WORKSHOP MANUAL TM 93 – TM 93A OIL H20 A B H20 OIL C Pag. 1 di 37 MANUALE DI OFFICINA TM 93 – TM 93A USE OF THE MANUAL Consignee: ¾ Operator ¾ Service Maintenance The good functioning and the efficiency of the mechanical components mainly depend on a constant and correct maintenance. TAKING VISION OF THE ENTIRE MANUAL allows to properly perform the operations of ordinary and extraordinary maintenance. The lack of the recommended operations can compromise the lifetime and the integrity of the transmission and bring to failure or injury to the operator. In the event of breakdown or anomaly, the prompt reaction from the specialized personnel will guarantee a higher lifetime of the assembly, preventing further damage in the years. GENERAL SAFETY RECOMMENDATIONS IMPORTANT: Before starting any operation, read this paragraph carefully. Safety precautions The correct use and the correct repair of the assembly and its components are very important for security and reliability. The recommended procedures, that are listed on this service manual, have been tested as operative ways to act. Strictly follow each procedure making use both of writings and illustrations. Some of these procedures show the usage of pertinent tools designed to perform every operation clearly and correctly. Some specific tools must be used, where necessary, to perform some proper operations. It is impossible to manage every working procedure or all the possible methods with their own risks, therefore whoever uses not recommended tools must be aware that the safety of the operator and the boat will be endangered. Pag. 2 di 37 MANUALE DI OFFICINA TM 93 – TM 93A Recall icons = DANGEROUS OPERATIONS FOR THE SAFETY OF THE OPERATOR = WEAR PROTECTIVE GLOVES FOR HIGH TEMPERATURE = OPERATION REQUIRING PARTICULAR ATTENTION AND PRECISION FROM THE OPERATOR = OPERATION DAMAGING THE COMPONENT OR PRODUCT IF NOT PERFORMED CORRECTLY Repair The procedure for assembly / disassembly of the transmission allows to perform the complete overhaul of the group and is assisted with photos, for a complete and safe guide for each operation. It is assumed that the transmission has been removed from the vessel. The deep knowledge of the assembly allows the correct estimate of the kind of procedure to be followed, which may only require the disassemble of a few components, operating on a part of the transmission only. Pag. 3 di 37 MANUALE DI OFFICINA TM 93 – TM 93A Rif. Ref. 1 2 3 4 5 5 5 5 5 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 31 31 Denominazione Denomination Cuscinetto - Bearing Quantità Codice Code Quantity 1 4622037 Rasamento - Ring Cuscinetto reggispinta – Thrust bearing Ralla – Thrust block Pignone TM93 r 1,51 – Gear TM93 r 1,51 Pignone TM93 r 2,09 – Gear TM93 r 2,09 Pignone TM93 r 2,40 – Gear TM93 r 2,40 Pignone TM93 r 2,77 – Gear TM93 r 2,77 Pignone TM93A r 1,51 – Gear TM93A r 1,51 Pignone TM93A r 2,09 – Gear TM93A r 2,09 Pignone TM93A r 2,40 – Gear TM93A r 2,40 Seeger - Seeger Molla a tazza - Spring Disco di ritenuta – Back plate Disco sinterizzato – Clutch plate Disco in