Yanmar-meridieselmoottorit ja -perävetolaitteet sekä Yanmar ... - … · Manual before you operate your boat to ensure that you follow safe operating practices and maintenance procedures

KMHseries

OPERATION MANUALKMH60AKMH61AKMH61V

P/N: 0AKMH-G00201

MARINEGEAR

Disclaimers:All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / or specificationsto explain and / or exemplify a product, service or maintenance improvement. We reservethe right to make any change at any time without notice. Yanmar and areregistered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or othercountries.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 storageand retrieval systems - without the written permission of Yanmar Marine International.© 2007 Yanmar Marine International

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ii KMH60A / KMH61A / KMH61V Operation Manual© 2007 Yanmar Marine International

TABLE OFCONTENTS

PageIntroduction .............................................................. 1

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Safety ....................................................................... 3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Before You Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4During Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . 5

Product Overview ...................................................... 9Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Significance of Marine Gear Designations . . . . . . . . . . . . 11Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Marine Gear Operation .............................................. 13Before Operating the Marine Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Marine Gear Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 14Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Shifting the Marine Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Towing or Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Maintenance ............................................................ 19Tightening Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

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

KMH60A / KMH61A / KMH61V Operation Manual iii© 2007 Yanmar Marine International

The Importance of Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . 24Keep a Log of Engine Hours and Daily Checks . . . . . 24Yanmar Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Ask Your Authorized Yanmar Marine Dealer orDistributor For Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 25

Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26After Initial 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . 26Every 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Troubleshooting ....................................................... 31

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Specifications .......................................................... 33

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

KMH60A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34KMH61A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35KHM61V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Optional Accessories ................................................ 37Electric Shift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation of Electric Shift Valve . . . . . . . . . . . . . . . . . . . . . . . 37Emergency Operation of Electric Valve . . . . . . . . . . . . . . . 37

Trolling Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Mechanical Trolling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Electric Trolling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

PTO Spline Sleeve and Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Installation of the PTO Spline Sleeve andFlange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

TABLE OF CONTENTS

iv KMH60A / KMH61A / KMH61V Operation Manual© 2007 Yanmar Marine International

INTRODUCTIONWelcome to the world of Yanmar Marine!Yanmar Marine offers engines, drivesystems and accessories for all types ofboats, from runabouts to sailboats, and fromcruisers to mega yachts. In marine leisureboating, the worldwide reputation of YanmarMarine is second to none.Yanmar marine gears are designed for awide range of applications. Our parallel,down angle, saildrive and V-drive marinegears are designed to reduce the vibrationand make your cruising more pleasurable.To help you enjoy your Yanmar Marineproducts for many years to come, pleasefollow these recommendations:

• Read and understand this OperationManual before you operate your boat toensure that you follow safe operatingpractices and maintenance procedures.

• Keep this Operation Manual in aconvenient place for easy access.

• If this Operation Manual is lost ordamaged, order a new one from yourauthorized Yanmar marine dealer ordistributor.

• Make sure this manual is transferred tosubsequent owners. This manual shouldbe considered a permanent part of theboat and remain with it.

• Constant efforts are made to improve thequality and performance of Yanmarproducts, so some details included in thisOperation Manual may differ slightly fromyour marine gear. If you have anyquestions about these differences,please contact your authorized Yanmarmarine dealer or distributor.

KMH60A / KMH61A / KMH61V Operation Manual 1© 2007 Yanmar Marine International

RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar forservice, parts or literature.

Marine Gear Model:

Marine Gear Serial No.:

Date Purchased:

Dealer:

Dealer Phone:

INTRODUCTION

2 KMH60A / KMH61A / KMH61V Operation Manual© 2007 Yanmar Marine International

SAFETYYanmar considers safety of greatimportance and recommends that anyonethat comes into close contact with itsproducts, such as those who install,operate, maintain or service Yanmarproducts, exercise care, common senseand comply with the safety information inthis manual and on the engine and marinegear's safety labels. Keep the labels frombecoming dirty or torn and replace them ifthey are lost or damaged. Also, if you needto replace a part that has a label attached toit, make sure you order the new part andlabel at the same time.

!

This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alertsymbol.

SAFETY PRECAUTIONS! DANGER

Indicates a hazardous situation which, ifnot avoided, will result in death orserious injury.

! WARNINGIndicates a hazardous situation which, ifnot avoided, could result in death orserious injury.

! CAUTIONIndicates a hazardous situation which, ifnot avoided, could result in minor ormoderate injury.

NOTICEIndicates a situation which can causedamage to the engine and marine gear,personal property and / or the environmentor cause the equipment to operateimproperly.


General InformationThere is no substitute for common senseand careful practices. Improper practices orcarelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines that mustbe followed to reduce risk to personal safety.Special safety precautions are listed inspecific procedures. Read and understandall of the safety precautions before operationor performing repairs or maintenance.

Before You Operate! DANGER

The safety messages that follow haveWARNING level hazards.

