Yanmar 4LHA-STP Operating instructions

KMH

series

OPERATION MANUAL

KMH40A

KMH50A

KMH50V

P/N: 0AKMH-G00100

MARINE

GEAR

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 without notice. Yanmar and are

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

countries.

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.

1006

ii KMH40A / KMH50A / KMH50V Operation Manual

TABLE OF

CONTENTS

Page

Introduction .............................................................. 1

Record of Ownership .............................................. 2

Safety ....................................................................... 3

Safety Precautions ................................................. 3

General Information ......................................... 4

Before You Operate ......................................... 4

During Operation and Maintenance ..................... 5

Product Overview ...................................................... 9

Overview ............................................................. 9

Component Identification ........................................ 10

Nameplate .......................................................... 12

Significance of Marine Gear Designations ............ 12

Technical Data ..................................................... 13

Marine Gear Operation .............................................. 15

Daily Checks ....................................................... 16

Visual Checks ............................................... 16

Shifting the Marine Gear ......................................... 18

Towing or Anchoring .............................................. 18

Maintenance ............................................................ 19

Tightening Fasteners ............................................. 22

Torque Charts ...................................................... 23

Standard Torque Values .................................. 23

Torque Specifications ..................................... 23

Periodic Maintenance ............................................ 24

The Importance of Periodic Maintenance ............. 24

The Importance of Daily Checks ........................ 24

Keep a Log of Engine Hours and Daily Checks ..... 24

KMH40A / KMH50A / KMH50V Operation Manual iii

Yanmar Replacement Parts .............................. 24

Tools Required .............................................. 24

Ask Your Authorized Yanmar Marine Dealer or

Distributor For Help ........................................ 24

Periodic Maintenance Schedule ........................ 25

Periodic Maintenance Procedures ............................ 26

After Initial 50 Hours of Operation ...................... 26

Every 250 Hours of Operation ........................... 28

Every 1000 Hours of Operation ......................... 29

Long-Term Storage ............................................... 30

Troubleshooting ....................................................... 31

Troubleshooting Chart ........................................... 31

Specifications .......................................................... 33

General Specifications ........................................... 33

Outline Drawings .................................................. 34

KMH40A ...................................................... 34

KMH50A ...................................................... 35

KMH50V ...................................................... 36

Optional Accessories ................................................ 39

Electric Shift Valve ................................................ 39

Installation of Electric Shift Valve ....................... 39

Emergency Operation of Electric Valve ............... 39

Trolling Valves ..................................................... 41

Mechanical Trolling Valve ................................ 41

Electric Trolling Valve ...................................... 42

PTO Spline Sleeve and Flange ................................ 42

Specifications ................................................ 42

Installation of the PTO Spline Sleeve and

Flange ......................................................... 42

TABLE OF CONTENTS

iv KMH40A / KMH50A / KMH50V Operation Manual

INTRODUCTION

Welcome to the world of Yanmar Marine!

Yanmar Marine offers engines, drive

systems and accessories for all types of

boats, from runabouts to sailboats, and from

cruisers to mega yachts. In marine leisure

boating, the worldwide reputation of Yanmar

Marine is second to none.

Yanmar marine gears are designed for a

wide range of applications. Our parallel,

down angle, saildrive and V-drive marine

gears are designed to reduce the vibration

and make your cruising more pleasurable.

To help you enjoy your Yanmar Marine

products for many years to come, please

follow these recommendations:

• Read and understand this Operation

Manual before you operate your boat to

ensure that you follow safe operating

practices and maintenance procedures.

• Keep this Operation Manual in a

convenient place for easy access.

• If this Operation Manual is lost or

damaged, order a new one from your

authorized Yanmar marine dealer or

distributor.

• Make sure this manual is transferred to

subsequent owners. This manual should

be considered a permanent part of the

boat and remain with it.

• Constant efforts are made to improve the

quality and performance of Yanmar

products, so some details included in this

Operation Manual may differ slightly from

your marine gear. If you have any

questions about these differences,

please contact your authorized Yanmar

marine dealer or distributor.

