tm 345 - tm 345a - allpa manual/w… · 15 pignone – gear r. 1,54 tm 345 1 2061613 46 spessore di...

Pag. 1 di 37

WORKSHOP MANUAL

TM 345 – TM 345A

ton

allpa Logo

MANUALE DI OFFICINA TM 345 – TM 345A

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

Denominazione Denomination Quantità

QuantityCodice Code

1 Vite T.E. – Screw hex. 1 4615149 39 Corona - Gear r. 1,54 TM 345A

1 2061596 2 Rosetta di rame – Washer 3 4609029 39 Corona - Gear r. 2,00 1 2061597 3 Nipple 3-8 - Nipple 2 4624007 39 Corona - Gear r. 2,47 1 2061598 4 Tappo – Plug 3 4588028 40 Spina – Dowel pin 2 4614007 5 Rosetta di rame – Washer 3 4609009 41 Vite T.E. – Screw hex. 5 4615134 6 Tappo di sfiato – Breather 1 2055032 42 Paratia – Bulkhead 1 2026009 7 Asta livello olio – Gauge 1 2070167 43 Rosetta ondulata – Washer 12 4611208 8 Fascia elastica – Seal ring 2 2024016 44 Valvola by pass – By pass valve 1 1036002 9 Disco frizione conduttore–Clutch plate 20 2022058 45 Pignone – Gear r. 1,54

TM 345 1 2061613

10 Disco frizione condotto – Steel plate 18 2022052 45 Pignone – Gear r. 2,00 1 2061614 11 Anello di fermo – Ring 2 2054028 45 Pignone – Gear r. 2,47 1 2061615 12 Rasamento – Ring 2 2016030 45 Pignone – Gear r. 1,54

TM 345A 1 2061593

13 Distanziale – Spacer 2 2013637 45 Pignone – Gear r. 2,00 1 2061594 14 Seeger – Seeger 2 4601080 45 Pignone – Gear r. 2,47 1 2061595 15 Pignone – Gear r. 1,54

TM 345 1 2061613 46 Spessore di registro – Shim 6 2013624

15 Pignone – Gear r. 2,00 1 2061614 47 Cuscinetto – Bearing 2 4622060 15 Pignone – Gear r. 2,47 1 2061615 48 Pistone – Piston 2 2017015 15 Pignone – Gear r. 1,54

TM 345A 1 2061590 49 Albero di rinvio – Intermediate shaft 1 2021476

15 Pignone – Gear r. 2,00 1 2061591 50 Campana frizione – Clutch housing 1 2061589 15 Pignone – Gear r. 2,47 1 2061592 51 Molla – Spring 2 2020082 16 Tappo 3-8 Gas – Plug 1 4588108 52 Coperchio – Cover TM 345 1 2010295 17 Ralla – Thrust block 4 4603025 52 Coperchio – Cover TM 345A 1 2010278 18 Gabbia a rullini – Needle bearing 4 4607016 53 Spessore – Shim 3 2013189 19 Rasamento – Shim 2 2016029 54 Cuscinetto – Bearing 1 4622047 20 Cuscinetto - Bearing 2 4622025 55 Albero secondario – Output shaft 1 2021478 21 Fascia elastica – Seal ring 4 2024015 56 Targhetta – Plate 1 2028008 22 Tappo conico - Plug 2 4588006 57 Anello di tenuta – Oil seal 1 4596111 23

Kit pompa olio Oil pump kit 1 1009034

58 Albero primario – Input shaft 1 2021559 24 59 Rosetta di rame – Washer 1 4609011 25 60 Tappo scarico olio – Drain plug 1 4588030 26 61 Vite T.E. – Screw hex 2 4615141 27 62 Vite T.E. – Screw hex 1 4615214 28 63 Guarnizione OR – “O” ring 2 4598016 29 64 Tubo di aspirazione – Tube 1 2042077 30 65 Filtro olio – Oil filter 1 2056039 31 66 Perno di chiusura – Pin 1 2035062 32 67 Guarnizione OR – “O” ring 1 4598148 44 68 Distanziale – Spacer 1 2014099 32 Guarnizione OR – “O” ring 1 4598138 69 Dado – Nut 1 4633025 33 Vite T.E. – Screw hex. 1 4615234 70 Molla – Spring 1 2020084 34 Dado – Nut. 1 2038024 71 Leva di comando – Lever 1 2037036 35 Flangia uscita-Output flange TM 345 1 2062262 72 Piastrina di fermo – Plate 1 2054024 35 Flangia uscita-Output flange TM 345A 1 2062249 73 Stelo distributore – Selector valve 1 2056115 36 Anello di tenuta – Oil seal 1 4596153 74 Valvola – Valve 1 2069002 37 Cuscinetto – Bearing 1 4622041 75 Molla – Spring 1 2020083 38 Scatola – Housing TM 345 1 2009105 76 Grano – Dowel 1 4583004 38 Scatola – Housing TM345A 1 2009091 77 Interruttore – Switch 1 4639001 39 Corona - Gear r. 1,54

