Yanmar Marine Gear Kmh40a Kmh50a Kmh50v Service Repair Manual Instant Download

KMH series SERVICE MANUAL KMH40A/KMH50A/KMH50V

P/N: 0BKMH-G00100 0BKMH-G00200 0BKMH-G00300

MARINE GEAR

This Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service professional before working on your Yanmar product.

Disclaimers: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance improvement. We reserve the right to make any change at any time.

Yanmar and or other countries.

are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and /

All Rights Reserved: No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems without the written permission of Yanmar Marine International. Š 2007 Yanmar Marine International 0107

ii

KMH series SERVICE MANUAL KMH40A

P/N: 0BKMH-G00100

MARINE GEAR

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TABLE OF CONTENTS Page Introduction ......................................................................................... 1-1 Safety.................................................................................................... 2-1 General Service Information .............................................................. 3-1 Service.................................................................................................. 4-1 Troubleshooting .................................................................................. 5-1 Optional Accessories.......................................................................... 6-1

TABLE OF CONTENTS

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KMH40A Service Manual

Section 1

INTRODUCTION This Service Manual gives specific instructions for proper repair on KMH40A transmissions.

Please follow the procedures carefully to ensure quality service.

Yanmar recommends that you read this Service Manual completely before starting with repairs, as some of the procedures described are rather complex.

Yanmar products are continuously undergoing improvement. This Service Manual has been checked carefully in order to avoid errors. However Yanmar is not liable, for any misrepresentations, errors of description or omissions. Contact an authorized Yanmar marine dealer or distributor for any questions you have regarding this Service Manual.

Along with standard tools, Yanmar recommends the use of special tools necessary to perform repairs correctly.

KMH40A Service Manual

1-1

INTRODUCTION

Revision History

REVISION HISTORY This manual is a living document. Periodic manual revisions are published to document product improvements and changes. This practice ensures the manual has the most current information.

At times the revision involves inserting additional pages in one or more sections. Insert the new information and only the Revision Control Table should be replaced.

As manual revisions become necessary, individual pages are prepared and sent to those who need the information. If a page, or number of pages should be replaced, the replacement information is sent along with a revised Revision Control Table.

Discard the older, obsolete information.

This method of revision control represents the most cost-effective solution to providing current, updated information as needed.

Revision Control Table Revision Date Revision Number JAN 2007 Rev. 00

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New Page Numbers Involved All

Remarks New Manual

KMH40A Service Manual

Initiating Dept.

YMU

Section 2

KMH40A Service Manual

SAFETY Page Safety Precautions ..........................................................................

General Information...................................................................

Before You Service the Marine Gear.........................................

During Servicing ........................................................................

KMH40A Service Manual

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2-1

SAFETY

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KMH40A Service Manual

SAFETY 12/05

Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products exercise care, common sense and comply with the safety information in this manual and on the machine’s safety labels. Keep the labels from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a label attached to it, make sure you order the new part and label at the same time.

A

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a situation which can cause damage to the machine, personal property and / or the environment or cause the equipment to operate improperly.

KMH40A Service Manual

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SAFETY

SAFETY PRECAUTIONS

Safety Precautions

During Servicing

General Information There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.

Before You Service the Marine Gear The safety messages that follow have CAUTION level hazards.

NEVER permit anyone to install or operate the engine without proper training.

Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures.

Safety signs and labels are additional reminders for safe operating and maintenance techniques.

See your authorized Yanmar marine dealer or distributor for additional training. ◆

◆

◆

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The safety messages that follow have DANGER level hazards.

Crush Hazard NEVER stand under hoisted engine. If the hoist mechanism fails, the engine will fall on you.

Fire Hazard Keep fire extinguishers handy in case of fire. Clearly indicate the location of the fire extinguishers with a safety sign.

Ensure that the type of fire extinguishers are appropriate for material that might catch fire. Check with local authorities.

Have all fire extinguishers checked periodically for proper operation and / or readiness.

Post evacuation routes prominently. Periodically conduct fire drills.

Ensure that appropriate fire detection and extinguishing equipment are installed and checked periodically for proper operation. Check with local authorities.

