Barrus 4JH57 User manual

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

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SAFETY
E.P. Barrus is concerned for your safety. We use safety statements throughout the manual
to call your attention to the potential hazards associated with the operation of your engine.
Follow the precautions listed throughout the manual before operation, during operation and
during servicing/maintenance procedures for your safety, the safety of others and to protect
the performance of your engine.
Safety alert symbol appears throughout the manual. It meansattention, be alert as your safety
is involved. Please read and follow the message that appears after the safety alert symbol.
NOTICE:
This indicates a situation which can cause damage to the
machine, personal property and/or the environment or cause the
equipment to operate improperly
CAUTION:
This indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
WARNING:
This indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
DANGER:
This indicates a hazardous situation which, if not avoided, will
result in death or serious injury.

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Engine Details
Engine Number:
Please enter your engine serial number in the space provided above. Please quote the
engine identification number during any enquiry or when ordering spare parts. Information
about the engine serial number and its location on the engine can be found in SECTION 2 of
the manual.

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Operators Manual
NOTICE:
THIS MANUAL FORMS AN INTEGRAL PART OF THE ENGINE IT ACCOMPANIES, IF
A TRANSFER OF TITLE OCCURS, IT MUST ALWAYS BE HANDED OVER TO THE
NEW OWNER.
Thank you for purchasing this 4JH57 Barnes Engine from E.P.Barrus. This manual has been
compiled to help you to operate your engine and its associated parts with safety and pleasure.
Please read it carefully in conjunction with the Yanmar Manual and familiarise yourself with
the engine and its parts before operation.
The information and recommendations given in this manual are based on the latest
information available at the time of publication. E.P.Barrus reserve the right to change the
specification of its products and manuals without prior notice.
Depending upon the equipment specification of the engine and accessories fitted, there may
be discrepancies with the information presented in this handbook. No claims may be
pursued in this respect.

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WARRANTY
This UK Limited Warranty provides coverage for five (5) years (or 2000 hours whichever
occurs first) for recreational users and three (3) years (or 2000 hours whichever occurs first)
for commercial users from the date of warranty registration. The warranty is for non-
serviceable items. The repair or replacement of parts, or the performance of service under
this warranty, does not extend the life of this warranty beyond its original expiry date.
To ensure that you have been registered for your warranty, please ask your Boat Builder or
Engine Supplier to provide your portion of the registration form.
The Warranty will only apply if the following have been carried out:
1) The boat builder or engine installer has completed the Boat Builder Section on the Service
Record Card (located at the back of this manual) regarding hand over and commissioning of
boat.
2) The registration form has been completed and returned to E.P Barrus.
Engine alternator, starter motor and electrical components are only covered by a one (1) year
warranty.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE
Warranty coverage is only available from an authorised dealer in the country in which the
sale occurred. Routine maintenance outlined in the Owner’s Manual must be performed using
genuine parts in order to maintain warranty coverage. If the customer performs maintenance,
Barrus reserves the right to make future warranty coverage possible only with proof of proper
maintenance.
WARRANTY CLAIMS
Warranty claims shall be made by an authorised dealer or boat builder.
The dealer or boat builder will then arrange for the inspection and any necessary repairs. If
the repairs carried out are not covered by the warranty, the purchaser shall pay for all related
labour and material, and any other expenses associated with that service.
WHAT IS NOT COVERED
This limited warranty does not cover routine maintenance items, adjustments, normal wear
and tear, damage caused by abnormal use, operation of the product in a manner inconsistent

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with the recommended operation/duty cycle section of the Owner’s Manual, accident,
submersion, improper installation (proper installation specification and techniques are set
forth in the Operations and First time running sections in this manual), use of an accessory
or part not manufactured or sold by us, or alteration or removal of parts. Expenses related
to crane-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance
coverage, loan payments, loss of time, loss of income, or any other types of accidental or
consequential damages are not covered by this warranty.
Damage due to rust or corrosion, submersion, or unreasonable exposure to the environment,
such as exposure to high humidity, rain fall, or seawater, or conditions resulting in the freezing
of cooling water are also not covered.
Engine and fuel equipment is not covered by warranty if bio-diesel is used in the fuel system.
Also if no type of water trap is incorporated into the fuel system.

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Index Page
SECTION 1 –Safety Precautions .................................................................8
1. General...................................................................................................8
2. Lifting......................................................................................................8
3. Rotating Shafts and Belts........................................................................8
4. Exhaust System......................................................................................9
5. Launching and Lifting Boats....................................................................9
6. Batteries..................................................................................................9
SECTION 2 –Engine Identification.............................................................11
SECTION 3 –Component Identification.....................................................12
1. 4JH57 Barnes.......................................................................................12
2. 4JH57 Barnes 180 ................................................................................13
3. 4JH57 Barnes 24 120 ...........................................................................14
4. Engine Mounts......................................................................................15
SECTION 4 –Installation.............................................................................16
1. Calorifier ...............................................................................................16
SECTION 5 –Operation...............................................................................17
1. Starting the engine for the first time.......................................................17
2. Starting Procedure................................................................................17
3. Stopping Procedure ..............................................................................17
SECTION 6 –Service Procedure................................................................18
1. Engine Oil and Filter Change................................................................18
2. Disposal of Oil and Related Items.........................................................18
SECTION 7 –Wiring Diagrams...................................................................20
1. 4JH57 Barnes Engine Loom .................................................................20
2. 4JH57 Barnes Panel Loom ...................................................................21
SECTION 8 –Technical Data ......................................................................22
1. Dry Weight of Engine Data....................................................................22
SECTION 9 –Additional Part Numbers......................................................23
SECTION 10 –Afterlife Recycling ..............................................................24

