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TLDI MD 115A SERIES
TOHATSU TLDI MD 115A SERIES User Manual
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OB
No
.003-21060-0
07-05
NB-2600
OB No.003-21060-0
07-05 NB-2600
Printed in Japan
MD115AcoverE.qxd
07.6.8
2:32
PM
ページ1
2
Table of Contents
1.Service Information
6
Service Information
5
Table of Contents
6
Identification (Engine Serial Number)
12
Securing of Work Safety
12
Fire Prevention
12
Ventilation
12
Protection
12
Genuine Parts
12
Tools
13
Recommendations on Service
13
Cautions in Disassembling and Assembling Components
14
Tools and Instruments
15
Test Propeller
15
Measuring Instruments
15
List of Special Tool
16
Pre-Delivery Inspection
20
Steering Handle
20
Gear Shift and Throttle
20
Engine Oil
20
Gear Oil
20
Check Quantity of Engine Oil
21
Fuel Line
22
Installation of Outboard Motor (Rigging)
22
Inspection of PTT Unit
22
Inspection of Start Switch and Stop Switch
23
Propeller Selection
24
Cooling Water Check Port
24
Trim Tab
25
Break-In Operation
25
Test Run
26
Checks after Test Run
26
Service Data
27
Outboard Dimensions
28
Body Dimensions
28
Clamp Dimensions
29
Cooling Water System Diagram
30
Specifications
32
Warning Indication List
34
Display for Abnormalities During Operation
34
Torque Specifications
36
Maintenance Data
38
Sealant and Lubricant
44
Inspections and Adjustments
48
Special Tool
49
Inspection Schedule
50
Top Cowl
51
Adjustment of Cover Hook
51
Oil Filter and Oil Tank
51
Air Bleeding
52
Fuel System
53
Inspection of Fuel Pipes and Joints
53
Inspection of Fuel Filter
54
Inspection of Air Compressor Air Filter
54
Inspection of Air Pressure
54
Inspection of Fuel Pressure
55
Cooling System
56
Inspection of Cooling Water Passage
56
Flushing with Water
57
Inspection of Compression Pressure
60
Power Unit
61
Inspection of Drive Belt
61
Adjustment of Drive Belt Tension
62
Inspection of Spark Plugs
63
Inspection of Thermostat
64
Operating System
65
Adjustment of Throttle Cable
65
Adjustment of Shift Cable
66
PTT System
67
Inspection of PTT Unit Operation
67
Inspection of PTT Fluid Quantity
67
Lower Unit
68
Inspection of Gear Oil Quantity
68
Replacement of Gear Oil
69
Inspection of Gear Case (for Leakage)
70
Others
71
Replacement of Anode
71
Inspection of Battery
72
Greasing
73
Fuel System (TLDI
74
Fuel System (TLDI)
75
Special Tools
75
Parts Layout
76
Vapor Separator & Fuel Line
76
FFP Ass'y
77
High Pressure Fuel Filter & Air Rail
79
Air Compressor
81
Oil Pump
83
What Is TLDI
85
Direct Fuel Injection System
85
Inductive Ignition
86
Ecu
88
Removing Air Rail
92
Decompression of Fuel Line and Air Line
92
Removing Air Rail Ass'y
92
Assembling Air Rail
94
Installing Injectors and Regulators
94
Removing Fuel System
98
Removing Fuel Hose Ass'y
98
Attaching Fuel Hose Ass'y
98
Draining Fuel from FFP Vapor Separator
99
Removing Vapor Separator
99
Disassembly and Inspection of Vapor Separator
100
Assembly of Vapor Separator
101
Assembly of Vapor Separator Ass'y
102
Removing FFP Ass'y
102
Disassembly and Inspection of FFP
102
Assembly of FFP Ass'y
103
Attaching FFP Ass'y to Cylinder
105
Inspection of Fuel Pump
106
Structure of Air Compressor
108
Removing Air Compressor
109
Removing Drive Belt
109
Inspection of Drive Belt
110
Removing Driven Pulley
111
Disassembly of Compressor Housing
112
Inspection of Reed Valve
112
Inspection of Cylinder and Piston
112
Assembly of Compressor Housing
113
Installation of Crank Shaft
