0000A0A1015-9112

SERVICE MANUAL

MARINE DIESEL ENGINE

3JH2 Series

2000. 3. 10
series
 Publication No. A0A1015
History of Revision Page No 1
Manual Name Service Manual for Marine Diesel Engine
Engine Model : 3JH2 series

Number of Date of Reason for Correction item

Outline of correction Corrected by
revision revision correction No. (page)

1st Apr. 2001 ● Crank shaft ● Added the standard V-pulley 10-32 Quality
V-pulley bolt (material: casting iron) tightening Assurance
tightening torque and general use nuts & bolts Dept.
torque tightening torque.
● Clutch lever ● Added the tightening torque of nut 8-3
control cable for the remote control cable connec-
connectlion. tion of clutch shifting lever.
● Injection timing changed. 1-3, 10-31

2nd Feb. 2003 ● Add ● Added the Exterior Views 1-2-1, 1-2-2 Quality
the model ● Added the Specifieations 1-3-1, 1-4-1 Assurance
3JH25A & ● Added the Engine Outiine 1-8-1 Dept.
3JH30A ● Added the Pertomance Curves 1-11-1, 1-11-2
● Added the Piping Diagrams 1-14-1
● Added the Fuel Injection Pump 3-1-1
Sewice Data
● Added the Intake and 4-1-1
Exhaust System figure
● Added the Lubrieation System 5-2-1
figure 5-6-1
● Added the Lube Oil Filter figure 6-3-1
● Added theSea water line flgure 7-29~7-56
● Added the Marine Gear Models

KM3P1,KM3P3,KM35P1 9-4-1
● Added the Wiring diagrams

Printed in Japan Printed in Japan

A0A1015-0302 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 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
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 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 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
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
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 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 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
Printed in Japan
A0A1015-0302
Chapter 1 General
1. Exterior Views 3JH2 Series

1-3 3JH25A/30A
Fuel injection pump
Mist separator
With KM3P3 Air intake manifold Fuel filter

Operating side

KM3P3

Torque limiter
Dipstic (clutch side) Lube filter
Dipstic (engine side) Fuel priming pump

Operating side
Fresh water tank
Pressure cap Exhaust manifold

Alternator Mixing elbow

Fresh water pump

Seawater pump Starting motor Clutch handle

Printed in Japan 1-2-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 1 General
1. Exterior Views 3JH2 Series

With KM3P1/ KM35P1

Fuel injection pump
Operating side Mist separator
Air intake manifold Fuel filter

KM3P1
KM35P1

Dipstic (clutch side) Lube filter

Dipstic (engine side) Fuel priming pump

Operating side Fresh water tank

Pressure cap Exhaust manifold
Alternator Mixing elbow
Fresh water pump

Seawater pump Starting motor Clutch handle

Printed in Japan 1-2-2 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 1 General
2. Specifications 3JH2 Series

Model Unit 3JH25A 3JH30A

Type ___ Vertical 4-cycle water cooled diesel engine

___ Direct injection
Combustion system
___ Normal aspiration
Aspiration
___ 3
Number of cylinders

Bore × stroke mm 82 × 86

Displ acement 1.303

20. 2 / 3300 24. 3 / 3000

Output/crankshaft speed kW(PS)/rpm
One hour rating (27.5 / 3300) (33.0 / 3000)
output
(DIN6270B) Brake mean effective
pressure MPa(kgf/cm2) 0.539 (5.50) 0.713 (7.27)
flywheel output

Piston speed m/sec. 9.5 8.6

18. 4 / 3200 22. 1 / 2900

Output/crankshaft speed kW(PS)/rpm
Continuous rating (25 / 3200) (30 / 2900)
output
(DIN6270A) Brake mean effective
pressure MPa(kgf/cm2) 0.506 (5.016) 0.670 (6.83)
flywheel output

Piston speed m/sec. 9.2 8.3

Compression ratio ___ 18.1

Fire order ___ 1—3—2—1

Fuel injection pump ___ YPES-CL

Fuel injection timing (b.T.D.C.) degree. 19±1

Fuel injection pressure MPa(kgf/cm2) 19.6±0.5(200±5)

