WORKSHOP MANUAL
TM 170 – TM 170A
OIL
H2O
H2 O
A
B
OIL
C
Pag. 1 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
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 34
MANUALE DI OFFICINA TM 170 – TM 170A
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 34
MANUALE DI OFFICINA TM 170 – TM 170A
Rif.
Ref.
Denominazione
Denomination
Quantità Codice
Quantity Code
Rif.
Ref.
Denominazione
Denomination
1
2
Cuscinetto – Bearing
Tappo – Plug
1
1
4622084
2055036
39
40
3
Campana Frizione – Clutch Housing
1
2011227
41
4
Fascia Elastica – Seal ring
1
2024005
41
5
Pistone – Piston
1
2017006
41
6
Disco Frizione conduttore-Clutch plate
9
2022030
41
7
Disco Frizione condotto-Steel plate
8
2022050
41
8
Chiavetta – Key
1
4620068
41
9
Fascia elastica – Seal ring
1
2024006
41
1
2
1
1
1
1
1
1
2021344
2024007
4588006
2020051
2065001
2022051
2020049
4601105
42
43
44
45
46
47
48
49
1
2061426
50
Corona – Gear
1
2061427
51
Distanziale - Spacer
1
2061428
48
Chiavetta – Key
1
2061440
49
Albero - shaft
1
2061426
50
Corona – Gear
1
2061427
51
Distanziale - Spacer
1
2061428
48
Chiavetta – Key
1
1
1
1
1
1
1
1
1
1
9
8
1
1
1
2
1
1
1
1
2050014
4603020
4607020
2016016
4622045
4622084
2055036
2011228
2024005
2017006
2022030
2022050
4620068
2024006
2021345
2024007
4588006
2020051
2065001
2022051
49
50
51
48
49
50
51
48
49
50
51
48
49
50
51
48
49
50
51
52
Albero - shaft
Corona – Gear
Distanziale - Spacer
Chiavetta – Key
Albero - shaft
Corona – Gear
Distanziale - Spacer
Chiavetta – Key
Albero - shaft
Corona – Gear
Distanziale - Spacer
Chiavetta – Key
Albero - shaft
Corona – Gear
Distanziale - Spacer
Chiavetta – Key
Albero - shaft
Corona – Gear
Distanziale – Spacer
Cuscinetto – Bearing
10
11
12
13
14
15
16
17
18
18
18
18
18
18
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Albero primario – Input shaft
Fascia elastica – Seal ring
Tappo conico – Plug
Molla – Spring
Cuscinetto – Bearing
Disco di ritenuta – Spacer ring
Molla a tazza – Spring
Anello Seeger – Seeger
PignoneTM170 r 1,50-Gear TM170 r
1,50
PignoneTM170 r 2,04-Gear TM170 r
2,04
PignoneTM170 r 2,50-Gear TM170 r
2,50
PignoneTM170 r 2,94-Gear TM170 r
2,94
PignoneTM170A r 1,53-Gear TM170A r
1,53
PignoneTM170A r 2,08-Gear TM170A r
2,08
PignoneTM170A r 2,60-Gear TM170A r
2,60
Boccola – Bushing
Ralla – Thrust block
Cuscinetto reggispinta – Thrust bearing
Rasamento – Ring
Cuscinetto – Bearing
Cuscinetto – Bearing
Tappo – Plug
Campana Frizione – Clutch housing
Fascia elastica – Seal ring
Pistone - Piston
Disco Frizione Conduttore–Clutch plate
Disco Frizione Condotto – Steel plate
Chiavetta – Key
Fascia elastica – Seal ring
Albero di rinvio – Intermediate shaft
Fascia elastica – Seal ring
Tappo conico – Plug
Molla – Spring
Cuscinetto – Bearing
Disco di ritenuta – Spacer ring
Quantità Codice
Quantity Code
Molla a tazza - Spring
Anello Seeger - Seeger