114
Installation of Piston
115
Installation of Compressor Housing Ass'y
116
Measurement of Fuel Pressure and Air Pressure
117
Inspection of Oil Filter
119
Inspection of Oil Tank
119
Air Bleeding
120
Power Unit
123
Special Tools
124
Parts Layout
125
Engine
125
Magneto
126
Electric Parts (Starter Motor)
128
Air Chamber
128
Throttle
132
Cylinder Crank Case
134
Piston & Crank Shaft
136
Inspection Items
137
Removing Power Unit
137
Removing Flywheel
141
Removing Stator Coil
142
Removing Cord Ass'y
143
Removing Throttle Link
146
Removing Air Chamber
147
Inspection of Throttle Body
148
Exploded Diagram of Short Block
150
Exploded Diagram of Piston-Crank Shaft Assembly
151
Removing Thermostat
152
Removing Cylinder Head / Head Cover
153
Inspection of Cylinder Head
154
Removing Exhaust Cover
155
Inspection of Exhaust Cover
155
Removing Crank Case
156
Removing Pistons
157
Disassembly of Crank Shaft
158
Inspection of Crank Shaft
158
Inspection of Engine Parts
160
Inspection of Pistons
161
Assembling Crank Shaft
164
Installing Pistons
165
Assembling Power Unit Parts
166
Assembling Crank Case Halves
168
Assembling Exhaust Cover Parts
169
Assembling Cylinder Head Parts
171
Assembling Coil Bracket Parts
172
Assembling Crank Case Head Parts
172
Installing Air Chamber
173
Attaching Coil Bracket
175
Attaching Recirculation Hoses
176
Installing Alternator
177
Installing Flywheel
177
Installing Power Unit
178
Lower Unit
179
Lower Unit
182
Parts Layout
182
Gear Case (Drive Shaft)
182
Gear Case (Propeller Shaft)
184
Inspection Items
186
Draining Gear Oil
186
Removing Propeller
186
Removing Lower Unit
187
Removing Water Pump
188
Inspection of Water Pump
189
Disassembly of Water Pump Case (Lower)
190
Assembly of Water Pump Case (Lower)
190
Removing Propeller Shaft Housing Ass'y
191
Disassembly of Propeller Shaft Housing Ass'y
192
Inspection of Propeller Shaft Housing
193
Assembly of Propeller Shaft Housing
194
Disassembly of Propeller Shaft Ass'y
197
Inspection of Propeller Shaft Ass'y
198
Assembly of Propeller Shaft Ass'y
198
Disassembly of Cam Rod
199
Inspection of Clutch Cam
200
Assembly of Clutch Cam Parts
200
Removing Forward (A) Gear Ass'y
201
Disassembly of Forward Gear (A) Gear
202
Inspection of Forward (A) Gear
202
Assembly of Forward (A) Gear Parts
203
Removing Drive Shaft Ass'y
204
Disassembly of Drive Shaft Ass'y
205
Inspection of Drive Shaft
206
Assembly of Drive Shaft Parts
206
Disassembly of Gear Case
208
Inspection of Forward (A) Gear and Pinion (B) Gear
209
Inspection of Gear Case
209
Assembly of Gear Case Parts
210
Assembly of Lower Unit Parts
212
Attaching Clutch Cam Ass'y
215
Installation of Lower Unit
216
Measurement of Pinion (B) Gear Height and Shim Selection
218
Pinion (B) Gears and Shim Selection
220
Reverse (C) Gears and Shim Selection
223
Measurement of Propeller Shaft Play and Selection of Washer Thickness
226
Cowl, Bracket and PTT
227
Special Tools
228
Parts Layout
229
Bottom Cowl
230
Shift
232
Drive Shaft Housing
234
Bracket
236
Power Trim & Tilt
238
Inspection Items
240
Inner Cowl
240
Removing Top Cowl
240
Adjustment of Cover Hook
240
Removing Bottom Cowl
241
Removing Drive Shaft Housing
242
Disassembly of Drive Shaft Housing
243
Inspection of Drive Shaft Housing
245
Assembly of Drive Shaft Housing Parts
246
Assembling Drive Shaft Housing Parts
249
Removing Steering Shaft Arm
250
Removing PTT Unit
251
Removing Clamp Bracket
253
Assembling Clamp Bracket Parts
254