Fuel injection nozzle ___ Hole type

___ Counter-clock wise

Direction of rotaion (Crankshaft)
viewed from stern

Power taka off ___ At Flywheel side

Constant high temperature fresh water cooling

Cooling system ___ Fresh water : Centrifugal pump
See water : Rubber impeller pump

Lubrication system ___ Forced lubrication with trochoid pump

Starting motor V-kW DC 12V-1.8kW

Starting system
AC generator V-A 12V- 35A

Overall length mm 730 770

Dimensions
Overall width mm 545
(with KM35P1)
Overall height mm 680

Engine weight without marine gear (dry) kg 185 190

Lubricating oi l capacity Effect/max. 0.9 / 7.0

Cooling water Fresh water tank 4.4
capacity
(Fresh water) Sub tank 0.8

Printed in Japan 1-3-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 1 General
2. Specifications 3JH2 Series

Model KM3P1 KM3P3 KM35P1

Clutch Type Cone clutch

Reduction ratio
2.36 / 3.1 6
(Forward/Reverse)

Direction of rotation(Forward)
Clock wise
viewed from stern
marine gear
system
Lubricating oil capacity
0.3 / 0.35 0.45 / 0.5
min/max

SAE #30
Lubricating oil
API CC or CD

mas kg 12 15 12
Torque limiter Not Eqipped Eqipped Eqipped

Printed in Japan 1-4-1 Printed in Japan

A0A1015-0302 A0A1015-0302
 3. Engine Outline
Chapter 1 General
A0A1015-0302

3JH25A/30A
22
Printed in Japan

φ63.5＋0.048
0
4-φ11 4-φ10.5 7 7.5

247.5
73 5

240
11 3 4
φ7
8
φ 78
pc pc

φ50 ＋0.025
φ50 −0.019 (VIEW FROM ARROW B)

φ134
φ100
φ100

530
φ22

φ40

0
φ52

35
0

445

240
70 4-φ16.5
(PROPELLER SHAFT COUPLING) (OUTPUT SHAFT COUPLING)

50
237.3 305 159

DIRECTION
OF ROTATI
ON
4-M8 TAPPEDHOLES
(DEPTH 12)
1-8-1

543
278 265
190.5

.5
82
MIXING ELBOW PT 11/4

φ
pc
DETAIL OF PULLY
(VIEW FROM ARROW A)
442.5

309.1

SEA WATER INLET φ26 JOINT φ8 FOR FO RETURN

680
33.5

ASTERN
119.5

6.5

JOINT φ8 FOR FO INLET

4.5 SOLE PLATE

237.5
31.5

AHEAD
183.8
A0A1015-0302

28.8
Printed in Japan

180.6
93 95

3JH2 Series
480 701.3
730.1
Chapter 1 General
4. Performance Curves 3JH2 series

3JH25A Performance Curve

Propeller curve curve
20
Propeller power curve (kW)

15

10

0
1500 1700 1900 2100 2300 2500 2700 2900 3100 3300
Crankshaft speed (min-1)

Specific fuel consumption

400
Specific fuel consumption (g/kW-h)

350

300

250

200

150
1500 1700 1900 2100 2300 2500 2700 2900 3100 3300
Crankshaft speed (min-1)

Exhaust Gas Temp.

400
Exhaust Gas Temp. (°C)

350

300

250

200

150

100
1500 1700 1900 2100 2300 2500 2700 2900 3100 3300
Crankshaft speed (min-1)

Printed in Japan 1-11-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 1 General
4. Performance Curves 3JH2 series

3JH30A Performance Curve

Propeller curve curve
25
Propeller power curve (kW)

20

15

10

0
1500 1700 1900 2100 2300 2500 2700 2900 3100
Crankshaft speed (min-1)

Specific fuel consumption

350
Specific fuel consumption (g/kW-h)

300

250

200

150
1500 1700 1900 2100 2300 2500 2700 2900 3100
Crankshaft speed (min-1)

Exhaust Gas Temp.

