dealer or distributor for repairment. v DTC list Note: When “UNKNOWN” is displayed, consult your authorized YANMAR Marine dealer or distributor. PO0BE 4 | When you are done browsing the DTC “i list, press the left button to go to “RETURN”. When “RETURN” is displayed, press Vv the right button to return to “ALARMS”. Press the right button again to return to _RETURN the initial hour meter. aires 5| 412534-00ENS9 Figure 14 YANMAR JH Series Operation Manual 25 PRODUCT OVERVIEW Setup screen access and control (Setting the temperature, 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. 4 | Press and hold both buttons until "SET UP" appears. 2 | 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". 2 | Press the left button to switch to Imperial units (°F, PSI). The display says "ENGL". 3 | Press the right button to select and go back to the "UNIT" screen. Select Scroll Select 4 | Press the left button and go to the next Imperial, Metric O57180-COENO1 screen "FUEL". Confirm that the display indicates "FUEL". Figure 15 Pressing the right button displays the fuel tank level setting screen. 26 JH Series Operation Manual VYVANAIAR PRODUCT OVERVIEW Selecting the fuel tank level gauge (Usually set at boat builder) The display indicates "FUEL". (You can select to the next setting by pressing the left button.) Press the right button to select the type of the gauges. Change the type by pressing the left ele eas 2 40h button. FUEL Fq 180 Press the right button to select the OE oe re type. t ft t t Press the left button and go to the next 4 : screen "dISPLAY". elec Scroll Select There are four types of fuel level gauge Figure 16 setting. The type of level gauge can be changed by scrolling and selecting the setting with the buttons. F3-180 r F240-3 ¥P F70-3 e CAN WHR AAI tH Series Operation Manual 27 PRODUCT OVERVIEW Selection of the display setting The following indicators can be displayed on LCD by this setting. TH POS TH ON it Throttle position TH OFF % ENG Ld Ld ON Engine load Ld OFF % LRT FR ON Fuel flow rate | FER OFF L/h or Gal/h dISPLAY AP ON Intake air pressure —> AIR PRS AP OFF Bar or PSI Ge | FT ON Fuel temperature t FLTMP FT OFF degC or degF Select RETURN Return to dISPLAY The display indicates "dISPLAY". < You can Sooo ou next setting by TH PAS “ TH HE pressing the left button. eS —— ——— | Cia “Gi a Press the right button to select the + + , indicator. Press the right button to display the setting screen. 057182-00ENO1 3 | Press the left button to toggle between Figure 17 On/Off. Press the right button to select the RETURN setting. Press the left button and go to the next screen "ENG Ld". ae Setting of the next indicator. Repeat the same procedure to set other 6) indicators. 6 | When "RETURN" is indicated on the Vv Display settings screen, press the right button to exit the "dISPLAY" mode. Press the left button and go to the next dISPLAY Cie screen "ENGINE". 112535-GGENOO0 Figure 18 28 JH Series Operation Manual VANATEAR PRODUCT OVERVIEW Setting of the engine model When “ENGINE?” is indicated, press the right button to select the engine model. 2 | Press the left button to select “JH”. Note: Initial setting indicates “JH”. When “JH” is indicated on the screen press the right button to return to “ENGINE”. When “ENGINE?” is indicated, press the left button to go to “EXIT”. §@ Press the right button when “EXIT” is Exit setup shown on the screen to exit the setup mode. All LCD light up for a while, and then returns to hour meter. 112583-01BMNOO Figure 19 YAN JH Series Operation Manual 29 PRODUCT OVERVIEW Scroll the LCD screen with the buttons. Fuel temperature These parameters are indicated if the display A Ww setting is set to "ON". Hour meter Throttle position HB 40H WN" a VW a Vv Water temperature Engine load fis of 886 |} te 909 A v ~A YF satin Fuel flow rate Bane eTSS FR AAA A Vv A Vv Engine oil pressure Intake air pressure 4 aan Loe ak S| 4b AP AB a Vv a VV Battery voltage Fuel temperature tet) |p Fr ag wr Vv a VW Alarms Hour meter - ALARMS <- a Figure 20 30 JH Series Operation Manual VYVANAIAR PRODUCT OVERVIEW Alarms Checking the Warning Devices Be Sure to Check the Warning Devices before Starting the Engine. If the devices are not working properly, it is impossible to prevent any accidents arising from problems like insufficient oil and water. NOTICE When the warning devices are activated and normal operation is impossible, stop the engine and do not use it until the problem has been solved. Before Engine Start 1. Turn on the battery switch. 2. Push the power switch on. * All alarm lamps light up for4 seconds. * After4 seconds, the hour 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 for repairs. Correct operation of the warning devices Instrument panel (power switch) Power ON Immediately After 2 seconds | After 4 seconds - Before start After start Starter switch OFF ON Alarm buzzer ON (0.3s) OFF OFF Charge lamp ON ON OFF OFF Coolant temperature lamp ON ON OFF OFF Engine lubricating oil pressure lamp ON ON OFF OFF LCD display YANMAR Full display Hour meter YAN JH Series Operation Manual 31 PRODUCT OVERVIEW 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 21) (Refer to the Service Manual.) The maximum current of this output terminal is 3 A (Fuse capacity). Do not use a current higher than 3A. to the Service Manual. For the content of the output terminal, refer Buzzer ig = ACC Output ——.P F1A- 3 AMP Fuse G43801-01ENO00 Figure 21 32 JH Series Operation Manual VYANMAR PRODUCT OVERVIEW Single-Lever Remote Control Handle Figure 23 Koo04504 Note: YANMAR recommends the use of a single-lever type for the remote Figure 22 control system. If only a two-lever type is available in the market, Note: Direction of travel will vary reduce engine speed to 1000 min? depending on installation location. or less before engaging and 1 —Low Speed - FWD or REV disengaging the marine gear clutch. 2 —Low Speed - FWD or REV 3 —-NEUTRAL - Power to the propeller shaft is cut off and the engine idles 4 —Maximum Engine Speed - FWD or REV 5 —Maximum Engine Speed - FWD or REV A single handle-type (Figure 22) should be used to operate the marine gear clutch (NEUTRAL, FORWARD and REVERSE) and to control the engine speed. The handle controls the direction of the boat (ahead or astem) 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 23, (1)), the engine speed can be controlled without engaging the clutch. The clutch remains in NEUTRAL, no load position. Turn the knob (Figure 23, (2)) counterclockwise to move the handle or clockwise to lock the handle. YANMAR JH Series Operation Manual 33 PRODUCT OVERVIEW VESSEL CONTROL SYSTEM (VC10) 3/4JH common rail series engine is a fully electronic control engine, which is controlled by YANMAR’s original “Vessel Control System (VC10)”. The control equipment consists of the Switch Panel, the Display, the Drive & Helm ECU, the Control Head and the Backup Panel, which are connected by the cable harness to the engine and marine gear or Shift Actuator for remote control operation. Note: The YANMAR Vessel Control System (VC10) was designed to operate the 3/4JH common rail series and drive system. There are many control functions and diagnostic functions that are integrated together to insure safe operation. If 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 3/4JH common rail series. The system has many functions that must be configured and calibrations must be made before the vessel can be operated. Please arrange to have a YANMAR trained technician inspect the vessel prior to the vessels operation. 4 5 Ee) [| YANMAR ‘OD ° cl ‘| ; a LI mt Marine gear or Shift Actuator oo oOo TITo engine \ \ \ To engine Figure 24 No. Description No. Description 4 Shift and Throttle Control Head 5 | Drive ECU 2 | Switch Panel (to start and stop the engine) 6 | Backup Panel * 3 | VC10 Digital Display 7 | Cable Harness Set 4 Helm ECU 8 | Adapter, Terminal * The backup panel has two design types. 34 JH Series Operation Manual YANMAR PRODUCT OVERVIEW Display Note: When starting the engine, make it a rule to check that when the switch The multi-function information display has panel is pressed to the power the following functions. switch, the welcome screen appears on the display and goes out. If the Display Function system does not function normally, Runtime Engine Data Tri-Screen consult your authorized YANMAR Marine dealer or distributor and ask for diagnostics. Diag Codes Screen oy eC Ee{ Diagcodes | > 180d YRNMAR mea Zs Z 062220-O00ENOO0 Figure 25 This screen displays real time engine data and alarm indications. 0937635-02X00 Alarm Indicators Figure 27 Alarm Indicator Functions The alarm indicators and buzzer are activated when sensors detect an fh ALARM! eG. ‘MAINTENANCE: \ abnormality during engine operation. ENGINE: The alarm indicators are off during normal eZ operation, but are activated as follows Say) Fo CBE rood east FH i204) when an abnormality arises: * The coolant temperature alarm indicator activates when the coolant gets too hot. a Se O37635-O1R01 * The engine oil pressure alarm indicator activates when the engine oil pressure Figure 26 drops. The alarm window appears with an audible * The electric charge alarm indicator alarm when abnormal engine activity activates when there is a charging occurs. failure. YANMAR JH Series Operation Manual 35 PRODUCT OVERVIEW Operation of the Display’s Buttons Buttons * Act on pop-up menu (MAIN MENU) ENTER * Perform the function A Up Arrow moves menu selection up Teo G MS P20! V Down Arrow moves menu selection down Left Arrow acts on current menu item > Right Arrow acts on current menu item O61584-O0ENOO Figure 28 Hot Key List Item Operation Indication MAIN MENU Press the [ENTER] button. Display MAIN MENU. MENU LAYER Hold the < button down for1 second. | Close MENU and return to the normal screen. SKIP ICON INFO Press the W button while the icon with | Display the related setting screen ofthe relevant a detail information indication function | icon. Ifthere are multiple items, execute with the is displayed. [ENTER] button after selecting with the <¢ > buttons. Adjusting Press the A button. Display the brightness adjustment screen and Brightness adjust brightness with the & W buttons. Switching Night Press the < button. Switch to the night mode indication. Mode Setting Complete | Hold the [ENTER] button down for 1 Close the setting screen and MENU and return to second while the El icon is highlighted. | the normal indication. Switching Monitor | Press the > button. Switch to the monitor screen in the normal Display Indication indication. Send the screen in order with the <¢ > buttons. The monitor screen is fixed when there is no operation with the < » buttons for 5 seconds. 36 JH Series Operation Manual VYVANAIAR PRODUCT OVERVIEW Switch Panel (to start and stop the engine) The switch panel has the following functions. a (START. Eng. START/STOP switch Ney, ll Check Eng. indicator Emergency stop switch Power switch O37627-00F00 Figure 29 To start and stop the engine: Press the START/STOP switch. 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. WR MAGA JH Series Operation Manual 37 PRODUCT OVERVIEW VESSEL CONTROL SYSTEM (VC20) 3/4JH common rail series engine is a fully electronic control engine, which is controlled by YANMAR’s original “Vessel Control System (VC20)”. The control equipment consists of the Switch Panel, the Display, the Drive & Helm ECU, the Control Head and the Backup Panel, which are connected by the cable harness to the engine and marine gear or Shift Actuator for remote control operation. Note: The YANMAR Vessel Control System (VC20) was designed to operate the 3/4JH common rail series and drive system. There are many contro! functions and diagnostic functions that are integrated together to insure safe operation. If 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 (VC20) in conjunction with the 3/4JH common rail series. The system has many functions that must be configured and calibrations must be made before the vessel can be operated. Please arrange to have a YANMAR trained technician inspect the vessel prior to the vessels operation. 5 L_] (e] o Marine gear or pet] Shift Actuator \ iC ae \ (J To engine 8 To engine Figure 30 No. Description No Description 1 Shift and Throttle Control Head 6 | Drive ECU 2 Emergency Stop Switch (Option) 7 | Backup Panel * 3 | Switch Panel (to start and stop the engine) 8 | Cable Harness Set 4 Display 9 | Adapter, Terminal 5 | HelmECU * The backup panel has two design types. 38 JH Series Operation Manual VYVANAIAR PRODUCT OVERVIEW NOTICE Compass safety distance for Shift and Throttle Control Head Follow the compass safe distances to prevent interference to a magnetic compass. Standard compass Steering compass 0.45 m 0.30 m WR MAGA JH Series Operation Manual 39 PRODUCT OVERVIEW Display Note: When starting the engine, make it a rule to check that when the switch The multi-function information display has panel is pressed to the power the following functions. switch, the welcome screen appears on the display and goes out. If the Display Function system does not function normally, Runtime Engine Data Tri-Screen consult your authorized YANMAR Marine dealer or distributor and ask for diagnostics. Diag Codes Screen 062220-00EN00 Figure 31 This screen displays real time engine data and alarm indications. 037635-02K00 Alarm Indicators Figure 33 Alarm Indicator Functions ENGHe sheen. The alarm indicators and buzzer are activated when sensors detect an ALARM! ( MAINTENANCE BIND ‘ abnormality during engine operation. : ENGINE: [suas \ The alarm indicators are off during normal (o . Be yrooah ee Yd operation, but are activated as follows when an abnormality arises: * The coolant temperature alarm indicator activates when the coolant gets too hot. * The engine oil pressure alarm indicator 037635-01xX01 activates when the engine oil pressure Figure 32 drops. The alarm window appears with an audible * The electric charge alarm indicator alarm when abnormal engine activity activates when there is a charging occurs. failure. 40 JH Series Operation Manual YANMAR PRODUCT OVERVIEW Operation of the Display’s Buttons Buttons * Act on pop-up menu (MAIN MENU) ENTER * Perform the function A Up Arrow moves menu selection up V Down Arrow moves menu selection down Left Arrow acts on current menu item > Right Arrow acts on current menu item o61584-00 ENOO Figure 34 Hot Key List Item Operation Indication MAIN MENU Press the [ENTER] button. Display MAIN MENU. MENU LAYER Hold the <¢ button down for 1 second. | Close MENU and return to the normal screen. SKIP ICON INFO Press the W button while the icon with | Display the related setting screen ofthe relevant a detail information indication function | icon. Ifthere are multiple items, execute with the is displayed. [ENTER] button after selecting with the <¢ > buttons. Adjusting Press the A button. Display the brightness adjustment screen and Brightness adjust brightness with the & W buttons. (Manual dimmer mode only) Switching Night Press the ¢ button. Switch to the night mode indication. Mode Setting Complete Hold the [ENTER] button down for 1 Close the setting screen and MENU and return to second while the El icon is highlighted. the normal indication. Switching Monitor Press the » button. Switch to the monitor screen in the normal Display Indication indication. Send the screen in order with the <¢ > buttons. The monitor screen is fixed when there is no operation with the < » buttons for 5 seconds. YANMAH JH Series Operation Manual 41 PRODUCT OVERVIEW Dimmer Linkage The same brightness as the setting of Display is applied to Switch panel and Control head. (— _ Ld mo) Oa raRT re) Ne Figure 35 Auto Dimmer 2. Select “Auto dimmer limit”. (Display: Auto dimmer limit) Auto dimmer is enabled, the brightness of each device is automatically adjusted according to the ambient brightness. MAIN MENU | Alarms/DIAGs 1. Select “Auto dimmer’. Display Choices (Display: Auto dimmer) Engine spee Split window * “YES”: Auto dimmer mode Monitor setti Window select Li Synchro LANT TEMP Brightness * “NO”: Manual dimmer mode Utility Night mode Auto dimmer High limit MAIN MENU UOw T limit | Display Choices 122767-0GENO1 Engine speeq Split window Monitor settil Window select Figure 37 _| Synchro LANT TEMP Brightness Utility Night mode . Set the minimum and maximum Auto dimmer brightness as required. ¢ The brightness is adjusted in 8 steps. 122767-Q0RNOO Figure 36 por Biclny— COOLANT TEMP NL A ° )) (0) 122767-Q0ENOZ Figure 38 42 JH Series Operation Manual VYANMAH PRODUCT OVERVIEW Switch Panel (to start and stop the Emergency Stop Switch (Option) engine) Use this switch only in an emergency. The switch panel has the following functions. — ae 2© Af Power switch a7 061304-00K00 iam] start Engine START/STOP switch Figure 40 Check Engine indicator NOTICE Under normal circumstances, do not use the Emergency stop switch to stop the 122768-O0ENOO engine. Figure 39 The engine shuts down suddenly when the Emergency stop switch is pressed. To Start and stop the engine: After the engine has stopped, press the Emergency stop switch to release the Press the START/STOP switch. emergency stop. YANMAHR JH Series Operation Manual 43 PRODUCT OVERVIEW This Page Intentionally Left Blank 44 JH Series Operation Manual VYVANAIAR 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. 45 YANMAR JH Series Operation Manual BEFORE YOU OPERATE DIESEL FUEL If the B7 biodiesel fuel used does not meet the approved specifications, it will cause Diesel Fuel Specifications abnormal wear of injectors, reduce the life of the engine and it may affect the warranty coverage of your engine. Fire and Explosion Hazard B7 diesel fuels must meet certain specifications. Diesel fuel is flammable and explosive under certain conditions. The biodiesel fuels must meet the minimum specifications for the country in NOTICE which they are used: Only use diesel fuels recommended by In Europe, biodiesel fuels must comply YANMARfor the best engine performance, with the European Standard to prevent engine damage and to comply EN590-2009, EN14214. with EPA warranty requirements. Only use In the United States, biodiesel fuels must clean diesel fuel. comply with the American Standard ASTM D-6751 Grade-S15, D7467 Grade B7-S15. Diesel fuel should comply with the following specifications. The table lists Biodiesel should be purchased only from several worldwide specifications for diesel recognized and authorized diesel fuel fuels. suppliers. DIESEL FUEL Precautions and concerns regarding SPECIFICATION LOCATION the use of biofuels: ASTM D975 No. 2-D $15, USA Biodiesel fuels have a higher content of No. 1-D $15 methyl-esters, which may deteriorate EN590-2009 European Union certain metal, rubber and plastic ISO 8217 DMX International components of the fuel system. The customer and/or boat builder are BS 2869-A1 or A2 United Kingdom responsible to verify the usage of JIS K2204 Grade No. 2 Japan biodiesel compatible components on the vessel fuel supply and return systems. Biodiesel Fuels Free water in biodiesel may result in YANMAR approves the use of biodiesel plugging of fuel filters and increased fuels that do not exceed a blend of 7% bacterial growth. non-mineral oil based fuel with 93% High viscosity at low temperatures may standard diesel fuel. Such biodiesel fuels result in fuel delivery problems, supply are known in the marketplace as B7 pump seizures and poor injection nozzle biodiesel fuels. B7 biodiesel fuel can spray atomization. reduce particulate matter and the emission Biodiesel may have adverse effects on of “greenhouse” gases compared to some elastomers (Seal materials) and standard diesel fuel. may result in fuel leakage and dilution of the engine lubricating oil. 46 JH Series Operation Manual VYANMAH BEFORE YOU OPERATE Even biodiesel fuels that comply with a * PAH (polycyclic aromatic hydrocarbons) suitable standard as delivered will content should be below 10% by volume. require additional care and attention to * Do not use Biocide. maintain the quality of the fuel in the * Lubricity: Wear mark of WS1.4 should be equipment or other fuel tanks. It is Max. 0.016 in. (400 pm) at HFRR test. important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and/or fuel storage containers, may be necessary. The use of biodiesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or biodiesel fuels that have degraded as per the precautions and concerns above, may affect 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% by volume. Keep the fuel tank and fuel-handling equipment clean at all times. Ash content not to exceed 0.01% by volume. Carbon residue content not to exceed 0.35% by volume. Less than 0.1% is preferred. Total aromatics content should not exceed 35% by volume. Less than 30% is preferred. YANMAR JH Series Operation Manual 47 BEFORE YOU OPERATE Handling of Diesel Fuel 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 extract the clear, filtered Fire and Explosion Hazard fuel from the top of the container. ¢ Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may Fuel Tank (Optional) result in a fire and will damage the engine. Never refuel with the engine running. Wipe up all spills immediately. Keep sparks, open flames or any other form of ignition (match, cigarette, static electric source) well away when refueling. ¢ Always put the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container. Hold the hose nozzle firmly against the side of the container while Ko004542 filling it. This prevents static electricity buildup which could cause Figure 2 sparks and ignite fuel vapors. 1 —Sediment Bowl 2 —Drain Cock 3 —Fuel Line to Engine 1. Water and dust in the fuel may cause engine failure. When fuel is stored, be Install a drain cock (Figure 2, (2)) at the sure that the inside of the storage bottom of the fuel tank to remove water container is clean and dry, and that the and contaminants from the sediment bowl fuel is stored away from dirt or rain. (Figure 2, (1)). The fuel outlet should be positioned 20 to 30 mm (0.79 to 1.18 in.) above the bottom of the tank so that only clean fuel is distributed to the engine. Ko004512 Figure 7 48 JH Series Operation Manual VYANMAR BEFORE YOU OPERATE Fuel System To fill the fuel tank: 7> Fire and Explosion Hazard Operate bilge ventilation (blowers) fora minimum of 5 minutes to purge fumes a _ from engine compartment after refueling. Never operate bilge blower while refueling. Doing so can pump ott vIN explosive fumes into the engine iN) compartment and result in an O57347-00R00 explosion. Figure 3 1 —Fuel Tank 1. Clean the area around the fuel cap. 2 —Fuel Cock 2. Remove the fuel cap from the fuel tank. 3 —Pre-filter (Water separator with o Fill the tank with clean fuel free of oil priming pump) and dirt. 4 —Fuel filter 5 —Fuel supply pump 6 —Common rail 7 —Fuel return line Fire and Explosion Hazard 8 -—Drain cock 9 —Approximately 20 to 30 mm Hold the hose nozzle firmly against (0.79 to 1.18 in.) the filler port while filling. 10-—Less than 500 mm (19.7 in.) This prevents static electricity 11 - Orifice for air bleeding buildup which could cause sparks Install the fuel line from the fuel tank to the and ignite fuel vapors. fuel supply pump as shown in Figure 3. The pre-filter (fuel/water separator: Standard accessories) is installed at the 4. Stop fueling when the gauge shows the intermediate section of that line. fuel tank is full. Filling the Fuel Tank Fire and Explosion Hazard Before filling fuel tank for the first Never overfill the fuel tank. time: 5. Replace the fuel cap and hand-tighten. Fire and Explosion Hazard Over-tightening the fuel cap will damage it. Never refuel with the engine running. Rinse fuel tank with kerosene or diesel fuel. Dispose of waste properly. YANMAHR JH Series Operation Manual 49 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 2 1 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 attempts. The fuel system needs to be primed under 056904-02X00 certain conditions: ¢ Before starting the engine for the first Figure 4 time. 1 -—Priming Pump ¢ After running out of fuel and fuel has 2 —Air Bleed Screw been added to the fuel tank. 1. Check the fuel level in the fuel tank. * After fuel system maintenance such as Refill if necessary. changing the fuel filter and draining the 2. Open the fuel cock of the fuel tank. fuel filterAvater separator, or replacing a 3. Loosen the air bleed screw fuel system component. (Figure 4, (2)) two to three turns. 4. Push up and down on the priming pump (Figure 4, (1)) to release air out of the air bleed screw. Fire and Explosion Hazard 5. Continue pumping until a stream of fuel ¢ Diesel fuel is flammable and with no air bubbles begins to flow. explosive under certain conditions. (approx. 60 times.) ¢ Failure to comply could result in 6. Tighten the air bleed screw. death or serious injury. Exposure Hazard Always wear safety glasses when bleeding the fuel system. 