NEVER permit anyone toinstall or operate the engine ormarine gear without propertraining.

• Read and understand this OperationManual before you operate or service theengine or marine gear to ensure that youfollow safe operating practices andmaintenance procedures.

• Safety signs and labels are additionalreminders for safe operating andmaintenance techniques.

• See your authorized Yanmar marinedealer or distributor for additional training.

SAFETY


During Operation andMaintenance

! DANGERThe safety messages that follow haveDANGER level hazards.

Fire HazardEnsure that appropriate firedetection and extinguishingequipment are installed andchecked periodically forproper operation.

! WARNINGThe safety messages that follow haveWARNING level hazards.

Explosion HazardAvoid serious personal injuryor equipment damage. Whilethe engine is running or thebattery is charging, hydrogengas is being produced and can

be easily ignited. Keep the area around thebattery well-ventilated and keep sparks,open flame and any other form of ignition outof the area.

Diesel fuel is flammable and explosiveunder certain conditions.

Never use a shop rag to catch the fuel.Wipe up all spills immediately.

Fire HazardAvoid injury or equipmentdamage from fire. Undersizedwiring systems can cause anelectrical fire.

Sever HazardNEVER service the marinegear while under tow or if theengine is running at idlespeed. The propeller mayrotate under these

circumstances.

Alcohol and Drug HazardNEVER operate the enginewhile under the influence ofalcohol or drugs or whenfeeling ill.

SAFETY


! WARNINGExposure Hazard

To avoid injury, ALWAYSwear personal protectiveequipment includingappropriate clothing,gloves, work shoes, eye

and hearing protection as required by thetask at hand.

Entanglement HazardNEVER leave the key in thekey switch when you areservicing the engine or marinegear. Someone mayaccidentally start the engine

and not realize you are servicing it.

Avoid personal injury. NEVER operate theengine while wearing a headset to listen tomusic or radio because it will be difficult tohear the warning signals.

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

Burn HazardAvoid serious injury. Some ofthe engine and marine gearsurfaces become very hotduring operation and shortlyafter shut-down. Keep handsand other body parts away

from hot surfaces.

Sudden Movement HazardAvoid personal injury. ALWAYS stop theengine before beginning service.

Exhaust HazardAvoid serious injury or death.NEVER block windows, vents,or other means of ventilation ifthe engine is operating in anenclosed area. All internal

combustion engines create carbonmonoxide gas during operation and specialprecautions are required to avoid carbonmonoxide poisoning.

SAFETY


! CAUTIONThe safety messages that follow haveCAUTION level hazards.

Poor Lighting HazardAvoid personal injury or equipment damage.Ensure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.

Tool HazardAvoid personal injury or equipment damage.ALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening machine parts.

Flying Object HazardAvoid personal injury.ALWAYS wear eye protectionwhen servicing the engine orwhen using compressed air orhigh-pressure water. Dust,

flying debris, compressed air, pressurizedwater or steam may injure your eyes.

NOTICEThe safety messages that follow haveNOTICE level hazards.It is important to perform daily checks aslisted in this Operation Manual.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine or marine gearperformance and can help extend the life ofthe engine and marine gear.

ALWAYS be environmentallyresponsible.

Follow the guidelines of the EPA or othergovernmental agencies for the properdisposal of hazardous materials such aslubrication oil, diesel fuel and enginecoolant. Consult the local authorities orreclamation facility.

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

Before operating the engine, check marinegear oil level.

SAFETY


NOTICEObserve the following environmentaloperating conditions to maintain marinegear performance and avoid prematuremarine gear wear:• NEVER run the marine gear if the ambient

temperature is above +45˚C (+113˚F) orbelow -15˚C (+5˚F).

• If the ambient temperature exceeds+45˚C (+113˚F) the marine gear mayoverheat and cause the marine gear oil tobreak down.

• If the ambient temperature falls below-15˚C (+5˚F) rubber components such asgaskets and seals will harden causingpremature marine gear wear anddamage.

• Contact your authorized Yanmar marinedealer or distributor if the marine gear willbe operated in either temperatureextreme.

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

Observe the following environmentaloperating conditions to maintain marinegear performance and avoid prematuremarine 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 themarine gear oil level and check the oil coolerfor proper coolant and water flow.

New Marine Gear Break-In:On the initial engine start-up, allow theengine to idle for approximately 15 minuteswhile you check for proper marine gearfunction and marine gear oil leaks.During the break-in period, carefullyobserve marine gear indicators (if any) forproper marine gear function.During the break-in period, check the marinegear oil levels frequently.

SAFETY


PRODUCT OVERVIEWOVERVIEWThe KMH marine gear is ahydraulically-activated helical gear unit,developed for use in pleasure craft.The marine gear is equipped with adisk-type reversing clutch mounted on thesupport shaft and supplied with hydraulicpressure from an oil pump.Operation of the oil pump is dependent onthe engine speed.The marine gear is lubricated by splash andforce-feed lubrication.