KMH40A Service Manual

SAFETY

Safety Precautions 12/05

Exposure Hazard The safety messages that follow have WARNING level hazards.

Explosion Hazard Avoid serious personal injury or equipment damage. While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flame and any other form of ignition out of the area.

Diesel fuel is flammable and explosive under certain conditions.

Never use a shop rag to catch the fuel.

Wipe up all spills immediately.

Fire Hazard Avoid injury or equipment damage from fire. Undersized wiring systems can cause an electrical fire.

Sever Hazard Rotating parts can cause severe injury or death. NEVER wear jewelry, unbuttoned cuffs, ties or loose fitting clothing and ALWAYS tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts.

NEVER service the marine gear while under tow or if the engine is running at idle speed. The propeller may rotate under these circumstances.

To avoid injury, ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand.

Entanglement Hazard NEVER leave the key in the key switch when you are servicing the engine or marine gear. Someone may accidentally start the engine and not realize you are servicing it.

Avoid personal injury. NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals.

If the vessel has more than one engine, NEVER service a marine gear if either of the engines are running. In multi-engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running.

Burn Hazard Avoid serious injury. Some of the engine and marine gear surfaces become very hot during operation and shortly after shut-down. Keep hands and other body parts away from hot engine surfaces.

Sudden Movement Hazard Avoid personal injury. ALWAYS stop the engine before beginning service.

Alcohol and Drug Hazard NEVER operate the engine while under the influence of alcohol or drugs or feeling ill.

KMH40A Service Manual

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SAFETY

Safety Precautions

Exhaust Hazard Avoid serious injury or death. NEVER block windows, vents, or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning.

The safety messages that follow have CAUTION level hazards.

Poor Lighting Hazard Avoid personal injury or equipment damage.

Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps.

Tool Hazard Avoid personal injury or equipment damage.

ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts.

Flying Object Hazard Avoid personal injury. ALWAYS wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

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KMH40A Service Manual

Safety Precautions

SAFETY

12/05

The safety messages that follow have NOTICE level hazards.

Observe the following environmental operating conditions to maintain marine gear performance and avoid premature marine gear wear:

It is important to perform daily checks as listed in the Operation Manual.

• NEVER run the marine gear if the ambient temperature is above +45°C (+113°F) or below -15°C (+5°F).

Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

• If the ambient temperature exceeds +45°C (+113°F) the marine gear may overheat and cause the marine gear oil to break down.

ALWAYS be environmentally responsible.

Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.

NEVER dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways.

Make sure the engine is installed on a level surface.

If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Installation manuals, engine oil may enter the combustion chamber causing excessive engine speed, white exhaust smoke and serious engine damage. This applies to engines that run continuously or those that run for short periods of time.

Before operating the engine, check marine gear oil level.

• If the ambient temperature falls below -15°C (+5°F) rubber components such as gaskets and seals will harden causing premature marine gear wear and damage.

• Contact your authorized Yanmar marine dealer or distributor if the marine gear will be operated in either temperature extreme.

NEVER attempt to modify the marine gear’s design or safety features.

If you have more than one engine, you cannot shift the marine gear into the “B” position after you install the “emergency nut.”

Observe the following environmental operating conditions to maintain marine gear performance and avoid premature marine gear wear: • Avoid operating in extremely dusty conditions.

• Avoid operating in the presence of chemical gases or fumes.

Protect the electrical components from damage when you use steam or use high-pressure water to clean the engine or marine gear.

Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated. Failure to follow these guidelines will impair the marine gear’s safety and performance characteristics, shorten the marine gear’s life and may affect the warranty coverage on your marine gear.

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SAFETY

Safety Precautions

If the marine gear oil temperature is too high, stop engine immediately and check the marine gear oil level and check the oil cooler for proper coolant and water flow.

New Marine Gear Break-In: On the initial engine start-up, allow the engine to idle for approximately 15 minutes while you check for proper marine gear function and marine gear oil leaks.

During the break-in period, carefully observe marine gear indicators (if any) for proper marine gear function.

During the break-in period, check the marine gear oil levels frequently.