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SECTION 1 –Safety Precautions
1. General
NOTICE:
NEVER PERMIT ANYONE TO OPERATE THE ENGINE WITHOUT PROPER
TRAINING.
It is the responsibility of the installer/operator to ensure that the finished installation complies
with CE Marking, the relevant Health & Safety requirements and the recreational craft
directive before commissioning.
Ensure that the engine battery isolator switch is in the off position and the key removed from
the control panel before carrying out any maintenance or repairs.
2. Lifting
DANGER:
CRUSH HAZARD! NEVER STAND UNDER A HOISTED ENGINE. IF THE HOIST
MECHANISM FAILS, THE ENGINE WILL FALL ON YOU, CAUSING SERIOUS INJURY
OR DEATH.
The Lifting points supplied with the engine are for lifting the engine/gearbox only. A suitable
spreader bar must be employed to prevent over-stressing either bracket during any lift.
3. Rotating Shafts and Belts
WARNING:
SEVERE HAZARD! KEEP HANDS AND OTHER BODY PARTS AWAY FROM
MOVING/ROTATING PARTS. WEAR TIGHT FITTING CLOTHING AND KEEP YOUR
HAIR SHORT OR TIE BACK. REMOVE ALL JEWELLERY BEFORE COMMENCING
WORK. CHECK BEFORE STARTING THE ENGINE THAT ANY TOOLS OR RAGS
USED DURING MAINTENANCE HAVE BEEN REMOVED FROM THE AREA.

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The engine and its accessories are not intended to be put into operation until they are
integrated into the boat as a whole. No person should be in the engine compartment and the
engine cover or deck hatches should be closed whilst the engine is running.
4. Exhaust System
WARNING:
EXHAUST HAZARD! NEVER OPERATE ENGINE IN A BOATS ENGINE BAY
WITHOUT PROPER VENTILATION. NEVER BLOCK VENTS OR OTHER MEANS OF
VENTILATION. ALL COMBUSTION ENGINES CREATE CARBON MONOXIDE GAS
DURING OPERATION. ACCUMULATION OF THIS GAS COULD CAUSE ILLNESS OR
EVEN DEATH.
WARNING:
BURN HAZARD! WAIT UNTIL THE EXHAUST COOLS BEFORE YOU TOUCH IT.
Exhaust gases may have temperatures as high as 650°C and contain elements which are
harmful if ingested.
It is therefore essential that exhaust systems are gas tight and lagged to prevent accidental
burning and inhalation of exhaust gases when inside the boat cabin.
5. Launching and Lifting Boats
Care must be taken when launching or craning new boats into or out of the waterway, so that
water does not enter the engine via the exhaust system or air vents. It is recommended that
these are blocked temporarily whilst undertaking this procedure.
6. Batteries
DANGER:
EXPLOSION HAZARD! NEVER SHORT OUT THE BATTERY TERMINALS,
INCLUDING WHEN CHECKING THE REMAINING BATTERY CHARGE THIS WILL
RESULT IN A SPARK AND MAY CAUSE AN EXPLOSION OR FIRE.

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WARNING:
BURN HAZARD! BATTERIES CONTAIN SULPHURIC ACID. NEVER ALLOW
BATTERY FLUID TO COME IN CONTACT WITH SKIN, EYES OR CLOTHING. SEVERE
BURNS COULD RESULT. MAKE SURE THE CORRECT PERSONAL PROTECTION
EQUIPMENT IS WORN.
•Batteries can produce explosive gases; keep sparks andflames away from the battery.
NO SMOKING
•Batteries contain sulphuric acid; if splashed on skin or eyes, flush well with water and
seek medical advice.
•Keep battery tops and battery compartment ventilated at all times
•If disconnecting the battery; remove the earth lead FIRST; and re-connect it last.
•If charging the battery; ensure that the charger is switched off before connecting and
disconnecting.
•Do not tip the battery on its side.
•Please see label on battery or manufacturer’s instructions for specific information.