COMPONENT IDENTIFICATIONNote: KMH60A shown. Other models are similar.

0001587B_0001589A

(1)

(12)

(11)

(10)

(7)

(5)

(4)

(3)

(15) (16)

(17)(18)

(22) (23)

(19) (20) (21)

Section A-A

(2) (24)(14)

(13)

(9) (8)

A

A

Figure 11 – Control Pressure Sensor Location2 – O-Ring3 – Port To Heat Exchanger4 – Temperature Sensor Location5 – Oil Dipstick6 – Parallel Pin7 – Port From Heat Exchanger8 – Seal Washer9 – Drain Plug With Magnet10 – Output Flange11 – Oil Strainer12 – Oil Pump

13 – Gasket14 – Upper Cover15 – Nameplate16 – Neutral Safety Switch17 – Shifting Lever18 – Input Shaft19 – Spring Pin20 – Spring Retainer21 – Spring22 – 2nd Relief Shim23 – 2nd Relief Valve24 – Marine Gear Lifting Eye

PRODUCT OVERVIEW


NAMEPLATEThe nameplate is installed on the marinegear.

MODELGEAR RATIOOIL

MFG. NO.

0001606B

(1)(2)(3)(4)

Figure 21 – Marine Gear Model2 – Marine Gear Ratio3 – Lubrication Oil Type4 – Marine Gear Serial Number

Significance of Marine GearDesignations

KMH 60 A

Version of marinegear

Size of marine gear

Design of marinegear

PRODUCT OVERVIEW


TECHNICAL DATAWhen 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.

KMH60A KMH61A KMH61VShifting Pressure 3.67 to 3.77 MPa

(532 to 547 psi)4.33 to 4.43 MPa(628 to 642 psi)

4.33 to 4.43 MPa(628 to 642 psi)

Maximum Input Speed 3300 min-1 (rpm)

Oil Capacity without HeatExchanger

Available 2.8 L (3.0 qt) 7.5 L (7.9 qt)

Effective 0.5 L (0.5 qt) 0.4 L (0.4 qt)

PRODUCT OVERVIEW


MARINE GEAROPERATION

This section of the Operation Manualdescribes the procedure for performingdaily checks, checking the marine gear oillevel and shifting the marine gear.

! WARNINGSever HazardRotating parts can causesevere injury or death. NEVERwear jewelry, unbuttonedcuffs, ties or loose-fittingclothing, and ALWAYS tie

long hair back when working near moving /rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

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

Shift the marine gear into the NEUTRALposition ONLY when the engine is at idlespeed.


! CAUTIONPeriodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor machine performance and helpsextend the life of the marine gear.If any problem is noted during the visualcheck, the necessary corrective actionshould be taken before you operate themarine gear.

BEFORE OPERATING THEMARINE GEARNote: Before operating the marine gear forthe first time, be sure the plug covering thebreather (Figure 1, (1)) is removed. If thebreather is covered, the pressure in themarine gear may exceed the allowableoperating level during operation. This willcause oil to leak from the oil seal.

0001587A

(1)

Figure 1Marine Gear Oil SpecificationsRecommended Marine Gear Oil• API (American Petroleum Institute)

service grade: Class CD or higher• Viscosity: SAE 30• Recommended oil: Yanmar Marine

Super Oil SAE 30NOTICE: ALWAYS use the specified SAE30 oil. NEVER use gear oil or ATF in KMHmarine gears. NEVER use multi-gradeoil or mix oil types.

MARINE GEAR OPERATION


DAILY CHECKSAll marine gears have been submitted to atest run before shipment.Visual checks for leakage should be madefrom time to time.Before operating the marine gear, makesure it is in good operating condition. Makesure you check the following items and haveany repairs completed before you operatethe marine gear.Visual ChecksCAUTION! If any problem is notedduring the visual check, the necessarycorrective action should be taken beforeyou 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 orcorroded connectors.



Checking Oil LevelKMH60A, 61A

0001587C

(1)

Figure 2KMH61V

0001598A

(1)

Figure 31. Remove dipstick (Figure 2, (1)) or

(Figure 3, (1)) and wipe with cleancloth. NOTICE: Prevent dirt anddebris from contaminating marinegear oil. Carefully clean the oil plugand dipstick and the surroundingarea before you remove thedipstick.

2. Fully reinsert dipstick (Figure 4, (2)) orreinsert the dipstick but don't thread itinto place (Figure 5, (2)).

KMH60A, 61A

0005836

(1)

(2)

Figure 4KMH61V

0005837

(1)

(2)

Figure 53. Remove the dipstick. The oil level

should be between the upper(Figure 4, (2)) or (Figure 5, (2)) andlower (Figure 4, (1)) or(Figure 5, (1)) lines on dipstick.

4. Fully reinsert dipstick.5. Move the shift lever to NEUTRAL.6. Start the engine. Let the engine run at

idle with the shift lever in the NEUTRALposition for several minutes. This willensure the oil is distributed to allpipelines, oil cooler and marine gear oilpassages.



