TOHATSU TLDI 40 Bedienungsanleitung

SERVICE MANUAL

OIL

WASH

OILLEVEL

Chapter 1 Specifications

1. Specifications Table ......................................................................1-3

2. Outline Dimensions .......................................................................1-4

3. Background on TLDI......................................................................1-6

1-2

1-3

1. Specifications Table

MODEL 40A 50A

Item EPTO EFTO EFO

Overall length (approx.) 630 mm (24.8 in) 1120 mm (44.1 in)

Overall width (approx.) 345 mm (13.6 in) 384 mm (15.1 in)

Transom (S) 1227 mm (48.3 in)

Overall height Transom (L) 1354 mm (53.3 in)

(approx.) Transom (UL) 1481 mm (58.3 in)

Transom (S) 95.5 kg (211 lb) 98.5 kg (217 lb) 88.5 kg (195 lb)

Weight Transom (L) 96.5 kg (213 lb) 99.5 kg (219 lb) 89.5 kg (197 lb)

(approx.) Transom (UL) 99.0 kg (218 lb) 102.0 kg (225 lb) 92.0 kg (203 lb)

Transom (S) 403 mm (15.9 in)

Transom length Transom (L) 530 mm (20.9 in)

(outboard) Transom (UL) 657 mm (25.9 in)

Engine type 3-cylinder inline

Piston displacement 697ml (42.5 cu.in)

Bore & stroke 68 mm (2.68 in) x 64 mm (2.52 in)

No. of cylinders 3

Maximum output 29.4 kW 36.8 kW

Full-throttle range 5150~5850 rpm

Trolling 700 rpm

Idling 700 rpm

Full-throttle fuel consumption (approx.) 17 L/Hr (4.5 US gal/Hr)

Starting system Electric starter motor

Intake system Reed valve

Scavenging system 5-port loop

Exhaust system Through hub

Lubrication system Auto-mixing

Cooling system Forced water-cooling

Water temp. control Thermostat

Ignition system L-CDI

Ignition timing control Electronically advanced

Firing order 1-2-3

Sparkplug Champion RC10ECC

Alternator 12V 280W

Battery 12V 100AH

12V 120AH (0°C or low)

Trim angle 8°~24° 4°~24°

Trim angle settings 5 6

Maximum tilt-up angle 75°

Transom board thickness 31~70 mm (1.22 ~ 2.76 in)

Maximum steering angle 70° 80°

Gear shift Dog clutch (F-N-R)

Gear ratio 1.85 : 1 (13 : 24)

Throttle control Remote-control Tiller handle

Fuel tank 25L (6.60 US gal)

Oil tank 2L (2.1 US qt)

Fuel Unleaded regular gasoline

Engine oil Genuine engine oil or TC-W, 2-stroke marine outboard oil*

Gear oil Genuine gear oil (500 ml) or API GL5, SAE #80

*: Only those products that have been approved.

1-4

2. Outline Dimensions

M 1

M 2

NOS

1-5

External Dimensions

Item Remarks

A 499 mm (19.6 in)

Transom (S) 728 mm (28.7 in)

B Transom (L) 855 mm (33.7 in)

Transom (UL) 982 mm (38.7 in)

Transom (S) 403 mm (15.9 in)

C Transom (L) 530 mm (20.9 in)

Transom (UL) 657 mm (25.9 in)

D 568 mm (22.4 in) Models EFTO, EFO

E 680 mm (26.8 in)

F 85 mm (3.3 in)

G 623 mm (24.5 in) Models EFTO, EFO

H 520 mm (20.5 in)

I 440 mm (17.3 in)

J 30-75 mm (1.2~3.0 in)

K 490 mm (19.3 in)

Transom (S) 800 mm (31.5 in)

L Transom (L) 910 mm (35.8 in)

Transom (UL) 1025 mm (40.4 in)

M1 384 mm (15.1 in) Models EFTO, EFO

M2 345 mm (13.6 in) Model EPTO

N 310 mm (12.2 in)

O 235 mm (9.3 in)

P 565 mm (22.2 in) Models EFTO, EFO

Q 120deg. Models EFTO, EFO

R 12deg.

S 35deg.

T 75deg.

U 161 mm (6.3 in)

Y 54 mm (2.1 in)

3. Background on TLDI

The abbreviation TLDI stands for Two-stroke Low-pressure Direct Injection and

is the name Tohatsu applies to direct fuel-injection system engines.

