Yanmar KMH Series Marine Gear Repair Service Manual

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This Workshop Service Repair manual PDF download for the KMH40A, KMH50A, KMH50V Yanmar Marine Gear has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar KMH40A
Yanmar KMH50A
Yanmar KMH50V


TABLE OF CONTENTS :

KMH40A - 0BKMH-G00100
Introduction
Safety
General Service Information
Service
Troubleshooting
Optional Accessories

KMH50A - 0BKMH-G00200
Introduction
Safety
General Service Information
Service
Troubleshooting
Optional Accessories

KMH50V - 0BKMH-G00300
Introduction
Safety
General Service Information
Service
Troubleshooting
Optional Accessories


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 260


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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KMH40A
Table of Contents
Introduction
Revision History
Revision Control Table
Safety
Safety Precautions
General Information
Before You Service the Marine Gear
During Servicing
General Service Information
Safety Precautions
General Information
Marine Gear System
Drive Flow in Shift Lever Position “A”
Drive Flow in Shift Lever Position “B”
Shifting the Marine Gear
Marine Gear Specifications
Hydraulic Diagram
Marine Gear Major Component Locations
Case Plate Component Location
Shifting Pressure
Function Test
Required Tests
Standard Performance Values
Service
Introduction
Before You Begin Servicing
Maintenance History
Special Service Tools
Measuring instruments
Standard Tools
Torque Charts
Standard Torque Values
Torque Specifications
Sealants and Compounds
Marine Gear Components
Case Plate Components
Marine Gear Sectional View
Clutch Pack Service
General Service Information
Clean the Marine Gear
Drain the Oil
Remove the Oil Strainer
Remove the Output Coupling
Remove the Hydraulic Oil Pump
Remove the Case Plate
Remove the Valves
Remove the Mounting Feet
Remove the Mounting Flange
Disassemble the Cases
Remove the Shafts and Gears
Remove the Oil Seals
Remove the Baffle Plate and Oil Suction Cover
Remove the Seal Rings
Remove the Tapered Roller Bearings
Remove the Tapered Roller Bearings’ Inner Races
Remove the Clutch Pack
Remove the Clutch Discs
Remove the Clutch Pistons
Inspect the Bearings
Inspect the Shafts and Gears
Inspect the Friction Discs
Inspect the Thrust Collars
Assemble the Input Shaft and Support Shaft
Reassemble the Friction Assembly
Assemble the Pinion Gear Assemblies
Assemble the Thrust Collars
Assemble the Tapered Roller Bearings onto Input and Support Shafts
Reassemble the Seal Rings
Reassemble the Tapered Roller Bearing onto Output Shaft
Inspect the Cases
Assemble the Oil Suction Cover (If Removed)
Assemble the Oil Seals
Assemble the Gear Set into Housing
Final Assembly of Cases
Assembly the Mounting Flange
Assemble the Valves
Assemble the Case Plate
Install the Oil Strainer
Install the Hydraulic Oil Pump
Install the Output Coupling
Fill the Marine Gear With Oil
Checking Oil Level
Gear Shimming Adjustment
Remove the Bearing Races
Adjust Gear Backlash
Adjust Gear Backlash
Assemble the Tapered Roller Bearing Outer Races into Case B
Measure Bearing Clearance / Adjusting Bearing Preload
Adjust Bearing Preload / Play
Adjust Bearing Clearance
Assemble the Tapered Roller Bearings Outer Races into Case A
Trial Run
Troubleshooting
Troubleshooting
Optional Accessories
Electric Shift Valve
Installation of Electric Shift Valve
Electric Shift Valve Wiring
Emergency Operation of Electric Valve
Current Production Models
Past Production Models
Mechanical Trolling Valve
Installation of Mechanical Trolling Valve
Oil Pressure Adjustment
Electric Trolling Valve
Installation
PTO Spline Sleeve and Flange
Specifications
Installation of the PTO Spline Sleeve and Flange
KMH50A
Table of Contents
Introduction
Revision History
Revision Control Table
Safety
Safety Precautions
General Information
Before You Service the Marine Gear
During Servicing
General Service Information
Safety Precautions
General Information
Marine Gear System
Drive Flow in Shift Lever Position “A”
Drive Flow in Shift Lever Position “B”
Shifting the Marine Gear
Marine Gear Specifications
Hydraulic Diagram
Marine Gear Major Component Locations
Case Plate Component Location
Shifting Pressure
Function Test
Required Tests
Standard Performance Values
Service
Introduction
Before You Begin Servicing
Maintenance History
Special Service Tools
Measuring instruments
Standard Tools
Torque Charts
Standard Torque Values
Torque Specifications
Sealants and Compounds
Marine Gear Components
Case Plate Components
Marine Gear Sectional View
Clutch Pack Service
General Service Information
Clean the Marine Gear
Drain the Oil
Remove the Oil Strainer
Remove the Output Coupling
Remove the Hydraulic Oil Pump
Remove the Case Plate
Remove the Valves
Remove the Mounting Feet