7. Stop the engine. WAIT AT LEAST 10MINUTES for the oil to drain back intothe sump. NOTICE: Never overfill.The oil level must be between theupper and lower level marks.

8. Check the oil level. If necessary, add oiluntil the level reaches the upper markon the dipstick. Check the oil level againafter operating the marine gear for ashort period of time.

Recommended Oil (Type of Oil)• APA (American Petroleum Institute)

service grade: Class CD or higher• Viscosity: SAE30• Recommended oil: Yanmar Marine Super

Oil SAE30

NOTICEALWAYS use the specified SAE30 oil.NEVER use gear oil or ATF in KMH marinegears. NEVER use multi-grade oil or mix oiltypes.

SHIFTING THE MARINEGEARNOTICE: During normal operation, themarine gear should only be shifted withthe engine at idle. Shifting at higherengine speed will damage the marinegear.The marine gear is shifted by moving theshifting lever.Shifting Positions:• A = Propeller rotation opposite of engine

rotation• N = NEUTRAL position• B = Propeller rotation same as engine

rotation

0004049

Figure 6Operating temperature of the marine gear:50˚ to 80˚C (122˚ to 176˚F).A connection port for a temperature sensorhas been provided. (See ComponentIdentification on page 10.)



TOWING OR ANCHORINGWhen a boat is being towed or is anchored,water current will cause the propeller to turn.(When the engine is off, the position of theshifting lever is irrelevant.) This will notcause damage to the marine gear. In a boatwith two engines, the propeller of the unusedmarine gear may rotate freely.



MAINTENANCEThis section of the Operation Manualdescribes the procedures for proper careand maintenance of the marine gear.

! CAUTIONNEVER permit anyone toinstall or operate the marinegear without proper training.Safety signs and labels areadditional reminders for safe

service and maintenance techniques.

Read and understand this OperationManual before you operate or service themarine gear to ensure that you follow safeservicing practices and maintenanceprocedures.


! DANGERCrush HazardALWAYS use liftingequipment with sufficientcapacity to lift marine gear.

NEVER stand under hoisted marine gear. Ifthe hoist mechanism fails, the marine gearwill fall on you, causing serious injury ordeath.

NEVER support marine gear withequipment not designed to support theweight of the marine gear such as woodenpieces, blocks or by only using a jack.

! WARNINGSudden Movement Hazard

When you install the “emergency nut” theboat will move as soon as you start theengine! Make sure the area is clear beforeyou start the engine.

Sever HazardRotating parts can causesevere injury or death. NEVERwear jewelry, unbuttonedcuffs, ties or loose-fittingclothing, and ALWAYS tie

long hair back when working near moving /rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

To prevent accidental equipmentmovement, NEVER start the engine in gear.

Before starting the engine, ALWAYS makesure that all bystanders are clear of the area.Keep children and pets away while theengine is operating.

Avoid personal injury or equipment damage.Always remove any tools or shop rags usedduring maintenance from the area beforeoperation.

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

Stop the engine before you begin to servicethe marine gear and secure the propeller soit will not turn.

MAINTENANCE


Entanglement HazardNEVER leave the key in the key switch whenyou are servicing the engine or marine gear.Someone may accidentally start the engineand not realize you are servicing it.

Electrical Shock HazardAvoid serious personal injuryor equipment damage.ALWAYS turn off the batteryswitch (if equipped) ordisconnect the negative

battery cable before servicing theequipment.

Avoid personal injury or equipment damage.ALWAYS keep the electrical connectorsand terminals clean. Check the electricalharnesses for cracks, abrasions, anddamaged or corroded connectors.

! CAUTIONSlipping and Tripping Hazard

Ensure that adequate floorspace is set aside for servicingmarine gear. The floor spacemust be flat and free of holes.

Keep floor free of dust, mud, spilled liquidsand parts to help prevent slipping andtripping.

MAINTENANCE


NOTICEAlways tighten components to the specifiedtorque. Loose parts can cause equipmentdamage or cause it to operate improperly.

Only use replacement parts specified. Otherreplacement parts may affect warrantycoverage.

NEVER attempt to modify the marine gear’sdesign or safety features.Failure to comply may impair the marinegear’s safety and performancecharacteristics and shorten the marinegear’s life. Any alterations to this marinegear may affect the warranty coverage ofyour marine gear.

NEVER use the marine gear lifting eye to liftthe engine and marine gear as an assembly.Use the engine lifting eyes to lift the engineand marine gear. Only use the marine gearlifting eye to lift the marine gear as aseparate component.

TIGHTENING FASTENERSUse the correct amount of torque whentightening fasteners. Applying excessivetorque may damage the fastener orcomponent and too little torque may causea leak or component failure.

The tightening torque in theStandard Torque Chart should beapplied only to the bolts with a “7”head. (JIS strength classification:7T).

