Yanmar 4JH45 Manuel utilisateur

MARINE ENGINES

OPERATION MANUAL

4JH45

4JH57

4JH80

4JH110

http://yanmar.com 0AJHC-M00011

OPERATION MANUAL 4JH45 4JH57 4JH80 4JH110

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ڦMarine Operations Business

Quality Assurance Division

Overseas Office

ڦYanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands

Phone: +31-36-5493200 Fax: +31-36-5493209

ڦYanmar Asia (Singapore) Corporation Pte Ltd. (YASC)

4 Tuas Lane, Singapore 638613

Phone: +65-6861-3855 Fax: +65-6862-5189

5-3-1, Tsukaguchi-honmachi, Amagasaki

Hyogo, 661-0001, Japan

Phone: +81-6-6428-3251 Fax: +81-6-6421-5549

ڦYanmar Engine (Shanghai) Co., Ltd.

10F, E-Block Poly Plaza, No.18 Dongfang Road

Pudong Shanghai, China P.R.C. 200120

Phone: +86-21-6880-5090 Fax: +86-21-6880-8090

ڦYanmar America Corporation (YA)

101 International Parkway

Adairsville, GA 30103, U.S.A.

Phone: +1-770-877-9894 Fax: +1-770-877-9009

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 are registered trademarks of YANMAR CO., LTD. in

Japan, the United States and/or other countries.

No part of this 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 CO., LTD.

MODEL

OPERATION MANUAL CODE

4JH45, 4JH57, 4JH80, 4JH110

0AJHC-M00011

1st edition: October 2013

2nd edition: June 2014

OPERATION MANUAL

4JH45, 4JH57, 4JH80, 4JH110

Issued by: YANMAR CO., LTD. Marine Operations Business

Edited by: YANMAR TECHNICAL SERVICE CO., LTD.

JH Series Operation Manual i

TABLE OF

CONTENTS

Page

INTRODUCTION .............................................................. 1

RECORD OF OWNERSHIP ...................................... 2

SAFETY ........................................................................... 3

SAFETY PRECAUTIONS .......................................... 4

General Information ............................................. 4

Before You Operate............................................. 4

During Operation and Maintenance..................... 4

LOCATION OF SAFETY DECALS ............................ 8

PRODUCT OVERVIEW ................................................. 11

YANMAR 4JH COMMON RAIL SERIES

FEATURES AND APPLICATIONS .......................... 11

New Engine Break-In......................................... 12

COMPONENT IDENTIFICATION ............................ 13

Right Side (Viewed from Flywheel)

- 4JH45/4JH57................................................... 13

Left Side (Viewed from Flywheel)

- 4JH45/4JH57................................................... 13

Right Side (Viewed from Flywheel)

- 4JH80/4JH110................................................. 14

Left Side (Viewed from Flywheel)