acciaio – Steel plate Boccola - Bushing Ralla – Thrust block Cuscinetto reggispinta – Thrust bearing Ralla – Thrust block Molla ritorno pistone - Spring Fascia elastica – Seal ring Pistone - Piston Fascia elastica – Seal ring Tappo conico - Plug Albero di rinvio – Intermediate shaft Fascia elastica – Seal ring Chiavetta - Key Campana frizione – Clutch housing Cuscinetto - Bearing Distanziale - Spacer Tappo forato - Plug Cuscinetto - Bearing Rasamento - Shim Cuscinetto reggispinta-Thrust bearing Ralla – Thrust block Pignone TM93 r 1,51 – Gear TM93 r 1,51 Pignone TM93 r 2,09 – Gear TM93 r 2,09 Pignone TM93 r 2,40 – Gear TM93 r 2,40 Pignone TM93 r 2,77 – Gear TM93 r 2,77 Rif. Ref. 31 1 2016019 31 1 4607019 31 1 1 4603022 2061509 32 33 1 2061507 34 1 2061505 35 1 2061503 36 1 2061515 37 1 2061516 38 1 2061514 39 1 1 1 10 9 1 1 1 1 1 1 1 1 1 1 2 1 1 1 x 1 1 1 1 1 1 4601095 4578010 2022053 2022041 2022039 2050022 4603024 4607019 4603023 2020035 2024004 2017011 2024009 4588006 2021378 2024007 4620054 2061500 4622073 2013189 2055036 4622037 2016019 4607019 4603022 2061509 40 41 42 43 44 45 46 47 48 49 50 51 52 53 55 56 53 55 56 53 55 56 53 55 56 53 1 2061507 55 1 2061505 56 1 2061503 Denominazione Denomination Pignone TM93A r 1,51 – Gear TM93A r 1,51 Pignone TM93A r 2,09 – Gear TM93A r 2,09 Pignone TM93A r 2,40 – Gear TM93A r 2,40 Seeger - Seeger Quantità Codice Quantity Code 1 2061509 Molla a tazza - Spring Disco di ritenuta – Back plate Disco sinterizzato – Clutch plate Disco in acciaio – Steel plate Boccola - Bushing Ralla – Thrust block Cuscinetto reggispinta – Thrust bearing Ralla – Thrust block Molla ritorno pistone - Spring Fascia elastica – Seal ring Pistone - Piston Fascia elastica – Seal ring Fascia elastica – Seal ring Tappo conico - Plug Albero primario – Input shaft Campana frizione – Clutch housing Chiavetta – Key Tappo forato – Plug Cuscinetto – Bearing Cuscinetto – Bearing Corona-Gear Albero-Shaft TM93 r 1,51 Chiavetta-Key Corona-Gear Albero-Shaft TM93 r 2,09 Chiavetta-Key Corona-Gear Albero-Shaft TM93 r 2,40 Chiavetta-Key Corona-Gear Albero-Shaft TM93 r 2,77 Chiavetta-Key 1 2061507 1 2061505 1 1 4601095 4578010 1 2022053 10 2022041 9 2022039 1 2050022 1 4603024 1 4607019 1 1 1 1 1 2 1 1 1 1 1 1 1 4603023 2020035 2024004 2017011 2024009 2024007 4588006 2021377 2061500 4620054 2055036 4622073 4622052 1 1012001 1 1012002 1 1012003 1 1012004 1 1012011 Corona-Gear Albero-Shaft TM93A r 1,51 Chiavetta-Key Pag. 4 di 37 MANUALE DI OFFICINA TM 93 – TM 93A Rif. Ref. Denominazione Denomination Quantità Quantity 53 55 56 53 55 56 54 57 58 59 60 61 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 Corona-Gear Albero-Shaft TM93A r 2,09 Chiavetta-Key Corona-Gear Albero-Shaft TM93A r 2,40 Chiavetta-Key Guarnizione or – “O” Ring Cuscinetto – Bearing Vite – Screw Rosetta elastica – Washer Coperchio pompa – Cover Boccola – Bushing Spina cilindrica – Dowel pin Tappo chiusura filtro olio – Plug Boccola - Bushing Coperchio pompa - Cover Rondella - Washer Vite - Screw Sfera - Ball Molla - Spring Seeger - Seeger Filtro olio – Filter Rondella - Washer Coperchio - Cover Vite - Screw Vite - Screw Piastrina - Plate Rosetta elastica - Washer Vite - Screw Guarnizione OR – “O” Ring Leva di comando – Lever Vite - Screw Stelo distributore – Selector valve Valvola - Valve 85 Molla - Spring 86 Molla - Spring 87 88 89 90 91 Tappo - Plug Vite - Screw Rondella - Washer Rondella piana - Washer Raccordo - Nipple Gruppo valvola by pass – By pass valve Rondella piana - Washer Tappo di sfiato - Breather Rondella piana - Washer Golfare - Eyebolt Tappo - Plug Rondella piana - Washer 92 93 94 95 96 97 98 Codice Code Rif. Ref. 1 1012012 1 1012013 1 1 4 4 1 2 2 1 2 1 1 1 4598127 4622046 4615238 4611108 2010330 4584002 4614013 2055037 4584002 2010331 4609028 4615129 4630020 2020045 4601017 2056039 4609007 2010237 4615129 4615253 2054024 4611106 4615134 4598016 2037036 4615214 2056072 2056073 99 100 101 102 103 104 105 106 107 107 108 109 110 111 112 113 114 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 2020056 131 2020055 132 1 1 1 1 1 1 4587022 4615129 4609007 4609030 4624002 133 134 1 1 1 1 1 1 4609011 2055032 4609011 4642010 2055033 4609021 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1 Denominazione Denomination Quantità Quantity Prigioniero - Stud 2 Paraolio – Oil seal 1 Coperchio asse entrata - Cover 1 Rondella elastica - Washer 6 Vite - Screw 6 Coperchio - Cover 1 Vite - Screw 8 Asta livello olio - Gauge 1 Scatola TM93 – Housing TM93 1 Scatola TM93A – Housing TM93A 1 Paratia – Bulkhead 1 Tubo - Tube 1 Vite - Screw 2 Raccordo - Nipple 1 Rondella piana - Washer 1 Spina cilindrica – Dowel pin 2 Coperchio TM93 – Cover TM93 1 1 Coperchio TM93A – Cover TM93A Rondella elastica – Washer 9 Vite – Screw 9 Rondella piana – Washer 1 Tappo scarico olio – Drain plug 1 Vite – Screw 1 Coperchio – Cover 1 Rondella elastica – Washer 4 Vite – Screw 4 Rondella elastica – Washer 4 Vite - Screw 4 Paraolio – Oil seal 1 Flangia uscita – Output flange 1 Rosetta di fermo - Washer 1 Spina elastica - Pin 1 Rosetta elastica - Washer 1 Vite - Screw 1 Ingranaggio condotto pompa – Pump 1 gear Ingranaggio conduttore pompa – Pump 1 gear Rondella elastica - Washer 3 Vite – Screw 3 Codice Code 4617081 4596111 2010238 4611108 4615214 2010240 4615138 2070049 2009072 2009073 2026007 2042044 4615202 4624002 4609030 4614012 2010233 2010234 4611108 4615214 4609015 4588034 4615246 2010239 4611108 4615214 4611108 4615214 4596165 2062233 2014072 4613004 4611114 4615426 2061456 2061446 4611108 4615229 1036001 Pag. 5 di 37 MANUALE DI OFFICINA TM 93 – TM 93A ALBERO DI RINVIO – INTERMEDIATE SHAFT – ARBRE DE RENVOI VORGELEGEWELLE - CONTRAEJE Pag. 6 di 37 MANUALE DI OFFICINA TM 93 – TM 93A ALBERO DI ENTRATA – INPUT SHAFT – ARBRE D’ENTREE EINGANGSWELLE – EJE DE ENTRADA Pag. 7 di 37 MANUALE DI OFFICINA TM 93 – TM 93A ALBERO DI USCITA – OUTPUT SHAFT – ARBRE DE SORTIE AUSGANGSWELLE – EJE DE SAIDA Pag. 8 di 37 MANUALE DI OFFICINA TM 93 – TM 93A Pag. 9 di 37 MANUALE DI OFFICINA TM 93 – TM 93A TM 93/93A AND TM 545A - - WARM UP THE OUTPUT GEAR UP TO 120°C MOUNT KEY (56) ON SHAFT (55) Pag. 10 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - INSERT