1. Two-Stroke Low-Pressure Direct Injection (TLDI)

TLDI is the name Tohatsu uses for two-stroke engines that utilize the air-assisted, low-pressure direct

injection system.

The air-assisted, low-pressure direct injection system has been combined with the L-CDI or (Long-arc

duration CDI ignition system and Engine Control Unit (ECU), which performs precision control of fuel

mixture, injection timing and ignition timing to maximize combustion efficiency in the TLDI-50 engine.

The result is better fuel economy, smaller size and greater power in a two-stroke engine.

2. Air-Assisted Low-Pressure Direct Injection

With TLDI, the air-assisted, low-pressure direct injection process involves using an air compressor to

pressurize the fuel supplied by the fuel pump to in order to propel or inject it directly into combustion

chambers in the form of a finely atomized mixture to achieve maximum combustion efficiency.

CARBURETOR TLDI

Compressed air

Pressurized fuel

ExhaustExhaust

Oil

Air

AirAir

Gasoline + Oil

Atomized fuel mixture

1-6

q Fuel injector

w Air injector

eSpark plug

rCarburetor

1-7

3. ECU Control

With TLDI, a network of connected sensors enables the Engine Control Unit (ECU) to precisely

regulates fuel mixture injection rate and ignition timing. The ECU also uses a stratified fuel feed process

to provide lean combustion in the low-speed range, while utilizing more homogenized change to ensure

the fuel mixture is distributed uniformly throughout the combustion chamber when operating in the high-

speed range to ensure maximum combustion efficiency.

L-CDI charge coil

Crank-position sensor

(CPS)

Throttle-position sensor

(TPS)

Water-temperature sensor

(WTS)

Oil level sensor

Battery

Key switch

Stop switch

#1, #2 & #3

Fuel injectors

#1, #2 & #3

Air injectors

#1, #2 & #3

Ignition coils

Tachometer

Warning indicators

Warning horn

Fuel-feed pump

(FFP)

Engine Control Unit

(ECU)

➞

Long-duration CDI (L-CDI)

The L-CDI or Long-arc duration CDI ignition system is used as the TLDI ignition system to maximize

combustion efficiency, fuel economy and minimize exhaust emissions. The L-CDI system offers a longer

plug sparking interval, via spark plug, than used with conventional two-stroke engines. This is designed to

ensure more complete combustion of the mixture in the chamber. L-CDI minimizes mis-firing and reduces

fluctuation in engine speed during idling to offer a much smoother engine feel when compared with

conventional two-stroke engines.

Throttle-Position Sensor (TPS)

The throttle-position sensor system is comprised of TPS1 and TPS2. These are used in combination to

detect throttle butterfly valve, position advancer arm position, and to relay the information to the ECU.

Crank-Position Sensor (CPS)

The crank-position sensor is designed to sense the encoder located above the ring gear on the flywheel in

order to detect crankshaft position and transmit the information to the ECU.

Water-Temperature Sensor (WTS)

Positioned on the water jacket installed on the cylinder, the water-temperature sensor (WTS) is used detect

temperature of the cooling water in the cylinder and relay the information to the ECU.

Oil Level Sensor

The oil level sensor is used to detect the level of remaining oil and relay the information to the ECU.

The oil level sensor operates by lighting the indicator on the tachometer and sounding the beeper when

engine oil is low.

Air Injectors

The air injectors are used to inject a fine mist of fuel and air into the combustion chamber for each piston.

The ECU determines the mixture and timing for injecting fuel according to current engine operating

conditions based on information relayed from the various sensors.

Fuel Injector

The fuel injectors supply the fuel in the air rail to the air injectors via the set pieces. The ECU determines the

mixture for injecting fuel according to current engine operation based on information relayed from the

various sensors.

1-8

1-9

4. Fuel Supply System

OUT

Starting the engine activates the fuel pump e, which draws

gasoline from the fuel tank qand routes it through the fuel filter

wto the vapor separator r. The gasoline is pressurized in the

fuel-feed pump FFP t; then passes through the high-pressure

filter yto the air rail u, from there it is injected into the

combustion chambers. The fuel regulator iregulates

components tthrough uin order to maintain gasoline at a

differential pressure of 80 kPa (11.4 psi). Any excess gasoline is

depressurized and diverted through the FFP case oand back to

the vapor separator r. The returned gasoline contains air

bubbles left over from being pressurized at t. These bleed from

the top of the vapor separator rto the throttle body !0 and is

fed to the air intake system.

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