50 JH Series Operation Manual YANMAHR BEFORE YOU OPERATE Priming the Fuel System ENGINE OIL Bleeding the fuel filter Engine Oil Specifications Using engine oil that does not meet or An automatic bleeding device is installed exceed the following guidelines or on the fuel filter. Therefore an air bleed specifications may cause seizure of parts, screw is not required. abnormal wear and shorten engine life. 1. Push up and down on the priming pump to bleed the fuel filter. (approx. 60 Service Categories times) Use an engine oil that meets or exceeds 2. When you begin to feel resistance, the following guidelines and classifications: bleeding is complete. * API Service Categories CD, CF, CF-4, Cl and Cl-4. NOTICE * SAE Viscosity: 10W-30, 15VV-40. Engine Never use the starter motor to crank the oil 10WW-30 and 15W-40 can be used engine in order to prime the fuel system. throughout the year. This may cause the starter motor to overheat and damage the coils, pinion and/or ring gear. NOTICE : * Be sure the engine oil, engine oil storage containers and engine oil filling equipment are free of sediment or water. * Change the engine oil after the first 50 hours of operation and then at every 250 hours thereafter. * 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”. YANMAR JH Series Operation Manual 51 BEFORE YOU OPERATE Checking the Engine Oil ements SLE TDWY-30 meen SAE 15W-4€ ¥ °F 14°F 32°F 50°F 68°F 86°F 104°F (-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) Koooo00s Figure 5 Handling Engine Oil 1. When handling and storing engine oil, 056900-02K00 be careful not to allow dust and water to contaminate the oil. Clean around the Figure 6 filler port before filling. 1 -—Engine oil filler port cap Do not mix lube oils of different types or (On the rocker arm cover) brands. Mixing may cause the chemical 2 —Engine oil filler port cap characteristics of the oil to change and (On the gearcase) lubricating performance to decrease, 3 —Dipstick reducing the engine’s life. 4 —Upper Limit Engine oil should be replaced at the 5 —Lower Limit specified intervals, regardless if the Note: 4JH45/57 shown. Other models are engine has been operated. similar. Engine Oil Viscosity . Make sure the engine is level. SAE 10W-30 or SAE 15WW-40 are the . Remove dipstick (Figure 6, (3)) and recommended oil viscosities. wipe with clean cloth. . Fully reinsert dipstick. If you operate your equipment at temperatures outside the limits shown, . Remove dipstick. The oil level should consult your authorized YANMAR dealer or be between upper (Figure 6, (4)) and distributor for special lubricants or starting lower (Figure 6, (5)) lines on the aids. dipstick. . Add oil if necessary. See ADDING ENGINE OIL on page 53. . Fully reinsert dipstick. 52 JH Series Operation Manual VINA BEFORE YOU OPERATE ADDING ENGINE OIL MARINE GEAR OR SAIL 1. Remove the yellow oil filler port cap DRIVE OIL from filler port (Figure 6, (1) (2)) and fill Marine Gear Oil Specifications with engine oil. Use marine gear oil that meets or exceeds the following guidelines and classifications: NOTICE KM35P, KM35A, KM35A2, KM4A1, Prevent dirt and debris from KM4A2, KMH4A, KMHS50V-2: contaminating engine oil. Carefully clean the dipstick and the * API Service Categories CD or higher surrounding area before you remove the * SAE Viscosity #20 or #30 cap. ZF30M, ZF25A, ZF25: * ATF (Automatic Transmission Fluid) 2. Fill with oil to the upper limit (Figure 6, (4)) on the dipstick Sail Drive Oil Specifications (Figure 6, (3)). Refer to the Operation Manual of the sail drive for the procedure to fill or replace the NOTICE sail drive oil. Never overfill the engine with engine oil. 3JH40, 4JH45, 4JH57 (SD60-5) 4JH80 (SD60-4): * API Service Categories CD or higher 3. Insert the dipstick fully to check the level. * SAE Viscosity 15W-40 NOTICE Always keep the oil level between upper and lower lines on the oil cap/dipstick. 4. Hand-tighten the filler port cap securely. YANMAR JH Series Operation Manual 53 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)). See Marine Gear Oil Specifications on page 53. NOTICE Never overfill the marine gear with oil. 4. Screw in the dipstick. 054317-00K00 Figure 7 5. Tighten the filler port cap by hand. 1 —Filler cap 2 ~—Dipstick Checking and Adding Sail Drive (Filler cap combined type) Oil 3 ~Upper Limit 4 ~—Lower Limit (Dipstick end) Refer to the operation manual for SD60 for Note: 4JH110 with KMH4A marine gear the procedure to check and fill the sail shown. drive oil. = . Make sure engine is level. 2. Remove the filler cap (Figure 7, (1)) at the top of the housing. 3. Remove dipstick (Figure 7, (2)) and wipe with clean cloth. 4. Re- insert the dipstick without screw in. See the illustration (Figure 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. 54 JH Series Operation Manual VYANMAR BEFORE YOU OPERATE ENGINE COOLANT Coolant (Closed Cooling System) Engine Coolant Specifications NOTICE Note: In the U.S., LLC is required for the Always add LLC to soft water especially warranty to be valid. when operating in cold weather. Never use * Texaco Long Life Coolant (LLC), both hard water. Water should be clean and free standard and premixed, product code from sludge or particles. Without LLC, 7997 and 7998 cooling performance will decrease due to scale and rust in the coolant system. * Havoline Extended Life Water alone may freeze and form ice; Antifreeze/Coolant, product code 7994 it expands approximately 9% in volume. Following the manufacturer’s Use the proper amount of coolant recommendations, use a proper LLC concentrate for the ambient temperature which will not have any adverse effects on as specified by the LLC manufacturer. the materials (cast iron, aluminum, copper, LLC concentration should be a minimum of etc.) of the engine’s cooling system. 30% to a maximum of 60%. Too much LLC will decrease the cooling efficiency. Always use the mixing ratios specified by Excessive use of antifreeze also lowers the antifreeze manufacturer for the the cooling efficiency of the engine. temperature range. Never mix different types or brands of LLC, as a harmful sludge may form. Mixing different brands of antifreeze may cause chemical reactions, and may make the antifreeze useless or cause engine problems. YANMAR JH Series Operation Manual 55 BEFORE YOU OPERATE Checking and Adding Coolant 3JH40 198120-01%01 Figure 9 2 —Coolant pump 3 -—Coolant tank (Heat exchanger) 4 -—Coolant drain cock Figure & (Coolant tank/Heat exchanger) 1 -—Coolant drain cock 5 —Seawater pump (Cylinderblock) (Drain from pump cover) 56 JH Series Operation Manual VYVANAIAR BEFORE YOU OPERATE 4JH45, 4JH57 4JH80, 4JH110 2 1 056983 -02K00 4 3 2 956988-03% Figure 10 Figure 12 1 -—Coolant drain cock 1 -— Turbocharger (Cylinderblock) 2 —Coolant drain cock 2 —Marine gear oil cooler (KM4A1) (Cylinderblock) 3 -—Seawater drain cock 3 —Marine gear oil cooler (KMH4A) (Marine gear oil cooler) 4 -Seawater drain cock (Marine gear oil cooler) 056984-02K00 056989-03K00 Figure 11 Figure 13 4 -—Coolant pump 5 —Coolant tank (Heat exchanger) 5 —Coolant pump 6 —Coolant drain cock 6 —Coolant tank (Heat exchanger) (Coolant tank/Heat exchanger) 7 —Coolant drain cock (Coolant 7 —Seawater pump tank/Heat exchanger) (Drain from pump cover) 8 —Seawater drain cock (Air cooler) 9 —Air cooler 10-—Seawater pump (Drain from pump cover) YANMAR JH Series Operation Manual 57 BEFORE YOU OPERATE 1. Ensure all drain cocks are closed. . Pour coolant slowly into coolant tank (Figure 14, (4)) to avoid air bubbles. Note: The drain cocks are opened Fill until coolant overflows from the filler before shipping from the factory. no) fo} Marine gear ZF25A does not have a drain cock on the marine gear cooler. NOTICE 2. Loosen the filler cap of coolant tank to Never pour cold coolant into a hot relieve the pressure, then remove the engine. filler cap. . Align filler cap tabs (Figure 14, (1)) with filler port notches (Figure 14, (3)) and Burn Hazard tighten filler cap (Figure 14, (2)) firmly. Never remove the coolant filler cap if the engine is hot. Steam and hot NOTICE engine coolant will spray out and Always tighten coolant tank cap securely seriously burn you. Allow the engine after checking coolant tank. Steam can to cool down before you attempt to spray out during engine operation if the remove the cap. cap is loose. Note: The coolant level rises in the reservoir during operation. After stopping the engine, the coolant will cool down and the extra coolant will return to coolant tank. 054746-00x00 Figure 14 1 -Filler Cap Tabs 2 -—Coolant Filler Cap 3 —Filler Port Notches 4 -Coolant Tank Koo04493 Figure 15 58 JH Series Operation Manual VYANMAH BEFORE YOU OPERATE 5. Check the coolant level in the reservoir. The level should be at the FULL mark (Figure 15, (2)). Add coolant if necessary. NOTICE Never pour cold coolant into a hot engine. 6. Remove reservoir cap (Figure 15, (4)) to add coolant if necessary. Do not add water. 7. Install filler cap and tighten it firmly. Failure to do so will cause water leakage. Reservoir Capacity 0.8 L (0.85 qt) 8. Check the rubber hose (Figure 15, (1)) connecting the reservoir to coolant tank/heat exchanger. Replace if damaged. Note: If fhe 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. YWRANRGAR su Series Operation Manual 59 BEFORE YOU OPERATE This Page Intentionally Left Blank 60 JH Series Operation Manual VYVANAIAR ENGINE OPERATION INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual Before performing any operations within describes the procedures for starting the this section, review the Safety section on engine, checking engine performance page 3. during operation and shutting down the engine. 61 YANMAR JH Series Operation Manual ENGINE OPERATION NOTICE Fire and Explosion If any indicator illuminates during engine Hazard operation, stop the engine immediately. Never jump-start the engine. Determine the cause and repair the Sparks caused by shorting problem before you continue to operate the battery to the starter the engine. terminals may cause a fire or explosion. If the vessel is equipped with a water lift Only use the start switch on (water lock) muffler, excessive cranking the instrument panel to start could cause seawater to enter the the engine. cylinders and damage the engine. If the engine does not start after cranking for 10 seconds, close the thru-hull water intake Sudden Movement Hazard valve to avoid filling the muffler with water. Be sure the boat is in open water away Crank for 10 seconds at a time until the from other boats, docks or other engine starts. When the engine does start, obstructions before increasing engine stop the engine immediately and turn off speed. Avoid unexpected equipment the switch. movement. Shift the marine gear into the NEUTRAL position any time the Be sure to re-open the seacock and restart engine is at idle. the engine. Operate the engine normally. To prevent accidental equipment Observe the following environmental movement, never start the engine in operating conditions to maintain engine gear. performance and avoid premature engine wear: * Avoid operating in extremely dusty Sever Hazard conditions. b Keep children and pets * Avoid operating in the presence of away while the engine is chemical gases or fumes. operating. * Never run the engine if the ambient temperature is above +40 °C (+104 °F) or below -16 °C (+5 °F). * Ifthe ambient temperature exceeds +40 °C (+104 °F), the engine may overheat and cause the engine oil to break down. 62 JH Series Operation Manual VYANMAH ENGINE OPERATION OPERATION (B25, C35-TYPE NOTICE INSTRUMENT PANEL) * If the ambient temperature is below -16 °C (+5 °F), rubber components such Starting the Engine as gaskets and seals will harden causing premature engine wear and damage. 1. Open the seacock (if equipped). 2. Open the fuel tank cock. * Consult your authorized YANMAR Marine engine dealer or distributor if the 3. Put remote control handle in engine will be operated outside ofthis NEUTRAL. standard temperature range. Note: Safety equipment should make it impossible to start the engine in any other position than Never engage the starter motor while the NEUTRAL. engine is running. Damage to the starter motor pinion and/or ring gear will result. Start switch Power switch 042590-02ENC0 Figure 7 . 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 when the engine does not operate. If all alarm lamps operate when you turn on the power switch on the instrument panel, the warning devices operate correctly. Pushing the start switch turns on the engine. Release the switch after the engine starts. YANMAR JH Series Operation Manual 63 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. If air is in the fuel system, fuel pinion gear ofthe starter motor will be cannot reach the fuel supply pump. damaged. Bleed the air out of the system. See Bleeding the Fuel System on page 50. NOTICE Starting at Low Temperatures Never hold for longer than 15 seconds or Comply with local environmental the starter motor will overheat. requirements. Do not use starting aids. Never attempt to restart the engine if the NOTICE engine has not stopped completely. Never use an engine starting aid such as Pinion gear and starter motor damage will ether. Engine damage will result. occur. To limit white smoke, run the engine at low Note: Push and hold the start switch for a speed and under moderate load until the maximum of 15 seconds. If the engine reaches normal operating engine does not start the first time, temperature. A light load on a cold engine wait for about 15 seconds before provides better combustion and faster trying again. engine warm-up than no load. NOTICE Avoid running the engine at idling speed any longer than necessary. 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 15 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 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. 64 JH Series Operation Manual YANMAR ENGINE OPERATION After the Engine has Started REMOTE CONTROL After the engine has started, check the HANDLE OPERATION following items at a low engine speed: Acceleration and Deceleration 1. Check that the gauges, indicators and alarm are normal. * Normal coolant operating temperature is approximately 76° to 90 °C (169° to 194 °F). * Normal oil pressure at 3000 min-1 is 0.28 to 0.54 MPa (41 to 78 psi). 2. Check for water, fuel or oil leakage from the engine. 3. Check that the smoke color, engine vibration and sound are normal. Ko004513 4. When there are no problems, keep the engine at low speed with the boat still Figure 2 stopped to distribute engine oil to all 1 —FORWARD or REVERSE parts of the engine. 2 -NEUTRAL 5. Check that sufficient seawater is 3 —REVERSE or FORWARD discharged from the seawater outlet. 4 -Throttle Handle/Shifting Handle Operation with inadequate seawater Note: Direction of travel will vary discharge will damage the impeller of depending on installation location. the seawater pump. If seawater discharge is too low, stop the engine Use the throttle handle (Figure 2, (4)) to immediately. Identify the cause and control acceleration and deceleration. repair. Move the handle slowly. NOTICE Shifting the Engine The engine will seizeif it is operated when seawater discharge is too small or if load is applied without any warming up Sudden Movement Hazard operation. The boat will start to move when the marine gear is engaged: Fortroubleshooting assistance, see ¢ Ensure the boat is clear of all TROUBLESHOOTING AFTER obstacles forward and aft. STARTING on page 135 or * Quickly shift to the FORWARD TROUBLESHOOTING CHART on page position then back to the NEUTRAL 137. lf necessary, consult authorized position. YANMAR dealer or distributor. * Observe whether the boat moves in the direction you expect. YANMAR JH Series Operation Manual 65 ENGINE OPERATION Switching to Trolling NOTICE (KMH4A Only) Shifting the marine gear while operating at Use the trolling handle to begin trolling. high speed or not pushing the handle fully When changing from FORWARD or into position (partial engagement) will REVERSE to trolling, the speed ofthe result in damage to marine gear parts and propeller revolution will be reduced to a abnormal wear. minimum. 1. Before using the marine gear, be sure to move the throttle handle to a low idle position (less than 1000 min-‘). Move the throttle handle slowly to a higher speed position after completing marine gear engagement. 2. When moving the handle between FORWARD (Figure 2, (1 or 3)) and REVERSE (Figure 2, (3 or 1)), bring the handle to NEUTRAL (Figure 2, (2)) and pause before slowly shifting to the desired position. Never shift abruptly from FORWARD to REVERSE or vice versa. NOTICE Ko004498 ¢ Never shift the marine gear at high engine speed. During normal Figure 3 operation, the marine gear should only be shifted with the engine at idle. 1 -—Cable Fitting 2 -—Trolling Lever ¢ When sailing, set the remote control 3 —Low Speed (trolling) handle in NEUTRAL. Not doing so 4 -—High Speed WILL introduce slippage or any 5 —Loosen damage and void your warranty. 6 -—Tighten * Incase thatthe marine gear can not be 7 —Normal Operation (high speed) shifted by remote control handle for 8 -—Trolling (low speed) some reason such as broken cable, 1. Operation continues at low engine remove the cable from shift lever on speed of 1000 min“ or less. the marine gear and shift manually by 2. Reduce the speed by moving the turning the lever. trolling handle from high speed (H) (Figure 3, (4)) to low speed (L) (Figure 3, (3)). Adjust the speed to the desired rate and secure the trolling handle in place. 66 JH Series Operation Manual YANMAR ENGINE OPERATION 3. Before returning to normal operation, CAUTIONS DURING be sure to put the trolling handle in high-speed (H) position. OPERATION 4. Increase engine speed and continue normal operation. 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: Ifthe 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 the discharge is small, 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. YANRAH JH Series Operation Manual 67 ENGINE OPERATION * Are there abnormal vibrations or noise? * When operating the engine at low speed for long periods of time, race the engine NOTICE once every 2 hours. Excessive vibration may cause damage NOTICE to the engine, marine gear, hull and onboard equipment. In addition, it Racing the engine: With the gear in causes able passenger and crew NEUTRAL, accelerate from the discomfort. low-speed position to the high-speed position and repeat this process about five times. This is done to clean out Depending on the hull structure, engine carbon from the cylinders and the fuel and hull resonance may suddenly injection valve. Neglecting to race the become great at a certain engine speed engine will result in poor smoke color range, causing heavy vibrations. and reduce engine performance. Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect. If possible, periodically operate the engine at near maximum engine speed ¢ Alarm buzzer sounds during operation. while underway. This will generate higher exhaust temperatures, which will NOTICE help clean out hard carbon deposits, If any alarm indicator with audible alarm maintaining engine performance and sound appears on the display during prolonging the life of the engine. engine operation, stop the engine immediately. Determine the cause and NOTICE repair the problem before you continue Never turn off the battery switch (if to operate the engine. equipped) or short the battery cables during operation. Damage to the electric system will result. « Is there water, oil or fuel leakage, or are there any loose bolts? Check the 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. 68 JH Series Operation Manual VYVANAIAR ENGINE OPERATION SHUTTING DOWN THE 4. Push and hold the stop switch. After the engine has stopped, push the ENGINE power switch off. Normal Shutdown NOTICE 1. Reduce engine speed to low idle and Continue to hold the stop switch in until put remote control handle in NEUTRAL. the engine is completely stopped. If the Accelerate from low speed to high switch is released before the engine has speed and repeat five times. This will completely stopped, it may restart. If the clean out the carbon from the cylinders engine does not shut down, see Engine and the fuel injection nozzles. Auxiliary Stop Switch on page 70 Allow engine to run at low speed and 77. (approximately 1000 min-1) without load for 5 minutes. 5. Wait 6 seconds or more before turning NOTICE the battery switch off for secure system settle down. For maximum engine life, YANMAR recommends that when shutting the NOTICE engine down, you allow the engine to idle, without load, for 5 minutes. This will * Do notturn the battery switch off allow the engine components that before turning the power switch off or operate at high temperatures, such as immediately afterturning off the power the turbocharger (if equipped) and switch. exhaust system, to cool slightly before * Turning the battery switch off before the engine itself is shut down. secure system settle down may cause alarmto be set at the next activation by turning on the power switch. In an emergency situation, you can start the engine even ifthe alarm is set. In order to release above alarm, turn Start switch off the power switch and wait 6 seconds before turning the power Stop switch switch on again. 6. Turn off the battery switch (if equipped). 7. Close the fuel cock. Power switch 042590-02ENO1 Figure 4 YANMAHR JH Series Operation Manual 69 ENGINE OPERATION 8. Close the seacock (if equipped). 1. Pressing the Auxiliary Stop switch on the ECU cover will stop the engine NOTICE immediately. « Be sure to close the seacock. 2. "AUX STP" will be shown on the LCD of Neglecting to close the seacock could the instrument panel. allow water to leak into the boat and 3. After the engine has stopped, release may cause it to sink. the switch by pressing and turning it to * If seawater is left inside the engine, it the RUN position. may freeze and damage parts ofthe cooling system when the ambient | ae temperature is below 0 °C (32 °F). F ) S 5. NS Engine Auxiliary Stop Switch NOTICE Never use the auxiliary stop switch for a normal engine shutdown. Use this switch only when stopping the engine suddenly in an emergency. Figure 5 70 JH Series Operation Manual VYANMAR ENGINE OPERATION Auxiliary Stop Switch CHECKING THE ENGINE (Option: It is recommended that AFTER OPERATION this switch is installed in an easily accessible location.) * Check that the power switch is off and that the battery switch (if equipped) is turned to off. * Fillthe fuel tank. See Filling the Fuel Tank on page 49. * 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 55. Figure 7 * If there is a risk of freezing, drain the 1. Pressing the upper part of the Auxiliary seawater system. See DRAIN Stop switch will stop the engine SEAWATER COOLING SYSTEM on immediately. page 148. 2. "AUX STP" will be shown on the LCD of the instrument panel. * At temperatures below 0 °C (32 °F), drain seawater system and connect the 3. After the engine has stopped, push the engine heater (if equipped). bottom part of the switch to release it. Note: The engine cannot be started while the Auxiliary Stop switch is pressed. (Auxiliary Stop mode not canceled) NOTICE * In case of emergency, turning off the battery switch for the engine control unit can also stop the engine immediately. * 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. YANMAR JH Series Operation Manual 71 ENGINE OPERATION OPERATION (VC10: VESSEL . If the “Start by ID” has been set, enter the password into the display. CONTROL SYSTEM) * The “Start by ID” has been set, the engine can be started in 10 seconds Starting the Engine after entering the password into the 1. Open the seacock (if equipped). display. 2. Open the fuel tank cock. . Move the remote control handle to the 3. Turn the battery switch on for engine N (Neutral) position. and engine control system. 4. Press the Power switch on the switch panel ofthe selected station (Figure 8, (1)). * The switch panel lamp will come on, and the control head (Figure 9) “SEL” = lamp (Figure 10) will come on or flash. * To use the Engine START/STOP switch, be sure to turn the Power switch ON. 4 Figure 9 ) (Control head panel PORT 8Ta0 © / ia FCot we) ENN RTCA 037638-00X00 Figure 10 037627-00%01 Figure 8 5. |fthe “Sys on by ID” has been set, enter the password into the display. 6. Press the control head “SEL” switch. * Wait until the display shows the engine data. The display is shown. 72 JH Series Operation Manual VYANATAR ENGINE OPERATION 9. Press the Engine START/STOP switch (Figure 8, (2)) and power on the starter. * When the engine starts, the VC10 display will show the screen with engine conditions (Figure 11). 962220-COENOO Figure 11 Note: 1. Conceming the contro! 