THE SHAFT WITH THE HELP OF A COPPER HAMMER - ASSEMBLE THE BEARINGS (52 – 57) Pag. 11 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - MOUNT KEY (22 – 49) AND SNAP RING (16 – 42) ON THE INPUT SHAFT (20) AND ON THE REVERSE GEAR SHAFT (47) - APPLY A THINK LAYER OF PASTE SUPERBOND 529 Pag. 12 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - ALIGN THE KEY WITH THE POSITION MARKED ON THE CLUTCH HOUSING (23 – 48) Pag. 13 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - - WARM UP THE CLUTCH HOUSING (23 – 48) UP TO 120° C ALIGN THE KEY WITH ITS LOCATION AND PRESS ALL THE WAY DOWN Pag. 14 di 37 MANUALE DI OFFICINA TM 93 – TM 93A PREASSEMBLY FORWARD AND REVERSE GEAR GROUPS. - PUT THE SEAL RING (18 - 44) ON THE PISTON (17 - 43) - MOUNT THE PISTON (17 - 43) ON REVERSE GEAR SHAFT (20) OR FORWARD GEAR SHAFT (47) MAKE SURE IT IS ALL THE DOWN IN ITS LOCATION AND IT IS FREE TO ROTATE AROUND THE SHAFT WITH NO OBSTACLES - Pag. 15 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - INSERT THE CLUTCH PLATES, BEGINNING WITH A CLUTCH PLATE (9 - 35) THEN A STEEL PLATE (10 - 36) FOR A TOTAL OF N° 10 CLUTCH PLATES AND N° 9 STEEL PLATES - INSERT THE PLATE (8 - 34) AND SPRING (7 - 33) Pag. 16 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - INSERT THE CIRCLIP (6 - 32) IN ITS LOCATION - ALIGN THE TOOTHING OF THE CLUTCH PLATES WITH THE PISTON Pag. 17 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - INSERT A SCREWDRIVER ON ONE OF SIDE HOLES OF THE HOUSING AND HOLD THE PLATES IN POSITION REMOVE THE PISTON. THE PLATES MUST STAY IN THEIR POSITION - PUT IN THE SPRING (15 - 41) INSERT THE DOWEL PIN (14 - 40) PUT IN THE THRUST BEARING (13 - 39) INSERT THE DOWEL PIN (12 - 39) - Pag. 18 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - PUT IN THE GEAR (5-31) IN AND HOLD IT IN ITS POSITION INSERT THE DOWEL PIN (4 - 30) - INSERT THE THRUST BEARING (3 – 29) AND THE DOWEL PIN (2 – 28) Pag. 19 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - WARM UP BEARING (1 – 27) UP TO 120°C – 150 °C. PUT THE BEARING IN WITH THE HELP OF A STOPPER Pag. 20 di 37 MANUALE DI OFFICINA TM 93 – TM 93A DISASSEMBLY OF THE CLUTCH GROUPS OF FORWARD GEAR AND REVERSE GEAR - OPEN UP THE SEAL RINGS (21 - 45) AND REMOVE THEM FROM THEIR LOCATIONS - REMOVE GEAR (5 - 31) AND BEARING (1 - 27) OUT OF THE SHAFT Pag. 21 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - SLIP OFF THE DOWEL PINS, THE THRUST BEARING AND THE SPRING - REMOVE SNAP RING (6 - 32) OFF ITS LOCATION Pag. 22 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - REMOVE FROM THE CLUTCH THESE COMPONENTS: SPRING (7-33), PLATE (8-34), CLUTCH PLATES (9 – 10 – 35 – 36) AND PISTON (17 – 43) TO REMOVE THE SHAFT FROM THE HOUSING, A PRESS IS NEEDED TO PUSH IT FROM THE SPLINE SIDE Pag. 23 di 37 MANUALE DI OFFICINA TM 93 – TM 93A PREASSEMBLY DISTRIBUTOR VALVE - INSERT THE VALVE (84) MOUNT THE O-RING (80) INSERRT SPRINGS (86 – 85) IN THE DISTRIBUTOR VALVE LOCATION INSERT THE DISTRIBUTOR VALVE MOUNT THE LOCK PLATE (77) MOUNT THE OPERATING LEVER (81) Pag. 24 di 37 MANUALE DI OFFICINA