TTM60 61A Service Manual

7/30/2019 TTM60 61A Service Manual

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TTM60ATTM61ASERVICE MANUAL

TTM60A TTM61A Service ManualP/N: M2-77624-3010


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ii TTM60A TTM61A Service Manual

2008 Tuff Torq by Kanzaki - Portions Reproduced with Permission

This Service Manualhas been developed for the exclusive use of service and repair professionals such asTuff Torq authorized Distributors and Tuff Torq authorized Dealers. It is written with these professionals inmind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and / or safely. Please contact an authorized Tuff Torqrepair or service professional before working on your Tuff Torq product.

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest information available atthe time of publishing. The illustrations used in this manual are intended as representative reference viewsonly. Moreover, because of our continuous product improvement policy, we may modify information,illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenanceimprovement. We reserve the right to make any change at any time without notice. Tuff Torq by Kanzaki,

and are registered trademarks of Tuff Torq Corporation in the United States and /or other countries.

All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means - graphic, electronic, ormechanical, including photocopying, recording, taping, or information storage and retrieval systems -without the written permission of Tuff Torq.


808


3/98

TTM60A TTM61A Service Manual iii


Section

TABLE OF

CONTENTS

TTM60A TTM61A Service ManualIntroduction ......................................................................................... 1-1

Safety.................................................................................................... 2-1

General Service Information .............................................................. 3-1

Overhaul............................................................................................... 4-1

Troubleshooting.................................................................................. 5-1


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TABLE OF CONTENTS

iv TTM60A TTM61A Service Manual


This Page Intentionally Left Blank


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TTM60A TTM61A Service Manual 1-1


Section 1

INTRODUCTION

TTM60A TTM61A Service ManualThis manual gives specific instructions for the

proper repair on TTM transmissions.Please follow the procedures carefully to ensurequality service.

Tuff Torq recommends that you read this ServiceManualcompletely before starting with repairs, assome of the procedures described are rathercomplex.

Along with standard tools, Tuff Torq recommendsthe use of special tools, necessary to performrepairs correctly.

Tuff Torq products are continuously undergoingimprovement. This Service Manualhas beenchecked carefully in order to avoid errors. HoweverTuff Torq is not liable, for any misrepresentations,errors of description or omissions. Contact anauthorized Tuff Torq marine dealer or distributor forany questions you have regarding this ServiceManual.


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INTRODUCTION Revision History

1-2 TTM60A TTM61A Service Manual


REVISION HISTORY

This manual is a living document. Periodic manualrevisions are published to document productimprovements and changes. This practice ensures

the manual has the most current information.

As manual revisions become necessary, individualpages are prepared and sent to those who needthe information. If a page, or number of pagesshould be replaced, the replacement information issent along with a revised Revision Control Table.Discard the older, obsolete information.

At times the revision involves inserting additionalpages in one or more sections. Insert the newinformation and only the Revision Control Table

should be replaced.

This method of revision control represents the mostcost-effective solution to providing fresh, updatedinformation as needed.

Revision Control Table

Revision Date

Revision Number

New Page Numbers

InvolvedRemarks

JAN 2008

Rev 00

All New Manual


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Section 2

SAFETY

TTM60A TTM61A Service Manual Page

Safety Precautions .......................................................................... 2-4Before You Service.................................................................... 2-4Precautions for Safe Servicing .................................................. 2-4


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SAFETY





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SAFETY



Tuff Torq is concerned for your safety and thecondition of your marine gear. Safety statementsare one of the primary ways to call your attention tothe potential hazards associated with Tuff Torqmarine gear. Follow the precautions listedthroughout the manual before operation, duringoperation and during periodic maintenanceprocedures for your safety, the safety of others andto protect the performance of your marine gear.Keep the labels from becoming dirty or torn andreplace them if they are lost or damaged. Also, ifyou need to replace a part that has a label attachedto it, make sure you order the new part and label atthe same time.

A

This safety alert symbol appears with mostsafety statements. It means attention,become alert, your safety is involved!Please read and abide by the messagethat follows the safety alert symbol.

