Barrus 4JH57 Manuel utilisateur

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.

RDG603A29 –Issue 4

Page 2 of 24

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.

RDG603A29 –Issue 4

Page 3 of 24

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.

RDG603A29 –Issue 4

Page 4 of 24

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.

RDG603A29 –Issue 4

Page 5 of 24

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

RDG603A29 –Issue 4

Page 6 of 24

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.

 
RDG603A29 –Issue 4 
 
Page 7 of 24 
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
 

RDG603A29 –Issue 4

Page 8 of 24

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.

RDG603A29 –Issue 4

Page 9 of 24

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.

RDG603A29 –Issue 4

Page 10 of 24

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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