400
Exhaust Gas Temp. (°C)

350

300

250

200

150

100
1500 1700 1900 2100 2300 2500 2700 2900 3100
Crankshaft speed (min-1)

Printed in Japan 1-11-2 Printed in Japan

A0A1015-0302 A0A1015-0302
 5. Piping Diagrams
Chapter 1 General
3JH25A/30A
A0A1015-0302
Printed in Japan

A WATER PT1 1/4

FUEL FEED PUMP

FUEL OVERFLOW
FUEL OIL INLET FUEL INJECTION PUMP
φ4.76 X t 0.7 STS

45
φ7 X t 3 RH

20
EXH. GAS
φ7 X t 3 RH LUB. OIL FILTER (CARTRIDGE TYPE)
φ7 X t 3 RH
φ7 X t 3 RH φ7 X t 3 RH PRESSURE CONTROL VALVE
φ4 X t 2 RH φ53
FUEL OIL FILTER
(CARTRIDGE TYPE) φ6.35X t 2.275 ST9 DETAIL OF PART B
FUEL HIGH PRESSURE PIPE
φ4 X t 2 RH

LUB. OIL PUMP FUEL INJECTION NOZZLE

OIL PRESSURE SWITCH
φ27 X t 4 RH
1-14-1

HOT WATER CONNECTION INLET TO OIL PAN Marks of PIPING NAME

COOLING WATER PUMP (FRESH WATER) RH RUBBER HOSE
SGP STEEL PIPE
φ28 X t 1.2 C1201T
HOT WATER CONNECTION OUTLET STS
C1201T COPPER PIPE
φ28 X t 4 RH
TO CAM SHAFT B UNION SCREW JOINT
THERMOSTAT FLANGE JOINT
MIXING ELBOW
φ28 X t 4 RH EYE JOINT
FRESH WATER COOLER φ25.4 X t 4.3 RH
FROM CYLINDER HEAD
φ25.4 X t 1.8 C1201T
INSERTION JOINT
LUB. OIL INLET FILTER φ25.4 X t 4.3 RH
COOLING WATER PUMP φ25.4 X t 4.3 RH DRILL HOLE
(SEA WATER) COOLING FRESH WATFR PIPING
MAIN BEARING
SER WATER INLET
COOLING SEA WATFR PIPING
A0A1015-0302

LUB.OIL PIPING
Printed in Japan

3JH2 series
FUEL OIL PIPING
MIST PIPE
Chapter 3 Fuel Injection Equipment
1. Fuel Injection Pump Service Data 3JH2 series

Engine 3JH25A 3JH30A

Item
Part No 729198-51300 729198-51320
Assemble code
I.D. mark B450 B451

Adjustment specs Engine spec. Cal. Spec. Engine spec. Cal. Spec.

Nozzle type I.D. mark 150P244HCO DN-12SD12 150P244HCO DN-12SD12

Injection starting pressure (kg / cm )

2
200∼210 165∼175 200∼210 165∼175

Fuel injection pipe (ODφ×IDφ× L) φ6×φ1.8×360 φ6×φ2.0×600 φ6×φ1.8×360 φ6×φ2.0×600

Top clearance/Pre stroke (mm) 0.95∼1.05 / 2.5 0.95∼1.05 / 2.5

Pump rpm:N1 (rpm) 1650 1500

Rack position:R1 (mm) 6 6

Rated load Measuring stroke (St) 1000 1000

Injection volume (cm3) 21.5 28.2 27 ——

Non unifomity (%) ±3 ±3

Pump rpm:N2 (rpm) ——— ———

No load
Rack position:R2 ——— ———

Pump rpm:N3 (rpm) 325 325

Measuring stroke (St) 1000 1000

Idling
Injection volume (cm )
3
6∼7 7∼8 6∼7 7∼8

Non uniformity (%) ±20 ±20

Pump rpm:N4 (rpm) 200 200

Rack position (mm) 11.5∼1.25 11.5∼1.25

Starting
Measuring stroke (St) 1000 1000

Injection volume (cm3) 60∼70 56∼66 60∼70 56∼66

Printed in Japan 3-1-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 4 Intake and Exhaust System
1. Intake and Exhaust System 3JH2 series