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SECTION 2 –Engine Identification
The engine serial number can be found engraved into the brass plate on the top of the engine
rocker cover and stamped to the crankcase next to the starter motor.
An example of the engine identification plate is shown below (Figure 1):
Figure 1: Engine Identification Badge
Description of Models:
Abbreviation
Type of Engine
Description*
WB
Work Boat
Seawater/Heat Exchanger cooled, dry exhaust manifold
with either a dry exhaust system (same as a Canal Boat)
or water injected exhaust system. Can also be used for
sea going applications
*Note: There are a number of optional extras that may be fitted to an engine that are not
listed here.
Description
1
Engine Model
2
Serial Number
3
Indicates Model Type or Optional Extras:
WB = Work Boat
D = Deluxe Panel
3 = 3:1 Ratio Gearbox
XX-XXXXX-XX

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SECTION 3 –Component Identification
1. 4JH57 Barnes
Figure 2: 4JH57 Barnes Left Side (Viewed from front)
Figure 3: 4JH57 Barnes Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
125 Amp 12 Volt Alternator
2
120 Amp 24 Volt Alternator
3
Calorifiers
4
Water Pump
5
Oil Cooler
Description*
6
Oil Filter
7
Fuel Filter

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2. 4JH57 Barnes 180
Figure 4: 4JH57 Barnes 180 Left Side (Viewed from front)
Figure 5: 4JH57 Barnes 180 Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
180 Amp 24 Volt Alternator
2
Calorifiers
3
Water Pump
4
Oil Cooler
Description*
5
Oil Filter
6
Fuel Filter

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3. 4JH57 Barnes 24 120
Figure 6: 4JH57 Barnes 24 120 Left Side (Viewed from front)
Figure 7: 4JH57 Barnes 24 120 Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
120 Amp 24 Volt Alternator
2
Calorifiers
3
Water Pump
4
Oil Cooler
Description*
5
Oil Filter
6
Fuel Filter

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4. Engine Mounts
There are two different types of engine mounts fitted to the engine. The engine mounts fitted
to the front and the rear of the engine have different numbers stamped on them. The front
mounts have a 200 stamped on them and the rear mounts have a 150 stamped on them. The
mounts should not be changed front to rear or rear to front as they are designed to carry
different loads.
Figure 8: Engine Mounts
Front of engine
Rear of engine
Mount with 250 Stamp
Mount with 150 Stamp

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SECTION 4 –Installation
1. Calorifier
•The temperature of coolant flowing to the calorifier from the engine can be between
85 and 90°C. A blender valve must be incorporated in the calorifier / hot water system
outlet to lower the hot water temperature for domestic use.
•The hose connections for the calorifier are for a 5/8” internal diameter hose.
•The connections for the calorifier are shown on (Figure 9)
Connections on Engine
4JH57 Barnes
Figure 9: Calorifier Connections
Inlet
Outlet

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SECTION 5 –Operation
NOTICE:
REFER TO THE YANMAR MANUAL PRIOR TO STARTING THE ENGINE.
1. Starting the engine for the first time
•Remove ignition key.
•Ensure all oil and coolant levels are checked.
•Ensure both the engine and domestic batteries are connected. All battery master
switches must be turned on. Failure to do so may damage the domestic alternator.
•Ensure that the raw water seacock is turned on.
2. Starting Procedure
•Ensure there is no one in the engine compartment.
•Ensure the engine compartment door is closed.
•Ensure the gearshift control lever & throttle lever are set to neutral and that all persons
are clear of any moving parts.
•Insert ignition key.
•Turn key to on position.
•The engine will start to crank for a set period of time and then start.
•If the engine fails to start, it will try this procedure a further two times. If the engine still
fails to start the “Fail to Start” light will illuminate. Turn the key to stop position and
contact the operator.
•Stop engine if any abnormal noises are detected.
•Visually check the engine for oil, fuel and coolant leaks, after initial start-up and at
regular intervals. Note: Engine must be stopped to carry out this check).
3. Stopping Procedure
•Move gearshift control lever & throttle lever to idle position.
•Turn key to off position.

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SECTION 6 –Service Procedure
NOTICE:
REFER TO THE YANMAR MANUAL PRIOR TO CARRYING OUT ANY SERVICE OR
MAINTENANCE WORK.
WARNING:
PRIOR TO CARRYING OUT ANY SERVICE OR MAINTENANCE WORK MAKE SURE
THE RELEVANT PERSONAL PROTECTION EQUIPMENT IS WORN.
1. Engine Oil and Filter Change
WARNING:
BURN HAZARD! WAIT UNTIL THE ENGINE COOLS SLIGHTLY BEFORE YOU DRAIN
THE ENGINE OIL. HOT ENGINE OIL MAY SPLASH AND BURN YOU.
•Change the engine oil while the engine is still warm.
•Remove the blanking plug in the sump pump spout (6mm Allen key).
•Place a plastic tube over the spout and into a container. Operate the pump handle to
empty the sump. Note: Remember to refit the blanking plug afterwards.
•To replace the engine oil and filter please follow the procedure as specified in the
Yanmar Marine Engine Manual.
2. Disposal of Oil and Related Items
NOTICE:
ALWAYS BE ENVIRONMENTALLY RESPONSIBLE.
•Please dispose of used oil and oil filters safely with due regard for the environment
and take to your local waste oil disposal point.

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•Do not allow oil or contaminated parts to enter the inland water way system.

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SECTION 7 –Wiring Diagrams
1. 4JH57 Barnes Engine Loom