Apply 60% torque to bolts that are not listed.Apply 80% torque when tightened toaluminum alloy.

MAINTENANCE


TORQUE CHARTSStandard Torque Values

M6 x 1.0 M8 x 1.25 M10 x 1.25or 1.5

M12 x 1.25or 1.5

M14 x 1.5 M16 x 1.5

Cast Ironor Steel

10.8 ± 1.0N·m8.0 ± 0.8lb-ft

25.5 ± 2.0N·m18.8 ± 1.5lb-ft

49.1 ± 4.9N·m36.2 ± 3.6lb-ft

88.3 ± 10.0N·m65.1 ± 7.4lb-ft

137.2 ± 4.9N·m101.2 ± 3.6lb-ft

225.4 ± 10.0N·m166.2 ± 7.4lb-ft

Aluminum 8.8 ± 1.0N·m6.5 ± 0.8lb-ft

20.6 ± 2.0N·m15.2 ± 1.5lb-ft

39.2 ± 2.0N·m28.9 ± 1.5lb-ft

70.6 ± 4.9N·m52.1 ± 3.6lb-ft

109.8 ± 4.9N·m81.0 ± 3.6lb-ft

180.3 ± 10.0N·m133.0 + 7.4lb-ft

Torque SpecificationsItem Size Torque CommentsShift Lever Bolt M10 x 1.5 39.2 ± 2.0 N·m 28.9 ± 1.5 lb-ft Tapered Plugs NPTF 3/8 39.2 ± 2.0 N·m 28.9 ± 1.5 lb-ft Do not use sealing tapeDrain Plugs M16 x 1.5 29.4 ± 2.0 N·m 21.7 ± 1.5 lb-ft Neutral Safety Switch M12 x

1.253.2 ± 2.0 N·m 2.4 ± 1.5 lb-ft

Hose Clamps forCooler

2.5 - 3.4 N·m 1.8 - 2.5 lb-ft

Hose for Cooler 3/4 - 16 49 ± 0.49 N·m 36.1 ± 0.36 lb-ft TransmissionAssembly Bolts

M8 18.6 - 22.6 N·m 13.7 - 16.7 lb-ft M10 37.2 - 41.2 N·m 27.5 - 30.4 lb-ft M12 65.7 - 75.5 N·m 48.5 - 55.7 lb-ft

Output Coupling Bolt M16 215.4 - 235.4 N·m 158.8 - 173.6 lb-ft Dipstick Hand-Tighten

MAINTENANCE


PERIODIC MAINTENANCECAUTION! Establish a periodicmaintenance plan according to themarine gear application and make sureyou perform the required periodicmaintenance at intervals indicated.Failure to follow these guidelines willimpair the marine gear’s safety andperformance characteristics, shortenthe marine gear’s life and may affect thewarranty coverage on your marine gear.See your authorized Yanmar marinedealer or distributor for assistancewhen checking items marked with a ●.The Importance of PeriodicMaintenanceMarine gear deterioration and wear occur inproportion to the length of time the marinegear has been in service and the conditionsit is subjected to during operation. Periodicmaintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor machine performance and helpsextend the life of the marine gear.The Importance of Daily ChecksThe Periodic Maintenance Scheduleassumes that the daily checks areperformed on a regular basis. Make it a habitof performing daily checks before the startof each operating day. See Daily Checks onpage 15 and refer to the Operation Manualfor your engine.Keep a Log of Engine Hours andDaily ChecksKeep a log of the number of hours the engineis run each day and a log of the daily checksperformed. Also note the date, type of repair(e.g., replaced bearings), and parts used forany service needed between the periodicmaintenance intervals. Periodicmaintenance intervals are every 250 enginehours. Failure to perform periodicmaintenance will shorten the life of themarine gear.

Yanmar Replacement PartsYanmar recommends that you use genuineYanmar parts when replacement parts areneeded. Genuine replacement parts helpensure long engine life.Tools RequiredBefore you start any periodic maintenanceprocedure, make sure you have the toolsyou need to perform all of the required tasks.Ask Your Authorized YanmarMarine Dealer or Distributor ForHelpOur professional service technicians havethe expertise and skills to help you with anymaintenance or service related procedures.Daily and periodic maintenance is importantto keep the marine gear in good operatingcondition. The following is a summary ofmaintenance items by periodicmaintenance intervals. Periodicmaintenance intervals vary depending onmarine gear application and are hard toestablish definitively. The following shouldbe treated only as a general guideline.Note: These procedures are considerednormal maintenance and are performed atthe owner’s expense.