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 START/STOP switch except for stopping the engine. WRI MAGA JH Series Operation Manual 73 ENGINE OPERATION Vessel Control System (VC10) has the Owner ID Change following functions, which can be set in the The ID used in “Sys on by ID’ and “Start by Utility screen of MAIN MENU in the Digital ID” can be set and changed as follows. Display. For more details, refer to the Vessel Control System Installation Manual. * If you select “Owner ID change’, the ID verification screen is displayed and you Station Protect are asked to enter the current ID It is a function to prevent the operation (Default: “O0000”). from the other stations while steering. * If you enter the wrong ID 5 times, the ID * Select “YES” to enable “Station protect”. is locked and you are no longer able to The display and control head of that make an input. The lock can be released station can no longer be operated. by turning off the system power. * Select “NO” or turn off the system power ID can be changed to any 5 digit number to disable “Station protect’. from 00000 to 99999. * Select the number from 0 to 9 with the A Sys on by ID, Start by ID ¥Y buttons. The fixed number is displayed It is a function to check ID for the purpose by an asterisk when you press the > of anti-theft. button and the next digit is highlighted. * If you select “YES’ in “Sys on by ID”, it is * Press the [ENTER] button after necessary to enter the Owner ID on the highlighting it with the ® bution when all display when turning on the system 5 digits are entered and the new ID power. If you select “YES” in “Start by becomes valid. ID”, it is necessary to enter the owner ID on the display at engine start. * The initial ID is “OOO00” and it can be changed with the below “Owner ID change” function. « Even when the system power is turned G39895-00x%00 off, the selected “Sys on by ID” and Figure 12 “Start by ID” cannot be disabled and it is required to enter the Owner ID at each time. 4] | Owner ID change | « After entering the ID and verification, if Input new Owner ID made you don’t operate for 10 seconds, the of five digits to replace entry becomes invalid and it is required current Owner ID to enter the Owner ID again. || Enter | 039896-O0E00 Figure 13 74 JH Series Operation Manual VYANMAH ENGINE OPERATION If the Engine Fails to Start Air Bleeding the Fuel System after Starting Failure Before pressing the Start switch again, confirm that the engine has stopped If the engine does not start after several completely. If the starter motor is operated attempts, there may be air in the fuel before the engine has completely stopped, system. If air is in the fuel system, fuel the starter motor pinion gear will be cannot reach the fuel supply pump. damaged. Bleed the air out of the system. See Bleeding the Fuel System on page 50. NOTICE Starting at Low Temperatures Never hold for longer than 15 seconds or Comply with local environmental the starter motor will overheat. requirements. Do not use starting aids. Never attempt to restart the engine if the NOTICE engine has not stopped completely. Never use an engine starting aid such as Pinion gear and starter motor damage will ether. Engine damage will result. occur. To limit white smoke, run the engine at low Note: Push and hold the start switch for a speed and under moderate load until the maximum of 15 seconds. If the engine reaches normal operating engine does not start the first time, temperature. A light load on a cold engine wait for about 15 seconds before provides better combustion and faster trying again. engine warm-up than no load. Avoid running the engine at idling speed NOTICE any longer than necessary. If the vessel is equipped with a water lift (water lock) muffler, excessive cranking After the Engine has Started could cause seawater to enter the After the engine has started, check the cylinders and damage the engine. If the following items at a low engine speed: engine does not start after cranking for 15 seconds, close the thru-hull water intake 1. Check that the gauges, indicators and valve to avoid filling the muffler with water. alarm are normal. Crank for 10 seconds at a time until the * Normal coolant operating temperature engine starts. When the engine does start, is approximately 76° to 90 °C (169° to stop the engine immediately and turn off 194 °F). the power switch. Be sure to re-open the * Normal oil pressure at 3000 min-1 is seacock and restart the engine. 0.28 to 0.54 MPa (41 to 78 psi). Operate the engine normally. 2. Check for water, fuel or oil leakage from the engine. 3. Check that the smoke color, engine vibration and sound are normal. YANMAH JH Series Operation Manual 75 ENGINE OPERATION 4. When there are no problems, keep the WARM UP MODE engine at low speed with the boat still stopped to distribute engine oil to all (SHIFT DISCONNECT) parts of the engine. 1. Move the remote control handle to the . Check that sufficient seawater is N (Neutral) position. (The NEUTRAL discharged from the seawater outlet. lamp will come on) Operation with inadequate seawater Press the “NTRL” switch of the selected discharge will damage the impeller of station control head. the seawater pump. If seawater The NEUTRAL lamp will come on, and discharge is too low, stop the engine the NEUTRAL lamp will flash. immediately. Identify the cause and repair. Move the remote control handle. The engine speed can be controlled while the gear shift is in neutral. NOTICE Move the remote control handle to the The engine will seize if it is operated N (Neutral) position, press the “NTRL” when seawater discharge is too small or switch and cancel warm up mode. ifload is applied without any warming up operation. (Control head panel) - POST are i a o as (su) oO NEUTRAL oS oo cae &9 >) 937638-00x%03 Figure 14 JH Series Operation Manual VYANMAR ENGINE OPERATION THROTTLE AND SHIFT Forward (Reverse) to Reverse CONTROL (Forward) Moving the handle quickly and switching from forward (reverse) to reverse (forward) will activate the gear shift delay (astern Sudden Movement Hazard delay). The engine speed to decrease to The boat will start to move when the idle speed for several seconds. marine gear is engaged: Note: The force required fo move the ¢ Ensure the boat is clear of all throttle or shift handles can be obstacles forward and aft. adjusted with the Adjusting Screw. * Quickly shift to the FORWARD position then back to the NEUTRAL position. ¢ Observe whether the boat moves in the direction you expect. Adjusting Neutral screw 037634-O00E00 1. Move the remote control handle to the N (Neutral) position. (The NEUTRAL Figure 15 lamp will come on) 2. When switching between forward and reverse, move the handle slowly between the forward and reverse positions. Move the handle firmly into either the forward 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. YANMAH JH Series Operation Manual 77 ENGINE OPERATION ENGINE SPEED LIMIT CAUTIONS DURING MODE OPERATION 1. Move the remote control handle to the Forward Idle position. (Both sides in the NOTICE case of twin engine.) Engine trouble can arise if the engine is Press the “NTRL” switch of the selected operated for a long time under overloaded station. (The lamp above “NTRL’ switch conditions with the control handle in the full will flash.) throttle position (maximum engine speed Even if you tilt the handle to accelerate, position), exceeding the continuous rated the engine speed increases only up to output engine speed. Operate the engine the setting value. at about 100 min-1 lower than the full throttle engine speed. Move the remote control handle to the N (Neutral), Forward Idle, or Reverse Idle position (both sides in the case of Note: If the engine is in the first 50 hours of twin engine) and press the “NTRL” operation, see New Engine Break-in switch to release the [Engine Speed on page 72. Limit Mode]. Always be on the lookout for problems Note: The setting value can be set by the during engine operation. VC10 display. The default value is 50%. Pay particular attention to the following: * Is sufficient seawater being discharged ) (Control head panel from the exhaust and seawater outlet pipe? PORT OTE (ser) 2 2 \f the discharge is small, stop the engine a ae aa boon immediately; identify the cause and - (vnc) ce) repair. Tene 037638-00X03 * Is the smoke color normal? Figure 16 The continuous emission of black exhaust smoke indicates engine overloading. This shortens the engines life and should be avoided. 78 JH Series Operation Manual YANhGAAR ENGINE OPERATION * Are there abnormal vibrations or noise? * When operating the engine at low speed for long periods of time, race the engine NOTICE once every 2 hours. Excessive vibration may cause damage NOTICE to the engine, marine gear, hull and onboard equipment. In addition, it Racing the engine: With the gear in causes able passenger and crew NEUTRAL, accelerate from the discomfort. low-speed position to the high-speed position and repeat this process about five times. This is done to clean out Depending on the hull structure, engine carbon from the cylinders and the fuel and hull resonance may suddenly injection valve. Neglecting to race the become great at a certain engine speed engine will result in poor smoke color range, causing heavy vibrations. and reduce engine performance. Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect. * lf possible, periodically operate the engine at near maximum engine speed * Alarm buzzer sounds during operation. while underway. This will generate higher exhaust temperatures, which will NOTICE help clean out hard carbon deposits, If any alarm indicator with audible alarm maintaining engine performance and sound appears on the display during prolonging the life of the engine. engine operation, stop the engine immediately. Determine the cause and NOTICE repair the problem before you continue Never turn off the battery switch (if to operate the engine. equipped) or short the battery cables during operation. Damage to the electric system will result. * Is there water, oil or fuel leakage, or are there any loose bolts? Check the 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. WR MAGA JH Series Operation Manual 79 ENGINE OPERATION SHUT-DOWN THE ENGINE 5. Wait 6 seconds or more before turning the battery switch off for secure system (STOPPING) settle down. Stop the engine in accordance with the NOTICE following procedures: * Do not turn the battery switch off Normal Stopping before turning the power switch off or 1. Move the remote control handle to the immediately after turning offthe power N (Neutral) position. (The NEUTRAL switch. lamp will come on.) * Turning the battery switch off before . Cool the engine down at low speed secure system settle down may cause (below 1000 min-' (rpm)) for about 5 alarmto be set at the next activation by minutes. turning on the power switch. In an emergency situation, you can start the engine even ifthe alarm is set. NOTICE In order to release above alarm, turn For maximum engine life, YANMAR off the power switch and wait 6 recommends that when shutting the seconds before turning the power engine down, you allow the engine to switch on again. idle, without load, for5 minutes. This will allow the engine components that operate at high temperatures, such as . Turn the battery switch off for engine the turbocharger and exhaust system, to and engine control system. cool slightly before the engine itself is . Close the fuel tank cock. shut down. . Close the seacock. A CAUTION Press the Engine START/STOP switch on the switch panel of the selected ¢ Be sure to close the seacock. station. Neglecting to close the seacock could allow water to leak into the Press the Power switch and turn the boat and may cause it to sink. power OFF. * If seawater is left inside the engine, it may freeze and damage parts of A CAUTION the cooling system when the Do not press the Engine START/STOP ambient temperature is below 0 °C switch when the engine is stopped. (32 °F). The engine will restart. 80 JH Series Operation Manual VYANMAH ENGINE OPERATION Normal Stopping (for folding / feathering propeller) When the boat sails with engine is off, the shift position of the sail drive can be in reverse position: ¢ To fold the folding propeller. ¢ To feather the feathering propeller. 1. Move the remote control handle to the N (Neutral) position. (The NEUTRAL lamp will come on.) 2. Cool the engine down at low speed (below 1000 min-' (rpm)) for about 5 minutes. Figure 17 NOTICE For maximum engine life, YANMAR recommends that when shutting the engine down, you allow the engine to Engine START/STOP idle, without load, for5 minutes. This will allow the engine components that operate at high temperatures, such as the turbocharger and exhaust system, to cool slightly before the engine itself is shut down. 3. Press the Engine START/STOP switch on the switch panel of the selected station. 4. Set the lever position to Full Reverse. Figure 18 5. Press the Power switch and turn the power OFF. For twin engine, turn the other power OFF within 10 seconds of turning one side OFF. A CAUTION Do not press the Engine START/STOP switch when the engine is stopped. The engine will restart. YANMAR JH Series Operation Manual 81 ENGINE OPERATION 6. Wait 6 seconds or more before turning the battery switch off for secure system settle down. NOTICE * Do not turn the battery switch off before turning the power switch off or immediately after turning offthe power switch. * Turning the battery switch off before secure system settle down may cause alarm to be set at the next activation by turning on the power switch. In an emergency situation, you can start the O37639-00E00 engine even if the alarm is set. In orderto release above alarm, turn : off the power switch and wait 6 Figure 19 seconds before turning the power switch on again. 7. Turn the battery switch off for engine (stan ST Pj Engine { START/STOP Nea switch and engine control system. (#7 8. Close the fuel tank cock. 9. Close the seacock. A CAUTION * Be sure to close the seacock. Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink. 037627-01BNOS * If seawateris left inside the engine, Figure 20 it may freeze and damage parts of the cooling system when the ambient temperature is below 0 °C (32 °F). 82 JH Series Operation Manual YANMAR ENGINE OPERATION Emergency Stop Electric Emergency Stop NOTICE Never use the Emergency Stop switch for anormal engine shutdown. Use this switch only when stopping the engine suddenly in Emergency stop switch an emergency. 1. Pressing the Emergency Stop switch on the switch panel will stop the engine immediately. 037627-01ENO1 2. The Emergency Stop screen will be Figure 21 shown on the display, and the buzzer will sound. NOTICE 3. After the engine has stopped, press the Emergency Stop switch to release the * In case of emergency, turning off the emergency stop. After releasing, it may battery switch for the engine control unit take sometime to restart. can also stop the engine immediately. Note: You can restart the engine but an alarm may be set up when the power switch is 1. The Emergency Stop switch should turned on. Unless you are in an only be used in emergencies. Use the emergency situation, in order to release Engine START/STOP switch to stop the above alarm, turn off the power switch engine normally. and wait 6 seconds before turning the 2. The engine cannot be started while the power switch on again. Emergency Stop switch is pressed (emergency stop mode not canceled). YANRIA JH Series Operation Manual 83 ENGINE OPERATION CONTROL THE BACKUP Engine START/STOP switch Lamp Power switch PANEL Cover — Only use this in an emergency. 1. Check that the power switch on the switch panel is OFF and that the (Shift switch position) Sub throttle volume remote control handle is in the N 037636-O1ENO2 (Neutral) position. Figure 22 2. Press the power switch to the “ON” position on the backup panel. The lamp State where cover is removed will come and control by the backup panel is enabled. Lamp Sub throttle volume 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 olYe (F ( sie QB © aD“@ | | Brn switch Ss engine speed) When controlling the throttle, first move it fully anti-clockwise. Engine START/STOP Shift switch switch NOTICE 132412-O00ENOO Figure 23 * The throttle of the engine that has been turned on can be controlled. State where cover is attached * When controlling the throttle, always move it fully anti-clockwise first. * Be sure to lower the engine speed by turning the sub throttle volume fully to anti-clockwise before stopping the engine. * The shift switch where is behind the left cover of Backup Panel. * Shift switch does not work on 3/4JH common rail engines. * In case that the marine gear can not be 132446-90x00 shifted by remote control handle for some Figure 24 reason such as broken cable, remove the cable from shift lever on the marine gear * Remove the cover when operating the and shift manually by turning the lever. backup panel. * The backup panel has two design types. 84 JH Series Operation Manual YANMAR 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 49. 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 55. If there is a risk of freezing, drain the seawater system. See DRAIN SEAWATER COOLING SYSTEM on page 148. At temperatures below 0 °C (32 °F), drain seawater system and connect the engine heater (if equipped). VAR AGa JH Series Operation Manual 85 ENGINE OPERATION OPERATION (VC20: VESSEL 6. Press the control head “SEL” switch. ¢ Wait untilthe display shows the engine CONTROL SYSTEM) data. The display is shown. Starting the Engine 7. Ifthe “Start by ID” has been set, enter the password into the display. 1. Open the seacock (if equipped). * The “Start by ID” has been set, the 2. Open the fuel tank cock. engine can be started in 10 seconds 3. Turn the battery switch on for engine after entering the password into the and engine control system. display. 4. Press the Power switch on the 8. Move the remote control handle to the switch panel of the selected station N (Neutral) position. (Figure 285, (1)). * Ifthe “YANMAR E-key” has been set, hold the key fob in front of the blinking lamp on the switch panel to authenticate the key. * The switch panel lamp will come on, and the control head (Figure 26) “SEL” lamp (Figure 27) will come on orflash. * To use the Engine START/STOP switch, be sure to turn the Power switch ON. Figure 26 Control head panel @ PORT NEUTRAL --} © STBD NEUTRAL = @ SYNC @ TROL __ ONTRL [ a 122768-00%00 122770-Q0ENOO0 Figure 25 Figure 27 5. Ifthe “Sys on by ID” has been set, enter the password into the display. 86 JH Series Operation Manual YANMAR ENGINE OPERATION 9. Press the Engine START/STOP switch (Figure 25, (2)) and power on the starter. * When the engine starts, the VC20 display will show the screen with engine conditions (Figure 28). 962220-COENOO Figure 28 Note: 1. Conceming the 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 START/STOP switch except for stopping the engine. WRI MAGA JH Series Operation Manual 87 ENGINE OPERATION Vessel Control System (VC20) has the Owner ID Change following functions, which can be set in the The ID used in “Sys on by ID’ and “Start by Utility screen of MAIN MENU in the Digital ID” can be set and changed as follows. Display. For more details, refer to the Vessel Control System Installation Manual. * If you select “Owner ID change’, the ID verification screen is displayed and you Station Protect are asked to enter the current ID It is a function to prevent the operation (Default: “O0000”). from the other stations while steering. * If you enter the wrong ID 5 times, the ID * Select “YES” to enable “Station protect”. is locked and you are no longer able to The display and control head of that make an input. The lock can be released station can no longer be operated. by turning off the system power. * Select “NO” or turn off the system power ID can be changed to any 5 digit number to disable “Station protect’. from 00000 to 99999. * Select the number from 0 to 9 with the A Sys on by ID, Start by ID ¥Y buttons. The fixed number is displayed It is a function to check ID for the purpose by an asterisk when you press the > of anti-theft. button and the next digit is highlighted. * If you select “YES’ in “Sys on by ID”, it is * Press the [ENTER] button after necessary to enter the Owner ID on the highlighting it with the ® bution when all display when turning on the system 5 digits are entered and the new ID power. If you select “YES” in “Start by becomes valid. ID”, it is necessary to enter the owner ID on the display at engine start. * The initial ID is “OOO00” and it can be changed with the below “Owner ID change” function. « Even when the system power is turned G39895-00x%00 off, the selected “Sys on by ID” and Figure 29 “Start by ID” cannot be disabled and it is required to enter the Owner ID at each time. 4] | Owner ID change | « After entering the ID and verification, if Input new Owner ID made you don’t operate for 10 seconds, the of five digits to replace entry becomes invalid and it is required current Owner ID to enter the Owner ID again. || Enter | 039896-O0E00 Figure 30 88 JH Series Operation Manual VYANMAH ENGINE OPERATION YANMAR E-key 2. Confirm the pop-up screen and select OK. (For two or more engines, turn on By registering the key, the key all switch panels) authentication function is enabled when the system power is turned on. Note: To register the key, the system version must support YANMAR Alarms/DIAGs Disp: ss E-key and the YANMAR E-key fengi{ ~~ NOTICE! Moni function must be enabled at initial PLEASE TURN ON settings. 7 ALL POWER NOTICE * If you lose your key, contact an authorized dealer or distributor. 14236G-00EN * If you are traveling to a country that has Figure 32 not obtained radio wave certification, you 3. Confirm the pop-up screen and select need to perform a Key reset to disable OK. the YANMAR E-key. Key registration Alarms/DIAGs Displ: am 1. Select “YANMAR E-key-ON’ from the Moni MAIN MENU. REGISTRATION oe NEW KEYS /__MANMENU Alarms/DIAGs Display Engine speed Monitor setti Station protect ED’ Synchro Sysonby|D — [ANT TEMP Figure 33 Start by ID a Owner ID change 4. When the key registration screen is User alarm displayed, the switch panel lamp blinks. nia Zi be 5 iow OFF 142299-00EN | a Set Key Figure 31 Move the keys closer to the blinking key mark on the switch panel. Up to 10 keys can be registered. Key1 :- Key6 :- Key2 : -- Key7 : -- Key3 : -- Key8 : - Key4 : - Key9 : - Key5 : -- Key 10: -- 142302-O0EN Figure 34 WRAAJPSIEAR] JH Series Operation Manual 89 ENGINE OPERATION 5. Hold the key to be registered over the * Upto 10 keys can be registered. key icon on the switch panel and make If you attempt to register more than 10 sure that the pop-up display and keys, the following notice shows and registration status have been updated. cannot register. (If you wish to register multiple keys, repeat this procedure.) 4 | Set Key | Move the kaves claser ta the hlinking key m eys NOTICE! FULL OF KEYS — = 142708-O0EN Figure 37 142303 -00X% 6. Close the key registration screen to Figure 35 complete the registration process. Press the ENTER button with the “<<” icon (left side on the top) highlighted. Set Key | Move the keve claser ta the blinking key | Set Key | r eys NOTICE! Move the keys closer to the blinking key mark on the switch panel. Up to 10 keys COMPLETE can be registered. Key 1 : OK Key6 : - Key2 : -- Key7 2 - Key3 :- Key8 : ~ Key4 : -- Key9Q :- Key5 : -- Key 10: ~ 142304-00EN Figure 36 Figure 38 90 JH Series Operation Manual VYANMAR ENGINE OPERATION Key reset 3. Confirm the pop-up screen and select OK. Note; When the key authentication function is disabled, all key [ss MAINMENU sd registration information will also be deleted. Alarms/DIAGs Displ: 1. Select “YANMAR E-key-OFF” from the [Engit NOTICE! MAIN MENU. DELETE ALL mT REGISTRATED KEYS | | CANCEL | Alarms/DIAGs Display Engine speed s Monitor settiy Station protect Tugs05-00nN | Synchro Sys on by ID LANT TEMP Starl by ID . Figure 41 Owner ID change 4. The key reset is completed. User alarm rae a ON 342306-00RN Alarms/DIAGs a View 5 Figure 39 Engit NOTICE! 2. Confirm the pop-up screen and select | Moni OK. (For two or more engines, turn on - COMFLEIE all switch panels) | MAIN MENU | Alarms/DIAGs Disp! 142309-00EN Engit NOTICE! Figure 42 Moni PLEASE TURN ON ALL POWER 142307-00EN Figure 40 YANMAR JH Series Operation Manual 91 ENGINE OPERATION Power on with YANMAR E-key 3. Hold the key fob in front of the lamp while it is blinking. 1. Press the power switch on the switch panel. a ‘a Oo be START STOP START £ % STOP. oe [ 142303-00% 142310-90% Figure 45 Figure 43 4. The Power switch lamp will come on. 2. The green light will start blinking for 10 seconds. 142312-00% Figure 46 * In the case of two or more engines, once 142311-90% Figure 44 the key is authenticated in one place, the power can be turned on by simply pressing the power switch for the others. 