ADANGERDanger (the word DANGER is in whiteletters with a red rectangle behindit) - indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury. Danger

is limited to the most extremesituations.

0000001en

AWARNINGWarning (the word WARNING is inblack letters with an orange rectanglebehind it) indicates a potentiallyhazardous situation which, if notavoided, could result in death or serious

injury.0000001en

ACAUTIONCaution (the word CAUTION is inblack letters with a yellow rectangle

behind it) indicates a potentiallyhazardous situation which, if notavoided, may result in minor ormoderate injury.

0000001en

CAUTION

Caution without the safety alert symbolindicates a potentially hazardoussituation that can cause damage to themarine gear, personal property and / or

the environment or cause the marinegear to operate improperly.

0000001enTrans


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SAFETY Safety Precautions



SAFETY PRECAUTIONS

Before You Service

Precautions for Safe Servicing

CAUTION

NEVER permit anyone to install oroperate the marine gear without propertraining.

Read and understand this ServiceManual before you operate or servicethe marine gear to ensure that youfollow safe servicing practices andmaintenance procedures.

Safety signs and labels are additionalreminders for safe service andmaintenance techniques.

See your authorized Tuff Torq marinedealer or distributor for yourinstallation, service and trainingneeds.

0000002enTransSMTT

ADANGER

CRUSH HAZARD!

Always use lifting equipment withsufficient capacity to lift marine gear.

Have a helper assist you attaching themarine gear to the hoist.

NEVER stand under hoisted marine

gear. If the hoist mechanism fails, themarine gear will fall on you, causingserious injury or death.

NEVER support marine gear withequipment not designed to supportthe weight of the marine gear such aswooden pieces, blocks or by onlyusing a jack.

Failure to comply will result in death orserious injury.

0000008enTransSM


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SAFETYSafety Precautions



ADANGER

FIRE HAZARD!

ALWAYS keep fire extinguishershandy in case of fire. Clearly indicatethe location of the fire extinguisherswith a safety sign.

ALWAYS ensure that the type of fireextinguishers are appropriate formaterial that might catch fire. Check

with local authorities.

ALWAYS have all fire extinguisherschecked periodically for properoperation and / or readiness.

ALWAYS post evacuation routesprominently. Periodically conduct firedrills.

ALWAYS ensure that appropriate firedetection and extinguishingequipment are installed and checked

periodically for proper operation.Check with local authorities.


0000018en

AWARNING

SUDDEN MOVEMENT HAZARD!

When you install the emergency nutthe boat will move forward as soon as

you start the engine! Make sure thearea is clear before you start theengine.

Failure to comply could result in deathor serious injury.

0000025en

AWARNING

SEVER HAZARD!

Keep hands and other body partsaway from moving / rotating partssuch as the flywheel or PTO shaft.

Wear tight-fitting clothing and keepyour hair short or tie it back while theengine is running.

Remove all jewelry before you operate

or service the marine gear. NEVER start the engine in gear.

Sudden movement of the engineand / or vessel could cause death orserious personal injury.

NEVER operate the marine gearwithout the guards in place.

Before you start the engine make surethat all bystanders are clear of thearea.

Keep children and pets away while theengine is operating.

Check before starting the engine thatany tools or shop rags used duringmaintenance have been removed fromthe area.


0000002enTrans


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AWARNING

ALCOHOL AND DRUG HAZARD!

NEVER operate the vessel while youare under the influence of alcohol ordrugs.

NEVER operate the vessel when youare feeling ill.


0000004enTrans

AWARNING

EXPOSURE HAZARD!

ALWAYS wear personal protectiveequipment such as gloves, workshoes, eye and hearing protection asrequired by the task at hand.

NEVER wear jewelry, unbuttonedcuffs, ties or loose-fitting clothingwhen you are working near

moving / rotating parts such as thecooling fan, flywheel or PTO shaft.

ALWAYS tie back long hair when youare working near moving / rotatingparts such as a cooling fan, flywheel,or PTO shaft.

NEVER operate the engine whilewearing a headset to listen to music orradio because it will be difficult to hearthe alert signals.