MAINTENANCE


Periodic Maintenance Schedule○: Check ◊: ReplaceSystem Item Periodic Maintenance Interval

Daily After Initial 50hours

Every 250hours or one

year,whichevercomes first

Whole Visual inspection of marine gearexterior

○Before starting

LubricatingSystem

Check the marine gear oil level andrefill if necessary

○Before starting

Change the marine gear oil andclean the oil strainer

◊ ◊

Change electric trolling valve oilfilter element (if equipped)

◊ ◊

MAINTENANCE


PERIODIC MAINTENANCEPROCEDURESAfter Initial 50 Hours ofOperation

Perform the following maintenance after theinitial 50 hours of operation.• Changing the Marine Gear Oil and

Cleaning the Marine Gear Oil Strainer• Changing the Electric Trolling Valve

Oil Filter Element (If Equipped)Changing the Marine Gear Oil andCleaning the Marine Gear OilStrainerOptimum effectiveness of oil can only beassured if the marine gear oil is changed andthe oil strainer is washed with clean oilregularly, according to the maintenanceschedule.1. Position a container under the marine

gear to collect the waste oil.2. Remove the M16 drain plug

((Figure 1, (1)), (Figure 2, (1))) andseal ((Figure 1, (2)), (Figure 2, (2))).

KMH60A / KMH61A

0001591A

(1)(2)

Figure 1

KMH61V

(1)(2)0005581

Figure 23. Check the drain plug seal for damage.

Replace if necessary.4. Remove three M8x40 bolts

((Figure 3, (2)), (Figure 4, (2))) andwashers.

KMH60A / KMH61A

0001592A

(5)(2) (3)(4)

(1)

Figure 3

MAINTENANCE


KMH61V

(1) (2)(3)(4)

(5)

0005583

Figure 45. Remove the cover ((Figure 3, (3)),

(Figure 4, (3))), seal, spring((Figure 3, (4)), (Figure 4, (4))) and oilstrainer ((Figure 3, (1)),(Figure 4, (1))).

6. Check the cover seal for damage.Replace if necessary.

Note: The oil strainer((Figure 3, (1)), (Figure 4, (1)))must be washed with clean oilwhenever the oil is changed.

7. Reinstall the oil strainer, spring, sealand cover.

8. Tighten the cover bolts to18.6 - 20.6 N·m (13.7 - 15.2 lb-ft).

9. Remove the oil cap (Figure 5, (1)). Fillwith the following quantities of oil, andadd the amount required for cooler andpipelines.• Quantities of oil:

KMH60A / KMH61A - 2.8 L (3.0 qt)KMH61V - 7.5 L (7.9 qt)

• Type of oil: (See Marine Gear OilSpecifications on page 14) .

10. After filling the marine gear with oil,reinstall the oil cap and hand-tighten.Over-tightening may damage the cap.NOTICE: NEVER overfill marinegear with oil.

(1)

0001593A

Figure 511. Perform a trial run after the oil change.12. Move the shift lever to the NEUTRAL

position.13. Start the engine. Let the engine idle with

the shift lever in the NEUTRAL positionfor several minutes. This will ensure theoil is distributed to all pipelines and theoil cooler.

14. Stop the engine. WAIT AT LEAST 10MINUTES for the oil to drain back intothe sump.

15. Check oil level. (See Checking OilLevel on page 16). If necessary, add oiluntil the level reaches the upper markon the dipstick. Check the oil level againafter operating the marine gear for ashort period of time.

MAINTENANCE


Changing the Electric Trolling ValveOil Filter Element (If Equipped)1. Remove four mounting bolts

(Figure 6, (1)) from electric trollingvalve (Figure 6, (2)).

1

2

0004538

Figure 6

2. Remove filter element housing(Figure 7, (3)).

28

5

4

3

0004539

Figure 73. Remove filter element (Figure 7, (4)).4. Remove and replace O-ring

(Figure 7, (5)).5. Install new filter element.6. Install filter element housing.7. Install four mounting bolts.

MAINTENANCE


Every 250 Hours of OperationPerform the following maintenance every250 hours of operation or yearly, whichevercomes first.• Changing the Marine Gear Oil and

Cleaning the Marine Gear Oil Strainer• Changing the Electric Trolling Valve

Oil Filter Element (If Equipped)Changing the Marine Gear Oil andCleaning the Marine Gear OilStrainerSee Changing the Marine Gear Oil andCleaning the Marine Gear Oil Strainer onpage 26.Changing the Electric Trolling ValveOil Filter Element (If Equipped)See Changing the Electric Trolling Valve OilFilter Element (If Equipped) on page 28.

MAINTENANCE


LONG-TERM STORAGEIf the marine gear is stored for six months orlonger, oil level should be checked and thegear should be driven for 5 minutes every 6months.Drain seawater from the cooling system,including the gear oil cooler.Before operating the marine gear after long-term storage, the marine gear oil must bechanged. See Changing the Marine Gear Oiland Cleaning the Marine Gear Oil Straineron page 26.

MAINTENANCE


TROUBLESHOOTINGTROUBLESHOOTING CHARTBefore performing troubleshooting, verify that all items of the operating instructions havebeen complied with.The following chart will assist in troubleshooting. CAUTION! If any indicator fails toilluminate when the key switch is in the ON position, see your authorized YanmarMarine dealer or distributor for service before operating the engine and marine gear.