92 JH Series Operation Manual VYANMAR ENGINE OPERATION If the Engine Fails to Start Air Bleeding the Fuel System after Starting Failure Before pressing the Start switch again, confirm that the engine has stopped If the engine does not start after several completely. If the starter motor is operated attempts, there may be air in the fuel before the engine has completely stopped, system. If air is in the fuel system, fuel the starter motor pinion gear will be cannot reach the fuel supply pump. damaged. Bleed the air out of the system. See Bleeding the Fuel System on page 50. NOTICE Starting at Low Temperatures Never hold for longer than 15 seconds or Comply with local environmental the starter motor will overheat. requirements. Do not use starting aids. Never attempt to restart the engine if the NOTICE engine has not stopped completely. Never use an engine starting aid such as Pinion gear and starter motor damage will ether. Engine damage will result. occur. To limit white smoke, run the engine at low Note: Push and hold the start switch for a speed and under moderate load until the maximum of 15 seconds. If the engine reaches normal operating engine does not start the first time, temperature. A light load on a cold engine wait for about 15 seconds before provides better combustion and faster trying again. engine warm-up than no load. Avoid running the engine at idling speed NOTICE any longer than necessary. If the vessel is equipped with a water lift (water lock) muffler, excessive cranking After the Engine has Started could cause seawater to enter the After the engine has started, check the cylinders and damage the engine. If the following items at a low engine speed: engine does not start after cranking for 15 seconds, close the thru-hull water intake 1. Check that the gauges, indicators and valve to avoid filling the muffler with water. alarm are normal. Crank for 10 seconds at a time until the * Normal coolant operating temperature engine starts. When the engine does start, is approximately 76° to 90 °C (169° to stop the engine immediately and turn off 194 °F). the power switch. Be sure to re-open the * Normal oil pressure at 3000 min-1 is seacock and restart the engine. 0.28 to 0.54 MPa (41 to 78 psi). Operate the engine normally. 2. Check for water, fuel or oil leakage from the engine. 3. Check that the smoke color, engine vibration and sound are normal. YANMAH JH Series Operation Manual 93 ENGINE OPERATION 4. When there are no problems, keep the WARM UP MODE engine at low speed with the boat still stopped to distribute engine oil to all (SHIFT DISCONNECT) parts of the engine. 1. Move the remote control handle to the . Check that sufficient seawater is N (Neutral) position. (The NEUTRAL discharged from the seawater outlet. lamp will come on) Operation with inadequate seawater Press the “NTRL” switch of the selected discharge will damage the impeller of station control head. the seawater pump. If seawater . The NEUTRAL lamp will come on, and discharge is too low, stop the engine the NEUTRAL lamp will flash. immediately. Identify the cause and repair. Move the remote control handle. The engine speed can be controlled while the gear shift is in neutral. NOTICE Move the remote control handle to the The engine will seizeif it is operated N (Neutral) position, press the “NTRL” when seawater discharge is too small or switch and cancel warm up mode. if load is applied without any warming up operation. Control head panel | @ PORT NEUTRAL f--} @ STBD NEUTRAL @syYNc @ SEL 122770-O0ENOL Figure 47 JH Series Operation Manual VYANMAH ENGINE OPERATION THROTTLE AND SHIFT Forward (Reverse) to Reverse CONTROL (Forward) Moving the handle quickly and switching from forward (reverse) to reverse (forward) will activate the gear shift delay (astern Sudden Movement Hazard delay). The engine speed to decrease to The boat will start to move when the idle speed for several seconds. marine gear is engaged: ¢ Ensure the boat is clear of all Neutral Forward Idle obstacles forward and aft. * Quickly shift to the FORWARD position then back to the NEUTRAL position. ¢ Observe whether the boat moves in the direction you expect. Figure 48 Neutral 1. Move the remote control handle to the N (Neutral) position. (The NEUTRAL lamp will come on) 2. When switching between forward and reverse, move the handle slowly between the forward and reverse positions. Move the handle firmly into either the forward 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. YANMAH JH Series Operation Manual 95 ENGINE OPERATION ENGINE SPEED LIMIT CAUTIONS DURING MODE OPERATION 1. Move the remote control handle to the Forward Idle position. (Both sides in the NOTICE case of twin engine.) Engine trouble can arise if the engine is 2. Press the “NTRL” switch of the selected operated for a long time under overloaded station. (The lamp above “NTRL’ switch conditions with the control handle in the full will flash.) throttle position (maximum engine speed 3. Even if you tilt the handle to accelerate, position), exceeding the continuous rated the engine speed increases only up to output engine speed. Operate the engine the setting value. at about 100 min-1 lower than the full throttle engine speed. 4. Move the remote control handle to the N (Neutral), Forward Idle, or Reverse Idle position (both sides in the case of Note: Ifthe engine is in the first 50 hours of twin engine) and press the “NTRL” operation, see New Engine Break-in switch to release the [Engine Speed on page 12. Limit Mode]. Always be on the lookout for problems Note: The setting value can be set by the during engine operation. VC20 display. The default value is 50%. Pay particular attention to the following: * Is sufficient seawater being discharged Control head panel from the exhaust and seawater outlet pipe? @& PORT NEUTRAL }-- @ STBD neuTRa @ SYNC If the discharge is small, stop the engine immediately; identify the cause and repair. * Is the smoke color normal? The continuous emission of black 122770-O0ENO1 exhaust smoke indicates engine overloading. This shortens the engines Figure 49 life and should be avoided. 96 JH Series Operation Manual YANMAR ENGINE OPERATION * Are there abnormal vibrations or noise? * When operating the engine at low speed for long periods of time, race the engine NOTICE once every 2 hours. Excessive vibration may cause damage NOTICE to the engine, marine gear, hull and onboard equipment. In addition, it Racing the engine: With the gear in causes able passenger and crew NEUTRAL, accelerate from the discomfort. low-speed position to the high-speed position and repeat this process about five times. This is done to clean out Depending on the hull structure, engine carbon from the cylinders and the fuel and hull resonance may suddenly injection valve. Neglecting to race the become great at a certain engine speed engine will result in poor smoke color range, causing heavy vibrations. and reduce engine performance. Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect. * lf possible, periodically operate the engine at near maximum engine speed * Alarm buzzer sounds during operation. while underway. This will generate higher exhaust temperatures, which will NOTICE help clean out hard carbon deposits, If any alarm indicator with audible alarm maintaining engine performance and sound appears on the display during prolonging the life of the engine. engine operation, stop the engine immediately. Determine the cause and NOTICE repair the problem before you continue Never turn off the battery switch (if to operate the engine. equipped) or short the battery cables during operation. Damage to the electric system will result. * Is there water, oil or fuel leakage, or are there any loose bolts? Check the 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. WR MAGA JH Series Operation Manual 97 ENGINE OPERATION SHUT-DOWN THE ENGINE 5. Wait 6 seconds or more before turning the battery switch off for secure system (STOPPING) settle down. Stop the engine in accordance with the NOTICE following procedures: * Do not turn the battery switch off Normal Stopping before turning the power switch off or 1. Move the remote control handle to the immediately after turning offthe power N (Neutral) position. (The NEUTRAL switch. lamp will come on.) * Turning the battery switch off before . Cool the engine down at low speed secure system settle down may cause (below 1000 min-' (rpm)) for about 5 alarmto be set at the next activation by minutes. turning on the power switch. In an emergency situation, you can start the engine even ifthe alarm is set. NOTICE In order to release above alarm, turn For maximum engine life, YANMAR off the power switch and wait 6 recommends that when shutting the seconds before turning the power engine down, you allow the engine to switch on again. idle, without load, for5 minutes. This will allow the engine components that operate at high temperatures, such as . Turn the battery switch off for engine the turbocharger and exhaust system, to and engine control system. cool slightly before the engine itself is . Close the fuel tank cock. shut down. . Close the seacock. A CAUTION Press the Engine START/STOP switch on the switch panel of the selected ¢ Be sure to close the seacock. station. Neglecting to close the seacock could allow water to leak into the Press the Power switch and turn the boat and may cause it to sink. power OFF. * If seawater is left inside the engine, it may freeze and damage parts of A CAUTION the cooling system when the Do not press the Engine START/STOP ambient temperature is below 0 °C switch when the engine is stopped. (32 °F). The engine will restart. 98 JH Series Operation Manual VYANMAH ENGINE OPERATION Normal Stopping (for folding / feathering propeller) When the boat sails with engine is off, the shift position of the sail drive can be in reverse position: ¢ To fold the folding propeller. ¢ To feather the feathering propeller. 1. Move the remote control handle to the N (Neutral) position. (The NEUTRAL lamp will come on.) 2. Cool the engine down at low speed (below 1000 min-' (rpm)) for about 5 Figure 50 minutes. NOTICE For maximum engine life, YANMAR recommends that when shutting the engine down, you allow the engine to idle, without load, for5 minutes. This will O allow the engine components that START Engine START/STOP switch STOP operate at high temperatures, such as the turbocharger and exhaust system, to cool slightly before the engine itself is shut down. 122768-O0ENOL 3. Press the Engine START/STOP switch Figure 51 on the switch panel of the selected station. 4. Set the lever position to Full Reverse. 5. Press the Power switch and turn the power OFF. For twin engine, turn the other power OFF within 10 seconds of turning one side OFF. A CAUTION Do not press the Engine START/STOP switch when the engine is stopped. The engine will restart. YANMAR JH Series Operation Manual 99 ENGINE OPERATION 6. Wait 6 seconds or more before turning the battery switch off for secure system settle down. NOTICE , * Do not turn the battery switch off before turning the power switch off or immediately after turning offthe power switch. * Turning the battery switch off before secure system settle down may cause alarm to be set at the next activation by turning on the power switch. In an 122769-Q0ENOG emergency situation, you can start the engine even if the alarm is set. Figure 52 In order to release above alarm, turn off the power switch and wait 6 seconds before turning the power A switch on again. “O 7. Turn the battery switch off for engine and engine control system. start STOP : Engine START/STOP switch . 8. Close the fuel tank cock. 9. Close the seacock. A CAUTION * Be sure to close the seacock. 122768-O0ENOL Neglecting to close the seacock Figure 53 could allow water to leak into the boat and may cause it to sink. ¢ If seawater is left inside the engine, it may freeze and damage parts of the cooling system when the ambient temperature is below 0 °C (32 °F). 100 JH Series Operation Manual YANhGAAR ENGINE OPERATION Emergency Stop Electric Emergency Stop NOTICE — Emergency stop switch Never use the Emergency Stop switch for anormal engine shutdown. Use this switch 061304-d00ENO0 only when stopping the engine suddenly in an emergency. Figure 54 1. Pressing the Emergency Stop switch NOTICE will stop the engine immediately. - In case of emergency, turning off the 2. The Emergency Stop screen will be battery switch for the engine control unit shown on the display, and the buzzer can also stop the engine immediately. will sound. * You can restart the engine but an alarm 3. After the engine has stopped, press the may be set up when the power switch is Emergency Stop switch to release the turned on. Unless you are in an emergency stop. After releasing, it may emergency situation, in order to release take sometime to restart. above alarm, turn off the power switch Note: and wait 6 seconds before turning the power switch on again. 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 Stop switch is pressed (emergency stop mode not canceled). YANMAH JH Series Operation Manual 101 ENGINE OPERATION CONTROL THE BACKUP Engine START/STOP switch Lamp Power switch PANEL Cover — Only use this in an emergency. 1. Check that the power switch on the switch panel is OFF and that the (Shift switch position) Sub throttle volume remote control handle is in the N 037636-O1ENO2 (Neutral) position. Figure 55 2. Press the power switch to the “ON” position on the backup panel. The lamp State where cover is removed will come and control by the backup panel is enabled. Lamp Sub throttle volume 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: j SUBae THROTTLE 1 ©] | Ss Lvs switch lower engine speed, clockwise: raise engine speed) YeSTOP @ OFF When controlling the throttle, first move it fully anti-clockwise. Engine START/STOP Shift switch switch NOTICE 132412-O0ENO0 Figure 56 * The throttle of the engine that has been turned on can be controlled. State where cover is attached * When controlling the throttle, always move it fully anti-clockwise first. * Be sure to lower the engine speed by turning the sub throttle volume fully to anti-clockwise before stopping the engine. * The shift switch where is behind the left cover of Backup Panel. * Shift switch does not work on 3/4JH common rail engines. * In case that the marine gear can not be 132446-900x00 shifted by remote control handle for some Figure 57 reason such as broken cable, remove the cable from shift lever on the marine gear * Remove the cover when operating the and shift manually by turning the lever. backup panel. * The backup panel has two design types. 102 JH Series Operation Manual YANMAR 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 49. 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 55. If there is a risk of freezing, drain the seawater system. See DRAIN SEAWATER COOLING SYSTEM on page 148. At temperatures below 0 °C (32 °F), drain seawater system and connect the engine heater (if equipped). VAR AGa JH Series Operation Manual 103 ENGINE OPERATION This Page Intentionally Left Blank 104 JH Series Operation Manual “Wael AeA an RP 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. Crush Hazard If the engine needs to be N transported for repair, have a helper assist you attach it toa 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 gear together. Always use lifting equipment with sufficient capacity to lift the marine engine. YANMAR JH Series Operation Manual 105 PERIODIC MAINTENANCE Welding Hazard Never use undersized wiring for the electrical system. * Always turn off the battery switch (if equipped) or disconnect the negative battery cable and the leads to the Tool Hazard alternator when welding on the equipment. Always remove any tools or shop rags used during maintenance from the area * Remove the engine control unit before operation. multi-pin connector. Connect the weld clamp to the component to be welded and as close as possible to the NOTICE welding point. Any part which is found defective as a result of inspection, or any part whose *« Never connect the weld clamp to the measured value does not satisfy the engine or in a manner which would standard or limit, must be replaced. allow current to pass through a mounting bracket. * When welding is completed, Modifications may impair the engine’s reconnect the alternator and engine safety and performance characteristics control unit prior to reconnecting the and shorten the engine’s life. batteries. Any alterations to this engine may void its warranty. Be sure to use YANMAR genuine replacement parts. Entanglement Hazard Never leave the power switch on when you are at, \y/ servicing the engine. “La Someone may accidentally start the engine and not realize you are servicing it. Shock Hazard Always turn off the battery lll switch (if equipped) or disconnect the negative G 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. 106 JH Series Operation Manual VYANMAH PERIODIC MAINTENANCE PRECAUTIONS Keep a Log of Engine Hours and Daily Checks The Importance of Periodic Keep a log of the number of hours the Maintenance engine is run each day and a log of the Engine deterioration and wear occur in daily checks performed. Also note the proportion to the length of time the engine date, type of repair (e.g., replaced has been in service and the conditions the alternator) and parts used for any service engine is subjected to during operation. needed between the periodic maintenance Periodic maintenance prevents intervals. Periodic maintenance intervals unexpected downtime, reduces the are every 50, 250, 500 and 1000 engine number of accidents due to poor machine hours. Failure to perform periodic performance and helps extend the life of maintenance will shorten the life of the the engine. engine. Performing Periodic NOTICE Maintenance Failure to perform periodic maintenance will shorten the life of the engine and may void the warranty. Exhaust Hazard Never block windows, vents, or other means of ventilation if the engine is YANMAR Replacement Parts operating in an enclosed area. YANMAR recommends that you use All internal combustion engines create genuine YANMAR parts when replacement carbon monoxide gas during operation. parts are needed. Genuine replacement Accumulation of this gas within an parts help ensure long engine life. enclosure could cause illness or even death. Make sure that all connections Tools Required are tightened to specifications after repair is made to the exhaust system. Before you start any periodic maintenance Failure to comply could result in death procedure, make sure you have the tools or serious injury. you need to perform all of the required tasks. Consult Your Authorized The Importance of Daily Checks YANMAR Marine Dealer or The Periodic Maintenance Schedule Distributor for Help assumes that the daily checks are performed on a regular basis. Make it a Our professional service technicians have habit to perform daily checks before the the expertise and skills to help you with start of each operating day. See Daily any maintenance or service related Checks on page 116. procedures you need help with. YANMAR JH Series Operation Manual 107 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 a The tightening torque in the Standard Torque Chart should be applied only to the bolts with a “8.8” head (JIS strength classification: 8.8). Apply 60% torque to ‘ “bolts that are not listed. Apply 80% torque when tightened to aluminum alloy. Bolt Diameter x M6x1.0 mex1.25 | M1ox1.s | M12x1.75 | M14x1.5 M16x1.5 Pitch (mm) Tightening | Nem | 10841.0 | 255+30| 4945.0 |88.2+100] 140.0+10.0 | 230.0+10.0 Torque ft-lb 80407 | 188+22 | 36.24+3.7 | 65.1474] 103+72 170472 Taper Plugs 1/8 1/4 3/8 1/2 Tightening | N-m 98 19.6 29.4 58.8 Torque ft-lb 7.4 145 21.7 43,2 When lock adhesive is applied, decide separately. Pipe Joint Bolts Ms M10 M12 M14 M16 Tightening | N-m 14742 22.543 29.445 44145 53.945 Torque ft-lb 10.9415 16.6422 21.7437 32.6 +3.7 69.8 43.7 When seal washer applied, torque is 34 + 5 N-m (25.1 + 3.7 ft-lb). 108 JH Series Operation Manual VWANMAH PERIODIC MAINTENANCE Main Bolts and Nuts Lubricating Oil Name Thread Diameter Application Torque x Pitch (thread portion and N-m (ft-lb) seat surface) Head bolt M10 x 1.25 Apply oil 88.2 + 2.9 (65.1 + 2.1) Connecting rod bolt M9 x 1.0 Apply oil 44,144.90 (32,5+3.6/0) Flywheel bolt M10 x 1.25 Apply oil 83.3+4.910 (61 .4*3.6/0) Metal cap bolt M12 x 1.5 Apply oil 98.0 + 2.0 (72.3 + 1.5) Crank pulley bolt M14 x 1.5 Apply oil 88.2 + 4.9 (65.1 + 3.6) Injector retainer bolt M8 x 1.25 Without oil 26.4 + 2.0 (19.5 + 1.5) Rocker arm support bolt M8 x 1.25 Without oil 25.54 1.5 (18.8 + 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 M6 x 1.0 Without oil 8.042.0(59+1.5) Flywheel speed sensor Retainer bolt for M6 x 1.0 Without oil 8.0+0.5 (5.9 + 0.4) Cam shaft speed sensor Retainer nut for M20 x 1.5 Without oil 78.5 + 4.9 (57.9 + 3.6) Lubricating Oil Cooler High pressure Injector M12x 1.5 Without oil 29.4t21-4.4 (21, 741.5/3.2) pipe nut Rail M12x 1.5 Without oil Pump M16 x 1.0 Without oil Glow plug M10 x 1.25 Without oil Body 14.7 to 19.6 (10.8 to 14.5) M4 x 0.7 Terminal 1.0to1.5 nut (0.7 to 1.1) Heat exchanger set bolt M8 x 1.25 Without oil 37.2 + 3.0 (27.4 + 2.2) Pressure sensor M6 x 1.0 Without oil 7.04+1.4 (6.24 1.0) Starter relay terminal nut M6 x 1 Without oil 3.6 + 0.6 (2.7 + 0.4) YANMAR JH Series Operation Manual 109 PERIODIC MAINTENANCE EPA MAINTENANCE REQUIREMENTS To maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations for Engines, it is essential that you follow the PERIODIC MAINTENANCE SCHEDULE on page 113 and the PERIODIC MAINTENANCE PROCEDURES on page 116. EPA Requirements for USA and Other Applicable Countries The EPA emission regulation is applicable only in the USA and other countries that have adopted the EPA requirements in part or in whole. Determine and follow the emission regulations in the country where your engine will be operating to assist you in specified compliance. 110 JH Series Operation Manual WAR RE SRF PERIODIC MAINTENANCE Environmental Condition for operation and maintenance The following environmental operating conditions and maintenance should be observed, in order to keep engine performance. * Ambient temperature: -20 °C to +40 °C (-4 °F to +104 °F) * Relative humidity: 80% or lower The diesel fuel should be: * ASTM D975 No. 1-D $15, No. 2-D S15, or equivalent (minimum of cetane No. 45) The lubricating oil should be: * API Service Categories CD, CF, CF-4, Cl and Cl-4. Be sure to perform inspections as outlined in PERIODIC MAINTENANCE PROCEDURES on page 176 and keep a record of the results. Pay particular attention to these important points: * Replacing the engine oil * Replacing the engine oil filter * Replacing the fuel filter * Cleaning the intake silencer (air cleanen Note: Inspections are divided into two sections in accordance with who is responsible for performing the inspection: the user or the maker. YANMAH JH Series Operation Manual 111 PERIODIC MAINTENANCE Inspection and Maintenance See Inspection and Maintenance of Emission-Related Parts on page 115 for the EPA emission-related parts. Inspection and maintenance procedures not shown in /nspection and Maintenance of Emission-Related Parts on page 115 are covered in PERIODIC MAINTENANCE SCHEDULE on page 113. This maintenance must be performed to keep the emission values of your engine in the standard values during the warranty period. The warranty period is determined by the age of the engine or the number of hours of operation. Installation of Exhaust Sampling Port All engines subject to emission standards shall be equipped with a connection in the engine exhaust system that is located downstream of the engine, and before any point at which the exhaust contacts water (or any other cooling / scrubbing medium), for the temporary attachment of gaseous and/or particulate emissions sampling equipment. This connection shall be internally threaded with standard pipe threads of a size not larger than 12.7 mm (0.5 in.), and shall be closed by a pipe plug when not in use. Equivalent connections 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 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 requirement that the connection be located before any point at which the exhaust contacts water (or any other cooling / scrubbing medium) does not include contact with water used to cool exhaust manifolds, unless the water is allowed to come into direct contact with the exhaust gases; 3. To allow ready access to the sample port, the connection should be located, if possible given the constraints of vessel design, approximately 0.6 to 1.8 m (2 to 6 ft) above a deck or walkway; 4. To facilitate insertion and withdrawal of an exhaust sample probe, there should be no obstructions for at least one and one-half exhaust pipe / stack diameters perpendicular, i.e., 90 degrees, from the sample port; and 5. If a threaded connection is used, both the internal and external threads should be coated with a high-temperature, anti-seize compound before the initial installation and at every subsequent re-installation to facilitate removal of the connection for testing. 