TM 345 1 2061616 78 Guarnizione or – O ring 1 4598070

39 Corona - Gear r. 2,00 1 2061617 79 Rullino cilindrico – Needle 1 4627007 39 Corona - Gear r. 2,47 1 2061618 / / / /


Pag. 5 di 37


Pag. 6 di 37


Pag. 7 di 37


Pag. 8 di 37


Pag. 9 di 37

TM 345/345A PREASSEMBLY OF OUTPUT GEAR

- WARM UP OUTPUT GEAR (39) UP TO 120 °C


Pag. 10 di 37

- PRESS OUTPUT SHAFT (55) ALL THE WAY DOWN


Pag. 11 di 37

PREASSEMBLY OF CLUTCH GROUPS

- MOUNT SEAL RING (8) ON PISTON (48)

- MOUNT PISTON (8) ONTO THE REVERSE GEAR SHAFT (49) OR FORWARD GEAR SHAFT (58)

- MAKE SURE THAT IT IS ALL THE WAY DOWN TO ITS LOCATION AND IT IS FREE TO MOVE FREELY AROUND THE SHAFT


Pag. 12 di 37

- INSERT CLUTCH PLATES BEGINNING WITH A BRONZE PLATE (9) THEN A STEEL PLATE (10) FOR A TOTAL OF N° 10 BRONZE PLATES AND N° 9 STEEL PLATES


Pag. 13 di 37

- INSERT PLATE (13)

- INSERT SNAP RING (14) ON ITS LOCATION


Pag. 14 di 37

- INSERT THE SNAP RING (11)

- WITH THE PISTON, ALIGN THE TOOTHING OF THE CLUTCH PLATES


Pag. 15 di 37

- INSERT SPRING (51)

- INSERIRT BUSHING (12)


Pag. 16 di 37

- INSERT THRUST BEARING

- INSERT BUSHING


Pag. 17 di 37

- INSERT GEAR (15 – 45) ALL THE WAY DOWN IN ITS LOCATION


Pag. 18 di 37

- INSERT SHIM (17) AND DOWEL PIN (18)

- INSERT SHIM (19) ALL THE WAY DOWN, CHECKING THAT THERE IS A CERTAIN THICKNESS AND THERE IS LEFT AN AXIAL PLAY WITH THE THRUST BEARINGS.


Pag. 19 di 37

- WARM UP BEARING UP TO 120°C – 150 °C

- INSERT BEARING (20) ON THE SHAFT ALL THE WAY DOWN WITH THE HELP OF A STOPPER


Pag. 20 di 37

DISASSEMBLY OF CLUTCH GROUPS

- OPEN THE SEAL RINGS (21) AND REMOVE THEM FROM THEIR POSITIONS

- SLIP THE GEAR (15-45) AND BEARING (20) OFF THE SHAFT


Pag. 21 di 37

- SLIP THE FOLLOWING SEQUENCE: THRUST BEARING, DOWEL PIN (12), SPRING (51)

- REMOVE SNAP RING (14) FROM ITS POSITION


Pag. 22 di 37

- REMOVE PLATE (13) AND ALL THE CLUTCH PLATES

- REMOVE SNAP RING (11) FROM ITS LOCATION - REMOVE THE PISTON FROM ITS LOCATION


Pag. 23 di 37

PREASSEMBLY OF DISTRIBUTOR VALVE

- INSERT SPRING (70) AND VALVE (74) ON THE REAR OF THE DISTRIBUTOR VALVE


Pag. 24 di 37

- APPLY LOCTITE THREAD LOCKER ON PIN (76)

- SCREW DOWEL PIN (76) UNTIL OBTAINING A 6mm PROTUBERANCE FROM THE BOTTOM OF THE DISTRIBUTOR VALVE

- ASSEMBLE O-RING (63)


Pag. 25 di 37

GEARBOX ASSEMBLY

- INSERT THE BEARING CARRIER ALL THE WAY DOWN (20-37) IN THE HOUSING (38)

- INSERT THE BEARING CARRIERS (47-54) ALL THE WAY DOWN INTO THE COVER (52)

- THEY MUST ENTER FREELY WITHOUT EFFORTS.