PignoneTM170 r 1,50-Gear TM170 r
1,50
PignoneTM170 r 2,04-Gear TM170 r
2,04
PignoneTM170 r 2,50-Gear TM170 r
2,50
PignoneTM170 r 2,94-Gear TM170 r
2,94
PignoneTM170A r 1,53-GearTM170A r
1,53
PignoneTM170A r 2,08-GearTM170A r
2,08
PignoneTM170A r 2,60-GearTM170A r
2,60
Boccola – Bushing
Ralla – Thrust block
Cuscinetto reggispinta- Thrust bearing
Rasamento - Ring
Cuscinetto – Bearing
Cuscinetto – Bearing
Chiavetta – Key
Albero - shaft
1
1
2020049
4601105
1
2061426
1
2061427
1
2061428
1
2061440
1
2061429
1
2061430
1
2061431
1
1
1
1
1
1
2050014
4603020
4607020
2016016
4622045
4622076
TM 170 r. 1,50
1
1012021
TM 170 r. 2,04
1
1012022
TM 170 r. 2,50
1
1012023
TM 170 r. 2,94
1
1012024
TM 170 r. 1,53
1
1012031
TM 170 r. 2,08
1
1012032
TM 170 r. 2,60
1
1012033
1
4622071
Pag. 4 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
Rif.
Ref.
Denominazione
Denomination
Quantità Codice
Quantity Code
Rif.
Ref.
53
54
55
56
57
58
59
60
Flangia uscita – Output flange
Guarnizione OR – “O” Ring
Rosetta – Washer
Spina elastica - Pin
Rondella elastica - Washer
Vite – Screw
Vite – Screw
Rondella elastica - Washer
1
1
1
1
1
1
6
6
2062231
4598029
2014064
4613005
4611116
4615479
4615214
4611108
97
98
99
100
101
102
103
104
61
Coperchietto - Cover
1 2010210
105
62
63
64
65
66
Paraolio – Oil seal
Tappo di sfiato - Breather
Targhetta – Name plate
Prigioniero – Stud
Rondella – Washer
1
1
1
2
1
4595129
2055032
2028004
4617081
4609021
108
109
110
111
112
67
Golfare – Eyebolt
1 4642010
113
68
69
70
71
72
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
Rondella – Washer
Tappo - Plug
Asta livello olio – Oil gauge
Prigioniero – Stud
Coperchio TM170 – Cover TM170
Coperchio TM170A-Cover TM170A
Rondella – Washer
Raccordo – Nipple
Valvola BY Pass – BY Pass valve
Rondella – Washer
Tappo – Plug
Coperchio – Cover
Rondella – Washer
Raccordo – Nipple
Guarnizione OR – “O” Ring
Leva di comando – Lever
Rondella elastica – Washer
Vite – Screw
Vite – Screw
Rondella elastica – Washer
Piastrina – Plate
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
4609011
2055033
2070050
4617063
2010215
2010203
4609030
4624002
1036001
4609009
4588009
2010202
4609030
4624002
4598016
2037036
4611108
4615214
4615134
4611106
2054024
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
88
Stelo distributore – Selector valve
1 2056072
135
89
Valvola – Valve
1 2056073
135
90
91
92
93
94
95
96
Rondella elastica – Washer
Vite – Screw
Rondella elastica – Washer
Vite – Screw
Rondella elastica – Washer
Vite – Screw
Rondella – Washer
4
4
5
5
1
1
1
136
137
138
139
139
140
141
4611110
4615301
4611110
4615301
4611110
4615334
4609009
Denominazione
Denomination
Quantità Codice
Quantity Code
Tappo – Plug
Tubo di raccordo - Pipe
Guarnizioni OR – “O” Ring
Tubo di raccordo - Pipe
Guarnizioni OR – “O” Ring
Rondella elastica - Washer
Vite - Screw
