0000A0A1015-9112

SERVICE MANUAL

MARINE DIESEL ENGINE

3JH2 Series

2000. 3. 10

series

Manual Name

Engine Model :

Number of revision

Date of revision

Publication No.

A0A1015

History of Revision

Page No

Service Manual for Marine Diesel Engine

3JH2 series

Reason for correction

Outline of correction

1

Correction item

No. (page)

Corrected by

1st

2nd

Apr. 2001

Feb. 2003

● Crank shaft

V-pulley bolt tightening torque

● Clutch lever control cable connectlion.

● Added the standard V-pulley

(material: casting iron) tightening torque and general use nuts & bolts tightening torque.

10-32

● Added the tightening torque of nut for the remote control cable connection of clutch shifting lever.

● Injection timing changed.

8-3

1-3, 10-31

● Add the model

3JH25A &

3JH30A

●

●

●

●

Added the Exterior Views

Added the Specifieations

Added the Engine Outiine

Added the Pertomance Curves

●

Added the Piping Diagrams

●

Added the Fuel Injection Pump

Sewice Data

●

Added the Intake and

Exhaust System figure

●

Added the Lubrieation System figure

●

●

Added the Lube Oil Filter figure

Added theSea water line flgure

●

Added the Marine Gear Models

KM3P1,KM3P3,KM35P1

●

Added the Wiring diagrams

1-2-1, 1-2-2

1-3-1, 1-4-1

1-8-1

1-11-1, 1-11-2

1-14-1

3-1-1

4-1-1

5-2-1

5-6-1

6-3-1

7-29~7-56

9-4-1

Quality

Assurance

Dept.

Quality

Assurance

Dept.

Printed in Japan

A0A1015-0302

Printed in Japan

A0A1015-0302

CONTENTS

CHAPTER 1 GENERAL

1.Exterior Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2.Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

3.Engine Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

4.Performance Curves . . . . . . . . . . . . . . . . . . . . . . . 1-10

5.Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

CHAPTER 7 REDUCTION AND REVERSING GEAR

KM3A

1.Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

2.Shifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

3.Inspection And Servicing . . . . . . . . . . . . . . . . . . . . 7-12

4.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

5.Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

CHAPTER 2 BASIC ENGINE PARTS

1.CylinderBlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3.Piston and Piston Pins . . . . . . . . . . . . . . . . . . . . . . 2-11

4.Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

5.Crankshaft and Main Bearing . . . . . . . . . . . . . . . . 2-18

6.Camshaft and Tappets . . . . . . . . . . . . . . . . . . . . . . 2-21

7.Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

8.Flywheel and Housing . . . . . . . . . . . . . . . . . . . . . . 2-26

KM3P1,KM3P3,KM35P1

1.Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

2.Shifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

3.Inspection And Servicing . . . . . . . . . . . . . . . . . . . . 7-40

4.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

5.Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53

CHAPTER 3 FUEL INJECTION EQUIPMENT

1.Fuel Injection Pump Service Data . . . . . . . . . . . . . . 3-1

2.Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.Disassembly Reassembly and Inspection of Fuel

Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4.Adjustment of Fuel Injection Pump and Governor . . 3-21

5.Fuel Feed Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

6.FuelInjection Nozzle . . . . . . . . . . . . . . . . . . . . . . . 3-29

7.Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

8.Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

9.Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

10.Fuel Tank (Optional). . . . . . . . . . . . . . . . . . . . . . . . 3-38

CHAPTER 4 INTAKE AND EXHAUST SYSTEM

1.Intake and Exhaust System . . . . . . . . . . . . . . . . . . 4-1

2.Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

3.Mixing Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

CHAPTER 8 REMOTE CONTROL

1.Remote Control System . . . . . . . . . . . . . . . . . . . . . . 8-1

2.Remote Control Installation . . . . . . . . . . . . . . . . . . . 8-2

3.Remote Control Inspection . . . . . . . . . . . . . . . . . . . 8-5

4.Remote Control ADJUSTMENT . . . . . . . . . . . . . . . . 8-6

5.Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

CHAPTER 9 ELECTRICAL SYSTEM

1.Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

2.Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

3.Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

4.Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

5.Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

6.Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36

7.Air Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . 9-39

8.Electric Type Engine Stop Device (Optional) . . . . . 9-40

9.Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42

10.AIternator 12V/80A(Optional) . . . . . . . . . . . . . . . . . 9-45

CHAPTER 5 LUBRICATION SYSTEM

1. Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2.Lube Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