Failure to comply could result in death

or serious injury.0000005en


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AWARNING

SHOCK HAZARD!

ALWAYS turn off the battery switch (ifequipped) or disconnect the negativebattery cable before servicing theelectrical system.

Check the electrical harnesses forcracks, abrasions, and damaged orcorroded connectors. ALWAYS keep

the connectors and terminals clean.


0000009en

AWARNING

SEVER HAZARD!

Stop the engine before you begin toservice the marine gear.

Secure the propeller so it will not turnbefore you service the marine gear.

NEVER leave the key in the key switchwhen you are servicing the marinegear. Someone may accidentally start

the engine and not realize you areservicing it. This could result in aserious injury.

If you must service the marine gearwhile it is operating, remove alljewelry, tie back long hair, and keepyour hands, other body parts andclothing away from moving / rotatingparts.


0000010enTrans

AWARNING

BURN HAZARD!

If you must drain the marine gear oil

while it is still hot, stay clear of the hotmarine gear oil to avoid being burned.

ALWAYS wear eye protection.


0000011enTrans


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AWARNING

BURN HAZARD!

ALWAYS wait until the engine coolsbefore you drain the engine coolant.Hot engine coolant may splash andcause burns.


0000016en

AWARNING

SEVER HAZARD!

NEVER service the marine gear whileunder tow or if the engine is running atidle speed. The propeller may rotateunder these circumstances.


0000021en

AWARNING

SEVER HAZARD!

If the vessel has more than oneengine, NEVER service a marine gearif either of the engines are running. Inmulti-engine configurations thepropeller for an engine that is shutdown may rotate if any of the otherengines are running.


0000022en

AWARNING


Shift the marine gear into the

NEUTRAL position any time theengine is at idle.


0000023en

AWARNING

BURN HAZARD!

Keep your hands, and other bodyparts, away from hot engine andmarine gear surfaces such as themuffler, exhaust pipe, turbocharger (ifequipped), engine block and marinegear chassis during operation andshortly after you shut down theengine. These surfaces are extremely

hot while the engine is operating andcould seriously burn you.


0000015enTrans

AWARNINGUse heat resistant gloves when handlingthe hot housing halves and outer races.

0000102en


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AWARNING

FUME / BURN HAZARD!

ALWAYS read and follow safetyrelated precautions found oncontainers of hazardous substanceslike parts cleaners, primers, sealantsand sealant removers.


0000014en


0000102en

AWARNING

BURN HAZARD!

Handle heated thrust collars with heatresistant gloves!


0000103en

AWARNING

BURN HAZARD!

Handle heated tapered roller bearingswith heat resistant gloves!


0000104en

AWARNING

BURN HAZARD!

Handle heated tapered roller bearingouter races with heat resistant gloves!


0000105en

AWARNING

BURN HAZARD!

Handle heated output coupling withheat resistant gloves!


0000106en


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ACAUTION

COOLANT HAZARD!

Wear eye protection and rubber gloveswhen you handle long life or extendedlife engine coolant. If contact with theeyes or skin should occur, flush eyesand wash immediately with cleanwater.

Failure to comply may result in minor

or moderate injury.0000005en

ACAUTION

FLYING OBJECT HAZARD!

ALWAYS wear eye protection whenservicing marine gear and when usingcompressed air or high-pressurewater. Dust, flying debris, compressedair, pressurized water or steam mayinjure your eyes.

Failure to comply may result in minoror moderate injury.

0000003enTrans

ACAUTION

SLIPPING AND TRIPPING

HAZARD!

Ensure that adequate floor space isset aside for servicing marine gear.The floor space must be flat and freeof holes.

Keep floor free of dust, mud, spilled

liquids and parts to help preventslipping and tripping.

Failure to comply may result in minor ormoderate injury.

0000022en

ACAUTION

POOR LIGHTING HAZARD!

Ensure that the work area isadequately illuminated.

Use task lighting to illuminate areasthat need additional illumination.

Always place wire cage on portablesafety lamps.


0000023en


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ACAUTION

TOOL HAZARD!