KMH40A / KMH50A / KMH50V Operation Manual 1

RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar for

service, parts or literature.

Marine Gear Model:

Marine Gear Serial No.:

Date Purchased:

Dealer:

Dealer Phone:

INTRODUCTION

2 KMH40A / KMH50A / KMH50V Operation Manual

SAFETY

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.

!

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.

SAFETY PRECAUTIONS

!

DANGER

Indicates a hazardous situation which, if

not avoided, will result in death or

serious injury.

!

WARNING

Indicates a hazardous situation which, if

not avoided, could result in death or

serious injury.

!

CAUTION

Indicates a hazardous situation which, if

not avoided, could result in minor or

moderate injury.

NOTICE

Indicates a situation which can cause

damage to the machine, personal property

and / or the environment or cause the

equipment to operate improperly.

KMH40A / KMH50A / KMH50V Operation Manual 3

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 Operate

!

DANGER

The safety messages that follow have

WARNING level hazards.

NEVER permit anyone to

install or operate the engine or

marine gear without proper

training.

• Read and understand this Operation

Manual before you operate or service the

engine or marine gear 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.

SAFETY

4 KMH40A / KMH50A / KMH50V Operation Manual

During Operation and

Maintenance

!

DANGER

The safety messages that follow have

DANGER level hazards.

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.

!

WARNING

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

NEVER service the marine

gear while under tow or if the

engine is running at idle

speed. The propeller may

rotate under these

circumstances.

Alcohol and Drug Hazard

NEVER operate the engine

while under the influence of

alcohol or drugs or when

feeling ill.

SAFETY

KMH40A / KMH50A / KMH50V Operation Manual 5

!

WARNING

Exposure Hazard

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 surfaces.

Sudden Movement Hazard

Avoid personal injury. ALWAYS stop the

engine before beginning service.

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.

SAFETY

6 KMH40A / KMH50A / KMH50V Operation Manual

!

CAUTION

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.

NOTICE

The safety messages that follow have

NOTICE level hazards.

It is important to perform daily checks as

listed in this Operation Manual.

Periodic maintenance prevents unexpected

downtime, reduces the number of accidents

due to poor engine or marine gear

performance and can help extend the life of

the engine and marine gear.

ALWAYS be environmentally

responsible.

Follow the guidelines of the EPA or other

governmental agencies for the proper

disposal of hazardous materials such as

lubrication 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.

Before operating the engine, check marine

gear oil level.

SAFETY

KMH40A / KMH50A / KMH50V Operation Manual 7

NOTICE

Observe the following environmental

operating conditions to maintain marine

gear performance and avoid premature

marine gear wear:

• NEVER run the marine gear if the ambient

temperature is above +45˚C (+113˚F) or

below -15˚C (+5˚F).

• If the ambient temperature exceeds

+45˚C (+113˚F) the marine gear may

overheat and cause the marine gear oil to

break down.

• 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.

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.

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.

SAFETY

8 KMH40A / KMH50A / KMH50V Operation Manual

PRODUCT OVERVIEW

OVERVIEW

The KMH marine gear is a

hydraulically-activated helical gear unit,

developed for use in pleasure craft.

The marine gear is equipped with a

disk-type reversing clutch mounted on the

support shaft and supplied with hydraulic

pressure from an oil pump.

Operation of the oil pump is dependent on

the engine speed.

The marine gear is lubricated by splash and

force-feed lubrication.

KMH40A / KMH50A / KMH50V Operation Manual 9

COMPONENT IDENTIFICATION

Note: KMH40 shown. Other models are similar.