112 JH Series Operation Manual YANMAR PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline. NOTICE Establish a periodic maintenance plan according to the engine application and make sure to perform the required periodic maintenance at the intervals indicated. Failure to follow these guidelines will impair the engine’s safety and performance characteristics, shorten the engine’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 @. O: Check or Clean : Replace @: Consult your authorized YANMAR Marine dealer or distributor Periodic Maintenance Interval . Every 50 | Every 250 | Every 500 cod Daily hours or | hoursor | hoursor | |org of System item See Daily | monthly 1 year 2 years 4 years Checks which- which- which- which- on ever ever ever ever page 116 comes comes comes comes first first first first Whole Visual inspection of engine O exterior Fuel Check the fuel level and refill O System if necessary Drain water and sediment O O from fuel tank Initial 50 Drain the fuel/water O separator Replace the fuel filter } element Lubricating | Check the Engine e) System lube oil level Marine Gear Oo Replace the Engine © > lube oil Initial 50 Marine Gear © > Initial 50 Replace the Engine © > oil filter Initial 50 element Marine Gear © © (if equipped) Initial 50 VWRAINPGGAFE JH Series Operation Manual 113 PERIODIC MAINTENANCE ©: Check or Clean ©: Replace @: Consult your authorized YANMAR Marine dealer or distributor Periodic Maintenance Interval . Every 50 | Every 250 | Every 500 e woe, Daily hours or | hoursor | hoursor | |oir of System Item See Daily | monthly 1 year 2 years 4which- years Checks which- which- which- on ever ever ever ever age 116 comes comes comes pag first first first first Cooling Seawater outlet e) System During Operation Check coolant level e) Check or replace the O S seawater pump impeller Replace coolant Every year. When Long Life Coolant is used, replace every 2 years. See Engine Coolant Specifications on page 55. Clean and check the e seawater passages Air Intake Clean intake silencer (air O and cleaner) element Exhaust Clean or replace the System exhaust/water mixing elbow © ° Wash the turbocharger e blower - 4JH80/4JH110 only Check diaphragm assembly e 3JH40/4JH45/4JH57 only Electrical Check the alarm and O System indicators Check the electrolyte level in O the battery Adjust the tension ofthe O alternator V-ribbed belt or Initial 50 e) © replace V-ribbed belt Check the wiring connectors e) Engine Check for leakage of fuel, e) Cylinder engine oil and engine coolant After Head and starting Block Tighten all major nuts and bolts e Adjust intake/exhaust valve a: clearance @ Initial 50 e Miscellane | Check the remote control a ous Items | cable operation O Initial SO e Adjust the propeller shaft @ Initial 50 e alignment Replace rubberized hoses Replace every 2 years. (fuel and water) Note: These procedures are considered normal maintenance and are performed at the owner's expense. 114 JH Series Operation Manual VYANMAH PERIODIC MAINTENANCE Inspection and Maintenance of Emission-Related Parts * Marine Compression-Ignition (Cl) engines less than 37 kW: 3JH40 and 4JH45 common rail engines are certified by EPA and ARB * Marine diesel engines greater than 37 kW: 4JH57, 4JH80 and 4JH110 common rail engines are certified as EPA Cl marine engines Inspection and Maintenance of Emission-Related Parts of Marine Cl Engines Parts Minimum Interval Clean fuel injectors 1500 hours Check fuel injectors Check turbocharger adjustment (if equipped) 3000 hours Check electronic engine control unit and its associated sensors and actuators (if equipped) Note: YANMAR recommends that the inspection and maintenance items shown above be performed at an authorized YANMAR dealer or distributor. YANMAH JH Series Operation Manual 115 PERIODIC MAINTENANCE PERIODIC MAINTENANCE PROCEDURES Always use a piece of wood or cardboard. Have your authorized YANMAR Marine dealer or distributor Exposure Hazard repair any damage. Always wear personal protective equipment when performing periodic 3. Check for engine coolant leaks. maintenance procedures. 4. Check for damaged or missing parts. 5. Check for loose, missing or damaged fasteners. Daily Checks 6. Check the electrical harnesses for Before you head out for the day, make cracks, abrasions, and damaged or sure the YANMAR engine is in good corroded connectors. operating condition. 7. Check hoses for cracks, abrasions, and damaged, loose or corroded clamps. NOTICE 8. Check the fuel filterAwater separator for It is important to perform the daily checks as presence of water and contaminants. listed in this Operation Manual. If you find any water or contaminants, Periodic maintenance prevents unexpected drain the fuel filterAwater separator. downtime, reduces the number of accidents See Draining Fuel Filter/Water due to poor engine performance and helps Separator on page 123. If you have to extend the life of the engine. drain the fuel filterAwater separator frequently, drain the fuel tank and check for the presence of water in your Make sure you check the following items. fuel supply. See Draining the Fuel Tank on page 117. Visual Checks 1. Check for engine oil leaks. NOTICE 2. Check for fuel leaks. If any problem is noted during the visual check, the necessary corrective action should be taken before operating the engine. Piercing Hazard Avoid skin contact with the high-pressure diesel fuel spray caused Check Diesel Fuel, Engine Oil and by afuel system leak, such as a broken Engine Coolant Levels fuel injection line. High-pressure fuel Follow the procedures in DIESEL FUEL on can penetrate your skin and result in page 46, ENGINE OIL on page 57 and serious injury. If you are exposed to ENGINE COOLANT on page 55 to check high-pressure fuel spray, obtain these levels. prompt medical treatment. Never check for a fuel leak with your hands. 116 JH Series Operation Manual VYANMAH PERIODIC MAINTENANCE Checking and Refilling Marine Gear After Initial 50 Hours of Oil 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 Check the battery electrolyte level before * Changing the Engine Oil and use. See Checking the Battery Electrolyte Replacing the Engine Oil Filter Level (Serviceable Batteries Only) on Element page 124. * Changing the Marine Gear Oil and Checking the Alternator Belt Replacing the Marine Gear Oil Filter (If Equipped) Check the belt tension before use. See Checking and Adjusting the Alternator * Checking and Adjusting the V-ribbed belt Tension on page 119. Alternator V-ribbed belt Tension Checking the Remote Control * Inspecting and Adjusting Intake/Exhaust Valve Clearance Handle * Checking and Adjusting the Remote Check the operation of the remote control Control Cables handle and ensure it moves smoothly. If it is hard to operate, grease the joints of the ¢ Adjusting Propeller Shaft Alignment remote control cable and lever bearings. If the lever is too loose, adjust the remote Draining the Fuel Tank control cable. See Checking and Adjusting Remote Contro! Cables on page 127. Checking the 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 20. Preparing Fuel, Oil and Coolant in Reserve Prepare sufficient fuel for the days operation. Always store engine oil and Figure 7 coolant in reserve (for at least one refill) onboard, to be ready for emergencies. Note: Optional fuel tank shown. Actual equipment may differ. YANMAR JH Series Operation Manual 117 PERIODIC MAINTENANCE 1. Put a pan under the drain cock 3. Remove the engine oil filter (Figure 2) (Figure 1, (2)) to catch fuel. with a filter wrench (turn 2. Open the drain cock and drain water counterclockwise). and sediment. Close the drain cock when the fuel is clean and free of air bubbles. Changing the Engine Oil and Replacing the Engine Oil Filter Element The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil replacement is performed as scheduled. O57148-01K00 It is easiest and most arailable to drain the Figure 2 engine oil after operation while the engine is still warm. Note: 4JH45/4JH57 shown. 4. Install a new filter element and tighten by hand until the seal touches the Burn Hazard housing. If you must drain the engine oil while it 5. Turn filter an additional 3/4 turn is still hot, stay clear of the hot engine clockwise with a box wrench. Tighten to oil to avoid being burned. Always wear 20 to 24 N-m (177 to 212 in.-Ib). eye protection. 6. Fill with new engine oil. See ADDING ENGINE OIL on page 53. 1. Tur the engine off. NOTICE 2. Remove the engine oil dipstick. — Never mix different types of engine oil. Attach the oil drain pump (if equipped) This may adversely affect the lubricating and pump out the oil. properties of the engine oil. For easier draining, remove the engine Never overfill. Overfilling may result in oil fill cap. Dispose of used oil properly. white exhaust smoke, engine overspeed NOTICE or internal damage. * Prevent dirt and debris from ; contaminating engine oil. 7. Perform a trial run and check for oil Carefully clean the dipstick and the leaks. surrounding area before removing the dipstick. * Always be environmentally responsible. 118 JH Series Operation Manual WAAR SAR PERIODIC MAINTENANCE 8. Approximately 10 minutes after 2. KMH4A Marine Gear: stopping the engine, remove the oil Wash the marine gear oil filter: dipstick and check the oil level. Add oil (a) Remove side cover (Figure 3, (5)) if the level is too low. and remove the filter (Figure 3, (2)). (b) Clean the filter thoroughly with NOTICE kerosene or clean diesel fuel. Be careful not to get any oil on the (c) Hold the filter in place with the coil V-ribbed belt. Oil on the belt causes spring (Figure 3, (3)) and insert into slipping and stretching. Replace the belt the case. Install a new O-ring if it is damaged. (Figure 3, (4)) in the side cover. (d) Install side cover and tighten side cover bolts. Changing the Marine Gear Oil and 3. Fill marine gear with clean marine gear Replacing the Marine Gear Oil Filter oil. See Marine Gear Oil Specifications (If Equipped) on page 53. 4. Perform a trial run and check for oil leaks. 5. Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil level. Add oil if the level is too low. Checking and Adjusting the Alternator V-ribbed belt Tension Ko004495 Sever Hazard Figure 3 Perform this check with the power switch off and the battery switch turned Note: 4JH80/4JH110 engines with KMH4A off to avoid contact with moving parts. marine gear shown. Refer to the Operation Manual for the marine gear or Sail drive for procedure. NOTICE 1. Remove cap from the filler port and * When there is not enough tension in the attach an oil drain pump. Drain marine V-ribbed belt, it will slip and the coolant gear oil. pump will fail to supply coolant. Engine overheating and seizure will NOTICE result. Always be environmentally responsible. * Never get any oil on the belt(s). Oil on the belt causes slipping and stretching. Replace the belt if it is damaged. WR MAGA JH Series Operation Manual 119 PERIODIC MAINTENANCE 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. 056901-00x%00 Figure 4 Note: 4JH110 shown. 1. Remove the belt cover. 2. Check the belt by pushing on the 037421-00x06 middle ofthe belt (Figure 4, (1)) with Figure 5 your finger. (Pressed by 100 N) With proper tension, the belt should deflect 8 to 9mm. SS Note: Check the tension of the V-ribbed CORRECT belt after operating the engine at idle for 5 minutes. 3. Loosen the 3 bolts of alternator (Figure 4, (2) (3) (4)). CESSES (EE 4. Screw in the adjusting bolt INCORRECT (Figure 4, (4)) and move the alternator 037422-00RNO0 to adjust the belt tension properly. Figure 6 5. Tighten the 3 bolts of the alternator. Inspecting and Adjusting 6. Install the belt cover. Intake/Exhaust Valve Clearance Inspecting V-Ribbed Belt Proper adjustment is necessary to maintain the correct timing for opening and 1. Visually check the belt for excessive closing the valves. Improper adjustment wear, frayed cords, etc. will cause the engine to run noisily, If any defects are found, replace the resulting in poor engine performance and V-ribbed belt. engine damage. Consult authorized 2. Check that the belt fits properly in the YANMAR Marine dealer or distributor to ribbed grooves. adjust the intake/exhaust valve clearance. 120 JH Series Operation Manual YANMAHR PERIODIC MAINTENANCE Checking and Adjusting Remote Adjusting Marine Gear Remote Control Control Cables Cable KM35P Adjusting Engine Speed Remote Control Cable Ensure the control lever on the engine 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. Figure 7 1 -—Cable 2 —High-speed stop position 3 -—High-speed stop pin 4 -—Control lever 5 —Low-speed stop pin 6 —Low-speed stop position 7 -—Adjustment screw 1. To adjust, loosen the adjustment screw (Figure 7, (7)) for the remote control Figure 9 cable and adjust. 2. Adjust the low-speed stop position 1. Ensure that the remote control lever (Figure 7, (6)) first and then adjust the (Figure 8, (2)) or (Figure 9, (2)) moves high-speed stop position to the correct position when the remote (Figure 7, (2)), with the adjustment control handle is in the NEUTRAL, screw on the remote control lever FORWARD and REVERSE positions. (Figure 7, (4)). Use the NEUTRAL position as the standard for adjustment. 2. To adjust, loosen and retighten the cable fitting (Figure 8, (1)) or (Figure 9, (1)). YANMAR JH Series Operation Manual 121 PERIODIC MAINTENANCE Adjusting Trolling Remote Control Adjusting Propeller Shaft Alignment Handle - If Equipped 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 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. O57454-00xK60 If there is unusual noise and/or vibration, Figure 10 this maintenance requires specialized knowledge and techniques. 1 -—Cable Fitting Consult authorized YANMAR Marine 2 -Trolling Lever dealer or distributor to adjust the propeller 3 —Low Speed (trolling) shaft alignment. 4 -—High Speed 5 —Loosen 6 —Tighten 7 -—Normal Operation (high speed) 8 -Trolling (low speed) Note: KMH4A marine gear shown. 1. Ensure that the trolling lever (Figure 10, (2)) is in the high-speed (Figure 10, (4)) position when the trolling remote control handle is in high-speed position (Figure 10, (7)). Ensure that the trolling lever is in the low-speed (Figure 10, (3)) position when the trolling remote control handle is in low-speed position (Figure 10, (8)). 3. To adjust, loosen the adjustment screw of the cable fitting (Figure 10, (1)) and adjust the position of the cable. 122 JH Series Operation Manual VALNAGEAR PERIODIC MAINTENANCE 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 056904-01xK%60 Fire and Explosion Hazard Figure 11 When removing any fuel system component to perform maintenance 1 -Filter element (such as changing the fuel filter), put an 2 —Drain plug approved container under the opening 3 —Cover (fire-resistant) 4 —Clamp screw to catch the fuel. Never use a shop rag to catch the fuel. Vapors from the rag are flammable and NOTICE explosive. Wipe up any spills If the fuel filterAwater separator is immediately. positioned higher than the fuel level in the fuel tank, water may not drip out when the fuel filterAvater separator drain cock is Exposure Hazard opened. If this happens, turn the air vent Wear eye protection. The fuel system is screw on the top of the fuel filterwater under pressure and fuel could spray separator two to three turns out when removing any fuel system counterclockwise. Be sure to tighten the air component. vent screw after the water has drained out. 1. Close the fuel tank cock. 2. Loosen the clamp screw and remove the fire-resistant cover, which is installed to the lower part ofthe fuel filter;water separator to protect the water alarm switch. 3. Attach a tube to the drain plug. 4. Loosen the drain plug (Figure 11, (2)) at the bottom of the fuel filter/water separator by turning counterclockwise and drain off any water or sediment. YANMAH JH Series Operation Manual 123 PERIODIC MAINTENANCE Note: If there is a large quantity of water and sediment in the fuel NOTICE filter/water separator, also drain Never operate with insufficient battery the fuel tank See Draining the electrolyte. Operating with insufficient Fuel Tank on page 117. electrolyte will destroy the battery. NOTICE Battery fluid tends to evaporate in high Always be environmentally responsible. temperatures, especially in summer. Dispose ofthe collected water and dirt In such conditions, inspect the battery properly. earlier than specified. 5. Tighten the drain plug. 1. Turn off the battery switch (if equipped) 6. Remove the drain tube. or disconnect the negative (-) battery 7. Install the fire-resistant cover and cable. tighten the clamp screw. 2. Do not operate with insufficient battery 8. Bleed air from the fuel system. electrolyte, as the battery will be See Bleeding the Fuel System on destroyed. page 50. 3. Remove the plugs and check the electrolyte level in all cells. Checking the Battery Electrolyte Level (Serviceable Batteries Only) NOTICE Never attempt to remove the covers or fill a maintenance-free battery. Exposure Hazard Batteries contain sulfuric acid. Never allow battery fluid to come in 4. Ifthe level is lower than the minimum fill contact with clothing, skin or eyes. level (Figure 12, (1)), fill with distilled Severe burns could result. Always wear water (Figure 12, (2)) (available in the safety goggles and protective clothing grocery store) up to the upper limit when servicing the battery. If battery (Figure 12, (3)) of the battery. fluid contacts the eyes 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. 124 JH Series Operation Manual VYANMAH PERIODIC MAINTENANCE Every 250 Hours of Operation Perform the following maintenance every 250 hours or1 year of operation, whichever comes first. * Draining the Fuel Tank * Replacing the Fuel Filter Element * Changing the Engine Oil and Replacing the Engine Oil Filter Element * Changing the Marine Gear Oil and Replacing Marine Gear Oil Filter —_ ani aap SES< . Element (If Equipped ) €) * Checking or Replacing the Seawater x< K0004566 Impeller Figure 12 * Changing the Coolant * Cleaning the Intake Silencer (Air Note: The maximum fill level is Cleaner) Element approximately 10 to 15 mm (3/8 to 9/16 in.) above the plates. * Cleaning the Exhaust/Water Mixing Elbow * Wash the Turbocharger blower (If Equipped) ¢ Adjusting the Alternator V-ribbed belt Tension * Checking the Wiring Connectors * Tightening All Major Nuts and Bolts Draining the Fuel Tank See Draining the Fuel Tank on page 117. YWRANRGAR su Series Operation Manual 125 PERIODIC MAINTENANCE Replacing the Fuel Filter Element 1. Close the fuel tank cock. 2. Loosen the clamp screw and remove the fire-resistant cover, which is installed to the lower part ofthe fuel Fire and Explosion Hazard pre-filter / water separator to protect the When removing any fuel system water alarm switch. component to perform maintenance 3. Attach a tube to the drain plug. (such as changing the fuel filter), put an approved container under the opening 4. Loosen the drain plug and drain the fuel to catch the fuel. from the drain plug. Never use a shop rag to catch the fuel. 5. Disconnect the electrical connectors Vapors from the rag are flammable and and remove the alarm switch with a explosive. Wipe up any spills spanner wrench. immediately. 6. Remove the filter element with a filter wrench. 7. Clean the filter element mounting Exposure Hazard surface. Install new filter element. Wear eye protection. The fuel system is under pressure and fuel could spray Component Part No. out when removing any fuel system Fuel pre-filter 121857-55710 component. 8. Install the alarm switch to the fuel pre-filter. Apply clean fuel to the gasket Fuel pre-filter/water separator of the new fuel pre-filter. 9. Install filter element into engine and hand-tighten until the gasket comes into contact with the seat. Use a filter wrench and tighten approximately 3/4 turn to 12.7 to 16.7 N-m (9.4 to 12.3 ft.-Ib). 10. Install the fire-resistant cover and tighten the clamp screw. 11. Bleed the fuel system. See Bleeding the Fuel System on page 50. 12.Dispose of waste properly. 056904-01X00 Figure 13 1 —-Filter element 2 —Drain plug 3 —Cover (fire-resistant) 4 -—Clamp screw 126 JH Series Operation Manual VYANMAH PERIODIC MAINTENANCE Fuel filter Changing the Engine Oil and Replacing the Engine Oil Filter Element See Changing the Engine Oil and Replacing the Engine Oil Filter Element on page 178. Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter Element (if equipped) o56905-01x00 See Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter Figure 14 Element (if equipped) on page 127. 1. Close the fuel tank cock. Checking or Replacing Seawater 2. Remove the fuel filter with a filter Pump Impeller wrench. 1. Loosen side cover bolts and remove Note: When removing the fuel filter, the side cover. hold the bottom of the fuel filter 2. Inspect the inside of the seawater with a cloth to prevent the fuel pump with a flashlight. If any of the from spilling. Wipe up any spilled following are found, disassembly and fuel immediately. maintenance are required: 3. Apply a thin film of clean diesel fuel to ¢ Impeller blades are cracked or nicked. the sealing surface ofthe new filter Edges or surfaces of the blades are gasket. marred or scratched. « Wear plate is damaged. Component Part No. 3. Ifno damage is found when inspecting Fuel filter 129A00-55800 the inside of the pump, install the O-ring and side cover. 4. Install a new filter and hand-tighten. 4. Ifa large amount of water leaks Use a filter wrench and tighten to 20 to continuously from the water drain line 24 N-m (14.75 to 17.7 ft-lb). below the seawater pump during 5. Bleed the fuel system. See Bleeding operation, replace the mechanical seal. the Fuel System on page 50. Consult authorized YANMAR Marine Dispose of waste properly. dealer or distributor. 6. Check for fuel leaks. Replacing the Seawater Pump Impeller Note: The impeller must be replaced periodically (every 1000 hours) even if there is no damage. YANMAR JH Series Operation Manual 127 PERIODIC MAINTENANCE ceca Ko0004510 Figure 15 Special service tools for removing the impeller: A (standard) Puller Part No. 129671-92110 Ko004501 Figure 16 Ko004568 Puller A Jack Screw B Figure 18 M18x1.5 M10x40 mm length Note: When replacing a used impeller with . a new one, the impeller must have 1. Remove the side cover of the seawater an M18 x1.5 thread (Figure 17, (1)). pump. Turn the M18 screw side of the 2. Install puller (Figure 16, (A)) in the impeller to the cover side and install impeller. (Figure 18). 3. Turn the jack screw (Figure 16, (B)) clockwise to remove the impeller from the pump body. 128 JH Series Operation Manual YANMAR PERIODIC MAINTENANCE Changing the Coolant 3JH40 A. 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. NOTICE Never mix different types and/or colors of coolants. Discard old coolant in an approved manner according to environmental laws. Figure 19 Note: If Long Life coolant is used, replace coolant every 2 years. 1 —Coolant drain cock (Cylinderblock) WR MAGA JH Series Operation Manual 129 PERIODIC MAINTENANCE 4JH45, 4JH57 4 O56983-02xK00 Figure 21 1 —Coolant drain cock (Cylinderblock) 198120-01%01 2 —Marine gear oil cooler (KM4A1) Figure 20 3 —Seawater drain cock (Marine gear oil cooler) 2 -Coolant pump 3 —Coolant tank (Heat exchanger) 4 -Coolant drain cock (Coolant tank/Heat exchanger) 5 —Seawater pump (Drain from pump cover) 956984-02x00 Figure 22 4 -Coolant pump 5 —Coolant tank (Heat exchanger) 6 —Coolant drain cock (Coolant tank/Heat exchanger) 7 -—Seawater pump (Drain from pump cover) 130 JH Series Operation Manual WAR ARVEALR PERIODIC MAINTENANCE 4JH80, 4JH110 Note: The drain cocks are opened before shipping from the factory. Marine gear ZF25A does not have a drain cock on the marine gear cooler. 1. Open all coolant drain cocks. 2. Allow to drain completely. Dispose of waste properly. 3. Close all the drain cocks. 4. Fill coolant tank and reservoir with appropriate coolant. 4 Re See Engine Coolant Specifications on 4 3 2 ccoos-oe page 55 and Checking and Adding ” Coolant on page 56. Figure 23 Cleaning the Intake Silencer (Air 1 — Turbocharger 2 —Coolant drain cock Cleaner) Element (Cylinderblock) 1. Disassemble the intake silencer (air 3 —Marine gear oil cooler (KMH4A) cleaner). 4 —Seawater drain cock (Marine gear oil cooler) 2. Remove element. Clean element and housing with a neutral detergent. 3. Dry completely and reassemble. Cleaning the Exhaust/Water Mixing Elbow The mixing elbow is attached to the turbocharger. The exhaust gas is mixed with seawater in the mixing elbow. 1. Remove the mixing elbow. 2. Clean dirt and scale out of the exhaust and seawater passages. 9 Bosc 3. Ifthe mixing elbow is damaged, repair Fi 24 or replace. Consult authorized igure YANMAR Marine dealer or distributor. 