Coperchio pompa lato motore - Cover
Ingranaggio condotto pompa – Pump
gear
Vite - Screw
Rondella elastica - Washer
Corpo pompa – Oil pump body
Vite - Screw
Boccola - Bushing
Ingranaggio conduttore pompa – Pump
gear
Spina – Dowel pin
Corpo distributore – Valve body
Tappo a espansione - Plug
Molla – Spring
Molla – Spring
Vite – Screw
Rondella elastica - Washer
Rondella – Washer
Tappo – Plug
Filtro olio – Oil filter
Anello Seeger - Seeger
Molla – Spring
Sfera – Ball
Rondella – Washer
Tappo – Plug
Coperchio albero secondario - Cover
Paraolio – Oil seal
Tappo – Plug
Rondella – Washer
Vite – Screw
Rondella elastica - Washer
Tubo di aspiraz. TM170 – Tube for
TM170
Tubo di aspiraz. TM170A–Tube for
TM170A
Spina – Dowel
Paratia – Bulkhead
Vite – Screw
Scatola TM170 – Housing TM170
Scatola TM170A – Housing TM170A
Spessori di registro - Shim
Spessori di registro
1
1
2
1
2
2
2
1
4588009
2042016
4598067
2042017
4598024
4611110
4615302
2010292
1
2061456
4
4
1
3
4
4615238
4611108
2010291
4615144
4584002
1
2061446
2
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
9
9
4614013
2056090
4587022
2020056
2020055
4615317
4611110
4609009
4588009
2056039
4601017
2020045
4630020
4609028
2055037
2010209
4596183
4588034
4609015
4615301
4611110
1
2042033
1
2042034
2
1
2
1
1
x
x
4614010
2026005
4615202
2009066
2009064
2013184
2013189
Pag. 5 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
ALBERO DI ENTRATA – INPUT SHAFT – ARBRE D’ENTREE - EINGANGSWELLE – EJE DE
ENTRADA
ALBERO DI RINVIO – INTERMEDIATE SHAFT – ARBRE DE RENVOI VORGELEGEWELLE –
CONTRAEJE
Pag. 6 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
ALBERO DI RINVIO – INTERMEDIATE SHAFT – ARBRE DE RENVOI VORGELEGEWELLE –
CONTRAEJE
Pag. 7 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
ALBERO DI USCITA – OUTPUT SHAFT – ARBRE DE SORTIE
AUSGANGSWELLE – EJE DE SAIDA
Pag. 8 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
TM 170 – TM 170 A – TM 880 A
THE POSITIONS ARE REFERRED TO THE PERTINENT SERVICE MANUAL
-
-
WARM UP THE OUTPUT GEAR (50) UP TO 120°C
MOUNT KEY (48) ON THE SHAFT (49)
Pag. 9 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
INSERT THE SHAFT AND BRING IT ALL THE WAY DOWN WITH A COPPER HAMMER
-
MOUNT SPACER (51) and BEARINGS (52 – 47)
Pag. 10 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
MOUNT KEY (8) and (31) and SNAP RING (9-32) ON THE INPUT SHAFT (10) AND ON
THE REVERSE GEAR SHAFT (33)
-
APPLY A THIN LAYER OF SEALANT PASTE SUPERBOND 529
Pag. 11 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
-
-
WARM UP THE CLUTCH HOUSING (3-26) UP TO 120°C
BY MEANS OF A PRESS, ALIGN THE KEY ON ITS LOCATION AND BEAT IT UP
MAKE SURE THAT THE KEY IS SMOOTH ENOUGH AND DOES NOT LOSE METAL
PARTICLES
CHECK WITH AN AIR GUN ANY DIRT IN THE KEY AREA
Pag. 12 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
