Yanmar KMH Series Marine Gear Repair Service Manual
Yanmar KMH Series Marine Gear Repair Service Manual
- 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 !!!!
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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