5 —Coolant pump 4. Inspect the gasket and replace if 6 —Coolant tank (Heat exchanger) necessary. 7 -—Coolant drain cock (Coolant tank /Heat exchanger) 8 —Seawater drain cock (Air cooler) 9 —Air cooler 10-—Seawater pump (Drain from pump cover) WAUNPMISAR 4H Series Operation Manual 131 PERIODIC MAINTENANCE Wash the Turbocharger blower Every 500 Hours of Operation (If Equipped) Contamination of the turbocharger causes Perform the following maintenance every revolutions to drop and engine output to 500 hours or 2 years of operation, fall. whichever comes first. If a significant drop in engine output is * Replacing the Exhaust/Water Mixing noted (10% or more), wash the Elbow turbocharger blower. * Replacing Rubber Hoses This should be done only by a trained and qualified technician. Consult authorized Replacing the Exhaust/Water Mixing YANMAR Marine dealer or distributor. Elbow 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. See Checking and Adjusting the Alternator Consult authorized YANMAR Marine V-ribbed belt Tension on page 119. dealer or distributor. Checking the Wiring Connectors Replacing Rubber Hoses Consult authorized YANMAR Marine Replace rubber hoses every 2000 hours or dealer or distributor. 2 years, whichever comes first. Tightening All Major Nuts and Bolts Consult authorized YANMAR Marine See Tightening Fasteners on page 108 or dealer or distributor. consult authorized YANMAR Marine dealer or distributor. 132 JH Series Operation Manual VYANMAH PERIODIC MAINTENANCE Cleaning and Checking the Every 1000 Hours of Operation Seawater Passages After prolonged use, clean the seawater Perform the following maintenance every passages to remove trash, scale, rust and 1000 hours or 4 years of operation, other contaminants that collect in the whichever comes first. seawater passages. This can cause * Replacing the Seawater Pump declining cooling performance. The Impeller following items need to be inspected: ¢ Heat Exchanger * Cleaning and Checking the Seawater Passages « Pressure Cap * Checking Diaphragm Assembly Consult authorized YANMAR Marine (3JH40/4JH45/4JH57 Only) dealer or distributor. * Replacing the Alternator V-ribbed belt Checking Diaphragm Assembly (3JH40/4JH45/4JH57 Only) * Adjusting Intake/Exhaust Valve Clearance * Checking the Remote Control Cable Operation * Adjusting the Propeller Shaft Alignment Replacing the Seawater Pump Impeller The seawater impeller must be replaced every 1000 hours even if it is not damaged. See Checking or Replacing Seawater Pump Impeller on page 127. 108128-01x%900 Figure 25 1 —Diaphragm Cover 2 -Spring 3 —Center Plate 4 —Diaphragm 5 —Rocker Arm Cover 6 -Breather Baffle 7 —Baffle Plate 8 -—Intake Silencer 9 -Breather Pipe Consult authorized YANMAR Marine dealer or distributor. YANMAH JH Series Operation Manual 133 PERIODIC MAINTENANCE Replacing the Alternator V-ribbed belt See Checking and Adjusting the Alternator V-ribbed belt Tension on page 119. 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. 134 JH Series Operation Manual VYANMAH TROUBLESHOOTING SAFETY PRECAUTIONS TROUBLESHOOTING Before performing any troubleshooting AFTER STARTING procedures within this section, review the Just after the engine has started, check the Safety section on page 3. following items at a low engine speed: If a problem occurs, stop the engine Is sufficient water being discharged immediately. Refer to the Symptom column from the seawater outlet pipe? in the Troubleshooting Chart to identify the problem. 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 heavy vibrations. Avoid operation in this speed range. If any abnormal sounds are heard, stop the engine and inspect for cause. Alarm sounds during operation. If the alarm sounds during operation, lower the engine speed immediately, check the alarm lamps and stop the engine for repairs. YANMAH JH Series Operation Manual 135 TROUBLESHOOTING Is there water, oil or fuel leakage? TROUBLESHOOTING Are there any loose bolts or connections? INFORMATION Check the engine room daily for any leaks If the engine does not operate properly, or loose connections. refer to the TROUBLESHOOTING CHART on page 137 or consult authorized Is there sufficient fuel in the fuel tank? YANMAR Marine dealer or distributor. Refill fuel in advance to avoid running out Supply the authorized YANMAR Marine of fuel. If the tank runs out of fuel, bleed dealer or distributor with the following the fuel system. See Bleeding the Fuel information: System on page 50. * Model name and serial number of your When operating the engine at low speed engine for long periods of time, race the engine once every 2 hours. Racing the engine ¢ Boat model, hull material, size (tons) with the clutch in NEUTRAL, accelerate « Use, type of boating, number of hours from the low-speed position to the run high-speed position and repeat this process about five times. This is done to * Total number of operation hours (refer to clean out carbon from the cylinders and hour meter), age of boat the fuel injection valves. * The operating conditions when the problem occurs: NOTICE * Engine speed (min-") Neglecting to race the engine will result in * Color of exhaust smoke poor smoke color and reduce engine * Type of diesel fuel performance. * Type of engine oil ¢ Any abnormal noises or vibration Periodically operate the engine near * Operating environment such as high maximum speed while underway. This will altitude or extreme ambient generate higher exhaust temperatures, temperatures, etc. which will help clean out hard carbon « Engine maintenance history and deposits, maintain engine performance previous problems and prolong the life of the engine. * Other factors that contribute to the problem 136 JH Series Operation Manual VYANMAH TROUBLESHOOTING 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. Engine does not start or starts with difficulty Pinion gear does not engage Loose terminal of battery/engage Tighten magnet Poor contact of starting switch Correct with sandpaper or replace Open coil of magnet switch Replace Burr at gear tooth tip Correct Poor clearance between pinion and Correct ting gear Pinion gear is engaged with Loose battery/starter terminal Tighten ring gear, but does not rotate Poor contact of starting switch Correct with sandpaper or replace Worn brush Replace Open circuit of starter coil Replace Slippage of starter/clutch Replace Excessive resistance of cable Increase the cable size or shorten between battery and starter 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 valve seat Replace Sticking of nozzle Replace Worn nozzle Replace Clogged injection hole Replace Failure in fuel injection system | Loose fuel injection pipe joint Tighten Broken fuel injection pipe Replace Air trapped in fuel injection pipe Bleed air from pipe Engine compressed air leak Air leak from exhaust valve Carry out fitting of valve and seat Faulty gasket/packing Replace Worn upper portion of cylinder Replace Worn piston ring Replace Sticking piston ring Overhaul or replace Broken valve spring Replace No revolution indication on Poor connection of crank & cam Check connection of the wire harness Tachometer during cranking. position sensors. Other Failure of engine system Conduct servicing Clogged intake or exhaust pipe Clean Controller defects system error Check DTC and conduct servicing YANMAR JH Series Operation Manual 137 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 Other Overload operation Reduce load Moving parts seized Disassemble, inspect and conduct servicing Slippage of gear box Inspect and repair Engine stops suddenly No fuel feed Fuel level in fuel tank is low Add fuel and prime Air trapped in fuel system or fuel Bleed air injection Water trapped in fuel tank Drain water 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 needle valve Replace Reduction in injection pressure Replace Poor atomization Replace Carbon deposit Clean Turbocharger failure Clogged air cleaner Clean (If equipped) Dirty compressor side Clean Clogged turbine side Clean Damaged bearing Replace Other Overload operation Reduce load Lubricant level too high Lower the oil level Accumulated carbon deposit at Clean intake/exhaust valve Dirty air cooler (If equipped) Clean Improper fuel Replace with proper fuel Clogged intake/exhaust valve Clean 138 JH Series Operation Manual VINA TROUBLESHOOTING Symptom Probable Cause Measure Insufficient output 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 Replace Loose fuel injection pipe joint Tighten Worn nozzle Replace Compressed gas leak in the Gas leak from intake/exhaust valve Conduct fitting of the valve engine cylinder Worn upper portion of cylinder bore Lap or replace Worn piston ring Replace Sticking piston ring Overhaul or replace Turbocharger failure Clogged air cleaner Clean (If equipped) 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 Controller defects system error Inspect DTC and conduct servicing Knocking Failure of fuel injector Broken fuel valve spring Replace Sticking nozzle Replace Poor atomization Replace Other Insufficient seawater Replace seawater pump impeller Piston clearance excessive Replace Bearing clearance excessive Replace Improper fuel Replace with correct fuel Water trapped in fuel Replace fuel Poor compression Inspect and service YANMAR JH Series Operation Manual 139 TROUBLESHOOTING Symptom Probable Cause Measure Breakdown of turbocharger (If equipped) Drop in intake pressure Dirty air cleaner 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 cleaner Drop in air pressure in engine room Ensure intake air path is unrestricted from outside air Broken turbine impeller Replace Dirty turbine impeller Clean Clogged exhaust pipe Clean Abnormal vibration Broken turbine impeller Replace Broken compressor impeller Replace Deposit of carbon or oxides on turbine Remove and repair or replace Broken bearing Replace Bent turbine shaft Replace Loose parts or fasteners Tighten Noise Damaged bearing Replace Contact by revolving parts Repair or replace Dirty or carbon deposit on turbine and Clean compressor Entrapment of foreign matter (at Repair or replace turbine entrance) Rapid change in load (surging) Stabilize the load or replace turbine nozzle Quick contamination of engine Gas trapped in bearing housing Repair oil Clogged seal air path Clean Damaged seal ring Replace Clogged pressure balance path Clean Pulsation of intake air pressure Uneven cylinder combustion Adjust for uniform combustion Rapid change in load Operate correctly Excessively dirty compressor side Clean Intake temperature too high Clean cooling fin Complete thermal insulation of exhaust pipe Ensure intake air path is unrestricted from outside air Other Bearing seizure Replace Corrosion in compressor/turbine Increase the coolant temperature impeller or bearing housing Other malfunctions Noise generation Loose flywheel set bolts Tighten bolts Loose connecting rod bolts Tighten bolts Worn crank pin Replace Excessive gear backlash Inspect the gear; replace worn gear, shaft, and/or bushing with new ones 140 JH Series Operation Manual VYANMAR TROUBLESHOOTING Symptom Probable Cause Measure Low lubrication oil pressure Clogged engine oil filter Replace Engine oil temperature too high Check the coolant level Failure of oil pump Overhaul or replace Faulty operation of oil pump relief Tighten the adjusting valve valve Replace the safety valve Low viscosity of engine oil used Replace the engine oil Insufficient engine oil quantity Add oil Faulty pressure switch Replace Coolant temperature too high Insufficient seawater Check seawater system Faulty thermostat Replace Loose drive belt of coolant pump Adjust the belt tension Overloaded operation Decrease the load Other Controller defects system error Inspect and conduct servicing Symptom Probable Cause Measure Reference + Water in sail drive seal Rubber sail drive seal broken. Consult authorizedYANMAR indicator comes on Marine dealer or distributor. Indicators Do Not Go On: * The tachometer does not No electrical current available. Consult authorizedYANMAR turn on, even though the The battery switch is turned off, the Marine dealer or distributor. power switch is turned on fuse (3A) on the instrument panel is burned out or the circuit is broken. * One of the indicators does Sensor switch is faulty. Consult authorizedYANMAR not go out Marine dealer or distributor. * Battery low charge indicator V-ribbed belt is loose or broken. Replace V-ribbed belt or See Checking and does not go out during adjust tension. Adjusting the operation Alternator V-ribbed belt Tension on page 119. Battery is defective. Check battery fluid level, See Checking the specific gravity or replace Battery Electrolyte battery. Level (Serviceable Batteries Only) on page 124. Alternator power generation failure. Consult authorized YANMAR Marine dealer or distributor. * Instrument panel does not No electrical current available. Consult authorizedYANMAR turn on, even though the The battery switch for the engine Marine dealer or distributor. power switch is turned on control system is turned off, the fuse(10A) in the fuse box is burned out or the circuit is broken. Starting Failures: * Starter does not turn or Faulty starter relay Consult authorizedYANMAR turns slowly Marine dealer or distributor. (engine can be turned The fuse(50A) near the starter is Consult authorizedYANMAR manually) burned out or the circuit is broken. Marine dealer or distributor. Faulty marine gear position. Shift to NEUTRAL and start. Faulty safety switch device. Consult authorized YANMAR Marine dealer or distributor. YANMAR JH Series Operation Manual 141 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 With Failsafe Action LcD DTC | SPN | FMI FFD DTC Description Level|Level|Level] Level] ENG Note 1 2 | 3 | 4 [Stop CHKENG/POOOF; 157 | 16 | - |Rail Pressure Limit Valve Open x - - - - CHK ENG! P0088} 157 0 x |Rail Pressure Too High - Exceed x . . . . the limit CHK ENG| P0093] 157 | 15 | x [Rail Pressure Deviation Error - x . . . . Higher Than The Target CHK ENG/ P0094; 157 | 18 | x {Rail pressure Deviation Error - x . . . __ [Suspicious Fuel Leak on Lower Than The Target the high pressure line CHK ENG/P0117} 110 4 - |Coolant Temperature Sensor . . . . _ [Engine is still Error - High Range operational. CHK ENG/P0118| 110 | 3 | - [Coolant Temperature Sensor _|_].[. [ _ [Suspicious Broken Error - Low Range sensor or wire AC1ERR|P0122| 91 4 - |Main Analog Throttle Sensor 1 . . . . _ JOne signal of the dual Error - Low Range throttle sensor is out of ACTERR|P0123] 91 3 | - [Main Analog Throttle Sensor 1 ~ |... i] _ jlimit. Error - High Range AC2 ERR|P0222| 28 4 - |Main Analog Throttle Sensor 2 . . . . . Error - Low Range AC2 ERR|P0223| 28 3 - |Main Analog Throttle Sensor 2 . . . . . Error - High Range AC1 ERR| P0223] 91 4 - |Main Analog Throttle Sensor 1 Both signal of the dual AC2 ERR|P0222| 28 4 Error - Low Range . _ |x . __ |throttle sensor are out of Main Analog Throttle Sensor 2 limit > Error - Low Range e AC1ERR|P0123/} 91 3 - [Main Analog Throttle Sensor 1 @ |AC2 ERR}|P0122} 28 3 Error - High Range S Main Analog Throttle Sensor 2 oe ee one ee 2 Error - High Range at CHK ENG/P0168} 174 0 x |Fuel Temperature Too High x . . . __ |Suspicious insufficient fuel in the fuel tank CHK ENG/P0182} 174 4 - |Fuel Temperature Sensor Error- | _ . . . _ [Engine is still Low Range operational. CHK ENG/P0183|/ 174 | 3 | - [Fuel Temperature Sensor Error - Suspicious Broken High Range - - - - - |sensor or wire, poor connection CHK ENG/P0192} 157 4 - |Rail Pressure Sensor Error-Low Range] x - - - - |Suspicious Broken CHK ENG| P0193] 157 3 - [Rail pressure Sensor Error-High Range] . | _ | _ | _ | _ [Sensor or wire, poor connection CHK ENG/ P0201} 651 5 - {Injector 1 - Open Circuit x - - - - |Suspicious Broken CHK ENG/P0202| 652 | 5 | - [Injector 2- Open Circuit x [| - | - [- [_-_|iniector or wire, poor CHK ENG/P0203/ 653 | 5 | - [Injector 3 - Open Circuit xf-]-f[- [- |eonnection CHK ENG|P0204| 654 5 - {Injector 4 - Open Circuit x - - - - OV HEAT}P0217} 110 0 x |Engine Coolant Temperature Too High | x - - - - OV REV |P0219|] 190 0 x |Engine Overspeed Condition - - - - | x - P0227] 29 4 - |Sub Throttle Sensor Error - Low Range | - - - - - |(When Backup Panel is - P0228] 29 3 | - |SubThrottle Sensor Error-HighRange| - | - | - | - | - [operated only) bOOST | P0234] 102 0 x |Boost Pressure Too High x - - - - CHK ENG! P0237} 102 4 - |Boost Pressure Sensor Error - LowRange] - - - - - |Engine is still operational. CHK ENG/P0238/ 102 | 3 | - [Boost pressure Sensor Eror-HighRangel _ [ _ | _ [ _ | _ [Suspicious Broken sensoror wire 142 JH Series Operation Manual VINA TROUBLESHOOTING With 7 Failsafe Action LcD DTC | SPN | FMI FFD DTC Description LevellLevel]Level|Levell ENG Not 1] 2] 3 | 4 IStop ote CHK ENG! P0262} 651 6 - |Injector1 Coil - Short Circuit x - - - - |Suspicious Broken CHK ENG|P0265| 652 6 - |Injector2 Coil - Short Circuit x] - - - -_ |injector or wire, poor CHK ENG| P0268] 653 6 - |Injector3 Coil - Short Circuit x] - - - = [connection CHK ENG| P0271] 654 6 - |Injector4 Coil - Short Circuit x] - - - - CHK ENG| P0336 [522400] 2 - |Crankshaft Position Sensor - x . . . . Irregular Signal CHK ENG| P0337 [522400] 5 - |Crankshaft Position Sensor - No x . . . . Signal CHK ENG! P0341 |522401} 2 - |Camshaft Position Sensor - . . . . __ [Engine is still operational. Irregular Signal Suspicious Broken sensor or CHK ENG] P0342 |522401] 5 - |Camshaft Position Sensor - No Signal] - : : : = |wire, poor connection CHK ENG] P0541 |522243) 6 - |Glow relay - Short Circuit - - - - - Only for 3JH40 CHK ENG] P0543 |522243) 5 - |Glow relay - Open Circuit - - - - - CHK ENG! P0601} 630 | 12 | - /ECU Error - EEPROM Memory . . . . _ [ECU internal failure Deletion CHK ENG} P0611 |523492) 12 | - {Injector Driver IC Error - - - - | x |ECU internal failure CHK ENG! P0627] 633 5 - |Fuel Pump - Open Circuit - | x - - - |Suspicious fuel pomp CHK ENG| P0629] 633 3 - [Fuel Pump - High side VB Short ~ tx] - . . failure, poor connection Circuit of wire CHK ENG|P062A [522572] 6 - |Fuel Pump - Over Current - | x - - - CHK ENG/PO68A} 1485 | 2 - |Main Relay In ECU - Early Open Battery switch has been turned off before ECU has shutdown at the - - - - - |previous shutdown. See SHUTTING DOWN THE ENGINE on page 69. Or ECU internal failure CHK ENG/P068B} 1485 | 7 - |Main Relay In ECU - Stuck - - - - - ECU internal failure CHK ENG] P1004 |523016] 5 - |Accessory Relay - Open Circuit - - - - - 5 CHK ENG| P1005 [522778] 7 - [Stop Switch - Stuck - - - - - o SEAL |P1006/522775) 0 - |Water In Sail drive Seal - - - - - @ |CHK ENG| P1146] 2797 | 6 - |Injector Bank1 - Short Circuit x] - - - | (&) ]3JH40: ENG Stop & CHK ENG| P1149] 2798 | 6 - {Injector Bank2 - Short Circuit x - - - - ui 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 x {Oil Pressure Too Low - | x - - - CHK ENG! P1262} 651 3 - {Injector 1 - Short Circuit x - - - | (x) |Suspicious Broken CHK ENG| P1265] 652 3 - |Injector 2 - Short Circuit x] - - - | &) injector or wire, poor CHK ENG| P1268] 653 3 - |Injector 3 - Short Circuit x | - - - 1@&) connection CHK ENG|P1271| 654 3 - |Injector 4 - Short Circuit x | - . . - |3JH40: ENG Stop CHK ENG] P1341 |522401] 7 - |Camshaft Position Sensor Signal - Suspicious cam gear Angle Offset - - - - - offset, loose installation of sensor or pulsar CHK ENG] P1467 |523471] 6 - Starter relay coil side Short Circuit] - - - - - CHK ENG| P1469 [523473] 12 | - |ECU Error - AD Converter1 - - - - | x |ECU internal failure CHK ENG| P1470 [523474] 12 | - |ECU Error - AD Converter2 - - - - | x |ECU internal failure CHK ENG! P1471 |523475) 12 | - |ECUError-ExternalmonitoringIC] _ . . - |x ECU internal failure & CPU1 CHK ENG! P1472 |523476) 12 | - /ECU Error- External monitoring IC ECU internal failure & CPU2 eee ee ee CHK ENG| P1473 [523477] 12 | - |ECU Error- ROM - - - - | x |ECU internal failure CHK ENG! P1474 |523478] 12 | - /ECU Error - Shutoff Path’ - - - - | x |Suspicious Broken CHK ENG| P1475 [523479] 12 | - |ECU Error - Shutoff Path2 - - - - | x |injector or wire, poor CHK ENG| P1476 |523480| 12 | - |ECU Emor - Shutoff Path3 > [- | - | - J x [connection of the wire CHK ENG| P1477 [523481| 12 | - |ECU Enor - Shutoff Path4 [== P= x Or hamess to injector. ECU internal failure CHK ENG| P1478 [523482] 12 | - |ECU Error - Shutoff PathS - - - - | x CHK ENG| P1479 [523483] 12 | - |ECU Error - Shutoff Pathé - - - - | x CHK ENG| P1480 [523484] 12 | - |ECU Error - Shutoff Path7 - - - - | x CHK ENG| P1481 [523485] 12 | - |ECU Error - Shutoff Path8 - - - - | x CHK ENG| P1482 [523486] 12 | - |ECU Error - Shutoff Path9 - - - - | x CHK ENG| P1483 [523487] 12 | - ECU Error - Shutoff Path10 - - - - | x WRARJRSIEAR] JH Series Operation Manual 143 TROUBLESHOOTING With 7 Failsafe Action LCD DTC | SPN | FMI DTC Description Level]LevellLevel/Level] ENG FFD Note 1 2 | 3 | 4 [Stop CHK ENG| P1484 [523488] 0 - |ECU Error- Engine Speed Recognition | - - - - | x |ECU internal failure ALT P1568| 167 1 - |Charging System Error - - - - - CHK ENG! P1608 |522588) 12 | - ECU Error - Actuator Supply1 . . . _| x ECU internal failure Voltage High Range CHK ENG|/ P1609 }522590) 12 | - |ECU Error- Sensor Supply1 . . . . _ |ECU internal failure Voltage bT VOLT |P160C} 158 0 - |Battery Voltage Too High - - - - - CHK ENG! P160E /522576] 12 | - |ECU Error - EEPROM Memory . . . . _ [ECU internal failure Read CHK ENG! P160F /522578) 12 | - /ECU Error - EEPROM Memory . . . . _ [ECU internal failure Write CHK ENG| P1613 /522585| 12 | - |ECU Error - CY146 SPI ~ tx] - . _ [ECU internal failure Communication CHK ENG! P1617 |522589) 12 | - |ECU Error - Actuator Supply1 . . . - |x ECU internal failure Voltage Low Range CHK ENG! P1618 |522591) 12 | - {ECU Error- Sensor Supply2 . . . . _ |ECU internal failure Voltage CHK ENG! P1619 |522592) 12 | - {ECU Error- Sensor Supply3 . . . . _ |ECU internal failure Voltage CHK ENG] P1626 |522744) 4 - JECU Error - Actuator Drive1 Short] _ . . . _ [ECU internal failure Circuit CHK ENG] P1633 }522994) 4 - JECU Error - Actuator Drive2 Short] _ . . . _ [ECU internal failure Circuit bT VOLT |P1638} 158 1 - |Battery Voltage Too Low - - - - - CHK ENG] P1641 |522571] 3 - |Fuel Pump - Low side VB Short - |x . . _ |Suspicious fuel pomp Circuit failure, poor connection CHK ENG| P1642] 633 6 - |Fuel Pump - High side GND Short | _ x | - . . of wire Circuit CHK ENG| P1643 [522571] 6 - |Fuel Pump - Low side GND Short Fs] Circuit oe one ee ee 3 CHK ENG| P1645 [522572] 11 - |Fuel Pump - Over Load - | x - - - = CHK ENG| P1648 [523462] 13 | - [Injector 1 - Q@R Code Data Error x - - - - Input failure of the iG [CHK ENG! P1649 [523463] 13 | - Injector 2 - QR Code Data Error x] - - - -_ |injector correction value CHK ENG| P1650 [523464] 13 | - [Injector 3 - QR Code Data Error x - - - - CHK ENG| P1651 [523465] 13 | - [Injector 4 - QR Code Data Error x - - - - CHK ENG] P1665 |523468] 9 - |Rail Pressure Error After Pressure | _ . . . x Limit Valve Open CHK ENG] P1666 |523469] 0 - |Rail Pressure Limit Valve Open - Exceed Specified Time oe one ee ee CHK ENG] P1667 |523470] 0 - |Rail Pressure Limit Valve Error - . x . . . Exceed Specified Opening Hour CHK ENG] P1668 |523489] 0 - |Rail Pressure Limit Valve Error - . . . . x Not Open CHK ENG] P1669 |523491] 0 - |Fuel Temperature Error under _| x . . . Limp Home Mode CHK ENG] P1670 |523460] 7 - |Double error - Rail pressure sensor and MPROP or fuel - - - - x temperature sensor CHK ENG| P2530 |522308] 7 - |Start Switch - Stuck - - - - - CHK ENG] U0292 |522596] 9 - |CAN Communication Error-TCS1) _ . . . __ [Suspicious Loose connection of CAN cable} CHK ENG| U0593 |}522596) 19 | - |CAN Throttle Signal Error- TCS1 | - - - | x - |Throttle control system error CHK ENG| U0593 [522596] 19 | - |CAN Throttle Signal Error - TCS1 PQ228| 29 3 Sub Throttle Sensor Error - High Range or] - - | x - - P0227] 29 4 Sub Throttle Sensor Error- Low Range CHK ENG] U1304 | 459726] 9 - |CAN Communication Error - . . . . _ |Suspicious Loose Y_PM1 connection of CAN cable} CHK ENG! U1305 | 459726) 19 | - |CAN Throttle Signal Error-Y_PM1| - - - | x - |Throttle control system error SAFE MD - - - - |Power reduction (Engine xl xix lx . Status indication under Protection Mode) Engine Protection Mode ST LOCK - - - - |Starter Interlock . . . . _ |Neutral safety is active. Can not start the engine 144 JH Series Operation Manual Wee RoR gs ee TROUBLESHOOTING With 7 Failsafe Action LCD DTC | SPN | FMI DTC Description Levell|Level|Level]/Level] ENG FFD | 21314 Isto Note Pp EMG STP - - - - |Emergency Stop - - - - - |Digital Display (/C10) 3 AUX STP - - - - |Emergency Stop - - - - - |LCD (B25, C35)) wi {COM ERR - - - - |Communication error between Suspicious Loose g panel and engine ECU connection of Extention > - - - - - harness. Ww Suspicious blown fuse(20A/ECU). - Po920| 773 3 - |SHIFT FORWARD H RANGE - - - - - - Po920| 773 4 - {SHIFT FORWARD L RANGE - - - - - [Shift Valve (F) shuts off - P0924| 784 3 - |SHIFTREVERSE H RANGE - - - - - - P0924| 784 4 - {SHIFT