TM 93 - TM93A - TM 545A...MANUALE DI OFFICINA TM 93 – TM 93A Pag. 5 di 37 Rif. Ref. Denominazione Denomination Quantità Quantity Codice Code Rif. Ref. Denominazione Denomination

Pag. 1 di 37

WORKSHOP MANUAL

TM 93 – TM 93A

H20

A B

C

OIL

OIL

H20

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MANUALE DI OFFICINA TM 93 – TM 93A

Pag. 2 di 37

USE OF THE MANUAL Consignee:

Operator 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. 3 di 37

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. 4 di 37

Rif. Ref.

Denominazione Denomination Quantità

QuantityCodice Code

Rif. Ref.


QuantityCodice Code

1 Cuscinetto - Bearing 1 4622037 31 Pignone TM93A r 1,51 – Gear TM93A r 1,51

1 2061509

2 Rasamento - Ring 1 2016019 31 Pignone TM93A r 2,09 – Gear TM93A r 2,09

1 2061507

3 Cuscinetto reggispinta – Thrust bearing 1 4607019 31 Pignone TM93A r 2,40 – Gear TM93A r 2,40

1 2061505

4 Ralla – Thrust block 1 4603022 32 Seeger - Seeger 1 4601095 5 Pignone TM93 r 1,51 – Gear TM93 r

1,51 1 2061509 33 Molla a tazza - Spring 1 4578010

5 Pignone TM93 r 2,09 – Gear TM93 r 2,09

1 2061507 34 Disco di ritenuta – Back plate 1 2022053


1 2061505 35 Disco sinterizzato – Clutch plate 10 2022041


1 2061503 36 Disco in acciaio – Steel plate 9 2022039

5 Pignone TM93A r 1,51 – Gear TM93A r 1,51

1 2061515 37 Boccola - Bushing 1 2050022


1 2061516 38 Ralla – Thrust block 1 4603024


1 2061514 39 Cuscinetto reggispinta – Thrust bearing

1 4607019

6 Seeger - Seeger 1 4601095 40 Ralla – Thrust block 1 4603023 7 Molla a tazza - Spring 1 4578010 41 Molla ritorno pistone - Spring 1 2020035 8 Disco di ritenuta – Back plate 1 2022053 42 Fascia elastica – Seal ring 1 2024004 9 Disco sinterizzato – Clutch plate 10 2022041 43 Pistone - Piston 1 2017011

10 Disco in acciaio – Steel plate 9 2022039 44 Fascia elastica – Seal ring 1 2024009 11 Boccola - Bushing 1 2050022 45 Fascia elastica – Seal ring 2 2024007 12 Ralla – Thrust block 1 4603024 46 Tappo conico - Plug 1 4588006 13 Cuscinetto reggispinta – Thrust bearing 1 4607019 47 Albero primario – Input shaft 1 2021377 14 Ralla – Thrust block 1 4603023 48 Campana frizione – Clutch housing 1 2061500 15 Molla ritorno pistone - Spring 1 2020035 49 Chiavetta – Key 1 4620054 16 Fascia elastica – Seal ring 1 2024004 50 Tappo forato – Plug 1 2055036 17 Pistone - Piston 1 2017011 51 Cuscinetto – Bearing 1 4622073 18 Fascia elastica – Seal ring 1 2024009 52 Cuscinetto – Bearing 1 4622052 19 Tappo conico - Plug 1 4588006 53 Corona-Gear

TM93 r 1,51 1 1012001 20 Albero di rinvio – Intermediate shaft 1 2021378 55 Albero-Shaft 21 Fascia elastica – Seal ring 2 2024007 56 Chiavetta-Key 22 Chiavetta - Key 1 4620054 53 Corona-Gear

TM93 r 2,09 1 1012002 23 Campana frizione – Clutch housing 1 2061500 55 Albero-Shaft 24 Cuscinetto - Bearing 1 4622073 56 Chiavetta-Key 25 Distanziale - Spacer x 2013189 53 Corona-Gear

TM93 r 2,40 1 1012003 26 Tappo forato - Plug 1 2055036 55 Albero-Shaft 27 Cuscinetto - Bearing 1 4622037 56 Chiavetta-Key 28 Rasamento - Shim 1 2016019 53 Corona-Gear