Use tools appropriate for the task at

hand.

Use the correct size tool for looseningor tightening machine parts.


0000024en

CAUTION

If any problem is noted during the visual

check, ALWAYS take the necessarycorrective action before you operate theengine.

0000021en

CAUTION

NEVER hold the key in the STARTposition for longer than 15 seconds orthe starter motor will overheat.

0000007en

CAUTION

The illustrations and descriptions ofoptional equipment in this manual, suchas the operators console, are for atypical marine gear installation. Refer tothe documentation supplied by theoptional equipment manufacturer forspecific operation and maintenanceinstructions.

0000018enTrans

CAUTION

Observe the following environmentaloperating conditions to maintain marine

gear performance and avoid prematuremarine gear wear:

Avoid operating in extremely dustyconditions.

Avoid operating in the presence ofchemical gases or fumes.

0000003enTrans

CAUTION

Observe the following environmental

operating conditions to maintain marinegear performance and avoid prematuremarine gear wear:

NEVER run the marine gear if theambient temperature is above +45C(+113F) or below -15C (+5F).

If the ambient temperature exceeds+45C (+113F) the marine gear mayoverheat and cause the marine gear oilto break down.

If the ambient temperature falls below -15C (+5F) rubber components suchas gaskets and seals will hardencausing premature marine gear wearand damage.

Contact your authorized Tuff Torqmarine dealer or distributor if themarine gear will be operated in eithertemperature extreme.

0000065enKMH60A


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CAUTION

Only use the marine gear oil specified.Other marine gear oils may affect

warranty coverage, cause internalmarine gear components to seize and /or shorten marine gear life.

Prevent dirt and debris fromcontaminating marine gear oil.Carefully clean the oil plug anddipstick and the surrounding areabefore you remove either one.

NEVER mix different types of marinegear oil. This may adversely affect thelubricating properties of the marine

gear oil. NEVER overfill. Overfilling may result

in internal damage.

0000005enTrans

CAUTION

The correct level of marine gear oil isvery important for proper marine gearfunction:

Check the marine gear for the proper

amount of marine gear oil before youstart the engine for the first time.

Running the engine with insufficientoil level in the marine gear will causedamage to internal marine gearcomponents.

NEVER overfill the marine gear withmarine gear oil. An excessive oil levelmay cause leakage at the shaft sealsand the marine gear breather, andraise the operating temperature

considerably.

ALWAYS keep the oil level betweenupper and lower lines on the dipstick.

0000089enKMH60AOM

CAUTION

Before operating the engine, checkmarine gear oil level.

0000072enKMH60AOM

CAUTION

During normal operation, the marinegear should only be shifted with theengine at idle.

Shifting at higher engine speed willdamage the marine gear.

0000073en

CAUTION

If the marine gear oil temperature is toohigh, stop engine immediately andcheck the marine gear oil level andcheck the oil cooler for proper coolantand water flow.

Have the marine gear serviced by anauthorized Tuff Torq marine dealer ordistributor before you start the engineagain.

0000074enTT

CAUTION

After you add marine gear oil, run theengine for several minutes and shut itdown. Wait at least 10 minutes to checkthe marine gear oil level. This allows theoil to drain back into the sump,otherwise, you may overfill the marinegear with oil.

0000075enKMH60AOM


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CAUTION

New Marine Gear Break-In:

On the initial engine start-up, allow the

engine to idle for approximately 15minutes while you check for propermarine gear function and marine gearoil leaks.

During the break-in period, carefullyobserve marine gear indicators (if any)for proper marine gear function.

During the break-in period, check themarine gear oil levels frequently.

0000011enTrans

CAUTION

NEVER engage the starter motor whilethe engine is running. This may damagethe starter motor pinion and / or ringgear.

0000012en

CAUTION

NEVER attempt to modify the marine

gears design or safety features.

Failure to comply may impair themarine gears safety and performancecharacteristics and shorten the marinegears life. Any alterations to thismarine gear may affect the warrantycoverage of your marine gear.

0000044enKMH60AOM

CAUTION

ALWAYS be environmentallyresponsible.