PREASSEMBLY OF CLUTCH GROUPS
-
-
MOUNT SEAL RING (4- 27) ON THE PISTON (5 - 28)
MOUNT PISTON (28 - 5) ON THE REVERSE GEAR SHAFT (33) OR FORWARD GEAR
SHAFT (10). MAKE SURE IT BEATS UP TO ITS LOCATION AND IT IS FREE TO ROTATE
FREE AROUND THE SHAFT
INSERT THE CLUTCH PLATES, BEGINNING WITH A CLUTCH PLATE (6 - 29) THEN A
STEEL PLATE (7 - 30) FOR A TOTAL OF N° 9 CLUTCH PLATES AND N° 8 STEEL
PLATES
Pag. 13 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
INSERT RING (15 - 38) and SPRING (16- 39)
-
-
INSERT SNAP RING (17 - 40) IN ITS LOCATION
Pag. 14 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
WITH THE PISTON, ALIGN THE TOOTHING OF THE CLUTCH PLATES
INSERT A SCREWDRIVER IN ONE OF THE SIDE HOLES OF THE HOUSING AND
HOLD THE DISCS IN POSITION
REMOVE THE PISTON. DISCS MUST MAINTAIN THEIR POSITION
Pag. 15 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
-
INSERT SPRING (13 - 36)
INSERT BEARING (14 - 37)
INSERT GEAR (18 - 41) ALL THE WAY DOWN AND HOLD IT IN POSITION
INSERT BUSHING ( 20 – 43)
INSERIRE DOWEL PIN (21 - 44)
INSERIRE BUSHING (22 – 45)
Pag. 16 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
WARM UP BEARING (23 – 46) UP TO 120°C – 150°C. INSERT THE
BEARING ON THE SHAFT, BEATING IT DOWN BY MEANS OF A PROPER STOPPER
Pag. 17 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
WARM UP BEARING (1-24) UP TO 120°C AND PLACE IT ON THE
-
CLUTCH HOUSING ALL THE WAY DOWN THRU A STOPPER
SCREW DOWEL PIN (2-25) WITH SEALING LOCTITE THREAD LOCKER
-
SCREW DOWEL PIN (12-35) WITH SEALING LOCTITE THREAD LOCKER
Pag. 18 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
DISASSEMBLY OF CLUTCH GROUPS
-
OPEN SEAL RINGS (11-31) AND REMOVE THEM FROM THEIR LOCATIONS
-
REMOVE GEAR (18-41) AN D BEARING (23-26) FROM THE SHAFT
Pag. 19 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
SLIP THE DOWEL PIN, THE BEARING AND THE SPRING
-
REMOVE SNAP RING (40 - 17) FROM ITS LOCATION
Pag. 20 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
REMOVE FROM THE CLUTCH THESE ITEMS : SPRING (16 - 39), PLATE (15 – 38),
CLUTCH PLATES AND PISTON
TO REMOVE THE SHAFT FROM THE HOSUING, IT IS NECESSARY TO PRESS IT FROM
THE SPLINE SIDE
Pag. 21 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
PREASSEMBLY DISTRIBUTOR VALVE
-
INSERT VALVE (89)
MOUNT O-RING (81)
INSERT SPRINGS (118 - 117) FOR GEARBOX TM 170 – TM 170A. GEARBOX TM 880A
has SPRING 2020087 INTO THE DISTRIBUTOR VALVE
INSERT THE DISTRIBUTOR VALVE
MOUNT THE LOCK PLATE (87)
MOUNT THE OPERATING LEVER (82)
Pag. 22 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
GEARBOX ASSEMBLY
-
INSERT THE BEARING CARRIER (47 – 1 – 24) INTO THE HOUSING
INSERT GASKET (137) AND BOLT IT WITH SCREWS (138)
-
INSERT THE PREVIOUSLY ASSEMBLED SHAFT GROUPS INTO THE HOUSING
ASSEMBLE THE PISTON RINGS (11 – 34)
Pag. 23 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