Installation of PTT Unit
254
Assembling Steering Arm Parts
256
Removing Motor
257
Inspection of Power Trim and Tilt Motor
258
Assembling Power Trim and Tilt Motor Parts
260
Removing Reservoir
261
Disassembly of Gear Pump
261
Disassembling Bracket Unit and Assembling the Parts
262
Trim Cylinder, and Assembly of the Parts
262
Assembling PTT Unit Parts
263
Air-Purging PTT Unit
267
Electrical System
268
Electrical System
269
Special Tools
269
Parts Layout
270
Starter Motor
270
Inspection Items
271
Disassembly of Starter Motor
271
Inspection of Armature
271
Inspection of Brushes
272
Inspection of Pinion
272
Inspection of Ignition and Sparks
273
Inspection of Plug Cap
273
Inspection of Ignition Coils
274
Inspection of Pick up Coil (Crank Position Sensor)
274
Inspection of Pick up Coil Air Gap
274
Inspection of Alternator
275
Inspection of Rectifier Complete
276
Inspection of Throttle Position Sensor
277
Inspection of Water Temperature Sensor
277
Inspection of Power Relay
278
Inspection of Air Injectors
278
Inspection of Fuel Injectors
278
Inspection of MAT (Manifold Temperature) Sensor
279
Inspection of MAP Sensor (Manifold Air Pressure Sensor)
279
Inspection of Starter Solenoid
279
Inspection of Oil Level Sensor
280
Inspection of Oil Pump
280
Inspection of PTT Solenoid
281
Inspection of PTT Switch
281
9 Troubleshooting O
282
Default Chapter
282
Function
282
Troubleshooting O K
282
Troubleshooting
289
Rigging
295
Ignition System
297
Fuel System
299
Air System
301
Ignition System
304
Fuel System
305
Lubrication System
305
Cooling System
307
Power Unit
295
State 1 Engine will Not Start or Is Hard to Start
295
State 3 Engine Rotation Is Unstable or Surging Occurs in Low Speed Range
308
Ignition System
309
Fuel System
310
PTT Unit
311
State 1 PTT Unit will Not Operate
311
State 2 PTT Is Not Capable of Sustaining Outboard Motor
312
Self-Diagnosis Function of TLDI
313
Terms Related to Self-Diagnosis Function
313
Operation Procedure of Self-Diagnosis Function
314
Operating Hour Indication List (Self Diagnosis • Mode 2)
319
Trouble Indication List (Self Diagnosis • Mode 3)
320
Resetting TPS Initial Values
324
10 Rigging R/Min
326
Service Data
327
Load Limit of Boat
327
Installation Dimensions
327
Clamp Dimensions
328
Hanging Outboard Motor
330
Installation of Outboard Motor
330
Service Information
327
Fuel System
331
Fuel
331
Oil
331
Electric Fuel Pump
331
Installation of Fuel Filter
331
Connection of Fuel Hose
332
Filling Fuel System
332
Filling Oil Tank
332
Priming Oil Pump
333
Connections to Outboard Motor
333
Steering Cable
333
Drag Link
334
Installation of Remote Control Cable (Engine Side)
335
Lower Unit
338
Installation of Propeller
338
Electric System
339
Battery Capacity
339
Connection of Battery Cables
339
Installation of Battery (Ies)
339
Accessories and Meters
340
Accessories
340
Installation of Meters
340
Wiring Remote Control and Meter Leads
342
Connections
343
TLDI Wire Harness Terminals and Connections
344
Wiring Diagram
344
Main Harness Diagram
345
EPTO Electrical Circuit
346
Instruction Diagram -1
348
Electrical Wiring Assembling Instruction Diagram -2
349
Electrical Wiring Assembling Instruction Diagram -3
350
Outboard Motor Installation Template
351
4
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TOHATSU TLDI MD 115A SERIES Specifications
General
Brand
TOHATSU
Model
TLDI MD 115A SERIES
Category
Outboard Motor
Language
English
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