3.Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

4.Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . 5-8

5.Lube Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

6.Piston Cooling Nozzle . . . . . . . . . . . . . . . . . . . . . . 5-10

7.Rotary Waste Oil Pump (Optional) . . . . . . . . . . . . . 5-11

CHAPTER 10 DISASSEMBLY AND REASSEMBLY

1.Disassembly and Reassembly Precautions . . . . . . 10-1

2.Disassembly and Reassembly Tools . . . . . . . . . . . 10-2

3.Disassembly and Reassembly . . . . . . . . . . . . . . . . 10-9

4.Bolt/nut Tightening Torque . . . . . . . . . . . . . . . . . . 10-32

5.Test Running . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33

CHAPTER 6 COOLING WATER SYSTEM

1.Cooling Water System . . . . . . . . . . . . . . . . . . . . . . 6-1

2.Sea Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

3.Fresh Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

4.Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

5.Pressure Cap and Sub Tank . . . . . . . . . . . . . . . . . 6-12

6.Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

7.Kingston Cock (Optional) . . . . . . . . . . . . . . . . . . . 6-16

8.Sea Water Filter (Optional) . . . . . . . . . . . . . . . . . . 6-17

9.Bilge Pump and Bilge Strainer (Optional) . . . . . . . 6-18

Printed in Japan

A0A1015-0302

Printed in Japan

A0A1015-0302

Chapter 1 General

1. Exterior Views

1-3 3JH25A/30A

With KM3P3

Operating side

KM3P3

Fuel injection pump

Mist separator

Air intake manifold

Fuel filter

3JH2 Series

Torque limiter

Dipstic (clutch side)

Dipstic (engine side)

Lube filter

Fuel priming pump

Operating side

Fresh water pump

Fresh water tank

Pressure cap

Exhaust manifold

Alternator

Mixing elbow

Printed in Japan

A0A1015-0302

Seawater pump Starting motor

1-2-1

Clutch handle

Printed in Japan

A0A1015-0302

Chapter 1 General

1. Exterior Views

With KM3P1/ KM35P1

Operating side

Fuel injection pump

Mist separator

Air intake manifold

Fuel filter

3JH2 Series

KM3P1

KM35P1

Dipstic (clutch side)

Dipstic (engine side)

Lube filter

Fuel priming pump

Operating side

Fresh water pump

Fresh water tank

Pressure cap

Alternator

Exhaust manifold

Mixing elbow

Printed in Japan

A0A1015-0302

Seawater pump Starting motor

1-2-2

Clutch handle

Printed in Japan

A0A1015-0302

Chapter 1 General

2. Specifications

3JH2 Series

Type

Combustion system

Aspiration

Number of cylinders

Bore × stroke

Displ acement

One hour rating output

(DIN6270B) flywheel output

Output/crankshaft speed

Brake mean effective pressure

Piston speed

Continuous rating output

(DIN6270A) flywheel output

Output/crankshaft speed

Brake mean effective pressure

Piston speed

Compression ratio

Fire order

Fuel injection pump

Fuel injection timing (b.T.D.C.)

Fuel injection pressure

Fuel injection nozzle

Direction of rotaion (Crankshaft)

Power taka off

___

___

___

___ mm kW(PS)/rpm

MPa(kgf/cm 2 ) m/sec.

kW(PS)/rpm

MPa(kgf/cm 2 ) m/sec.

___

___

___ degree.

MPa(kgf/cm 2 )

___

___

___

Cooling system

Lubrication system

Starting system

Dimensions

(with KM35P1)

Starting motor

AC generator

Overall length

Overall width

Overall height

Engine weight without marine gear (dry)

Lubricating oi l capacity Effect/max.