TM93 r 2,77 1 1012004 29 Cuscinetto reggispinta-Thrust bearing 1 4607019 55 Albero-Shaft 30 Ralla – Thrust block 1 4603022 56 Chiavetta-Key 31 Pignone TM93 r 1,51 – Gear TM93 r

1,51 1 2061509 53 Corona-Gear

TM93A r 1,51 1 1012011 31 Pignone TM93 r 2,09 – Gear TM93 r 2,09

1 2061507 55 Albero-Shaft


1 2061505 56 Chiavetta-Key


1 2061503


Pag. 5 di 37

Rif. Ref.


Quantity Codice Code

Rif. Ref.


QuantityCodice Code

53 Corona-Gear TM93A r 2,09 1 1012012

99 Prigioniero - Stud 2 4617081 55 Albero-Shaft 100 Paraolio – Oil seal 1 4596111 56 Chiavetta-Key 101 Coperchio asse entrata - Cover 1 2010238 53 Corona-Gear

TM93A r 2,40 1 1012013 102 Rondella elastica - Washer 6 4611108

55 Albero-Shaft 103 Vite - Screw 6 4615214 56 Chiavetta-Key 104 Coperchio - Cover 1 2010240 54 Guarnizione or – “O” Ring 1 4598127 105 Vite - Screw 8 4615138 57 Cuscinetto – Bearing 1 4622046 106 Asta livello olio - Gauge 1 2070049 58 Vite – Screw 4 4615238 107 Scatola TM93 – Housing TM93 1 2009072 59 Rosetta elastica – Washer 4 4611108 107 Scatola TM93A – Housing TM93A 1 2009073 60 Coperchio pompa – Cover 1 2010330 108 Paratia – Bulkhead 1 2026007 61 Boccola – Bushing 2 4584002 109 Tubo - Tube 1 2042044 63 Spina cilindrica – Dowel pin 2 4614013 110 Vite - Screw 2 4615202 64 Tappo chiusura filtro olio – Plug 1 2055037 111 Raccordo - Nipple 1 4624002 65 Boccola - Bushing 2 4584002 112 Rondella piana - Washer 1 4609030 66 Coperchio pompa - Cover 1 2010331 113 Spina cilindrica – Dowel pin 2 4614012 67 Rondella - Washer 1 4609028 114 Coperchio TM93 – Cover TM93 1 2010233 68 Vite - Screw 1 4615129 114 Coperchio TM93A – Cover TM93A 1 2010234 69 Sfera - Ball 1 4630020 115 Rondella elastica – Washer 9 4611108 70 Molla - Spring 1 2020045 116 Vite – Screw 9 4615214 71 Seeger - Seeger 1 4601017 117 Rondella piana – Washer 1 4609015 72 Filtro olio – Filter 1 2056039 118 Tappo scarico olio – Drain plug 1 4588034 73 Rondella - Washer 2 4609007 119 Vite – Screw 1 4615246 74 Coperchio - Cover 1 2010237 120 Coperchio – Cover 1 2010239 75 Vite - Screw 1 4615129 121 Rondella elastica – Washer 4 4611108 76 Vite - Screw 1 4615253 122 Vite – Screw 4 4615214 77 Piastrina - Plate 1 2054024 123 Rondella elastica – Washer 4 4611108 78 Rosetta elastica - Washer 2 4611106 124 Vite - Screw 4 4615214 79 Vite - Screw 2 4615134 125 Paraolio – Oil seal 1 4596165 80 Guarnizione OR – “O” Ring 1 4598016 126 Flangia uscita – Output flange 1 2062233 81 Leva di comando – Lever 1 2037036 127 Rosetta di fermo - Washer 1 2014072 82 Vite - Screw 1 4615214 128 Spina elastica - Pin 1 4613004 83 Stelo distributore – Selector valve 1 2056072 129 Rosetta elastica - Washer 1 4611114 84 Valvola - Valve 1 2056073 130 Vite - Screw 1 4615426