No. Problem Possible Cause Action1 Oil temperature Oil level high during operation Pump out oil until oil level is at

maximum mark on dipstick.Oil level low Add oil.Plugged or restricted heat exchanger Replace heat exchanger and flush

water system.No coolant in cooling system Check cooling system and repair.Unknown See your authorized Yanmar Marine

dealer or distributor.2 Oil on marine gear

housingLoose screws Tighten to specification.Loose hardware Tighten or replace.Loose dipstick Tighten or replace.Loose oil strainer Tighten or replace.Oil level too high during operation Pump out oil until oil level is at

maximum mark on dipstick.Unknown See your authorized Yanmar Marine

dealer or distributor.3 Oil and water mixed Damaged heat exchanger See your authorized Yanmar Marine

dealer or distributor.4 Shifts hard Selector control See your authorized Yanmar Marine

dealer or distributor.Linkage See your authorized Yanmar Marine

dealer or distributor.Unknown See your authorized Yanmar Marine

dealer or distributor.


No. Problem Possible Cause Action5 Slow engagement Selector control See your authorized Yanmar Marine

dealer or distributor.Low oil level Add oil.Linkage See your authorized Yanmar Marine

dealer or distributor.Unknown See your authorized Yanmar Marine

dealer or distributor.6 No movement of the

boatSelector control See your authorized Yanmar Marine

dealer or distributor.Improper selector position Adjust.Low oil level Add oil.Propeller missing Replace.Propeller shaft broken See your authorized Yanmar Marine

dealer or distributor.Marine gear malfunction See your authorized Yanmar Marine

dealer or distributor.Engine malfunction See your authorized Yanmar Marine

dealer or distributor.

TROUBLESHOOTING


SPECIFICATIONSGENERAL SPECIFICATIONS

Item SpecificationKMH60A KMH61A KMH61V

Type Down Angle Hydraulic V-Drive HydraulicAngle 8˚ 12˚Maximum Input Torque 960 N·m (708 ft·lb) 1070 N·m (789 ft·lb) 1070 N·m (789 ft·lb)Maximum Input Speed 3300 min-1 (rpm)Reduction Ratio (F/R) 1.55 / 1.55 2.43 / 2.43

2.04 / 2.04 1.98 / 1.982.43 / 2.43 1.49 / 1.49

– 1.24 / 1.24Direction ofRotation

Input Counterclockwise viewed from stern Clockwise viewedfrom stern

Output Clockwise (Recommendation) or Counterclockwise viewed from sternShift Mechanical CableLubrication Forced LubricationOil Capacity 2.8 L (3.0 qt) 7.5 L (7.9 qt)Bellhousing Size SAE #3Clutch Size SAE 11.5 in.Dry Mass 58 kg (127 lb) without heat exchanger or damper 83.9 kg without heat

exchanger ordamper


OUTLINE DRAWINGSKMH60A

0001607

Figure 1

SPECIFICATIONS


KMH61A

0003076

Figure 2

SPECIFICATIONS


KHM61V

0006253

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Ø 409.575

Figure 3

SPECIFICATIONS


OPTIONAL ACCESSORIESELECTRIC SHIFT VALVEInstallation of Electric Shift ValveSee your authorized Yanmar Marine dealeror distributor for assistance.Emergency Operation of ElectricValveIf the electric valve stops operating with theengine(s) not running, do the following:Current Production Models1. With the engine(s) not running, remove

cap (Figure 1, (1)) and emergency nut(Figure 1, (2)). CAUTION! If you havemore than one engine, you cannotshift the marine gear into the “B”position after you install the“emergency nut.”

0003073

(2)(1)

Figure 1

2. Reverse the emergency nut(Figure 2, (1)) and thread it ontoelectric valve. WARNING! When youreverse the “emergency nut” thetransmission is locked in gear andthe boat will move as soon as youstart the engine! There is no neutralsafety protection in this mode. Makesure the area is clear before youstart the engine.

0003074

(1)

Figure 2


0003075

Normal Operation

Emergency Operation

(1)

(2)

Figure 3Note the orientation of the spring pin in theemergency nut.• Normal operation (Figure 3, (1))• Emergency operation (Figure 3, (2))Past Production Models1. With the engine(s) off, remove cap

(Figure 4, (1)), nut (Figure 4, (2)) andcollar (Figure 4, (3)). CAUTION! Ifyou have more than one engine, youcannot shift the marine gear into the“B” position after you install the“emergency nut.”

0001600A

(1) (2)(3)

Figure 4

2. Thread the emergency nut(Figure 5, (1)) onto electric valve.WARNING! When you reverse the“emergency nut” the transmissionis locked in gear and the boat willmove as soon as you start theengine! There is no neutral safetyprotection in this mode. Make surethe area is clear before you start theengine.

