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