- 4JH80/4JH110................................................. 14

NAMEPLATES ......................................................... 15

FUNCTION OF MAJOR COMPONENTS ................ 16

ELECTRONIC CONTROL SYSTEM........................ 17

MAIN ELECTRONIC CONTROL COMPONENTS

AND FEATURES ..................................................... 18

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TABLE OF CONTENTS

ii JH Series Operation Manual

CONTROL EQUIPMENT.......................................... 19

Instrument Panel (Optional) ............................... 19

Accessory power output..................................... 29

Single-Lever Remote Control Handle ................ 30

VESSEL CONTROL SYSTEM (VC10)..................... 31

Display ............................................................... 32

BEFORE YOU OPERATE .............................................. 35

INTRODUCTION ...................................................... 35

SAFETY PRECAUTIONS......................................... 35

DIESEL FUEL........................................................... 36

Diesel Fuel Specifications .................................. 36

Filling the Fuel Tank........................................... 39

Bleeding the Fuel System .................................. 40

Priming the Fuel System .................................... 41

ENGINE OIL ............................................................. 41

Engine Oil Specifications .................................. 41

Engine Oil Viscosity ........................................... 42

Checking the Engine Oil..................................... 42

Adding Engine Oil .............................................. 43

MARINE GEAR OR SAIL DRIVE OIL ...................... 43

Marine Gear Oil Specifications........................... 43

Sail Drive Oil Specifications ............................... 43

Checking Marine Gear Oil.................................. 44

Adding Marine Gear Oil...................................... 44

Checking and Adding Sail Drive Oil ................... 44

ENGINE COOLANT ................................................. 45

Engine Coolant Specifications ........................... 45

Coolant (Closed Cooling System) ...................... 45

Checking and Adding Coolant............................ 46

ENGINE OPERATION .................................................... 49

INTRODUCTION ...................................................... 49

SAFETY PRECAUTIONS......................................... 49

OPERATION (B25,C35-TYPE INSTRUMENT

PANEL)..................................................................... 51

Starting the Engine............................................. 51

If the Engine Fails to Start.................................. 52

Starting at Low Temperatures............................ 52

After the Engine has Started .............................. 53

REMOTE CONTROL HANDLE OPERATION.......... 53

Acceleration and Deceleration ........................... 53

Shifting the Engine ............................................. 53

Switching to Trolling (KMH4A Only)................... 54

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TABLE OF CONTENTS

JH Series Operation Manual iii

12/05

CAUTIONS DURING OPERATION ......................... 55

SHUTTING DOWN THE ENGINE ........................... 57

Normal Shutdown .............................................. 57

Emergency Shutdown ....................................... 58

Emergency Stop Switch

(option: usually equipped near the instrument

panel)................................................................. 59

CHECKING THE ENGINE AFTER OPERATION .... 59

OPERATION (VC10: VESSEL CONTROL

SYSTEM) ................................................................. 60

Starting the Engine ............................................ 60

Station Protect ................................................... 62

Sys on by ID, Start by ID ................................... 62

Owner ID Change.............................................. 62

If the Engine Fails to Start ................................. 63

Starting at Low Temperatures ........................... 63

After the Engine has Started ............................. 63

WARM UP MODE (SHIFT DISCONNECT) ............. 64

THROTTLE AND SHIFT CONTROL........................ 65

Neutral ............................................................... 65

Forward ............................................................. 65

Reverse ............................................................. 65

Forward (Reverse) to Reverse (Forward).......... 65

ENGINE SPEED LIMIT MODE ................................ 66

CAUTIONS DURING OPERATION ......................... 66

SHUT-DOWN THE ENGINE (STOPPING).............. 68

Normal Stopping................................................ 68

Emergency Stop ................................................ 69

CONTROL THE BACKUP PANEL........................... 70

CHECKING THE ENGINE AFTER OPERATION .... 71

PERIODIC MAINTENANCE........................................... 73

INTRODUCTION...................................................... 73

SAFETY PRECAUTIONS ........................................ 73

PRECAUTIONS ....................................................... 75

The Importance of Periodic Maintenance .......... 75

Performing Periodic Maintenance ..................... 75

The Importance of Daily Checks ....................... 75

Keep a Log of Engine Hours and Daily Checks 75

Yanmar Replacement Parts .............................. 75

Tools Required .................................................. 75

Ask Your Authorized Yanmar Marine Dealer or

Distributor for Help............................................. 75

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TABLE OF CONTENTS

iv JH Series Operation Manual

EPA MAINTENANCE REQUIREMENTS ................. 78

EPA Requirements for USA and Other

Applicable Countries .......................................... 78

EPA Requirements............................................. 78

Installation of Exhaust Sampling Port ................ 80

PERIODIC MAINTENANCE SCHEDULE ................ 81

PERIODIC MAINTENANCE PROCEDURES........... 84

Daily Checks ...................................................... 84

After Initial 50 Hours of Operation...................... 85

Every 50 Hours of Operation.............................. 91

Every 250 Hours of Operation............................ 93

Every 500 Hours of Operation............................ 99

Every 1000 Hours of Operation........................ 100

TROUBLESHOOTING.................................................. 103

SAFETY PRECAUTIONS....................................... 103

TROUBLESHOOTING AFTER STARTING ........... 103

TROUBLESHOOTING INFORMATION ................. 104

TROUBLESHOOTING CHART .............................. 105

FAILSAFE DIAGNOSIS FUNCTIONAL

SPECIFICATION CHART....................................... 110

LONG-TERM STORAGE.............................................. 115

PREPARE ENGINE FOR LONG-TERM

STORAGE .............................................................. 115

DRAIN SEAWATER COOLING SYSTEM.............. 116

RETURNING THE ENGINE TO SERVICE ............ 117

SPECIFICATIONS ........................................................ 119

PRINCIPAL ENGINE SPECIFICATIONS............... 119

4JH45 Engine................................................... 120

4JH57 Engine................................................... 121

4JH45, 4JH57 Marine Gear or Sail Drive......... 122

4JH80 Engine................................................... 123

4JH110 Engine................................................. 124

4JH80, 4JH110 Marine Gear or Sail Drive....... 125

SYSTEM DIAGRAMS................................................... 127

PIPING DIAGRAMS ............................................... 127

WIRING DIAGRAMS .............................................. 141

EPA WARRANTY USA ONLY ..................................... 147

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TABLE OF CONTENTS

JH Series Operation Manual v

12/05

YANMAR CO., LTD. LIMITED EMISSION

CONTROL SYSTEM WARRANTY - USA ONLY... 147

Your Warranty Rights and Obligations: ........... 148

Warranty Period:.............................................. 148

Warranty Coverage: ........................................ 149

Exclusions: ...................................................... 149

Owner’s Responsibility: ................................... 149

Customer Assistance:...................................... 149

Maintenance Log ............................................. 150

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TABLE OF CONTENTS

vi JH Series Operation Manual

This Page Intentionally Left Blank

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JH Series Operation Manual 1

INTRODUCTION

Welcome to the world of Yanmar Marine!

Yanmar Marine offers engines, drive

systems and accessories for all types of

boats, from runabouts to sailboats, and

from cruisers to mega yachts. In marine

leisure boating, the worldwide reputation of

Yanmar Marine is second to none. We

design our engines to respect nature. This

means quieter engines, with minimal

vibrations, cleaner than ever. All of our

engines meet applicable regulations,

including emissions, at the time of

manufacture.

To help you enjoy your Yanmar JH series

engine for many years to come, please

follow these recommendations:

• Read and understand this Operation

Manual before you operate the machine

to ensure that you follow safe operating

practices and maintenance procedures.

• Keep this Operation Manual in a

convenient place for easy access.

•IfthisOperation Manual is lost or

damaged, order a new one from your

authorized Yanmar Marine dealer or

distributor.

• Make sure this manual is transferred to

subsequent owners. This manual should

be considered a permanent part of the

engine and remain with it.

• 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.

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INTRODUCTION

2JH Series Operation Manual

RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar for

service, parts or literature.

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

Date Purchased:_________________________________________________________

Dealer:_________________________________________________________________

Dealer Phone:___________________________________________________________

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