Cooling water capacity

(Fresh water)

Fresh water tank

Sub tank

___

___

V-kW

V-A mm mm mm kg

Printed in Japan

A0A1015-0302

1-3-1

3JH30A

Vertical 4-cycle water cooled diesel engine

Direct injection

Normal aspiration

3

82 × 86

1.303

20. 2 / 3300

(27.5 / 3300)

24. 3 / 3000

(33.0 / 3000)

0.539 (5.50)

9.5

18. 4 / 3200

(25 / 3200)

0.713 (7.27)

8.6

22. 1 / 2900

(30 / 2900)

0.506 (5.016) 0.670 (6.83)

9.2

8.3

18.1

1 — 3 — 2 — 1

YPES-CL

19 ±1

19.6

±0.5(200±5)

Hole type

Counter-clock wise viewed from stern

At Flywheel side

Constant high temperature fresh water cooling

Fresh water : Centrifugal pump

See water : Rubber impeller pump

730

Forced lubrication with trochoid pump

DC 12V-1.8kW

12V- 35A

770

545

680

185 190

0.9 / 7.0

4.4

0.8

Printed in Japan

A0A1015-0302

Chapter 1 General

2. Specifications

Model

Clutch Type

Reduction ratio

(Forward/Reverse)

Direction of rotation(Forward) viewed from stern marine gear system

Lubricating oil capacity min/max

Lubricating oil mas

Torque limiter kg

3JH2 Series

KM35P1 KM3P1 KM3P3

Cone clutch

2.36 / 3.1 6

Clock wise

0.3 / 0.35

12

Not Eqipped

SAE #30

API CC or CD

15

Eqipped

0.45 / 0.5

12

Eqipped

Printed in Japan

A0A1015-0302

1-4-1

Printed in Japan

A0A1015-0302

22

5

＋0.048

73

11 3

(PROPELLER SHAFT COUPLING)

4 φ 11 pc

φ

78

4-

φ

10.5

pc

φ

78

＋0.025

7 7.5

4

(OUTPUT SHAFT COUPLING)

SEA WATER INLET φ 26

278

190.5

93

543

480

95

265

MIXING ELBOW PT 11/4

ASTERN

AHEAD

183.8

180.6

701.3

730.1

(VIEW FROM ARROW B)

70

445

4 φ 16.5

237.3

305 159

4-M8 TAPPEDHOLES

(DEPTH 12)

DIRECTION OF ROTATION

JOINT

φ

8 FOR FO RETURN pc

φ

82.5

DETAIL OF PULLY

(VIEW FROM ARROW A)

JOINT

φ

8 FOR FO INLET

28.8

Chapter 1 General

4. Performance Curves

3JH2 series

3JH25A Performance Curve

Propeller curve curve

20

15

10

5

0

1500 1700 1900 2100 2300 2500

Crankshaft speed (min -1 )

2700

Specific fuel consumption

2900 3100 3300

400

350

300

250

200

150

1500 1700 1900 2100 2300 2500

Crankshaft speed (min -1 )

2700

Exhaust Gas Temp.

2900 3100 3300

400

350

300

250

200

150

100

1500 1700

Printed in Japan

A0A1015-0302

1900 2100 2300 2500

Crankshaft speed (min -1 )

2700

1 -11-1

2900 3100 3300

Printed in Japan

A0A1015-0302

Chapter 1 General

4. Performance Curves

3JH30A Performance Curve

Propeller curve curve

25

20

15

10

5

0

1500 1700 1900 2100 2300 2500

Crankshaft speed (min -1 )

Specific fuel consumption

2700

350

300

250

200

150

1500 1700 1900 2100 2300 2500

Crankshaft speed (min -1 )

Exhaust Gas Temp.

2700

400

350

300

250

200

150

100

1500 1700

Printed in Japan

A0A1015-0302

1900 2100 2300 2500

Crankshaft speed (min -1 )

1 -11-2

2700

3JH2 series

2900 3100

2900 3100

2900 3100

Printed in Japan

A0A1015-0302

FUEL OVERFLOW

φ 7

X t 3 RH

φ

7

X t 3 RH

φ 7

X t 3 RH

FUEL OIL FILTER

( CARTRIDGE TYPE )

φ 4

X t 2 RH

LUB. OIL PUMP

φ 27

X t 4 RH

HOT WATER CONNECTION INLET

COOLING WATER PUMP (FRESH WATER)