Follow the guidelines of the EPA orother governmental agencies for theproper disposal of hazardousmaterials such as engine oil, dieselfuel and engine coolant. Consult thelocal authorities or reclamationfacility.

NEVER dispose of hazardousmaterials irresponsibly by dumpingthem into a sewer, on the ground, orinto ground water or waterways.

Failure to follow these proceduresmay seriously harm the environment.

0000013en

CAUTION

Protect the electric components fromdamage when you use steam or usehigh-pressure water to clean the engineor marine gear.

0000014enTrans

CAUTION

ALWAYS stop the engine immediately ifany indicator illuminates during engineoperation. Determine the cause andrepair the problem before you continue

to operate the engine.0000029en


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CAUTION

Establish a periodic maintenance planaccording to the engine application and

make sure you perform the requiredperiodic maintenance at intervalsindicated. Failure to follow theseguidelines will impair the marine gearssafety and performance characteristics,shorten the marine gears life and mayaffect the warranty coverage on yourmarine gear.

0000024enKMH60AOM

CAUTION

If you have more than one engine, youcannot shift the marine gear into the Bposition after you install theemergency nut.

0000077en

CAUTION

It is important to perform daily checks.

Periodic maintenance preventsunexpected downtime, reduces the

number of accidents due to poormachine performance and helps extendthe life of the marine gear.

0000060enTrans

CAUTION

Only use replacement parts specified.Other replacement parts may affectwarranty coverage, cause internalmarine gear components to seize, or

shorten marine gear life.0000147en

CAUTION

Always tighten to the specified torque.Loose parts can cause equipment

damage or cause it to operateimproperly.

0000148en

CAUTION

Keep dirt out of marine gear housing.Dirt may shorten the life of the marinegear and cause it to operate improperly.

0000149en


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Section 3

GENERAL SERVICE

INFORMATION


Marine Gear System ....................................................................... 3-4

Specifications .................................................................................. 3-5

Marine Gear Component Location .................................................. 3-6

Case Plate Component Location..................................................... 3-8

Hydraulic Diagram......................................................................... 3-10

Shifting Pressure ........................................................................... 3-11

Function Test................................................................................. 3-11

Required Tests: ....................................................................... 3-11


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GENERAL SERVICE INFORMATION





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GENERAL SERVICE INFORMATION



This marine gear has a built-in wet type multi-discclutch and is operated by the oil pressure of thehydraulic pump.

The major components are:

damper input shaft assembly support shaft assembly output shaft assembly hydraulic pump housing

The lube oil for each of the parts is distributed bythe hydraulic pump in a forced lubrication system.

When the forward / reverse changing valve lever ismoved, oil pressure is applied to move the clutch to

the FORWARD or REVERSE position.

The clutch for clockwise rotation of O / P is fitted tothe input shaft, and the clutch for counterclockwiserotation of O / P is fitted to the support shaft.

The marine gear oil (lube oil) is cooled by amulti-pipe marine gear oil cooler.


24/98

GENERAL SERVICE INFORMATION Marine Gear System



MARINE GEAR SYSTEM

Marine gear rotation with shift lever in position A:

Damper (1)Input Shaft (2)Drive Gear (3)Input Shaft Clutch (5)nput Pinion (6)Output Gear

(7)Output Shaft (8)Output Coupling (9)

Marine gear rotation with shift lever in position B:

Damper (1)Input Shaft (2)Drive Gear (3)Driven Gear (4)Support Shaft Clutch (10)SupportPinion (11)Output Gear (7)Output Shaft (8)Output Coupling (9)

Figure 3-1

0001947

(1)

(4)(10)

(7) (11) (8)

(9)

(6)(5)(3)

(2)


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GENERAL SERVICE INFORMATIONSpecifications



SPECIFICATIONS

Items TTM60A TTM61A Remarks

Type Down Angle Hydraulic

Angle 8

Maximum Input Torque 960 Nm (708 ft-lb) 1070 Nm (789 ft-lb)

Input Speed 700 - 3300 min-1 (rpm)

