INS-KPH7-0011

INS-KPH7-0011
YANMAR CO., LTD.
YANMAR AMERICA CORP.
Supplement to Yanmar Kit Installation Instructions
SAFETY
This product is designed and intended only for use
with a YANMAR engine. All safety and warning
information contained in the Yanmar Operation
Manual and Service Manual is adopted and
incorporated to apply to the components,
accessories, and parts that are utilized with Yanmar
engines. Follow all instructions and precautions
before installing this product, before operating,
during operation, and during periodic maintenance
procedures for your safety, the safety of others, and
to protect the performance of your engine.
YANMAR CO., LTD.
YANMAR AMERICA CORP.
Item
Part No.
1
2
3
Description
119749-91160
119749-91180
119749-91190
Quantity
Wiring Harness
Starter Patch Harness
Patch for Altitude Compensation Solenoid
Remarks
1
1
1
TIER 4F MODELS
3TNV74F-SDSA
3TNV80F-SDSA
1
3
2
PAGE 1 OF 6
KPH7 - PANEL HARNESS
KIT INS-KPH7-0011
YANMAR CO., LTD.
YANMAR AMERICA CORP.
Installation Instructions
Hand tighten all bolts and nuts until assembly is completed, then torque according to specifications in Table 1. The numbers in ()
represent the item numbers.
1. Connect harness terminals to appropriate locations. See engine wiring harness diagram and schematics shown on page
3 and 4 of this document.
NOTE: The spare starter patch harness is used if the 1.2kW starter is used.
2. Mount the bracketed relays in the front exhaust side engine foot.
3. After connecting all terminals to appropriate locations, check the following:
a) Make sure the wires do not contact the exhaust manifold or muffler.
b) Make sure the wires do not contact any sharp or abrasive surfaces.
c) Use wire ties to secure the wire harness to the engine.
d) Cover all harness terminals not used after assembly is completed
WARNING: Be sure battery cables are connected correctly before operation. If at any time during operation, the battery cables are
removed, the harness could fail prematurely.
Refer to harness drawing for additional design requirements for consideration of application. A troubleshooting guide is
available through Yanmar's Distributor Website or by contacting Yanmar America's Service Department.
Diameter x Pitch
M8 x 1.25
M10 x 1.50
M12 x 1.75
Table 1: Proper torque specifications for bolts and nuts.
Kgf-m
Foot-lbf
1.5 ~ 2.9
10.6 ~ 20.9
4.5 ~ 5.5
32.5 ~ 39.8
8.0 ~ 10.0
57.8 ~ 72.3
PAGE 2 OF 6
N-m
14.4 ~ 28.3
44.0 ~ 54.0
78.4 ~ 98.0
KPH7 - PANEL HARNESS
KIT INS-KPH7-0011
87
W10 FUEL SIGNAL (D)
RELAYS
SONG CHUAN
896H-1CH-D1SW-R1
12065685 CONNECTOR
12066614 TERMINAL
W12 ALTITUDE LAMP (E)
W7 ALTERNATOR LAMP (C)
87
W18
W32
86
86
86
W25
W24
87
W19
W26
85
86
W3 FUEL PULL SIGNAL (F)
W1 BATTERY POSITIVE (A)
PREHEAT
W29 W2
30
W15,W29,W30,31
W2 CRANK SIGNAL (P)
RELAY
BATTERY POSITIVE
HDL-6-38
W8 COOLANT TEMP (M)
W1,W27
WIRE ENTRY SIDE
W30 W3
85
30
W28
W6
85
1
2
WIRE ENTRY SIDE
W5 ALTERNATOR TACH (K)
W11 OIL PRESSURE SWITCH (L)
87
30
INTERNAL RELAY SCHEMATIC
CRANK FUEL
W9 BATTERY NEGATIVE (G)
W4 PREHEAT SIGNAL (H)
87a
ALTERNATOR/CONTROLLER
BATTERY POSITIVE
HDL-6-38
W31 W4
30
85
ALTERNATOR DIODE
DT06-2S CONNECTOR
0462-201-16141 TERMINAL
W2S WEDGE LOCK
DT04-2P-RT02 DIODE
W32
STARTER SIGNAL
DELPHI
02977253 CONNECTOR
02965867 TERMINAL
CONTROLLER FUSE
FHAT0WH8R
3 AMP
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W5
W28
W7
ALTERNATOR PLUG
SUMITOMO
6189-0442 CONNECTOR
8100-0462 TERMINAL
15324973 CABLE SEAL
W8 ENGINE TEMP
HDW-10884
W23
W22
1
2
WIRE ENTRY SIDE
CONTROLLER
DELPHI
15336037 CONNECTOR
15359005 LOCK
15304720 TERMINAL
15326265 TERMINAL
15366060 CABLE SEAL
15366066 CABLE SEAL
EFP FUSE
FHAT0WH8R
2AMP
W20
W27
ALTERNATOR STUD
HDL-8-14
W21
1
2
WIRE ENTRY SIDE