85 Molla - Spring 1 2020056 131 Ingranaggio condotto pompa – Pump gear

1 2061456

86 Molla - Spring 1 2020055 132 Ingranaggio conduttore pompa – Pump gear

1 2061446

87 Tappo - Plug 1 4587022 133 Rondella elastica - Washer 3 4611108 88 Vite - Screw 1 4615129 134 Vite – Screw 3 4615229 89 Rondella - Washer 1 4609007 90 Rondella piana - Washer 1 4609030 91 Raccordo - Nipple 1 4624002

92 Gruppo valvola by pass – By pass valve

1 1036001

93 Rondella piana - Washer 1 4609011 94 Tappo di sfiato - Breather 1 2055032 95 Rondella piana - Washer 1 4609011 96 Golfare - Eyebolt 1 4642010 97 Tappo - Plug 1 2055033 98 Rondella piana - Washer 1 4609021


Pag. 6 di 37

ALBERO DI RINVIO – INTERMEDIATE SHAFT – ARBRE DE RENVOI VORGELEGEWELLE - CONTRAEJE


Pag. 7 di 37

ALBERO DI ENTRATA – INPUT SHAFT – ARBRE D’ENTREE EINGANGSWELLE – EJE DE ENTRADA


Pag. 8 di 37

ALBERO DI USCITA – OUTPUT SHAFT – ARBRE DE SORTIE AUSGANGSWELLE – EJE DE SAIDA


Pag. 9 di 37


Pag. 10 di 37

TM 93/93A AND TM 545A

- WARM UP THE OUTPUT GEAR UP TO 120°C

- MOUNT KEY (56) ON SHAFT (55)


Pag. 11 di 37

- INSERT THE SHAFT WITH THE HELP OF A COPPER HAMMER

- ASSEMBLE THE BEARINGS (52 – 57)


Pag. 12 di 37

- 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. 13 di 37

- ALIGN THE KEY WITH THE POSITION MARKED ON THE CLUTCH HOUSING (23 – 48)


Pag. 14 di 37

- WARM UP THE CLUTCH HOUSING (23 – 48) UP TO 120° C

- ALIGN THE KEY WITH ITS LOCATION AND PRESS ALL THE WAY DOWN


Pag. 15 di 37

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. 16 di 37

- 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. 17 di 37

- INSERT THE CIRCLIP (6 - 32) IN ITS LOCATION

- ALIGN THE TOOTHING OF THE CLUTCH PLATES WITH THE PISTON


Pag. 18 di 37

- 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. 19 di 37

- 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. 20 di 37

- WARM UP BEARING (1 – 27) UP TO 120°C – 150 °C. PUT THE

BEARING IN WITH THE HELP OF A STOPPER


Pag. 21 di 37

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. 22 di 37

- SLIP OFF THE DOWEL PINS, THE THRUST BEARING AND THE SPRING

- REMOVE SNAP RING (6 - 32) OFF ITS LOCATION


Pag. 23 di 37

- 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. 24 di 37

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. 25 di 37

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. 26 di 37

- 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. 27 di 37

- PUT SOME GREASE ON THE SEAL RINGS

- APPLY A THIN LAYER OF SEALANT PASTE


Pag. 28 di 37

- 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. 29 di 37

- USE A STOPPER TO PUT THE BEARING (52) ALL THE WAY DOWN

- INSERT O-RING (54)


Pag. 30 di 37

- WITH A DEPTH GAUGE, MEASURE THE COVER PLATE (120) AND THE BEARING LOCATION (52)


Pag. 31 di 37

- 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. 32 di 37

- 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. 33 di 37

- POSITION A THIN LAYER OF SEALANT PASTE ON THE OIL PUMP (66)

- MOUNT THE OIL PUMP - TIGHTEN THE FIXING BOLTS (58)


Pag. 34 di 37

- 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. 35 di 37

- WITH A DEPTH GAUGE, MEASURE THE COVER PLATE (104) AND THE BEARING LOCATION

- REPEAT THE OPERATION ON THE INPUT SHAFT


Pag. 36 di 37

- 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. 37 di 37

- 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)

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TM 93 - TM93A - TM 545A...MANUALE DI OFFICINA TM 93 – TM 93A Pag. 5 di 37 Rif. Ref. Denominazione Denomination Quantità Quantity Codice Code Rif. Ref. Denominazione Denomination