Reduction Ratio (F / R)

2.43 / 2.43

2.04 / 2.04

1.55 / 1.55

Direction ofRotation

I / P Counterclockwise

Viewed from SternO / P

Clockwise (Recommended)or Counterclockwise

Shift Mechanical Cable Electrical

Lubrication Forced Lubrication

Oil Type

API (American Petroleum Institute)Service Grade Class: CF

Never use multi-grade oil or mix oiltypes. Single-gradeoil must be used.Viscosity: SAE 30

Oil Quantity (Effective)2.8 L (0.5 L)

3.0 qt (0.5 qt)

Dimensions

L 286.0 mm (11.3 in.) SAE #3

A 145.4 mm (5.7 in.)

W 390 mm (15.4 in.)

Clutch Size SAE 11.5 in.

DryMass

Marine Gear 58.0 kg (127.9 lb)Without MountingFeet, Marine GearOil Cooler, Damper

Mounting Feet 2.3 x 2 kg (5 x 4 lb)

Marine Gear Oil Cooler 7.0 kg (15.4 lb) 8.0 kg (17.64 lb)With Bracket,

Hoses, Fittings

Damper 7.5 kg (16.5 lb)


26/98

GENERAL SERVICE INFORMATION Marine Gear Component Location



MARINE GEAR COMPONENT LOCATION

Figure 3-2

Section A-A

(2)

(1)

(3)(4)

(5)

(6) (7) (8) (9) (10)

(11) (12)

(13)

(14) (15)

(16) (17)

0001973

A

A


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GENERAL SERVICE INFORMATIONMarine Gear Component Location



1 Plug

2 Mounting Foot3 Upper Cover

4 Gasket5 Plug

6 O-ring7 Dipstick8 Parallel Pin

9 Breather10 Mounting Foot11 Magnet Plug

12 Seal Washer13 Spring Pin

14 Spring Retainer15 Spring16 2nd Relief Sheet

17 2nd Relief Valve


28/98

GENERAL SERVICE INFORMATION Case Plate Component Location



CASE PLATE COMPONENT LOCATION

Figure 3-3

(33)

D E

CE

D

C

(31)

(42)

(41)

(40)

(39)(38)(37)

(36)

(35)

(34)(32)

(30)

(29)

(28)

(27)(26)

(25)

(24)

(23)

(22)

(21)(20)

(19)

(12)

(13)

(14)

(15)

(16)

(17)

(1)

(2)(10)

(9)

(11)

(3)

(4)

(5)

(6)(7)

(8)

B

Section B-B

Section D-D

Section E-E

Mating Surface of Pump

B

(18)

0001974


29/98

GENERAL SERVICE INFORMATIONCase Plate Component Location



1 Pin

2 Bearing3 Pump Drive Gear

4 Bearing5 Pump Driven Gear

6 Pump Cover7 Pump Body8 Bearing

9 O-ring10 O-ring11 O-ring

12Clamp13 Wire Bracket

14 Switch Support15 Safety Switch16 Ball Joint

17 Shifting Lever18 Parallel Pin

19 Spring20Ball21Pin

22 Parallel Pin23 O-ring

24Cover25 O-ring26 Spring

27 Modulating Valve28 Spring

29Shim30 HO Relief Valve

31Cover32 Parallel Pin33 Parallel Pin

34Bolt35 Shifting Valve36 V-ring

37 O-ring38 O-ring

39Cover40 Pilot Valve41 Throttle Valve

42 Spring


30/98

GENERAL SERVICE INFORMATION Hydraulic Diagram



HYDRAULIC DIAGRAM

Figure 3-4

0001969

Clutch F

Clutch R

LO Press.

LO Press.

HO Press.

HO Press.

FR

Forward Astern

Strainer (150 Mesh)

M10 x 1.0

ModulatingValve LO Cooler

LO Relief Valve

HO Relief Valve NPTF 3/8

MECHANICAL SHIFT VERSION

ELECTRICAL SHIFT VERSION

Clutch F

Clutch R

LO Press.

LO Press.

HO Press.

HO Press.