φ

28

X t 1.2 C1201T

HOT WATER CONNECTION OUTLET

φ 28

X t 4 RH

THERMOSTAT

φ 28

X t 4 RH

FROM CYLINDER HEAD

COOLING WATER PUMP

(SEA WATER)

FUEL FEED PUMP

FUEL OIL INLET

φ 7

X t 3 RH

φ

7

X t 3 RH

FUEL INJECTION PUMP

φ 4.76

X t 0.7 STS

LUB. OIL FILTER (CARTRIDGE TYPE)

PRESSURE CONTROL VALVE

φ

4

X t 2 RH

φ 6.35

X t 2.275 ST9

FUEL HIGH PRESSURE PIPE

FUEL INJECTION NOZZLE

OIL PRESSURE SWITCH

TO OIL PAN

TO CAM SHAFT

φ 25.4

X t 1.8 C1201T

φ

25.4

X t 4.3 RH

SER WATER INLET

FRESH WATER COOLER

LUB. OIL INLET FILTER

MAIN BEARING

A WATER

DETAIL OF PART B

φ 53

PT1 1/4

20

45

B

MIXING ELBOW

φ 25.4

X t 4.3 RH

φ 25.4

X t 4.3 RH

Marks of PIPING NAME

R H RUBBER HOSE

SGP

STS

STEEL PIPE

C1201T COPPER PIPE

UNION SCREW JOINT

FLANGE JOINT

EYE JOINT

INSERTION JOINT

DRILL HOLE

COOLING FRESH WATFR PIPING

COOLING SEA WATFR PIPING

LUB.OIL PIPING

FUEL OIL PIPING

MIST PIPE

Chapter 3 Fuel Injection Equipment

1. Fuel Injection Pump Service Data

3JH2 series

Item

Engine

Assemble code

Part No

I.D. mark

Adjustment specs

Nozzle type I.D. mark

Injection starting pressure

Fuel injection pipe

Top clearance/Pre stroke

(kg / cm 2 )

(OD φ ×ID φ × L)

(mm)

Pump rpm:N1 (rpm)

Rack position:R1 (mm)

Rated load Measuring stroke (St)

Injection volume (cm 3 )

No load

Idling

Starting

Non unifomity (%)

Pump rpm:N2 (rpm)

Rack position:R2

Pump rpm:N3 (rpm)

Measuring stroke (St)

Injection volume (cm 3 )

Non uniformity (%)

Pump rpm:N4 (rpm)

Rack position (mm)

Measuring stroke (St)

Injection volume (cm 3 )

3JH25A

729198-51300

B450

Engine spec.

Cal. Spec.

150P244HCO

200 ∼210

φ 6

× φ 1.8

×360

DN-12SD12

165 ∼175

φ 6

× φ 2.0

×600

0.95

∼1.05 / 2.5

1650

6

1000

21.5

28.2

±3

———

———

325

1000

6 ∼7 7 ∼8

±20

200

11.5

∼1.25

1000

60 ∼70 56 ∼66

3JH30A

729198-51320

B451

Engine spec.

Cal. Spec.