Remove the Mounting Flange
Disassemble the Cases
Remove the Shafts and Gears
Remove the Oil Seals
Remove the Baffle Plate and Oil Suction Cover
Remove the Seal Rings
Remove the Tapered Roller Bearings
Remove the Tapered Roller Bearings’ Inner Races
Remove the Clutch Pack
Remove the Clutch Discs
Remove the Clutch Pistons
Inspect the Bearings
Inspect the Shafts and Gears
Inspect the Friction Discs
Inspect the Thrust Collars
Assemble the Input Shaft and Support Shaft
Reassemble the Friction Assembly
Assemble the Pinion Gear Assemblies
Assemble the Thrust Collars
Assemble the Tapered Roller Bearings onto Input and Support Shafts
Reassemble the Seal Rings
Reassemble the Tapered Roller Bearing onto Output Shaft
Inspect the Cases
Assemble the Oil Suction Cover (If Removed)
Assemble the Oil Seals
Assemble the Gear Set into Housing
Final Assembly of Cases
Assembly the Mounting Flange
Assemble the Valves
Assemble the Case Plate
Install the Oil Strainer
Install the Hydraulic Oil Pump
Install the Output Coupling
Fill the Marine Gear With Oil
Checking Oil Level
Gear Shimming Adjustment
Remove the Bearing Races
Adjust Gear Backlash
Adjust Gear Backlash
Assemble the Tapered Roller Bearing Outer Races into Case B
Measure Bearing Clearance / Adjusting Bearing Preload
Adjust Bearing Preload / Play
Adjust Bearing Clearance
Assemble the Tapered Roller Bearings Outer Races into Case A
Trial Run
Troubleshooting
Troubleshooting
Optional Accessories
Electric Shift Valve
Installation of Electric Shift Valve
Electric Shift Valve Wiring
Emergency Operation of Electric Valve
Current Production Models
Past Production Models
Mechanical Trolling Valve
Installation of Mechanical Trolling Valve
Oil Pressure Adjustment
Electric Trolling Valve
Installation
PTO Spline Sleeve and Flange
Specifications
Installation of the PTO Spline Sleeve and Flange
KMH50V
Table of Contents
Introduction
Revision History
Revision Control Table
Safety
Safety Precautions
General Information
Before You Service the Marine Gear
During Servicing
General Service Information
Safety Precautions
General Information
Marine Gear System
Drive Flow in Shift Lever Position “A”
Drive Flow in Shift Lever Position “B”
Shifting the Marine Gear
Marine Gear Specifications
Hydraulic Diagram
Marine Gear Major Component Locations
Case Plate Component Location
Shifting Pressure
Function Test
Required Tests
Standard Performance Values
Service
Introduction
Before You Begin Servicing
Maintenance History
Special Service Tools
Measuring instruments
Standard Tools
Torque Charts
Standard Torque Values
Torque Specifications
Sealants and Compounds
Marine Gear Components
Case Plate Components
Marine Gear Sectional View
Clutch Pack Service
General Service Information
Clean the Marine Gear
Drain the Oil
Remove the Oil Strainer
Remove the Output Coupling
Remove the Hydraulic Oil Pump
Remove the Case Plate
Remove the Valves
Remove the Mounting Feet
Remove the Mounting Flange
Disassemble the Cases
Removal of Shafts and Gears
Remove the Oil Seals
Remove the Oil Suction Pipe
Remove the Seal Rings
Remove the Tapered Roller Bearings
Remove the Tapered Roller Bearings’ Inner Races
Remove the Clutch Pack
Remove the Clutch Discs
Remove the Clutch Pistons
Inspect the Bearings
Inspect the Shafts and Gears
Inspect the Friction Discs
Inspect the Thrust Collars
Assemble the Input Shaft and Support Shaft
Reassemble the Friction Assembly
Assemble the Pinion Gear Assemblies
Assemble the Thrust Collars
Assemble the Tapered Roller Bearings onto Input and Support Shafts
Reassemble the Seal Rings
Reassemble the Tapered Roller Bearing onto Output Shaft
Inspect the Cases
Assemble the Oil Suction Pipe (If Removed)
Assemble the Oil Seals
Assemble the Gear Set into Housing
Final Assembly of Cases
Assemble the Mounting Flange
Assemble the Valves
Assemble the Case Plate
Install the Oil Strainer
Install the Hydraulic Oil Pump
Install the Output Coupling
Fill the Marine Gear With Oil
Checking Oil Level
Gear Shimming Adjustment
Remove the Bearing Races
Adjust Gear Backlash
Adjust Gear Backlash
Assemble the Tapered Roller Bearing Outer Races into Case B
Measure Bearing Clearance / Adjusting Bearing Preload
Adjust Bearing Preload / Play
Adjust Bearing Clearance
Assemble the Tapered Roller Bearings Outer Races into Case A
Trial Run
Troubleshooting
Troubleshooting
Optional Accessories
Electric Shift Valve
Installation of Electric Shift Valve
Electric Shift Valve Wiring
Emergency Operation of Electric Valve
Current Production Models
Past Production Models
Mechanical Trolling Valve
Installation of Mechanical Trolling Valve
Oil Pressure Adjustment
Electric Trolling Valve
Installation
PTO Spline Sleeve and Flange
Specifications
Installation of the PTO Spline Sleeve and Flange

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