ELECTRICAL FEED PUMP
TYCO
926522-1 CONNECTOR
154718-3 TERMINAL
FUEL PULL DIODE
DT06-2S CONNECTOR
0462-201-16141 TERMINAL
W2S WEDGE LOCK
DT04-2P-RT02 DIODE
W33
W34
ALTITUDE COMPENSATION
FCI
54200608 CONNECTOR
54001800 TERMINAL
W12
W13
W14
W15
W16
W10
W17
W18
W11
OIL PRESSURE
HDW-10884
FUEL HOLD DIODE
DT06-2S CONNECTOR
0462-201-16141 TERMINAL
W2S WEDGE LOCK
DT04-2P-RT02 DIODE
CONTROLLER NEGATIVE W9
SB-218-38
FUEL SOLENOID NEGATIVE
SB-218-38
W17
W19
GLOW PLUG
YAZAKI
7123-3010 CONNECTOR
170381-1 TERMINAL
FUEL SOLENOID
YAZAKI
7123-2237-00 CONNECTOR
7116-2090 TERMINAL
SUPPLIER PART NO. 700-1035 REV E
WIRE
NUMBER
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
COLOR
RED
YELLOW/RED
WHITE
VIOLET/RED
WHITE
TAN
ORANGE/WHITE
GREEN
BLACK
BROWN/RED
BLUE
ORANGE/RED
BLACK
YELLOW/RED
RED
BROWN/RED
BLACK
WHITE
VIOLET/RED
BROWN/RED
BLACK
BLACK
WHITE
RED
RED
RED
RED
TAN
RED
RED
RED
WHITE
BLACK
BROWN/RED
WIRE
GAUGE
LENGTH
(INCHES-REF)
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
14 AWG
16 AWG
16 AWG
14 AWG
14 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
16 AWG
8 AWG
16 AWG
14 AWG
14 AWG
14 AWG
16 AWG
16 AWG
16 AWG
41.0
53.0
53.0
53.0
59.0
55.0
59.0
65.0
45.0
41.0
47.0
66.0
38.0
46.0
48.0
38.0
26.0
32.0
38.0
5.0
5.0
5.0
5.0
6.0
6.0
6.0
30.0
36.0
23.0
23.0
23.0
23.0
27.0
27.0
END A CONNECTOR
END A TERMINAL/SEAL
15336037
15336037
15336037
15336037
15336037
SPLICE W/W10
15304720
15304720
15326265
15304720
15326265
N/A
15336037
15336037
15336037
15336037
15336037
15336037
SPLICE W/W9
SPLICE W/W32
N/A
SPLICE W/W10
N/A
12065685
12065685
SPLICE W/W16
SPLICE W/W17
SPLICE W/W17
SPLICE W/W18
SPLICE W/W29
SPLICE W/W30
SPLICE W/W31
N/A
DT06-2S
N/A
N/A
N/A
15326265
15326265
15304720
15326265
15326265
15326265
N/A
N/A
HDL-6-38
N/A
SB-218-38
12066614
12066614
N/A
N/A
N/A
N/A
N/A
N/A
N/A
HDL-8-14
0462-201-16141
HDL-6-38
HDL-6-38
HDL-6-38
12066614
N/A
N/A
12065685
SPLICE W/W9
SPLICE W/W10
END A
PORT
A
P
F
H
K
N/A
C
M
G
D
L
E
N/A
N/A
N/A
N/A
N/A
87
87
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1
N/A
N/A
N/A
87
N/A
N/A
END B CONNECTOR
END B TERMINAL/SEAL
N/A
12065685
12065685
12065685
6189-0442
DT06-2S
HDL-6-38
12066614
12066614
12066614
8100-0462
0462-201-16141
8100-0462
HDW-10884
SB-218-38
7116-2090
HDW-10884
54001800
54001800
54001800
54001800
54001800
7116-2090
7116-2090
7116-3010
0462-201-16141
0462-201-16141
0462-201-16141
0462-201-16141
12066614
12066614
12066614
HDL-6-38
8100-0462
12066614
12066614
12066614
02965867
154718-3
154718-3
6189-0442
N/A
N/A
7123-2237-00
N/A
54200608
54200608
54200608
54200608
54200608
7123-2237-00
7123-2237-00
7123-3010
DTO6-2S
DT06-2S
DT06-2S
DT06-2S
12065685
12065685
12065685
N/A
6189-0442
12065685
12065685
12065685
02977253
926522-1
926522-1
END B
PORT
N/A
85
85
85
3
2
1
N/A
N/A
R
N/A
3
2
6
4
5
B
W
1
1
2
2
1
86
86
86
N/A
2
30
30
30
N/A
2
1
WIRE FUNCTION
CONTROLLER BATTERY POSITIVE, B+
CRANK SIGNAL
FUEL PULL SIGNAL
GLOW PLUG SIGNAL
ALTERNATOR TACH
ALTERNATOR EXCITE
ALTERNATOR CHARGE LAMP
HIGH TEMPERATURE SWITCH
CONTROLLER BATTERY NEGATIVE, BFUEL HOLD SIGNAL
LOW PRESSURE SWITCH
HIGH ALTITUDE SIGNAL
ALTITUDE COMPENSATION GROUND, BALTITUDE COMPENSATION STARTER SIGNAL
ALTITUDE COMPENSATION POSITIVE, B+
ACCESSORY BATTERY POSITIVE, B+
FUEL SOLENOID GROUND, BFUEL PULL SIGNAL
GLOW PLUG SIGNAL
FUEL HOLD SIGNAL, DIODE
BATTERY NEGATIVE, BBATTERY NEGATIVE, BFUEL PULL SIGNAL, DIODE
CRANK RELAY COIL POSITIVE, B+
FUEL RELAY COIL POSITIVE, B+
PREHEAT RELAY COIL POSITIVE, B+
ALTERNATOR BATTERY POSITIVE, B+
ALTERNATOR EXCITE
CRANK RELAY BATTERY POSITIVE, B+
FUEL RELAY BATTERY POSITIVE, B+
PREHEAT RELAY BATTERY POSITIVE, B+
CRANK SIGNAL
BATTERY NEGATIVE, BFUEL HOLD SIGNAL
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