150P244HCO

200 ∼210

φ 6

× φ 1.8

×360

DN-12SD12

165 ∼175

φ 6

× φ 2.0

×600

0.95

∼1.05 / 2.5

1500

6

1000

27 ——

±3

———

———

325

1000

6 ∼7 7 ∼8

±20

200

11.5

∼1.25

1000

60 ∼70 56 ∼66

Printed in Japan

A0A1015-0302

3-1-1

Printed in Japan

A0A1015-0302

Chapter 4 Intake and Exhaust System

1. Intake and Exhaust System

3JH25A / 30A

Intake system

Intake air silencer

Exhaust system

Mixing elbow

3JH2 series

Printed in Japan

A0A1015-0302

4-1-1

Printed in Japan

A0A1015-0302

Chapter 5 Lubrication System

1. Lubrication System

3JH25A / 30A

3JH2 series

Lubricating oil filter

A

Oil return piper

Fuel injection pump lubricating pipe

A

B

B

Fuel injection pump

Printed in Japan

A0A1015-0302

Oil pan

5-2-1 Printed in Japan

A0A1015-0302

Chapter 5 Lubrication System

3. Lube Oil Filter

3JH25A / 30A

3JH2 series

Filter bracket

Oil pressure regulator valve

Cylinder block

Lubricating oil filter

Oil return pipe

Printed in Japan

A0A1015-0302

5-6-1

Oil pan

Printed in Japan

A0A1015-0302

Chapter 6 Cooling Water System

1. Cooling Water System

3JH25A / 30A

Mixing elbow

Heat exchanger

3JH2 series

A

Printed in Japan

A0A1015-0302

Kingston cock

A

Sea water pump

6-3-1

Printed in Japan

A0A1015-0302

Chapter 7 Reduction and Reversing Gear

1. Construction

Marine Gear Models

KM3P1, KM3P3, KM35P1

for Engine Models 3JH25A / 3JH30A

3JH2 series

1. Construction

1-1. Construction

These clutches are a cone-type, mechanically operated clutch.

When the drive cone (which is connected to the output shaft by the lead spline) is moved forward or backward, its taper contacts with the large gear and transfers power to the output shaft.

The construction is simple when compared with othertypes of clutch and if serves to reduce the number of components, making for a lighter, more compact unit which can be operated smoothly. Although it is small, the power transmission efficiency is high even under a heavy load.

Its durability is high and it is also reliable because high grade materials are used for the shaft and gear, and. a taper roller bearing is incorporated.

Power transmission is smooth because connection with the engine is made through the damper disc

●

The drive cone is made from special aluminum bronze, which has both higher wear-resistance and durability.

The drive cone is connected with the output shaft through the thread spline. The taper angle, diameter of the drive cone, twist angle, and diameter of the thread spline, are designed to give the greatest efficiency, thus ensuring that the drive cone can be readily engaged or disengaged.

●

Helical gears are used for greater strength.

The intermediate shaft is supported at 2 points to reduce deflection and gear noise.

●

The clutch ease and mounting flange are made from an aluminum alloy of special composition to reduce weight.

It is also anticorrosive against seawater.

●

As the damper disc is fitted to the input shaft, power can

● be transmitted smoothly.

There is small clearance between the dipstick and the inside of the dipstick tube. A small hole in the dipstick works as a breather.

● when the load on the propeller is removed, the engagement of the drive cone and the large gear is maintained by the shifter and V-groove of the drive cone.

Even when the drive cone's tapered area and V-groove are worn, this engagement is maintained by the shift lever device and accordingly no adjustment of the

● remote control cable is required.

The cup spring on the rear of the larger gear absorbs rotational fluctuations and stabilizes the engagement of the drive cone and the larger gear.

Thus, the durability of the cone against wear is enhanced.

NOTE:

KM3P3 marine gear differs from KM3P1 as follows.

●

Torque !imiter applied to KM3P3.

KM35P1 marlne gear differs from KM3P1 as follows.

● Output shaft dia. 28mm. (KM3P1 : 25mm).

●

Drive corn the same as the one for KM4A marine gear.

●

Marine gear oil reserve capacity up.

0.5L (0.35L KM3P1 )

Printed in Japan

A0A1015-0302

7-29

Printed in Japan

A0A1015-0302

Chapter 7 Reduction and Reversing Gear

1. Construction

1.2 Specifications

Mode

For engine models

Clutch

Forward

Reduction ratio

Reverse

Propeller shaft mirr1 (Forward)

Input shaft

Direction of rotation Forward

Remote control

Output shaft Reverse

Control head

Cable

Clamp

Output shaft coupling Pitch circle diameter

Connecting bolt holes

Position of shift lever

Cable connector

Outer diameter

Lubricating oil

Lubricating oil capscity

Dry mass

(min -1 )

(mm)

(mm)

(mm)

Note:

Torque limiter should be installed on KM3P3

No torque limiter installed on KM3P1 & KM35P1

( )

(kg)

3JH2 series

KM3P1 KM3P3 KM35P1

3JH25A 3JH30A

Constant mesh gear with servo cone clutch (wet type)

2.36

3.16

1356

2.61

3.16

1226

2.36

3.16

1229

2.61

3.16

1111

12

Counter-clockwise, viewed from stern

Clockwise, viewed from stern

Counter-clockwise, viewed from stern

Single lever control

Morse. 33-C (cable travel 76.2mm)