APPLY GREASE ON THE PISTON RINGS
-
APPLY A THIN LAYER OF SEALANT PASTE
Pag. 24 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
INSERT THE SUCTION HOSE (135) AND THE BEARING CARRIER (52-36-46) INTO THE
COVER
-
INSERT THE PINS (136)
POSITION COVER (72)
TIGHTEN THE FIXING BOLTS
Pag. 25 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
- HIT THE BEARING WITH A STOPPER
-
MEASURE THE POSITION OF BEARING (52) WITH A DEPTH GAUGE
Pag. 26 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
INSERT OIL SEAL (130) ALL THE WAY DOWN TO ITS LOCATION
MEASURE THE DEPTH OF THE COVER PLATE (129) AND AS MANY SHIMS AS
TO REACH A PRELOAD FROM 0,07mm TO 0,10mm
-
INSERT COVER PLATE (129) AND TIGHTEN THE FIXING HOLES (93)
INSERT ELASTIC PIN (56) ON THE OUTPUT SHAFT
Pag. 27 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
INSERT THE CONNECTION HOSES (98-100) WITH THE RESPECTIVE O-RINGS (99-101)
OF THE DISTRIBUTOR BODY (115)
-
INSERT THE BYPASS VALVE (75) OF THE COVER (78) AND CONSOLIDATE THE
EDGES SO AS TO PREVENT THE EJECTION
(TM 880A ONLY) INSERT O-RING IN THE DISTRIBUTOR BODY
JOIN TOGETHER THE DISTRIBUTOR BODY AND THE COVER
-
Pag. 28 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
POSITION BEARINGS (23-46) AND THEIR RESPECTIVE CARRIERS WITH A STOPPER
-
MEASURE THE POSITION OF THE BEARINGS (23 – 46) WITH A DEPTH GAUGE
-
MEASURE THE DEPTH OF THE CENTERING BORE ON THE DISTRIBUTOR BODY (115 )
AND THE COVER (78)
ADD AS MANY SHIMS (141) AS TO REACH A PRELOAD FROM 0,07mm TO 0,10 mm.
Pag. 29 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
APPLY A THINK LAYER OF SEALANT PASTE SUPERBOND 529
POSITION THE DISTRIBUTOR BLOCK, PAYING ATTENTION NOT TO FORCE THE
INSERTION OF THE PISTON RINGS
-
TIGHTENING THE FIXING BOLTS
SCREW THE NEUTRAL SWITCH, WHEN INCLUDED
Pag. 30 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
APPLY A THINK LAYER OF SEALANT PASTE SUPERBOND 529 ON THE OIL PUMP.
ALIGN THE ENGAGEMENT AND PLACE THE PUMP ON THE DISTRIBUTOR VALVE
TIGHTEN WITH FIXING BOLTS (109)
Pag. 31 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
WARM UP THE OUTPUT FLANGE (53) UP TO 120 °C
INSERT O-RING (54)
ASSEMBLE THE FLANGE ON THE SPLINE
POSTITION WASHER (55)
MOUNT FIXING BOLT (58) APPLYING SOME THREAD LOCKER LOCTITE
TIGHTEN WITH 35,7 kgm TIGHTENING TORQUE
POSITION A COMPARATOR WITH MAGNETIC BASIS ON THE FLANGE (126)
SURFACE. THE MISALIGNMENT MUST NOT BE HIGHER THAN 0.05 mm
Pag. 32 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
FIT THE OIL SEAL (62) IN ITS COVER PLATE (61)
-
APPLY A THIN LAYER OF SEALANT PASTE
INSERT COVER PLATE (61) WITHOUT DAMAGING THE OIL SEAL
TIGHTEN WITH THE FIXING HOLES
Pag. 33 di 34
MANUALE DI OFFICINA TM 170 – TM 170A
-
INSERT THE OIL FILTER (123)
TO PERFORM THE GEARBOX DISASSEMBLY, FOLLOW THE ABOVE INSTRUCTIONS
BACKWARDS.
Pag. 34 di 34