REVERSE L RANGE - - - - - - P0745| 740 3 - |CHANGE VALVE H RANGE - - - - - - P0745| 740 4 - ICHANGE VALVE L RANGE . . . . __ [Trolling function come to be unavailable - P0720] 191 8 - |PROP SPEED SENSOR L . . . . __ |C+type trolling functionis RANGE switched E-type - P0218] 177 0 - |GEAR OIL TEMP TOO HIGH . . . . __ [Trolling function come to be unavailable - PO710| 177 3 - |GEAR OIL TEMP H RANGE - - - - - - PO710| 177 4 - [GEAR OIL TEMP L RANGE - - - - - - U103 | 525 | 10 | - [CAN COM ERROR . . . . __ [Shift is changed to Neutral position - Ui100 | 190 | 10 | - /CANCOMERROR ENGINE SPEED] - - - - - - U404 | 525 2 - |CAN COM ERROR SHIFT . . . . __ [Shift is changed to Neutral position - U402 | 684 2 - |CAN COM ERROR TROLLING . . . . __ [Trolling function come to be unavailable - PO560| 158 1 - |BATTERY VOLTAGE TOO LOW | - - - - - - C1010 521238] 3 - |Tank1 level sensor HI range - - - - - - C1010 |521238) 4 - |Tank1 level sensor LO range - - - - - ss - C1011 521239] 3 - |Tank2 level sensor HI range - - - - - O - C1011 521239] 4 - |Tank2 level sensor LO range - - - - - ob - C1051 |521240] 3 - |Rudder angle sensor HI range - - - - - = - C1051 521240) 4 - |Rudder angle sensor LO range - - - - - - C1012 |521994) 13 | - |Tank1 level calibration error - - - - - - C1013 521995) 13 | - |Tank2 level calibration error - - - - - - C1052 |521996] 13 | - [Rudder angle calibration error - - - - - - P1070 |521243| 3 - |Seawater temperature sensor HI . . . . . range - P1070 |521243| 4 - |Seawater temperature sensorLO | _ . . . . range - P0070] 171 3 - |Outside air temperature sensor HI} _ . . . . range - P0070] 171 4 - |Outside airtemperature sensorLO| _ . . . . range - 01014 /521997| 13 | - |Seawater temperature calibration | _ . . . . error - C1015 |521998) 13 | - [Outside airtemperature calibration| _ . . . . error - U2003 }521233] 4 - |House battery voltage LO range - - - - - - P0840| 127 3 - |Gear oil pressure sensor HI range| - - - - - - P0840] 127 4 - |Gear oil pressure sensor LO range] - - - - - - P1628| 630 | 12 | - |Drive ECU EEPROM error - - - - - - PO605| 628 | 12 | - [ROM CRC abnormality - - - - - - P1826 |522017| 6 - |Trolling solenoid over current . . . . __ [Trolling feature will be failure unavailable. - P1827 |522017| 5 - |Trolling solenoid non current . . . . __ [Trolling feature will be failure unavailable. We REPS SAFE JH Series Operation Manual 145 TROUBLESHOOTING Failsafe Action LCD DTC | SPN | FMI bls DTC Description Levell|Level|Level]/Level] ENG 112 | 3 | 4 [stop Note - U100 |523760) 9 - |CAN COM ERROR ENG-ECUTO| _ . _| x __ [Station change comes to HELM-ECU be unavailable - U404 [523761] 9 - |CAN COM ERROR DRIVE-ECU . . _txy |. Shift change comes to TO HELM-ECU be unavailable - U1201 |523762] 9 - !CAN COM ERROR HELM-ECU . . _| x __ [Station change comes to TO HELM-ECU be unavailable - U1202 |523763] 9 - |CAN COM ERROR HELM-LOCAL Station change, Synch. Operation, Warmup - - - | x - Joperation, and Engine speed limit mode come to be unavailable - B1001 [523543] 4 - NEUTRAL SW ACTIVATED Station change, Synch. Operation, Warmup - - - - - Joperation, and Engine speed limit mode come to be unavailable - B1002 |523542| 4 - [SELECT SW ACTIVATED Station change and Indicator dimming “| " | ~ | ° | ~ loperation come to be unavailable - B1003 |523544| 4 - [SYNCHRO SW ACTIVATED Station change and - - - - - |Synchronization feature come to be unavailable - B1004 |523545| 4 - |TROLL SW ACTIVATED Station change and - - - - - |Trolling function come to be unavailable - B1005 [523541| 3 - |START/STOP SW ACTIVATED Station change comes to “7° |" 1 ~ | * Tbe unavailable - P0120] 91 3 - |MAIN THROTTLE SENSOR H . . _txy |. Station change and 5 RANGE Trolling function come to O - P0120] 91 4 - |MAIN THROTTLE SENSOR L . . _txy |. be unavailable & RANGE 2 - B1020] 91 13 | - [THROTTLE CALIBRATION . . _txy |. Station change function INCONSISTENCY come to be unavailable - B1043 [523768] 12 | - |HELM-ECU EEPROM ERROR Station change comes to “7° |" 1 ~ | * Tbe unavailable - B1071 [523779] 12 | - JANALOG CONVERTER . . _txy |. EEPROM ERROR - U1214 1523781} 9 - |SW PANEL CAN COM ERROR Station change comes to “| " |" | ~ | ~ Tbe unavailable. - B1100 [523782] 11 - |SW PANEL OPTICAL SENSOR ERROR ° ° ° ° ° - U1207 |522039] 9 - |Can com error Shift Actuator . . - |x __ Shift is changed to Neutral position. - B1061 |522040) 11 - |Shift Actuator failure . . - |x _ Shift is changed to Neutral position. - C1208 |522041| 9 - |Can com error Can-Control Head Station change, Synch. operation, Warmup - - - | x - Joperation, and Engine speed limit mode will be unavailable. - C1027 |522042| 11 - |Throttle/Shift sensor warning Can-Control Head ee ee ee - C1028 |522043] 11 - |Throttle/Shift sensor failure Station change and Can-Control Head - - - | x - |Trolling feature will be unavailable. - C1029 |522044] 11 - |Trolling sensor failure Trolling feature will be Can-Control Head “7 " |" 1" | ~ unavailable. - B1103 [523793] 11 - {IMMOBILIZER ANTENNA FAILURE ° ° ° ° ° - C1066 |523791] 11 - |SOFTWARE VERSION ERROR SW PANEL ° ° ° ° ° 146 JH Series Operation Manual VINA LONG-TERM STORAGE If the engine will not be used for an PREPARE ENGINE FOR extended period of time, special measures should be taken to protect the cooling LONG-TERM STORAGE system, fuel system and combustion Note: If the engine is close to a periodic chamber from corrosion and the exterior maintenance interval, perform those from rusting. maintenance procedures before The engine can normally stand idle for up putting the engine into long-term to 6 months. If it remains unused for longer storage. 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. within this section, review the Safety 3. Drain fuel tank completely or fill the section on page 3. tank to prevent condensation. In cold temperatures or before long-term 4. Grease the exposed areas and joints of storage, be sure to drain the seawater the remote control cables and the from the cooling system. bearings of the remote control handle. 5. Seal the intake silencer, exhaust pipe, NOTICE etc. to prevent moisture or contamination from entering engine. * Do not drain the coolant system. Afull coolant system will prevent corrosion 6. Completely drain bilge in hull bottom. and frost damage. 7. Waterproof the engine room to prevent rain or seawater from entering. * If seawater is left inside of the engine, it may freeze and damage parts of the 8. Charge the battery once a month to cooling system when the ambient compensate for battery’s temperature is below 0 °C (32 °F). self-discharge. 9. Make sure the power switch is off. YANMAR JH Series Operation Manual 147 LONG-TERM STORAGE DRAIN SEAWATER COOLING SYSTEM 3JH40 108120-01x%601 Figure 2 2 —Coolant pump Figure 1 3 —Coolant tank (Heat exchanger) 1 -—Coolant drain cock 4 -—Coolant drain cock (Cylinderblock) (Coolant tank/Heat exchanger) 5 —Seawater pump (Drain from pump cover) 148 JH Series Operation Manual WAAR SAR LONG-TERM STORAGE 4JH45, 4JH57 4JH80, 4JH110 3 2 1 O56983-02K00 4. 3 2 056958-03K Figure 3 Figure 5 1 -—Coolant drain cock 1 -— Turbocharger (Cylinderblock) 2 —Coolant drain cock 2 —Marine gear oil cooler (KM4A1) (Cylinderblock) 3 -—Seawater drain cock 3 —Marine gear oil cooler (KMH4A) (Marine gear oil cooler) 4 -Seawater drain cock (Marine gear oil cooler) 056984-02x00 O56989-03K00 Figure 4 Figure 6 4 -—Coolant pump 5 —Coolant tank (Heat exchanger) 5 —Coolant pump 6 —Coolant drain cock 6 —Coolant tank (Heat exchanger) (Coolant tank/Heat exchanger) 7 -—Coolant drain cock 7 —Seawater pump (Coolant tank /Heat exchanger) (Drain from pump cover) 8 —Seawater drain cock (Air cooler) 9 —Air cooler 10-—Seawater pump (Drain from pump cover) WR MAGA JH Series Operation Manual 149 LONG-TERM STORAGE Note: The drain cocks are opened before RETURNING THE ENGINE shipping from the factory. Marine gear ZF25A does not have a TO SERVICE drain cock on the marine gear 1. Replace the oil and the oil filter before cooler. running the engine. Supply fuel if the fuel in the fuel tank NOTICE was removed, and prime the fuel If seawater is left inside, it may freeze and system. damage parts of the cooling system (heat Confirm that there is engine coolant in exchanger, seawater pump, etc.) when the engine. ambient temperature is below 32 °F (0 °C). Operate the engine at idle speed for 1 minute. . Check fluid levels and check engine for 1. Open the seawater drain cock on the leaks. marine gear cooler (if equipped). Allow to 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. 150 JH Series Operation Manual VYVANAIAR SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS YWRANRGAR su Series Operation Manual 151 SPECIFICATIONS 3JH40 Engine Specification 3JH40 Marine Gear Model KM35P 2F25 KM35A ZF25A $D60-5 Bobtail Use Recreational use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders 3 Bore x Stroke 88 mm x 90 mm (3.46 in. x 3.54 in.) Displacement 1.642 L (100.2 cu in.) Continuous power 26.8 kW (36 hp metric) / 2907 min-1 Fuel stop power | Output at 29.4 kW (40 hp metric) / 3000 min-* crankshaft/ engine speed Output at propeller/ 28.2 kW (38 hp metric) / 3000 min-1* : : engine speed Installation Flexible mounting Fuel Injection Timing Variable timing (Electronic control) Fuel Injection Pressure Variable pressure (Maximum injection pressure: 150 Mpa) Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise Counter Clockwise Counter - - (ahead) viewed from | clockwise or | viewed from | clockwise or stern clockwise stern clockwise (Bi-rotation) (Bi-rotation) Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Cooling Water Capacity (coolant) Engine 4.5 L (4.76 qt), Reservoir: 0.8 L (0.85 qt) Lubricating Oil Rake angle at rake angle 7° at rake angle 0° Capacity (engine) T5137" 5.0 L 6.28 qt) 5.5L 6.81 qt) Oil pan only 4.5L (4.76 qt) 5.0 L (6.28 qt) Effective’ 1.1L (1.16 qt) 1.2L (1.27 qt) Starting System |Type Electric Starting motor DC 12 V-1.4 kW AC generator 12V-125A Engine Overall length 775 mm 896 mm 774mm 842 mm 705 mm 705 mm Dimension (30.5 in.) (35.3 in.) (30.5 in.) (33.1 in.) (27.8 in.) (27.8 in.) Overall width 577 mm (22.7 in.) Overall height 636 mm 645 mm 636 mm (25.0 in.) (25.4 in.) (25.0 in.) Engine Dry Mass 204 kg 225 kg 205 kg 225 kg 236 kg 192 kg (including marine gear) (450 Ib) (496 Ib) (452 Ib) (496 Ib) (520 Ib) (423 Ib) * Rating Condition: Temperature of fuel; 40 °C at fuel pump inlet; ISO 8665 ** — The “total” oil quantity includes oil in oif pan, channels, coolers and filter. ** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale. Note: + Density of fuel: 0.835 to 0.845 g/cm? at 15 °C. Fuel temperature at the inlet of the fuel supply pump. * 1 hp metric = 0.7355 kW 152 JH Series Operation Manual VYANMAH SPECIFICATIONS 3JH40 Marine Gear or Sail Drive ZF25 ZF25A $D60-5 Model KM35P (Mechanical shift/ KM35A (Mechanical shift/ (coupled at Electric Shift) Electric Shift) boat builder) Type Mechanical cone Hydraulic wet Mechanical cone Hydraulic wet Mechanical clutch multiple disk clutch clutch multiple disk clutch | multiple friction disc clutch Reduction Ratio 2.36 / 3.16 1.97/1.97 2.33 / 3.06 1.93 / 1.93 2.23 / 2.23 (forward/reverse) 2.61 / 3.16 2.80 / 2.80 2.64 / 3.06 2.29 / 2.29 2.49 / 2.49 2.48 / 2.48 2.71/2.71 Propeller Speed 1232 /921 1476/1476 1246 / 955 1506 / 1506 1304/ 1304 (forward/reverse) (min-1)’ 1114/921 1038/ 1038 1103 / 955 1269 / 1269 1167/ 1167 4172 (1172 1073 / 1073 Lubrication System Splash Trochoid pump Splash Trochoid pump Oil bath Lubricating Oil Capacity O5L 1.8L 0.65 L 1.8L 3.1L E3 qh (total) (0.53 qt) (1.90 qt)” (0.69 qt) (1.90 qt)” Long Reach (75 mm): 3.3 L (3.4 qt) Lubricating Oil Capacity 0.05 L : O.15L : : (effective) (0.05 qt) (0.16 qt) Cooling System Aircooling byfan | Seawater cooling | Air cooling by fan} Seawater cooling : Weight 12 kg 33 kg 13 kg 33 kg 44 kg (97.0 Ib) (26.5 Ib) (72.7 |b) (28.7 |b) (72.7 |b) Long Reach (75 mm): 48 kg (105.8 Ib) * At continuous power engine speed 2907 mint ** — ZF25, ZF25A Lubricating oil: ATF 153 YANMAR JH Series Operation Manual SPECIFICATIONS 4JH45 Engine Specification 4JH45 Marine Gear Model KM35P | ZFsoM | —ZF25 KM35A2 | KM4A1 | ZF25A | SD60-5 | Bobtail Use Recreational use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders 4 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 30.1 kW (41 hp metric) / 2907 min-1 Fuel stop power | Output at 33.1 KW (45 hp metric) / 3000 min-1* crankshaft/ engine speed Output at propeller/ 31.8 kW (43.3 hp metric) / 3000 min-'* - - engine speed Installation Flexible mounting Fuel Injection Timing Variable timing (Electronic control) Fuel Injection Pressure Variable pressure (Maximum injection pressure: 160 Mpa) Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise viewed Counter Clockwise | Counterclockwise - - (ahead) from stern clockwise or | viewed from or clockwise clockwise stern (Bi-rotation) (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 Rake angle at rake angle 7° at rake angle 0° Capacity (engine) T5137" 5.0L (5.28 at) 5.5L (5.81 at) Oil pan only 4.5L (4.76 qt) 5.0 L (6.28 qt) Effective’ 1.4L (1.48 qt) Starting System |Type Electric Starting motor DC 12V-1.4 kW AC generator 12V-125A Engine Overall length 870 mm| 950 mm} 990mm 868mm_ | 926 mm | 936 mm | 802 mm | 802 mm Dimension (34.3 in.)| (37.4 in.)| (9.0 in.) (34.2 in.) [(36.5in.)| (36.7 in.) | 31.6 in.) | (31.6 in.) Overall width 588 mm (23.1 in.) Overall height 631 mm (24.8 in.) Engine Dry Mass 235 kg | 243 kg 253 kg 236 kg 253 kg | 243 kg | 264 kg | 220 kg (including marine gear) (618 Ib) | (536 Ib) (658 Ib) (620 Ib) (558 Ib) | (636 Ib) | (582 Ib) | (485 Ib) * Rating Condition: Temperature of fuel; 40 °C at fuel pump inlet; ISO 8665 ** — The “total” oil quantity includes oil in oif pan, channels, coolers and filter. The effective amount of off shows the difference in maximum scale of the dipstick and minimum scale. kek Note: + Density of fuel: 0.835 to 0.845 g/cm? at 15 °C. Fuel temperature at the inlet of the fuel supply pump. * 1 hp metric = 0.7355 kW 154 JH Series Operation Manual VYANMAH SPECIFICATIONS 4JH57 Engine Specification 4JH57 Marine Gear Model Km35P | ZF30M | ZF25 KM35A2 | KM4A1 | ZF26A | SD60-5 | Bobtail Use Recreational use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Natural aspiration Number of Cylinders 4 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 38.1 kW (51.8 hp metric) / 2907 min-1 Fuel stop power ) Output at 41.9 kW (57 hp metric) / 3000 min” crankshaft/ engine speed Output at propeller/ 40.2 kW (54.7 hp metric) / 3000 min-1* - : engine speed Installation Flexible mounting Fuel Injection Timing Variable timing (Electronic control) Fuel Injection Pressure Variable pressure (Maximum injection pressure: 160 Mpa) Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise viewed Counter Clockwise | Counterclockwise - - (ahead) from stern clockwise or | viewed from or clockwise clockwise stern (Bi-rotation) (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 Rake angle at rake angle 7° at rake angle 0° Capacity (engine) [T5137 5.0L (5.28 ql) 5.5L (681 ql) Oil pan only 4.5 L (4.76 qt) 5.0 L (5.28 qt) Effective’ 1.4L (1.48 qt) Starting System | Type Electric Starting motor DC 12V-1.4 kW AC generator 12V-125A Engine Overall length 870 mm| 950 mm} 990mm 868 mm | 926 mm | 936 mm | 802 mm | 802 mm Dimension (34.3 in.)| (37.4in.)} 9.0 in.) (34.2 in.) | (36.5 in.) | (36.7 in.) | (31.6 in.) | (31.6 in.) Overall width 588 mm (23.1 in.) Overall height 631 mm (24.8 in.) Engine Dry Mass 235 kg | 243 kg 253 kg 236 kg 253 kg | 243 kg | 264 kg | 220 kg (including marine gear) (618 lb) | (536 Ib) (658 Ib) (620 Ib) (558 Ib) | (636 Ib) | (682 Ib) | (485 Ib) * Rating Condition: Temperature of fuel; 40 °C at fuel pump inlet; 1SO 8665 ** — The ‘total’ off quantity includes oil in off pan, channels, coolers and filter. ~The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale. Note: + Density of fuel: 0.835 to 0.845 g/cm at 15 °C. Fuel temperature at the inlet of the fuel supply pump. * 1 hp metric = 0.7355 kw Wea PR ga JH Series Operation Manual 155 SPECIFICATIONS 4JH45, 4JH57 Marine Gear or Sail Drive 2F25 ZF25A (Mechanical (Mechanical $D60-5 Model KM35P ZF30M shift / KM35A2 KM4A1 shift / (coupled at boat Electric Electric builder) Shift) Shift) Type Mechanical | Mechanical | Hydraulic | Mechanical | Mechanical | Hydraulic Mechanical multiple cone clutch | wet maliple | wet multiple | cone clutch | wetcone | wet multiple | friction disc clutch disk clutch | disk clutch clutch disk clutch Reduction Ratio 2.36/3.16 | 2.15/2.64 | 1.97/1.97 | 2.33/3.06 | 1.47/1.47 | 1.93/1.93 2.23 /2.23 (forward/reverse) 2.61/3.16 | 2.70/2.64 | 2.80/2.80 | 2.64/3.06 | 2.14/2.14 | 2.29/2.29 2.49 / 2.49 2.63 /2.63 | 2.48/ 2.48 2.71/2.71 Propeller Speed 1232 /921 | 1353/1103 | 1476/1476] 1246/950 | 1983/ 1981 | 1506/ 1506 1304/ 1304 (forward/reverse) 1114/921 | 1078/1103 | 1038/ 1038] 1103/950 | 1360/ 1359 | 1269/ 1269 1167/ 1167 (min-1)* 1106/1105] 1172/1172 1073 / 1073 Lubrication System Splash Trochoid Splash Centrifugal | Trochoid Oil bath pump pump pump Lubricating Oil O5L 1.1L 1.8L 0.65L 2.3L 1.8L 3.1L 3.3 qt) Capacity (total) (0.53 qt) (1.16 qt)” | (1.90 qt)” (0.69 qt) (2.43 qt) (1.90 qt)” | Long Reach (75 mm): 3.3L 3.4 qt) Lubricating Oil 0.05L 0.2L - 0.15L O2L - - Capacity (effective) (0.05 qt) (0.21 qt) (0.16 qt) (0.21 qt) Cooling System Air cooling Seawater cooling Air cooling Seawater cooling - by fan by fan Weight 15 kg 23 kg 33 kg 16 kg 33 kg 33 kg 44 kg (97.0 lb) (33.1 Ib) (60.7 Ib) (72.7 |b) (35.3 Ib) (72.7 |b) (72.7 |b) | Long Reach (75 mm): 48 kg (105.8 Ib) At continuous power engine speed 2907 min-1 * ** ZF30M, ZF25, ZF25A Lubricating oil: ATF 156 JH Series Operation Manual VYANMAH SPECIFICATIONS 4JH80 Engine Specification 4JH80 Marine Gear Model zF30M | ZF25 | KM4A2 | KMH4A| ZF25A | KMHS50V | sD60-4 | Bobtail Use Recreational use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Turbocharged with air cooler Number of Cylinders 4 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 53.5 KW (72.8 hp metric) / 3101 min-1 Fuel stop power | Output at 58.8 kW (80 hp metric) / 3200 min-1* crankshaft/ engine speed Output at propeller/ 56.4 kW (76.7 hp metric) / 3200 min 1* engine speed Installation Flexible mounting Fuel Injection Timing Variable timing (Electronic control) Fuel Injection Pressure Variable pressure (Maximum injection pressure: 160 Mpa) Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise Counter clockwise or clockwise : - (ahead) viewed from (Bi-rotation) stern 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 Rake angle at rake angle 7° at rake angle 0° Capacity (engine) [Totar" 5.5L (6.81 qt) 6.7L (7.08 qt) Oil pan only 5.2 L 6.49 qt) 6.4 L (6.76 qt) Effective” 2.4L (2.54 qt) Starting System | Type Electric Starting motor DC 12V-1.4 kW AC generator 12V-125A Engine Overall length 925mm _ | 959mm| 909 mm | 907 mm | 905 mm] 1011 mm | 787 mm| 787 mm Dimension (36.4 in.) | (37.8 in.)| (35.8 in.)| (35.7 in.) | (85.6 in.)| @9.8in.) | (31.0 in.) | (31.0 in.) Overall width 613 mm (24.1 in.) Overall height 675 mm 799 mm 675 mm (26.6 in.) (31.5 in.) (26.6 in.) Engine Dry Mass 254 kg 262 kg | 263 kg | 261 kg | 262 kg 305 kg 274 kg | 229 kg {including marine gear) (660 Ib) (578 Ib) | (680 Ib) | (575 Ib) | (578 Ib) | (72 Ib) | (604 Ib) | (605 Ib) * Rating Condition: Temperature of fuel; 40 °C at fuel pump inlet; 1SO 8665 The ‘total” oif quantity includes oil in oil pan, channels, coolers and filter. ** kek The effective amount of oif shows the difference in maximum scale of the dipstick and minimum scale. Note: + Density of fuel: 0.835 to 0.845 g/cm? at 15 °C. Fuel temperature at the inlet of the fuel supply pump. * 1 hp metric = 0.7355 kW YANMAR JH Series Operation Manual 157 SPECIFICATIONS 4JH110 Engine Specification 4JH110 Marine Gear Model ZF30M 2F25 KM4A2 | KMH4A 2ZF25A KMH50V | Bobtail Use Recreational use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection Air Charging Turbocharged with air cooler Number of Cylinders 4 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 73.6 kW (100 hp metric) / 3101 mins Fuel stop power | Output at 80.9 kW (110 hp metric) / 3200 min-1* crankshaft/ engine speed Output at propeller/ 77.7 kW (105.7 hp metric) / 3200 min-1* - engine speed Installation Flexible mounting Fuel Injection Timing Variable timing (Electronic control) Fuel Injection Pressure Variable pressure (Maximum injection pressure: 160 Mpa) Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller shaft Clockwise Counterclockwise or clockwise - (ahead) viewed from (Bi-rotation) stern 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 Rake angle at rake angle 7° at rake angle 0° Capacity (engine) [T5447 55L (581 qt) 6.7 L (7.08 qt) Oil pan only 5.2 L (6.49 qt) 6.4L (6.76 qt) Effective’ 2.4L (2.54 qt) Starting System | Type Electric Starting motor DC 12V-1.4 kW AC generator 12V-125A Engine Overall length 925 mm 959mm | 909mm | 907 mm | 905mm | 1011 mm | 787 mm Dimension (36.4 in.) (37.8in.) | @5.8in.) | (5.7 in.) | G5.6in.) | G98in.) | B1.0in.) Overall width 613 mm (24.1 in.) Overall height 675 mm 799 mm 675 mm (26.6 in.) (31.5 in.) | (26.6 in.) Engine Dry Mass 254 kg 262 kg 263 kg 261 kg 259 kg 305 kg 229 kg (including marine gear) (660 Ib) (678 Ib) (580 Ib) (675 Ib) (571 Ib) (672 lb) (505 Ib) * Rating Condition: Temperature of fuel; 40 °C at fuel pump inlet; SO 8665 ** — The “total” oil quantity includes oil in oif pan, channels, coolers and filter. The effective amount of off shows the difference in maximum scale of the dipstick and minimum scale. kek Note: » Density of fuel: 0.835 to 0.845 g/cm? at 15 °C. Fuel temperature at the inlet of the fuel supply pump. * 1 hp metric = 0.7355 kw 158 JH Series Operation Manual YANMAR SPECIFICATIONS 4JH80, 4JH110 Marine Gear or Sail Drive 2F25 ZF25A (Mechanical (Mechanical SD60-4" Model ZF30M shift / KM4A2 KMH4A shift / KMH50V (coupled at Electric Electric boat builder) Shift) Shift) Type Mechanical | Hydraulicwet | Mechanical | Hydraulic wet multiple disk | Hydraulic wet Mechanical wet maliple | multiple disk wet cone clutch multiple disk | multiple friction disk clutch clutch clutch clutch disc clutch Reduction Ratio 2.15 {2.64 197/197 147/147 | 2.04/2.04 193/193 1.22 (1.22 2.23/2.23 (forward/reverse) | 2.70/2.64 2.80 / 2.80 2.14/2.14 | 2.45/2.45 | 2.29/2.29 1.58 / 1.58 2.49 / 2.49 2.63 / 2.63 2.48 / 2.48 2.08 / 2.08 2.71/2.71 2.47/2.47 Propeller Speed | 1444/1176 | 1574/1574 | 2115/2113 | 1520/1520 | 1607/1607 | 2542 / 2542 1391 / 1391 (forward/reverse) | 1150/1176 | 1108/1108 | 1451/1450 | 1263/1263 | 1354/1354 | 1963/1963 1245/ 1245 (min-1)* 1180/1179 1250/1250 | 1491 / 1491 1144/1144 | 1255 / 1255 Lubrication Splash Trochoid Centrifugal Trochoid pump Oil bath System pump pump Lubricating Oil 1.1L 1.8L 3.0L 2.0L 1.8L 5.4L 3.1L 8.3 qt) Capacity (total) (1.16 qt)" (1.90 qt)” (3.17 qt) (2.11 qt) (1.90 qt)” (5.71 qt) Long Reach (75 mm): 3.3L 3.4 qt) Lubricating Oil 0.2L - 0.3L 0.2L - - - Capacity (0.21 qt) (0.32 qt) (0.21 qt) (effective) Cooling System Seawater cooling : Weight 25 kg 33 kg 33 kg 32 kg 33 kg 69 kg 45 kg (9.2 lb) (65.1 Ib) (72.7 |b) (72.7 |b) (70.5 Ib) (72.7 |b) (152.1 Ib) Long Reach (75 mm): 49 kg (108.0 Ib) * — $D60-4; Only for 4JH80 ** At continuous power engine speed 3101 min-1 ZF30M, ZF25, ZF25A Lubricating oil: ATF ek YANMAR JH Series Operation Manual 159 SPECIFICATIONS This Page Intentionally Left Blank 160 JH Series Operation Manual “Wael AeA an RP SYSTEM DIAGRAMS PIPING DIAGRAMS Notation Description Screw Joint (Union an | Flange Joint —p— Eye Joint — Insertion Joint Drilled Hole ween Coolant Piping —--—-- _ Cooling Seawater Piping Lubricating Oil Piping Diesel Fuel Piping Note: x thickness. * Dimension of steel pipe: outer diameter * Dimension of rubber pipe: inner diameterx thickness. * Fuel rubber pipes (marked *) satisfy ENASO7840. YANAAR JH Series Operation Manual 161 SYSTEM DIAGRAMS 3JH40 with KM35P or KM35A or SD60-5 Marine Gear y oOoxoo-6ZTSOt Figure 1 162 JH Series Operation Manual YANMAR SYSTEM DIAGRAMS 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 —* 9.5 x t3.5 Rubber hose 9 —* 9.5 x t3.5 Rubber hose 10-—* 10 x 11.2 Steel pipe 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-9 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22-—Mixing elbow 23-25.4 x t4.3 Rubber hose 24-Heat exchanger 25— Main bearing 26 -—Lubrication oil inlet strainer 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-— Coolant temperature sensor 34-To Camshaft 35 — Thermostat 36-—From Cylinderhead 37 —To Cylinderblock 38 —Cooling Water Pump (coolant) 39-—Hot water connection return 40 -Lubrication oil pump 41 -Lubrication oil pressure control valve 42-9 x t3.5 Rubber hose 43-To Oil pan YWRANRGAR su Series Operation Manual 163 SYSTEM DIAGRAMS 3JH40 with ZF25A or FZ25 Marine Gear oe BL 5 © -H--+ < = foe] S| is] adie A iS] OQ ] Figure 2 164 JH Series Operation Manual YANMAR SYSTEM DIAGRAMS 1 —Fuel overflow 46 —Fuel cooler (Option) 2 -* 7x t4.5 Rubber hose 47 - Seawater filter (Locally 3 —Fuel inlet procured) 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 —* 9.5 x t3.5 Rubber hose 9 -—* 9.5 x t3.5 Rubber hose 10-—* 10 x 11.2 Steel pipe 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-9 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22-—Mixing elbow 23 —25.4 x t4.3 Rubber hose 24-Heat exchanger 25— Main bearing 26 —Lubrication oil inlet strainer 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-— Coolant temperature sensor 34-—To Camshaft 35 —- Thermostat 36-—From Cylinderhead 37 —To Cylinderblock 38 —Cooling Water Pump (coolant) 39—Hot water connection return 40 -Lubrication oil pump 41 -Lubrication oil pressure control valve 42-9 x t3.5 Rubber hose 43-To Oil pan 44 - Marine gear lubrication oil cooler 45-25 x t4.5 Rubber hose YWRANRGAR su Series Operation Manual 165 SYSTEM DIAGRAMS 4JH45/4JH57 with KM35P or KM35A2 or SD60-5 Marine Gear 57225-00K00 Oe £928 @26 45 a8 98 D B Cc A ong = = AN — oOo m \F> lry=== = = " e3 ay a Figure 3 166 JH Series Operation Manual WARIN AG GARE SYSTEM DIAGRAMS 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 —* 9.5 x t3.5 Rubber hose 9 —* 9.5 x t3.5 Rubber hose 10-—* 10 x 11.2 Steel pipe 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-9 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22-—Mixing elbow 23-25.4 x t4.3 Rubber hose 24-Heat exchanger 25— Main bearing 26 -—Lubrication oil inlet strainer 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-— Coolant temperature sensor 34-To Camshaft 35 — Thermostat 36-—From Cylinderhead 37 —To Cylinderblock 38 —Cooling Water Pump (coolant) 39-—Hot water connection return 40 -Lubrication oil pump 41 -Lubrication oil pressure control valve 42-9 x t3.5 Rubber hose YWRANRGAR su Series Operation Manual 167 SYSTEM DIAGRAMS 4JH45/4JH57 with KM4A1 Marine Gear 13174 ge SL Oe SV € 918 COXGO-9ZE4L90 Figure 4 168 JH Series Operation Manual VYANMAR SYSTEM DIAGRAMS 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 —* 9.5 x t3.5 Rubber hose 9 —* 9.5 x t3.5 Rubber hose 10-—* 10 x t1.2 Steel pipe 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-9 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 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 strainer 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 hose 35 —Hot water connection outlet 36 —Coolant temperature sensor 37 -— To Camshaft 38 — Thermostat 39-—From Cylinderhead 40-To Cylinderblock 41-Cooling Water Pump (coolant) 42-Hot water connection return 43 -Lubrication oil pump 44-Lubrication oil pressure control valve 45-9 x t3.5 Rubber hose YWRANRGAR su Series Operation Manual 169 SYSTEM DIAGRAMS 4JH45/4JH57 with ZF30M Marine Gear 3 S iy Vv go 2 fe q Yd qa. | Op ciwetWe € re ee Figure 5 170 JH Series Operation Manual VYANATAR SYSTEM DIAGRAMS 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 —* 9.5 x t3.5 Rubber hose 9 —* 9.5 x t3.5 Rubber hose 10-—* 10 x t1.2 Steel pipe 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-9 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 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 strainer 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 water connection outlet 35-— Coolant temperature sensor 36 -— To Camshaft 37 — Thermostat 38 —From Cylinderhead 39-To Cylinderblock 40-Cooling Water Pump (coolant) 41-Hot water connection return 42-Lubrication oil pump 43 -Lubrication oil pressure control valve 44-9 x t3.5 Rubber hose WANS JH Series Operation Manual 171 SYSTEM DIAGRAMS 4JH80/4JH110 (air cooled turbocharger) with KM4A2 Marine Gear ~ Of oe — 2918 ‘ = 35 Figure 6 172 JH Series Operation Manual VYANMAH SYSTEM DIAGRAMS 1 —Fuel overflow 46-28 x t4 Rubber hose 2 -—* 7 x t4.5 Rubber hose 47 —Hot water connection outlet 3 —Fuel inlet 48 — Coolant temperature sensor 4 —Fuel oil pre-filter 49-— Thermostat 5 -—* 7 x t4.5 Rubber hose 50-—Cooling Water Pump (coolant) 6 —Fuel filter (cartridge type) 51 —-—Hot water connection return 7 —* 7.5 x t3 Rubber hose 52—From Cylinderhead 8 —* 9.5 x t3.5 Rubber hose 53-—To Cylinderblock 9 —* 9.5 x t3.5 Rubber hose 54—-Lubrication oil pump 10-—* 10 x t1.2 Steel pipe 55 —Lubrication oil pressure 11 -—* 7.5 x t3 Rubber hose control valve 12-—Fuel supply pump 56-15 x t3.5 Rubber hose 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-13 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22—-Piston cooling oil jet 23-13 x t4 Rubber hose 24-13 x t4 Rubber hose 25-8 xt1 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 -— Turbocharger 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 —Air cooler 37 —Heat exchanger 38 — Main bearing 39-—Lubrication oil inlet strainer 40- To Camshaft 41-25.4 x t4.3 Rubber hose (option) 42-25.4 x t4.3 Rubber hose 43 —-Seawater inlet 44-Cooling water pump (seawater) 45-28 x t4 Rubber hose WR MAGA JH Series Operation Manual 173 SYSTEM DIAGRAMS +|© Ss|Cl=wo ° Ss2 |fo) |N°iwo| 4a o-—-4p <5m t -—}- | o < w+ TM Ir co = xr = o fo} ° 2 xe] —_ WSe J=O &Vv t { 213is:°4 |;a= cob) :_ sc=0soO Ir w So “ _—F Nw Figure 7 174 JH Series Operation Manual VYANMAH SYSTEM DIAGRAMS 1 —Fuel overflow 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—Hot water connection return 5 -—* 7 x t4.5 Rubber hose 51-—From Cylinderhead 6 —Fuel filter (cartridge type) 52-—To Cylinderblock 7 —* 7.5 x t3 Rubber hose 53-—Lubrication oil pump 8 —* 9.5 x t3.5 Rubber hose 54—-Lubrication oil pressure 9 —* 9.5 x t3.5 Rubber hose control valve 10-—* 10 x t1.2 Steel pipe 55-15 x t3.5 Rubber hose 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-13 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22—-Piston cooling oil jet 23—-Marine gear 24-8 xt1 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- Turbocharger 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 —Air cooler 36 —Heat exchanger 37 —Main bearing 38 —Lubrication oil inlet strainer 39- To Camshaft 40- 25.4 x t5 Rubber hose (option) 41-25. x t4.5 Rubber hose 42 -—Seawater inlet 43-Cooling water pump (seawater) 44-28 x t4 Rubber hose 45-28 x t4 Rubber hose 46—- Hot water connection outlet VAMP AR JH Series Operation Manual 175 SYSTEM DIAGRAMS 4JH80/4JH110 (air cooled turbocharger) with ZF30M Marine Gear Figure 8 176 JH Series Operation Manual YANMABR SYSTEM DIAGRAMS 1 —Fuel overflow 47 -— Thermostat 2 -*7 x t4.5 Rubber hose 48 —Cooling Water Pump (coolant) 3 —Fuel inlet 49 —Hot water connection return 4 —Fuel oil pre-filter 50-—From Cylinderhead 5 -—* 7 x t4.5 Rubber hose 51-To Cylinderblock 6 —Fuel filter (cartridge type) 52—-Lubrication oil pump 7 -* 7.5 x t3 Rubber hose 53-—Lubrication oil pressure 8 —* 9.5 x t3.5 Rubber hose control valve 9 -—* 9.5 x t3.5 Rubber hose 54-15 x t3.5 Rubber hose 10-—* 10 x t1.2 Steel pipe 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-13 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22—-Piston cooling oil jet 23-8 xt1 STKM 24 —- Marine gear lubrication oil Cooler 25-—To Oil pan 26—From Cylinder block 27-17 x t3 rubber hose 28 — Turbocharger 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-—-Air cooler 35 —Heat exchanger 36-—Main bearing 37 —Lubrication oil inlet strainer 38 —To Camshaft 39-25.4 x ts Rubber hose (option) 40-25. x t4.5 Rubber hose 41 —-Seawater inlet 42-Cooling water pump (seawater) 43-28 x t4 Rubber hose 44-28 x t4 Rubber hose 45 —Hot water connection outlet 46 - Coolant temperature sensor WR MAGA JH Series Operation Manual 177 SYSTEM DIAGRAMS 4JH80/4JH110 (water cooled turbocharger) with KM4A2 Marine Gear COxXGO-CEsso “Ce Gece Figure 9 178 JH Series Operation Manual YANMAR SYSTEM DIAGRAMS 1 —Fuel overflow 46 —28 x t4 Rubber hose 2 -—* 7 x t4.5 Rubber hose 47-28 x t4 Rubber hose 3 —Fuel inlet 48 — Hot water connection outlet 4 —Fuel oil pre-filter 49-—Coolant temperature sensor 5 -—* 7 x t4.5 Rubber hose 50-— Thermostat 6 —Fuel filter (cartridge type) 51-—Cooling Water Pump (coolant) 7 —* 7.5 x t3 Rubber hose 52—Hot water connection return 8 —* 9.5 x t3.5 Rubber hose 53-—From Cylinderhead 9 —* 9.5 x t3.5 Rubber hose 54—-To Cylinderblock 10-—* 10 x t1.2 Steel pipe 55 —Lubrication oil pump 11 -—* 7.5 x t3 Rubber hose 56 —Lubrication oil pressure 12-—Fuel supply pump control valve 13-—Common rail 57-15 x t3.5 Rubber hose 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-13 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22—-Piston cooling oil jet 23-13 x t4 Rubber hose 24-13 x t4 Rubber hose 25-8 xt1 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 strainer 41-To Camshaft 42-25.4 x t4.3 Rubber hose (option) 43-25.4 x t4.3 Rubber hose 44 -—Seawater inlet 45 -Cooling water pump (seawater) VAMP AR JH Series Operation Manual 179 SYSTEM DIAGRAMS 4JH80/4JH110 (water cooled turbocharger) with KMH4A or KMH50V-2 or ZF25A or ZF25 Marine Gear OxO0-eETZT90 0€ ar iz 968 Seo Oe € 918 Figure 10 180 JH Series Operation Manual YANMAR SYSTEM DIAGRAMS 1 —Fuel overflow 47 —Hot water connection outlet 2 -*7 x t4.5 Rubber hose 48 — Coolant temperature sensor 3 —Fuel inlet 49-— Thermostat 4 —Fuel oil pre-filter 50-—Cooling Water Pump (coolant) 5 -—* 7 x t4.5 Rubber hose 51 —-—Hot water connection return 6 —Fuel filter (cartridge type) 52—From Cylinderhead 7 -* 7.5 x t3 Rubber hose 53-—To Cylinderblock 8 —* 9.5 x t3.5 Rubber hose 54—-Lubrication oil pump 9 -—* 9.5 x t3.5 Rubber hose 55 —Lubrication oil pressure 10-—* 10 x 11.2 Steel pipe control valve 11 -—* 7.5 x t3 Rubber hose 56-15 x t3.5 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-13 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22—-Piston cooling oil jet 23—-Marine gear 24-8 xt1 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 strainer 40-To Camshaft 41-25.4 x t5 Rubber hose (option) 42-25. x t4.5 Rubber hose 43 —- Seawater inlet 44-Cooling water pump (seawater) 45 — 28 x t4 Rubber hose 46 — 28 x t4 Rubber hose WR MAGA JH Series Operation Manual 181 SYSTEM DIAGRAMS 4JH80/4JH110 (water cooled turbocharger) with ZF30M Marine Gear 0€ Oe : py 8b ' cel te) 8‘ eel co i Qt © ny a 3 | < a a) 1| g ag 3 oe ier] + f 918 NN iO) Wd LL. 63 $ ~ N N --—-- eo=- ev ef 69 Nl N Oo o-=- NN e9 7 N NSN i i eames0 Pe mee| il pil MK pe | | @ eb = et | qh Le4 LJ be EE BR ws | _ = Ha tt ieee a in Dey83) i PP for) | mib e ; , — Figure 11 182 JH Series Operation Manual YANMAR SYSTEM DIAGRAMS 1 —Fuel overflow 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—Hot water connection return 5 -—* 7 x t4.5 Rubber hose 51-—From Cylinderhead 6 —Fuel filter (cartridge type) 52-—To Cylinderblock 7 —* 7.5 x t3 Rubber hose 53-—Lubrication oil pump 8 —* 9.5 x t3.5 Rubber hose 54—-Lubrication oil pressure 9 —* 9.5 x t3.5 Rubber hose control valve 10-—* 10 x t1.2 Steel pipe 55-15 x t3.5 Rubber hose 11 -—* 7.5 x t3 Rubber hose 12-—Fuel supply pump 13-—Common rail 14-Fuel high-pressure pipe 6.35 x 11.675 Steel pipe 15-—Lubricating oil filter (cartridge type) 16—-Lubricating oil cooler 17-Fuel return pipe 18-13 x t3.5 Rubber hose 19-Oil pressure switch 20-Ojil pressure sensor 21 —Fuel injector 22—-Piston cooling oil jet 23-8 xt1 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 strainer 39- To Camshaft 40- 25.4 x t5 Rubber hose (option) 41-25. x t4.5 Rubber hose 42 -—Seawater inlet 43-Cooling water pump (seawater) 44-28 x t4 Rubber hose 45-28 x t4 Rubber hose 46—- Hot water connection outlet WR MAGA JH Series Operation Manual 183 SYSTEM DIAGRAMS This Page Intentionally Left Blank 184 JH Series Operation Manual “Wael AeA an RP WARRANTY USA ONLY YANMAR POWER TECHNOLOGY CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY EPA and ARB Emission Control Label EPA and ARB Emission Control Label for 3JH40 (kW < 37) for 4JH45 (kW < 37) (n =) —\ EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U’S EPA VARINE AND CALIFORNIA OFF-ROAD THIS ENGINE COMPLIES WITH U’S EPA MARINEAND CALIFORNIA OFF-ROAD REGULATIONS FOR 2025 M.Y. DIESEL ENGINES. REGULATIONS FOR 2025 MY. DIESEL ENGINES. ULTRA LOW SULFUR DIESEL FUEL ONLY, ULTRA LOW SULFUR DIESEL FUEL ONLY. ENGINE FAMILY : SYDXNO2.2E4N _ DISPLACEMENT: 1.642 LITERS ENGINE FAMILY: SYDXNO2.2E4N DISPLACEMENT : 2.190 LITERS ENGINE MODEL: 3JH40__E.C.S.: ECM EMDFI_ ENGINE POWER: 29 4kWW ENGINE MODEL :4JH45 £.C.S.:ECMEMDFI__ ENGINE POWER: 33.1 EPA STANDARDS NOX+HC : 5.8g/kW-hr CO : 5. 5g/kW-hr PM : 0.20gkWehr EPA STANDARDS NOx+HC : 5.8g/kW-ht CO : 5.5g/kW-hr PM : 0.20g/kW-hr APPLICATION : VARIABLE-SPEED PROPULSION ENGINES USED WITH APPLICATION : VARIABLE-SPEED PROPULSION ENGINES USED WITH FIXED-PITCH PROPELLERS. FIXED-PITCH PROPELLERS. REFER TO OWNER’S MANUAL FOR MAINTENANCE AND ADJUSTMENTS. REFER TO OWNER’S MANUAL FOR MAINTENANCE AND ADJUSTMENTS. YAA PIRI AGR vows cower tecxnovocy co. L10. ) XQ VYANMAR YANMAR POWER TECHNOLOGY CO.,LTD. Jay — 129674-07526-S Figure 1 Figure 2 YANMAR JH Series Operation Manual 185 WARRANTY USA ONLY EPA Emission Control Label for 4JH57 EPA Emission Control Label for 4JH110 EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION 7 THIS MARINE ENGINE COMPLIES WITH US. EPA REGULATIONS FOR THIS MARINE ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR 2025, ULTRA LOW SULFUR DIESEL FUEL ONLY. 2025.ULTRALOW SULFUR DIESEL FUEL ONLY, ENGINE FAMILY : SYDXNO2.2D4C ENGINE MODEL : 4JH57 ENGINE FAMILY : SYDXNO2,0D4C ENGINE MODEL: 4JH110 STANDARDS NOxtHC : 5agikWthr CO: 5 0gKkW-hr PM: O.20gKWhr STANDARDS NOXxtHC :5.8gkW-hr CO: 5.0ghkW-hr PM: O.15g/kW-hr APPLICATION : VARIABLE-SPEED PROPULSION ENGINES USED APPLICATION : VARIABLE-SPEED PROPULSION ENGINES USED WITH FIXED-PITCH PROPELLERS. WITH FIMED-PITCH PROPELLERS. . EMISSION CONTROL SYSTEM: ECM EM DF _ EMISSION CONTROL SYSTEM : ECM EM DFI TC CAC REFER 70 OWNER'S MANUAL FOR MAINTENANCE REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. SPECIFICATIONS AND ADJUSTMENTS. WAG RE ROI AGRR veer Power TECHNOLOGY co. Lib. } WAPI FAIA enwar rower TECHNOLOGY CO.L1D. 129675-07523-8 129677-07523-S Figure 3 Figure 5 EPA Emission Control Label for 4JH80 EMISSION CONTROL INFORMATION THIS MARINE ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR 2025. ULTRA LOW SULFUR DIESEL FUEL ONLY. ENGINE FAMILY ; SYDXNO2.0E4C ENGINE MODEL : 4JH80 STANDARDS NOx#HC : 5.8q/kWehr CO: 5.0g/kW-hr PM: 0.20g/kW-hr APPLICATION ; VARIABLE-SPEED PROPULSION ENGINES USED WITH FIXED-PITCH PROPELLERS. EMISSION CONTROL SYSTEM : ECM EM DFI TC CAC REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. WRAPGFVGZGEE venwe power TecuNnoLoey co.L10. } 129676-07523-S Figure 4 186 JH Series Operation Manual VYVANAIAR YANMAR EMISSION CONTROL SYSTEM WARRANTY STATEMENT YOUR WARRANTY RIGHTS YANMAR’s warranty coverage: AND OBLIGATIONS: The 2025, 2026 or 2027 model year heavy-duty off-road (marine Cl) engines The California Air Resources Board are covered by the warranty period (CARB), the United States Environmental indicated in a table below. Protection Agency (EPA) and YANMAR POWER TECHNOLOGY CO., LTD. Engine Model Warranty Period (YANMAR) is pleased to explain emission 3JH40, 4JH45 5 years or 3000 hours of use, control system warranty on your 2025, 2026 (19 s kW < 37) whichever comes first. or 2027 model year marine 4JH57, 4JH80, 5 years or 5000 hours of use, compression-ignition (Cl) engine. 4JH110 whichever comes first. In California, new heavy-duty off-road (37 skW) (marine Cl) engines must be designed, built and equipped to meet the State’s stringent If any emission-related part on your engine anti-smog standards. In the remaining forty is defective, the part will be repaired or nine (49) states, new marine Cl engines replaced by YANMAR. must be designed, built and equipped to This warranty is transferable to each meet the United States EPA emissions subsequent purchaser for the duration of standards. YANMAR must warrant the the warranty period. emission control system on your engine for YANMAR recommends that repair or the periods of time listed below provided replacement of any warranted parts be there has been no abuse, neglect or performed at an authorized YANMAR improper maintenance of your engine. dealer or distributor. Your emission control system may include parts such as the fuel injection system, the air induction system. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, YANMAR will repair your heavy-duty off-road (marine Cl) engine at no cost to you including diagnosis, parts and labor. YANMAR JH Series Operation Manual 187 YANMAR EMISSION CONTROL SYSTEM WARRANTY STATEMENT Warranted parts not scheduled for Warranted Parts: replacement as required maintenance in the Operation Manual shall be warranted This warranty covers engine components for the warranty period. Warranted parts that are a part of the emission control scheduled for replacement as required system of the engine as delivered by maintenance in the operation manual are YANMAR to the original retail purchaser. warranted for the period of time prior to the Such components may include the first scheduled replacement. Any part following: repaired or replaced under warranty shall * Fuel Injection System be warranted for the remaining warranty * Intake Manifold period. * Exhaust Manifold During the warranty period, YANMAR is * Positive Crankcase Ventilation (PCV) liable for damages to other engine System components caused by the failure of any warranted part during the warranty period. * Electronic Engine Control Units and its associated Sensor and Actuators Any replacement part which is functionally identical to the original equipment part in * Hoses, belts, connectors and all respects may be used in the assemblies used in above systems maintenance or repair of your engine, and * Emission Control Information Labels shall not reduce YANMAR’s warranty Since emissions-related parts may vary obligations. Add-on modified parts that are slightly between models, certain models not exempted may not be used. The use of may not contain all of these parts and any non-exempted add-on or modified other models may contain the functional parts shall be grounds for disallowing a equivalents. warranty. Exclusions: Failures other than those arising from defects in material and/or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, improper storage or use of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable and/or consumable items made in connection with scheduled maintenance. YANMAR disclaims any responsibility for incidental or consequential damages such as loss oftime, inconvenience, loss of use of marine vessel / engine or commercial Joss. 188 JH Series Operation Manual VYANMAH YANMAR EMISSION CONTROL SYSTEM WARRANTY STATEMENT Owners Warranty Customer Assistance: Responsibilities: If you have any questions regarding your * As the off-road (marine Cl) engine warranty rights and responsibilities or owner, you are responsible for the would like information on the nearest performance ofthe required authorized YANMAR dealer or distributor, maintenance listed in your owner’s you should consult YANMAR Marine manual. International Americas Division. YANMAR recommends that you retain all Website: https:/Awww.yanmar.com/marine documentation, including receipts E-mail: aftersales@yanmar-marine.com covering maintenance on your off-road Toll free telephone number: 1-727-803-6565 (marine Cl) engine, but YANMAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. * As the off-road (marine Cl) engine owner, you should however be aware that YANMAR may deny your warranty coverage if your off-road (marine Cl) engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. * Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California’s and EPA’s emission requirements. * You are responsible for initiating the warranty process. The ARB and EPA suggest that you present your off-road (marine Cl) engine to an authorized YANMAR dealer as soon as problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. YVR AGAR JH Series Operation Manual 189 YANMAR EMISSION CONTROL SYSTEM WARRANTY STATEMENT Maintenance Log Stamp or Date Operating Hours Maintenance Performed Dealer Name A Signature 190 JH Series Operation Manual “Wael AeA an RP YANMAR EMISSION CONTROL SYSTEM WARRANTY STATEMENT Stamp or Date Operating Hours Maintenance Performed Dealer Name . Signature YWRANRGAR su Series Operation Manual 191 Version January 2016 Declaration of Conformity for Recreational Craft Propulsion Engines (inboard engines and stern drive engines without integral exhaust) with the requirements of Directive 2013/53/EU (To be completed by manufacturer or, if mandated, authorised representative) Name of engine manufacturer: Yanmar Power Technology CO., Lid. Address: 1-32, Chayamachi, Kita-ku Town: Osaka Post Code: 530-8311 Country: Japan Name of Authorised Representative: Yanmar Marine International B.V. Address: Brugplein 11 Town: Almere Post Code: 1332 BS Country: the Netherlands Name of Notified Body for exhaust emission assessment: DNV SE Address: Brooktorkai 18 Town: Hamburg Post Code: 20457 Country: Germany ID Number:0098 Conformity assessment medule used for exhaust emissions: [] B+C/C1 Kj] B+D IT] BEL] BeFOIGOH or engine type-approved according to: [[] Directive 97/68/EC (1) EC Regulation No 595/2009 Other Community Directives applied: 2014/30/EU DESCRIPTION OF ENGINE TYPE(s) Main Propulsion ExhaustType: Combustion Type: Combustion cycle: 1 With integral exhaust KJ Internal combustion, Diesel (CI) Ol 2 stroke Without integral exhaust (Internal combustion, Petrol (SI) 4 stroke (Other IDENTIFICATION OF ENGINE(S) COVERED BY THIS DECLARATION OF CONFORMITY Name of engine model Unique engine identification EC Type—examination certificate or engine family: number(s) or engine family code(s) _| or type-approval certificate number DNV Engine family: RCD2-2YM15X1 RCDBO0000BF Engine models: 2VM15, 3¥M20 Engine family: RCD2-3YM30X1 RCDBO0000BM Engine models: 3YM30AE Engine family: RCD2-3JH5X1 RCDBOG0OOBW Engine models: 3JHS5E Engine family: RCD2-4JH57X1 RCDBOOGOOBU Engine models: 43357, 47H45 Engine family: RCD2-4JH11X1 RCDBOO000BT Engine models: 4JH110, 47H80 Engine family: RCD2-3JH40X1 RCDBOOO00BV Engine models: 3JH40 This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the manufacturer that the recteational craft propulsion engine(s) mentioned above fulfil(s) the requirements specified in Article 4 (1) and Annex I of Directive 2013/53/EU. a Name / function:_Taro Kitamura / President Signature and title: President (identification of the person empowered to sign on behalf (or an equivalent marking) of the engine manufacturer or his authorised representative) Date and place of issue: (yy/mm/dd) 21/04/09, Almere: The Netherlands Partial Application , see tech. file Partial application, see tech. file Other reference documents 1 Other reference documents Other proof of conformity Harmonised standards Harmonised standards Essential requirements Specify the harmonised ? standards or other reference documents used See technical. file Full Application Full Application {reference to relevant articles in (with year of publication like “EN {SO 8666:2002”) Annex IB & IC of the Directive) All lines right of ticked boxes must be filled in ms] fa Ss one box per line iS io Oooo ooo Oooo ooo nooo ooo Oooo ooo Oooo ooo Inboard Engine (Annex | A. 5.1.1) /entilation (Annex | A.5.1.2) Exposed parts (Annex | A.5.1.3) Fuel system - General (Annex | A.5.2.1} Electrical System (Annex | A.5.3) Steering System (Annex | A.5.4) Fire protection - General (Annex | A.5.6.1) Discharge prevention (Annex | A.5.8) oO OO |e oOoOj}o Oooo OOo OOOO Propulsion Engine Identification (Annex | B.1) Exhaust Emission Requirements (Annex| B. 2) EN ISO 18854: 2015 Durability (Annex | B.3) Owner's manual (Annex | B.4) See Declaration of Conformity of the recreational craft in which the engine(s) has (have) been installed ' Such as non-harmonised ds, rules, 1 ? Standards published in EU Official Journal This Page Intentionally Left Blank YANMAR POWER TECHNOLOGY CO., LTD. @ Yanmar Marine International B.V. Brugplein 11, 1332 BS Aimere-de Vaart, Netherlands Phone: +31-36-5493534 Fax: +31-36-5493219 https:/Avww. yanmar.com/marine @ Yanmar Marine International Asia Co., Ltd. 5-3-1, Tsukaguchi Honmachi, Amagasaki, Hyogo 661-0001, Japan Phone: +81-6-6428-3131 Fax: +81-6-6421-2201 https: /Awww.yanmar.com/marine Overseas Office @ Yanmar Asia (Singapore) Corporation Pte. Ltd. (YASC) 4 Tuas Lane, Singapore 638613 Phone: +65-6861-3855 Fax: +65-6862-5189 https: /Avww. yanmar.com/sg/ @ YANMAR Marine International Americas Division 5400 118" Avenue N., Clearwater, FL 33760, USA Phone: +1-727-803-6565 Fax: +1-727-527-7013 hitps://www. yanmar.com/marine @ Yanmar Engine (Shanghai) Co., Ltd. Room 1101-1106, No.757 Mengzi Road, Huangpu District, Shanghai 200023 PRC Phone: +86-21-2312-0638 Fax: +86-21-6880-8090 https: /Avww.yanmar.corm/en/ As of November ist, 2022 OPERATION MANUAL 3JH40, 4JH45, 4JH57, 4JH80, 4JH110 1st edition: October 2013 12th edition: January 2023 13th edition: January 2024 14th edition: November 2024 15th edition: February 2025 issued by: YANMAR POWER TECHNOLOGY CO., LTD. Edited by: YANMAR GLOBAL CS CO., LTD. ie YANMAH YANMAR POWER TECHNOLOGY CoO., LTD. https://www.yanmar.com Feb.2025-0