A

0004046A

(5)

(6)

(7)

(10)

(9)

(8)

(11)

(12)

(13)

(14)

(1)

(2)

(15)

(16)

(17)

(18)

(4)

(3)

(24)

(22)

(23)

(19)

(20)

(21)

Section A-A

Figure 1

PRODUCT OVERVIEW

10 KMH40A / KMH50A / KMH50V Operation Manual

1 – Control Pressure Sensor Location

2 – O-Ring

3 – Port to Heat Exchanger

4 – Temperature Sensor Location

5 – Oil Dipstick

6 – Parallel Pin

7 – Port from Heat Exchanger

8 – Seal Washer

9 – Drain Plug with Magnet

10 – Output Flange

11 – Oil Strainer

12 – Oil Pump

13 – Gasket

14 – Upper Cover

15 – Nameplate

16 – Neutral Safety Switch

17 – Shifting Lever

18 – Input Shaft

19 – Spring Pin

20 – Spring Retainer

21 – Spring

22 – 2nd Relief Shim

23 – 2nd Relief Valve

24 – Marine Gear Lifting Eye

NOTICE: NEVER use the marine gear lifting eye (Figure 1, (24)) to lift the engine and marine

gear as an assembly. Use the engine lifting eyes to lift the engine and marine gear. Only use

the marine gear lifting eye to lift the marine gear as a separate component.

PRODUCT OVERVIEW

KMH40A / KMH50A / KMH50V Operation Manual 11

NAMEPLATE

The nameplate is installed on the marine

gear.

OSAKA JAPAN

MODEL

GEAR RATIO

OIL

NO.

(1)

(2)

(3)

(4)

0001606A

Figure 2

1 – Marine Gear Model

2 – Marine Gear Ratio

3 – Lubrication Oil Type

4 – Marine Gear Serial Number

Significance of Marine Gear

Designations

KMH 40 A

Version of marine

gear

Size of marine gear

Design of marine

gear

PRODUCT OVERVIEW

12 KMH40A / KMH50A / KMH50V Operation Manual

TECHNICAL DATA

When installing the KMH marine gears, the following items should be specially noted:

• Installation should be done by a specialist only.

• Align and install the marine gear and engine correctly.

• Align correctly with engine and propeller shaft.

• Select a suitable damping coupling between the engine and the marine gear. See your

authorized Yanmar dealer or distributor for assistance.

• Choose an adequate heat exchanger.

• Mount the marine gear correctly in the boat.

KMH40A KMH50A KMH50V

Maximum Input Speed 5000 min

-1

(rpm) 4000 min

-1

(rpm) 5500 min

-1

(rpm)

Oil Capacity without Heat Exchanger

Available 1.7 L (1.8 qt) 2.0 L (2.1 qt) 5.4 L (5.7 qt)

Effective 0.4 L (0.4 qt) 0.4 L (0.4 qt) 0.4 L (0.4 qt)

PRODUCT OVERVIEW

KMH40A / KMH50A / KMH50V Operation Manual 13

This Page Intentionally Left Blank

PRODUCT OVERVIEW

14 KMH40A / KMH50A / KMH50V Operation Manual

MARINE GEAR

OPERATION

This section of the Operation Manual

describes the procedure for performing

daily checks, checking the marine gear oil

level and shifting the marine gear.

!

WARNING

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.

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.

Shift the marine gear into the NEUTRAL

position any time the engine is at idle.

KMH40A / KMH50A / KMH50V Operation Manual 15

!

CAUTION

Periodic maintenance prevents unexpected

downtime, reduces the number of accidents

due to poor machine performance and helps

extend the life of the marine gear.

If any problem is noted during the visual

check, the necessary corrective action

should be taken before you operate the

marine gear.

DAILY CHECKS

All marine gears have been submitted to a

test run before shipment.

Visual checks for leakage should be made

from time to time.

Before operating the marine gear, make

sure it is in good operating condition. Make

sure you check the following items and have

any repairs completed before you operate

the marine gear.

Visual Checks

CAUTION! If any problem is noted

during the visual check, the necessary

corrective action should be taken before

you operate the marine gear.

1. Check for oil leaks.

2. Check for damaged or missing parts.

3. Check for loose, missing or damaged

fasteners.

4. Check the electrical harnesses for

cracks, abrasions, and damaged or

corroded connectors.

MARINE GEAR OPERATION

16 KMH40A / KMH50A / KMH50V Operation Manual

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