YANMAR made. standard accessory

YANMAR made, standard accessory

100

Right side, viewed from stern

API CC SAE 20/30

0.35

78

4-1 0.5

15

0.5

12

Reduction ratio

2.36

2.61

No. of blade

3

4

3

4

4

Diameter of the propeller

(mm)

450

425

470

440

460

Moment of inertia N-m 2

( kg-m 2 =GD 2 )

1.49 (0.15)

1.86 (0.19)

Material

Bronze

Printed in Japan

A0A1015-0302

7-30

Printed in Japan

A0A1015-0302

Chapter 7 Reduction and Reversing Gear

1. Construction

1-3 Power transmission system

1-3.1 Arrangement of shafts and gears

Idle gear

Forward small gear of input shaft

Reverse small gear of input shaft

input shaft

Large gear of output shaft

Intermediate shaft

3JH2 series

Output shaft

Shaft arrangement viewed from the stern Intermediate shaft

Forward large gear

Drive cone

Idle gear

Reverse large gear

Forward small gear with input shaft

Reverse small gear with input shaft

Output shaft

1-3.2 Reduction ratio

Forward

Model

KM3P1, KM3P3, KM35P1

No. of teeth of forward small gear Zif

25

23

No. of teeth of forward 18rge gear Zof

59

60

Reverse

Model

KM3P1

KM3P3

KM35P1

No. of teeth No. of teeth No. of teeth of reverse small gesr Zif of intemediate shaft gear Zi of reverse large gear Zdr

19 26 60

Printed in Japan

A0A1015-0302

7-31

Reduction retio Zof /Zif

59/25 = 2.36

60/23 = 2.61

Reduction ratio Zi/Zir・Zdr/Zi

60/19 = 3.16

Printed in Japan

A0A1015-0302

Chapter 7 Reduction and Reversing Gear

3. Inspection and Servicing

Dimensions

KM3P1

KM3P3

KM35P1

Standard dimensions

32.7-33.3

29.25-29.75

Limited dimensions mm

32.4

28.1

NOTE : When dismantled, the forward of reverse direction of the drive cone must be clearly identified.

(4) lf the wear of the V-groove of the drive cone is excessive, replace the part.

NOTE : When replacing the drive cone, the new cone and forward large gear and reverse large gear must be lapped prior to assembly.

The lapping procedure is described below.

3JH2 series

(3) Lap the large gear's cave and drive cone, pushing them together by hand.

(4) Push and turn the large gear about 5 times both clockwise and counter-clockwise.

3-5-1 Lapping Procedure for Drive Cone

(1) Coat the lapping powder onto the cave of the clutch gear (Lapping powder : 67 micron silicon carbide #280)

(5) After lapping them, wash them with washing oil. The lapped parts should be cleaned completely.

(2) Set the large gear on the output shaft with a needle bearing and then set the drive cone on the output shaft.

NOTE：

●

Do not mix the combination of the lapped parts.

The washing oil should be changed frequently in order to prevent residual powder being left on the parts.

When assembling the drive cone, be sure to check its alignment. The larger chamfering face should be on the forward large gear side.

Printed in Japan

A0A1015-0302

7-41

Printed in Japan

A0A1015-0302

Color coding

R Red

B Black

W White

Y Yellow

L Blue

G Green

O Orange

Lg Light green

Lb Light blue

Br Brown

P Pink

Gr Gray

Pu Purple

GW

Charge

Eng. Oil P.

C.W. Temp.

Fuel

Empty

Glow

G

Y

G

Tacho with

Hour meter

− P

O

G r B

RG

R

Buzzer

stop

Buzzer

Illumination

switch

Fuse 3A

LW

LY

L

17

AC

P2

P1

AR

Starte

G2

G1

3 R

3 L

3 W

RC

LB

YW

WL

WG

GY

RW

Y

W

B

Instument panel

B

B

Wire harness

A

5 L

Battery Switch

12 V

Battery

＋ −

S or C

12 V

Battery

＋ −

BR

Air heater

Starter

3R

3B

YW

WL

C.W.Temp

switch

Eng. Oil Pressure

switch

F

LB

R

L

Alternator

B

O

Earth

bolt

YG

Battery Switch

WR

Tacho sensor

YB

A