Yanmar 4JH45 Bedienungsanleitung

MARINE ENGINES

OPERATION MANUAL

4JH45

4JH57

4JH80

4JH110

http://yanmar.com 0AJHC-EN0010

OPERATION MANUAL 4JH45 4JH57 4JH80 4JH110

ڦMarine Operations Division

Quality Assurance Dept.

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: +65-6595-4200 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-EN0010

1st edition: October 2013

OPERATION MANUAL

4JH45, 4JH57, 4JH80, 4JH110

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

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

BEFORE YOU OPERATE .............................................. 31

INTRODUCTION ...................................................... 31

SAFETY PRECAUTIONS......................................... 31

DIESEL FUEL........................................................... 32

Diesel Fuel Specifications .................................. 32

Filling the Fuel Tank........................................... 35

Bleeding the Fuel System .................................. 36

Priming the Fuel System .................................... 37

ENGINE OIL ............................................................. 37

Engine Oil Specifications .................................. 37

Engine Oil Viscosity ........................................... 38

Checking the Engine Oil..................................... 38

Adding Engine Oil .............................................. 39

MARINE GEAR OR SAIL DRIVE OIL ...................... 39

Marine Gear Oil Specifications........................... 39

Sail Drive Oil Specifications ............................... 39

Checking Marine Gear Oil.................................. 40

Adding Marine Gear Oil...................................... 40

Checking and Adding Sail Drive Oil ................... 40

ENGINE COOLANT ................................................. 41

Engine Coolant Specifications ........................... 41

Coolant (Closed Cooling System) ...................... 41

Checking and Adding Coolant............................ 42

ENGINE OPERATION .................................................... 45

INTRODUCTION ...................................................... 45

SAFETY PRECAUTIONS......................................... 45

STARTING THE ENGINE ........................................ 47

If the Engine Fails to Start.................................. 48

Starting at Low Temperatures............................ 48

After the Engine has Started .............................. 49

REMOTE CONTROL HANDLE OPERATION.......... 49

Acceleration and Deceleration ........................... 49

Shifting the Engine ............................................. 49

Switching to Trolling (KMH4A Only)................... 50

CAUTIONS DURING OPERATION.......................... 51

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TABLE OF CONTENTS

JH Series Operation Manual iii

12/05

SHUTTING DOWN THE ENGINE ........................... 52

Normal Shutdown .............................................. 52

Emergency Shutdown ....................................... 53

CHECKING THE ENGINE AFTER OPERATION .... 54

PERIODIC MAINTENANCE........................................... 55

INTRODUCTION...................................................... 55

SAFETY PRECAUTIONS ........................................ 55

PRECAUTIONS ....................................................... 57

The Importance of Periodic Maintenance .......... 57

Performing Periodic Maintenance ..................... 57

The Importance of Daily Checks ....................... 57

Keep a Log of Engine Hours and Daily Checks 57

Yanmar Replacement Parts .............................. 57

Tools Required .................................................. 57

Ask Your Authorized Yanmar Marine Dealer or

Distributor for Help............................................. 57

PERIODIC MAINTENANCE SCHEDULE ................ 60

PERIODIC MAINTENANCE PROCEDURES .......... 62

Daily Checks...................................................... 62

After Initial 50 Hours of Operation ..................... 63

Every 50 Hours of Operation ............................. 69

Every 250 Hours of Operation ........................... 71

Every 500 Hours of Operation ........................... 77

Every 1000 Hours of Operation ......................... 78

TROUBLESHOOTING ................................................... 81

SAFETY PRECAUTIONS ........................................ 81

TROUBLESHOOTING AFTER STARTING ............. 81

TROUBLESHOOTING INFORMATION................... 82

TROUBLESHOOTING CHART................................ 83

FAILSAFE DIAGNOSIS FUNCTIONAL

SPECIFICATION CHART ........................................ 88

LONG-TERM STORAGE ............................................... 91

PREPARE ENGINE FOR LONG-TERM STORAGE 91

DRAIN SEAWATER COOLING SYSTEM ............... 92

RETURNING THE ENGINE TO SERVICE .............. 93

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TABLE OF CONTENTS

iv JH Series Operation Manual

SPECIFICATIONS .......................................................... 95

PRINCIPAL ENGINE SPECIFICATIONS................. 95

4JH45 Engine..................................................... 96

4JH57 Engine..................................................... 97

4JH45, 4JH57 Marine Gear or Sail Drive........... 98

4JH80 Engine..................................................... 99

4JH110 Engine................................................. 100

4JH80, 4JH110 Marine Gear or Sail Drive....... 101

SYSTEM DIAGRAMS................................................... 103

PIPING DIAGRAMS ............................................... 103

WIRING DIAGRAMS .............................................. 117

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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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JH Series Operation Manual 3

SAFETY

Yanmar considers safety of great

importance and recommends that anyone

that comes into close contact with its

products, such as those who install,

operate, maintain or service Yanmar

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

dirty or torn and replace them if they are

lost or damaged. Also, if you need to

replace a part that has a label attached to

it, make sure you order the new part and

label at the same time.

DANGER

Indicates a hazardous situation which,

if not avoided, will result in death or

serious injury.

WARNING

Indicates a hazardous situation which,

if not avoided, could result in death or

serious injury.

CAUTION

Indicates a hazardous situation which,

if not avoided, could result in minor or

moderate injury.

NOTICE

Indicates a situation which can cause

damage to the machine, personal property

and/or the environment, or cause the

equipment to operate improperly.

This safety alert symbol

appears with most safety

statements. It means

attention, become alert,

your safety is involved!

Please read and abide by

the message that follows

the safety alert symbol.

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SAFETY

4JH Series Operation Manual

SAFETY PRECAUTIONS

General Information

There is no substitute for common sense

and careful practices. Improper practices

or carelessness can cause burns, cuts,

mutilation, asphyxiation, other bodily injury

or death. This information contains general

safety precautions and guidelines that

must be followed to reduce risk to personal

safety. Special safety precautions are

listed in specific procedures. Read and

understand all of the safety precautions

before operation or performing repairs or

maintenance.

Before You Operate

DANGER

The safety messages that follow have

DANGER level hazards.

Never permit anyone to install

or operate the engine without

proper training.

Read and understand this

Operation Manual before you operate or

service the engine to ensure that you

follow safe operating practices and

maintenance procedures.

• Safety signs and labels are additional

reminders for safe operating and

maintenance techniques.

•Consult authorized Yanmar Marine

dealer or distributor for additional

training.

During Operation and

Maintenance

WARNING

The safety messages that follow have

WARNING level hazards.

Explosion Hazard

While the engine is running

or the battery is charging,

hydrogen gas is being

produced and can be easily

ignited. Keep the area

around the battery

well-ventilated and keep sparks, open

flames and any other form of ignition

out of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosive

under certain conditions.

Never use a shop rag to catch the fuel.

Wipe up all spills immediately.

Never refuel with the engine running.

Fire Hazard

Undersized wiring systems

can cause an electrical fire.

Store any containers containing fuel or

other flammable products in a

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.

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