TM 93 – TM 93A GEARBOX ASSEMBLY - PRESASSEMBLE COVER PLATES (101-104) ON THE HOUSING - INSERT THE GASKET (108) ON THE HOUSING AND FIX IT WITH THE SCREWS (110) Pag. 25 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - INSERT THE BEARING CARRIERS (24-51-57) ALL THE WAY DOWN IN THE HOUSING (107) - INSERT THE PREVIOUSLY ASSEMBLED CLUTCH SHAFT AND THE OUTPUT SHAFT IN THE HOUSING ASSEMBLE THE SEAL RINGS (21 – 45) - Pag. 26 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - PUT SOME GREASE ON THE SEAL RINGS - APPLY A THIN LAYER OF SEALANT PASTE Pag. 27 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - APPLY A THIN LAYER OF SEALANT PASTE ON THE COVER PLATE (74) - INSERT THE PINS (113) HOLD THE COVER (114) IN POSITION MOUNT THE OUTPUT GEARING CARRIER (52) MOUNT THE COVER PLATE (74) TIGHTEN THE FIXING BOLTS Pag. 28 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - USE A STOPPER TO PUT THE BEARING (52) ALL THE WAY DOWN - INSERT O-RING (54) Pag. 29 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - WITH A DEPTH GAUGE, MEASURE THE COVER PLATE (120) AND THE BEARING LOCATION (52) Pag. 30 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - ADD AS MANY SHIMS AS TO PRELOAD THE BEARING FOR TM 93 FROM 0,02mm TO 0,05mm (0,05 IS MOST ADVISABLE) PRELOAD FROM 0.07 mm TO 0.1 mm ON TM 545A (0.1 mm IS MOST ADVISABLE) - FIT O-RING (125) ON THE COVER PLATE (120) APPLY A THIN LAYER OF SEALANT PASTE ASSEMBLE THE COVER AND TIGHTEN THE FIXING BOLTS (122) - Pag. 31 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - WARM UP THE OUTPUT FLANGE (126) UP TO 120°C MOUNT THE FLANGE ON THE SPLINE MOUNT THE ELASTIC PIN (128) POSITION THE WASHER (127) ASSEMBLE THE FIXING BOLT (130) APPLYING LOCTITE THREAD LOCKER TIGHTENING TORQUE IS 23.5 KGM POSITION A COMPARATOR WITH MAGNETIC BASIS ON THE SURFACE OF THE FLANGE (126). ROTATING THE FLANGE, THE MISALIGNMENT MUST NOT BE HIGHER THAN 0,05mm Pag. 32 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - POSITION A THIN LAYER OF SEALANT PASTE ON THE OIL PUMP (66) - MOUNT THE OIL PUMP TIGHTEN THE FIXING BOLTS (58) Pag. 33 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - ON THE OPPOSITE SIDE OF THE GEARBOX, REMOVE COVER PLATE (104) AND (101) - HIT THE BEARING (24) AND THE EXTERNAL RING WITH A STOPPER REPEAT THE OPERATION FOR THE BEARING ON THE INPUT AXIS (51) Pag. 34 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - WITH A DEPTH GAUGE, MEASURE THE COVER PLATE (104) AND THE BEARING LOCATION REPEAT THE OPERATION ON THE INPUT SHAFT Pag. 35 di 37 MANUALE DI OFFICINA TM 93 – TM 93A ADD AS MANY SHIMS AS TO PRELOAD FROM 0,02mm TO 0,05mm ON TM 93 (0.05 mm IS ADVISABLE), FROM 0,07mm TO 0,1mm FOR TM 545A (0,1mm IS ADVISABLE) REPEAT THE OPERATION FOR INPUT SHAFT. - - APPLY A THIN LAYER OF SEALANT PASTE ASSEMBLE THE COVER PLATE (104) TIGHTEN THE FIXING BOLTS (105) Pag. 36 di 37 MANUALE DI OFFICINA TM 93 – TM 93A - MOUNT THE OIL SEAL (100) ON THE COVER PLATE (101) APPLY A THIN LAYER OF SEALANT PASTE ASSEMBLE THE COVER, PAYING ATTENTION NOT TO DAMAGE THE OIL SEAL. TIGHTEN THE FIXING BOLTS (103) Pag. 37 di 37