Pag. 26 di 37

- INSERT INPUT GROUP, REVERSE GROUP AND OUTPUT GROUP, EQUIPPED WITH BEARINGS, INTO THE COVER (52)

- POSITION REFERENCE PINS (40) ON THE COVER (52) - POSITION THE COVER (38) ON HOUSING (52)


Pag. 27 di 37

- SCREW TWO M6 SCREWS ON THE THREADS ON THE TOP OF INPUT SHAFT AND REVERSE SHAFT

- SCREW NUT (34) ON THE OUTPUT AXIS

- APPLY A COMPARATOR WITH MAGNETIC BASIS TO A BRACKET BOLT TO HOUSING (38)


Pag. 28 di 37

- POSITION THE COMPARATOR ON ONE OF THE M6 SCREWS PREVIOUSLY BOLTED ON THE TOP OF THE SHAFTS AND RESET THE TOOL

- LEVERAGING WITH A SCREWDRIVER OR ELSE, RAISE THE SHAFT AND REGISTER THE MEASUREMENT ON THE COMPARATOR

- REPEAT THE OPERATION WITH THE OTHER TWO SHAFTS


Pag. 29 di 37

- REMOVE THE COMPARATOR FROM THE HOUSING, UNSCREW M6 BOLTS AND THE NUT ON THE OUTPUT SHAFT. OPEN HOUSING AND COVER UP.

- REMOVE THE THREE SHAFTS FROM THE COVER - REMOVE THE THREE BEARING CARRIERS - ADD AS MANY SHIMS (46 –53) AS TO PRELOAD BEARINGS FROM 0.08 A 0.13 mm

(RECOMMENDED PRELOAD IS 0.1 mm) - REPOSITION BEARING CARRIERS - REPOSITION SHAFTS


Pag. 30 di 37

- APPLY LOCTITE ON M6 DOWEL PIN (22) - SCREW IT INTO THE THREAD ON THE TOP OF THE SHAFT (CORRESPONDING TO

THE HOLE SHOWN BY THE ARROW IN THE PICTURE)

- ASSEMBLE SEAL RINGS (21) (N°2 EACH SHAFT) - GREASE AND CENTRE THEM INTERNALLY TO THEIR LOCATIONS


Pag. 31 di 37

- MOUNT THE GASKET (42) - APPLY A LAYER OF SEALANT PASTE

- MOUNT HOSE (64) AND ITS O-RING (63) ON THE HOUSING (38)


Pag. 32 di 37

- INSERT THE OUTPUT SHAFT (55) IN THE HOUSING (38) - POSITION THE HOUSING (38) ON THE COVER (52) WITHOUT FORCING AND PAYING

ATTENTION NOT TO DAMAGE THE SEAL RINGS (21) - ONCE POSITIONED HOUSING AND COVER, TIGHTEN WITH THE FIXING BOLTS (33 –

26)


Pag. 33 di 37

- MOUNT OIL SEAL (36) - MOUNT OIL FILTER (65 – 66 – 67 – 68 – 69) - APPLY A THIN LAYER OF SEALANT PASTE AS SHOWN BY THE PICTURE

- BY MEANS OF LOCTITE, SCREW BY-PASS VALVE (44) ON THE PUMP BODY (24)


Pag. 34 di 37

- POSITION PUMP BODY (24) ON THE HOUSING (38) - MOUNT THE ROTORS AND OIL PUMP SHAFT (29 – 30 – 31)

- TIGHTEN PUMP BODY (24) WITH THE FIXING BOLTS (61-1) - MOUNT PUMP COVER (25) WITH PERTINENT O-RING (32) - TIGHTEN THE COVER WITH THE FIXING BOLTS (27) - MOUNT OUTPUT FLANGE (35) - APPLY SEALANT PASTE, AS SHOWN BY THE PICTURE


Pag. 35 di 37

- ASSEMBLE NUT (34) - CONSOLIDATE THE EDGE OF THE NUT TOWARD THE CUT ON THE SHAFT

- LOCK THE COMPARATOR WITH MAGNETIC BASIS TO THE HOUSING - RESET THE TOOL ON THE SURFACE OF THE OUTPUT FLANGE - TURN THE FLANGE MANUALLY. THE DIFFERENCE MUST NOT EXCEED 0,05 mm


Pag. 36 di 37

- INSERT SPRING (75) IN THE DISTRIBUTOR VALVE LOCATION - INSERT THE DISTRIBUTOR VALVE (PREVIOUSLY ASSEMBLED) - MOUNT THE LOCK PLATE (72) - MOUNT THE OPERATING LEVER (71)

- MOUNT FRONT OIL SEAL (57) - MOUNT THE PLUGS ON THE OIL DRAIN HOLE AND BREATHER HOLE - MOUNT NIPLES (3) - MOUNT NEUTRAL SWITCH (78 – 77) AND PERTINENT CYLINDRICAL DRIVE ROLLER

(79)


Pag. 37 di 37

TROLLING VALVE

ton

allpa Logo

tm 345 - tm 345a - allpa manual/w… · 15 pignone – gear r. 1,54 tm 345 1 2061613 46 spessore di...

Documents