3JH25A / 30A
Intake system

Intake air silencer

Exhaust system

Mixing elbow

Printed in Japan 4-1-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 5 Lubrication System
1. Lubrication System 3JH2 series

3JH25A / 30A

Lubricating oil filter

Oil return piper

Fuel injection pump

lubricating pipe
Fuel injection pump

Oil pan

Printed in Japan 5-2-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 5 Lubrication System
3. Lube Oil Filter 3JH2 series

3JH25A / 30A

Filter bracket

Cylinder block

Oil pressure regulator valve

Lubricating oil filter

Oil return pipe

Oil pan

Printed in Japan 5-6-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 6 Cooling Water System
1. Cooling Water System 3JH2 series

3JH25A / 30A

Mixing elbow

Heat exchanger

Kingston cock
A

Sea water pump

Printed in Japan 6-3-1 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 7 Reduction and Reversing Gear
1. Construction 3JH2 series

Marine Gear Models

KM3P1, KM3P3, KM35P1
for Engine Models 3JH25A / 3JH30A

1. Construction
1-1. Construction It is also anticorrosive against seawater.
● As the damper disc is fitted to the input shaft, power can
These clutches are a cone-type, mechanically operated
be transmitted smoothly.
clutch.
● There is small clearance between the dipstick and the
When the drive cone (which is connected to the output
inside of the dipstick tube. A small hole in the dipstick
shaft by the lead spline) is moved forward or backward, its
works as a breather.
taper contacts with the large gear and transfers power to
● when the load on the propeller is removed, the engage-
the output shaft.
ment of the drive cone and the large gear is maintained
The construction is simple when compared with other-
by the shifter and V-groove of the drive cone.
types of clutch and if serves to reduce the number of com-
Even when the drive cone's tapered area and V-groove
ponents, making for a lighter, more compact unit which
are worn, this engagement is maintained by the shift
can be operated smoothly. Although it is small, the power
lever device and accordingly no adjustment of the
transmission efficiency is high even under a heavy load.
remote control cable is required.
Its durability is high and it is also reliable because high
● The cup spring on the rear of the larger gear absorbs
grade materials are used for the shaft and gear, and. a
rotational fluctuations and stabilizes the engagement of
taper roller bearing is incorporated.
the drive cone and the larger gear.
Power transmission is smooth because connection
Thus, the durability of the cone against wear is enhanced.

with the engine is made through the damper disc

NOTE:

KM3P3 marine gear differs from KM3P1 as follows.

● The drive cone is made from special aluminum bronze, ● Torque !imiter applied to KM3P3.

which has both higher wear-resistance and durability.

The drive cone is connected with the output shaft KM35P1 marlne gear differs from KM3P1 as follows.
through the thread spline. The taper angle, diameter of ● Output shaft dia. 28mm. (KM3P1 : 25mm).

the drive cone, twist angle, and diameter of the thread ● Drive corn the same as the one for KM4A marine gear.

spline, are designed to give the greatest efficiency, thus ● Marine gear oil reserve capacity up.

ensuring that the drive cone can be readily engaged or 0.5L (0.35L KM3P1 )
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.

Printed in Japan 7-29 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 7 Reduction and Reversing Gear
1. Construction 3JH2 series

1.2 Specifications
Mode KM3P1 KM3P3 KM35P1

For engine models 3JH25A 3JH30A

Clutch Constant mesh gear with servo cone clutch (wet type)

Forward 2.36 2.61 2.36 2.61

Reduction ratio
Reverse 3.16 3.16 3.16 3.16

Propeller shaft mirr1 (Forward) (min-1) 1356 1226 1229 1111

Input shaft Counter-clockwise, viewed from stern

Direction of rotation Forward Clockwise, viewed from stern

Output shaft Reverse Counter-clockwise, viewed from stern

Control head Single lever control

Cable Morse. 33-C (cable travel 76.2mm)