(1)

0001601A

Figure 5

OPTIONAL ACCESSORIES


TROLLING VALVESThere are three types of trolling valvesavailable: mechanical and two types ofelectric trolling.The trolling mode option allows the boatoperator to slow the forward and aft speedof the boat for fishing.Electronic trolling mode is achieved by theECU electronically adjusting the pressurebypass valves in the gearbox, allowing theclutches to slip. The trolling option (ifequipped) is activated by putting the controllever in NEUTRAL and pressing the trollingswitch or button located near the shift /throttle control head. Refer to the electroniccontrol system manual for more information.NOTICE: The throttle lever does notoverride the trolling valve. The trollingfunction must be OFF before resumingnormal travel speed.Mechanical Trolling ValveThis trolling valve does not give feedback offluctuations in the propeller speed.Shifting Pressure Adjustment

0001603A

(1)(2) (3) (4)

Figure 6

(1)0001604A

Figure 7When the rubber cap (Figure 6, (1)) isremoved, the lock nut (Figure 6, (2)) isloosened, and the adjustment screw(Figure 6, (3)) is rotated clockwise(tightened), the angle of a lever(Figure 7, (1)) lowers the shifting pressureand reduces the speed of the boat. NOTICE:Use the trolling valve once daily. Theorifice (Figure 6, (4)) can clog when thetrolling valve is not used for extendedperiods of time, resulting in unexpectedengagement of the valve.Note: When the trolling valve is not beingused, secure it in place so that it does notmove from vibration of the boat.



Electric Trolling ValveThe E-type trolling valve does not givefeedback on fluctuations of the propellerspeed.The C-type trolling valve does give feedbackon fluctuations of the propeller speed.Electric Trolling Valve OperationRefer to the electronic control systemoperation manual.

PTO SPLINE SLEEVE ANDFLANGESpecifications

Item Specification

Spline Size SAE Z=9, DP16/32,30°Class I

Flange Size SAE Type A

PermissibleInputTorque

120 N·m (88.5 ft-lb)

Installation of the PTO SplineSleeve and Flange1. Remove the PTO cover bolts

(Figure 8, (3)).

0001596A

(3)

(2)

(1)

Figure 82. Remove the PTO cover

(Figure 8, (2)) and gasket(Figure 8, (1)). Discard the gasket.



3. Insert the spline sleeve (Figure 9, (1))into the input shaft.

0001605A

(1) (2)(3)

(5)

(6)(4)

Figure 94. Use a new gasket (Figure 9, (2)) and

position the PTO flange(Figure 9, (3)). Tighten the bolts(Figure 9, (4)) to specified torque. SeeStandard Torque Values on page 23.

5. Install the PTO device with M10×35bolts (Figure 9, (6)).

NOTICE: NEVER operate the marinegear without a PTO device or cover plateinstalled. Operating the marine gearwithout a PTO device or cover plateinstalled will cause marine gear oil toleak out.



This Page Intentionally Left Blank



Table of ContentsIntroductionRecord of Ownership

SafetySafety PrecautionsGeneral InformationBefore You OperateDuring Operation and Maintenance

Product OverviewOverviewComponent IdentificationNameplateSignificance of Marine Gear Designations

Technical Data

Marine Gear OperationBefore Operating the Marine GearMarine Gear Oil SpecificationsRecommended Marine Gear Oil

Daily ChecksVisual ChecksChecking Oil LevelRecommended Oil (Type of Oil)

Shifting the Marine GearTowing or Anchoring

MaintenanceTightening FastenersTorque ChartsStandard Torque ValuesTorque Specifications

Periodic MaintenanceThe Importance of Periodic MaintenanceThe Importance of Daily ChecksKeep a Log of Engine Hours and Daily ChecksYanmar Replacement PartsTools RequiredAsk Your Authorized Yanmar Marine Dealer or Distributor For HelpPeriodic Maintenance Schedule

Periodic Maintenance ProceduresAfter Initial 50 Hours of OperationChanging the Marine Gear Oil and Cleaning the Marine Gear Oil StrainerChanging the Electric Trolling Valve Oil Filter Element (If Equipped)

Every 250 Hours of OperationChanging the Marine Gear Oil and Cleaning the Marine Gear Oil StrainerChanging the Electric Trolling Valve Oil Filter Element (If Equipped)

Long-Term Storage

TroubleshootingTroubleshooting Chart

SpecificationsGeneral SpecificationsOutline DrawingsKMH60AKMH61AKHM61V

Optional AccessoriesElectric Shift ValveInstallation of Electric Shift ValveEmergency Operation of Electric ValveCurrent Production ModelsPast Production Models

Trolling ValvesMechanical Trolling ValveShifting Pressure Adjustment

Electric Trolling ValveElectric Trolling Valve Operation

PTO Spline Sleeve and FlangeSpecificationsInstallation of the PTO Spline Sleeve and Flange

Documents

Yanmar-meridieselmoottorit ja -perävetolaitteet sekä Yanmar ... - … · Manual before you operate your boat to ensure that you follow safe operating practices and maintenance procedures