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KMH40A Service Manual

KMH40A Service Manual

Section 3

GENERAL SERVICE INFORMATION Page Safety Precautions .......................................................................... 3-2 General Information......................................................................... 3-2 Marine Gear System ....................................................................... 3-3 Drive Flow in Shift Lever Position “A” ........................................ 3-3 Drive Flow in Shift Lever Position “B” ........................................ 3-4 Shifting the Marine Gear ................................................................. 3-5 Marine Gear Specifications ............................................................. 3-6 Hydraulic Diagram........................................................................... 3-7 Marine Gear Major Component Locations ...................................... 3-8 Case Plate Component Location................................................... 3-10 Shifting Pressure ........................................................................... 3-12 Function Test................................................................................. 3-13 Required Tests ........................................................................ 3-13

KMH40A Service Manual

3-1

GENERAL SERVICE INFORMATION

SAFETY PRECAUTIONS Only use the marine gear oil specified. Other marine gear oils may affect warranty coverage, cause internal marine gear components to seize and / or shorten marine gear life.

NEVER mix different types of marine gear oil. This may adversely affect the lubricating properties of the marine gear oil.

Safety Precautions

GENERAL INFORMATION This marine gear has a built-in wet type multi-disc clutch and is operated by the oil pressure of the hydraulic pump.

The major components are: • Damper • Input shaft assembly • Support shaft assembly • Output shaft assembly

ALWAYS keep the oil level between upper and lower lines on the marine gear dipstick.

• Hydraulic pump • Housing

NEVER overfill marine gear with oil. Overfilling may result in internal damage.

Prevent dirt and debris from contaminating marine gear oil. Carefully clean the oil plug and dipstick and the surrounding area before you remove either one.

The correct level of marine gear oil is very important for proper marine gear function: • Check the marine gear for the proper amount of marine gear oil before you start the engine for the first time.

The lube oil for each of the parts is distributed by the hydraulic pump in a forced lubrication system.

When the mechanical shift lever or electric shift valve is actuated, oil pressure is applied to move the clutch to the FORWARD or REVERSE position.

The clutch for clockwise rotation of the output shaft is fitted to the input shaft, and the clutch for counterclockwise rotation of output shaft is fitted to the support shaft.

The marine gear oil (lube oil) is cooled by a multi-pipe marine gear oil cooler.

• Running the engine with insufficient oil level in the marine gear will cause damage to internal marine gear components.

If the marine gear oil temperature is too high, stop engine immediately and check the marine gear oil level and check the oil cooler for proper coolant and water flow.

Never lift the marine gear and engine by the marine gear limiting eye. Use the engine lifting eye to lift he engine and marine gear as an assembly.

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KMH40A Service Manual

GENERAL SERVICE INFORMATION

Marine Gear System 12/05

MARINE GEAR SYSTEM Drive Flow in Shift Lever Position “A” Input shaft clutch engaged - Support shaft clutch disengaged.

Output shaft rotation is the same as input shaft (engine) rotation.

Drive Flow = Damper (1) Input Shaft (2)→Input Shaft Clutch Housing Gear (6)→Input Shaft Pinion Gear (3) →Output Shaft Gear (7)→Output Shaft (8)→Output Shaft Coupling (9) Figure 3-1

(1)

(2) (3)

(5)

(6)

(9)

(4) (11)

(10) (7)

(8) 0001947A

Figure 3-1

KMH40A Service Manual

3-3

GENERAL SERVICE INFORMATION

Marine Gear System

Drive Flow in Shift Lever Position “B” Support shaft clutch engaged - Input shaft clutch not engaged Output shaft rotation opposite of input shaft (engine) rotation.

Drive Flow = Damper (1) Input Shaft (2)→Input Shaft Clutch Housing Gear (6)→Support Shaft Clutch Housing Gear (11)→Support Shaft Pinion Gear (4)→Output Shaft (8)→Output Shaft Coupling (9) Figure 3-2

(1)

(2) (3)

(5)

(6)

(9)

(4) (10)

(11) (7)

(8) 0001947B

Figure 3-2

3-4

KMH40A Service Manual

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