Remote control
Clamp YANMAR made. standard accessory

Cable connector YANMAR made, standard accessory

Outer diameter (mm) 100

Output shaft coupling Pitch circle diameter (mm) 78

Connecting bolt holes (mm) 4-1 0.5

Position of shift lever Right side, viewed from stern

Lubricating oil API CC SAE 20/30

Lubricating oil capscity ( ) 0.35 0.5

Dry mass (kg) 12 15 12

Note:
Torque limiter should be installed on KM3P3
No torque limiter installed on KM3P1 & KM35P1

Diameter of the propeller Moment of inertia N-m2

Reduction ratio No. of blade Material
(mm) (kg-m2=GD 2 )
3 450
2.36 1.49 (0.15)
4 425

3 470 Bronze

2.61 4 440 1.86 (0.19)

4 460

Printed in Japan 7-30 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 7 Reduction and Reversing Gear
1. Construction 3JH2 series

1-3 Power transmission system

1-3.1 Arrangement of shafts and gears

Forward small gear of input shaft

Idle gear
Reverse small gear of input shaft

input shaft

Large gear of output shaft

Intermediate shaft

Forward small gear

Output shaft with input shaft

Reverse small gear

with input shaft
Shaft arrangement
viewed from the stern Intermediate
shaft

Output shaft
Forward large gear

Drive cone

Idle gear

Reverse large gear

1-3.2 Reduction ratio

Forward
No. of teeth No. of teeth
Model of forward small gear Zif of forward 18rge gear Zof Reduction retio Zof /Zif

25 59 59/25 = 2.36
KM3P1, KM3P3, KM35P1
23 60 60/23 = 2.61

Reverse
No. of teeth No. of teeth No. of teeth
Model of reverse small gesr Zif of intemediate shaft gear Zi of reverse large gear Zdr Reduction ratio Zi/Zir・Zdr/Zi

KM3P1
KM3P3 19 26 60 60/19 = 3.16
KM35P1

Printed in Japan 7-31 Printed in Japan

A0A1015-0302 A0A1015-0302
Chapter 7 Reduction and Reversing Gear
3. Inspection and Servicing 3JH2 series

mm (3) Lap the large gear's cave and drive cone, pushing
Standard Limited them together by hand.
dimensions dimensions
KM3P1
32.7-33.3 32.4
Dimensions KM3P3
KM35P1 29.25-29.75 28.1

NOTE : When dismantled, the forward of reverse direc-

tion of the drive cone must be clearly identified.

(4) lf the wear of the V-groove of the drive cone is exces-

sive, 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.
(4) Push and turn the large gear about 5 times both
The lapping procedure is described below.
clockwise and counter-clockwise.

3-5-1 Lapping Procedure for Drive Cone (5) After lapping them, wash them with washing oil. The
(1) Coat the lapping powder onto the cave of the clutch lapped parts should be cleaned completely.
gear (Lapping powder : 67 micron silicon carbide #280)

(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 7-41 Printed in Japan

A0A1015-0302 A0A1015-0302
 1. Electrical System
Chapter 9 Electrical System
3JH25A / 30A
A0A1015-0302
Printed in Japan

12V
Color coding
Battery
R Red ＋ −

1
B Black
Battery Switch

3
W White

2
Y Yellow 12V
L Blue S or C Battery
＋ −
G Green

BR
O Orange Air heater Starter
5L
Lg Light green 3R
3B
Lb Light blue YW

WL Battery Switch
Br Brown F

R
P Pink L Earth
LB
bolt
Gr Gray C.W.Temp Eng. Oil Pressure
switch switch Alternator
Pu Purple B
YG

WR
9-4-1

Buzzer Illumination Tacho sensor

Tacho with stop switch
Hour meter Buzzer
YB
LW B
＋− P LY
L

B
GrB Fuse 3A
RG
R
A
O Starte
GW AC
30switch
RB

P1
R

17
P2 AR
3R
G2 G1 3L
3W
RC

Charge LB
Eng. Oil P. YW
C.W. Temp. WL

Y WG
Fuel G GY
Empty W
Wire A
A0A1015-0302

RW harness
Printed in Japan

Glow G Y
B

3JH2 series
Instument panel