FR

Shifting Valve

Forward Astern

Hydraulic Oil

Pump

Strainer (150 Mesh)

M10 x 1.0

Modulating

Valve LO Cooler LO Relief Valve

HO Relief Valve NPTF 3/8

TEMPERATUREGAUGE

CONNECTION

PRESSUREGAUGE

CONNECTION

Shifting Valve

TEMPERATUREGAUGE

CONNECTION

PRESSUREGAUGE

CONNECTION

Hydraulic Oil

Pump


31/98

GENERAL SERVICE INFORMATIONShifting Pressure



SHIFTING PRESSURE

Shifting pressure is hydraulic pressure. Shifting pressure must be between min. and max. line in the belowperformance graph at any time. If not, See Troubleshooting on page 5-1.

Figure 3-5

FUNCTION TESTPerform a function test after servicing the marinegear. Be sure the marine gear is filled with oil.

This test can be performed on a bench test rig, or ina boat.

If a marine gear oil cooler is not installed, connect ahydraulic hose between the inlet and outlet of thehydraulic pump.

Required measuring instruments:

Pressure gauge - 0-5 MPa (0 - 750 psi), withconnecting thread M10 x 1.25.

Temperature gauge - 0-120C (0 250F),connecting thread 3/8-18 NPTF.

See Hydraulic Diagram on page 3-10 for pressureand temperature gauge location.

Required Tests:1. Fluid leaks

2. Noise emission

3. Direction of rotation, LH / RH

4. Lube oil temperature

5. Shifting pressure

6. Neutral performance

7. Shifting performance

0 1000 2000 3000 4000

Input Speed (min-1)

5

6

4

3

2

1

0

Sh

iftingPressure(MPa)

TTM61A MAX

TTM60A MAX

TTM60A MIN

TTM61A MIN

0002015TT


32/98

GENERAL SERVICE INFORMATION Function Test



The function test should be carried out as follows:

Note: See Shifting Pressure on page 3-11 and Standard Valve of Performance below.

Standard Value of Performance

No. Engine SpeedShift Lever Position

A: Lever is raisedB: Lever is lowered

Duration Test

1 800 - 1000 rpm neutral 5 1, 2

2 600 - 800 rpm (idling speed) AB position repeatedly - 1, 2, 3, 6, 7

3 1500 - 2500 rpm B position * 1, 2, 4

4 600 - 800 rpm (idling speed) AB position repeatedly - 1, 2, 3, 6, 7

5 idling - maximum speed A position - 1, 2, 5**

6 600 - 800 rpm (idling speed) A->B position - 1, 2

7 idling - maximum speed B position - 1, 2, 5**

*Until oil temperature of 75 - 80C (167 - 176F) has been reached.**At different speeds.

Items TTM60A TTM61A Remarks

Neutral Performance(Time Until Stopping)

20 secondsOil Temperature 30C(86F) Idling Speed

Shifting Time to Engage 1.0 secondsOil Temperature 30C(86F) Idling Speed

Oil Temperature 90C (194F)

OilPressure

HO

Maximum 4.09 MPa

(593 psi)

4.82 MPa

(699 psi)

Oil Temperature 30C

(86F) 3300 rpm

Setting3.72 0.05 MPa

(539 7 psi)4.38 0.05 MPa

(635 7 psi)Oil Temperature 60C

(140F) 3300 rpm

Minimum 1.86 MPa

(270 psi) 2.19 MPa

(318 psi)Oil Temperature 60C

(140F) 700 rpm

LO

Maximum 0.30 MPa

(44 psi) 0.65 MPa

(94 psi)Oil Temperature 30C

(86F) 3300 rpm

Setting0.25 0.05 MPa

(36 7 psi)0.60 0.05 MPa

(87 7 psi)Oil Temperature 60C

(140F) 3300 rpm

Minimum 0.01 MPa

(1.5 psi)

Oil Temperature 60C

(140F) 700 rpm


33/98



Section 4

OVERHAUL


Before You Begin Servicing ............................................................ 4-3Before You Operate................................................................... 4-3During Operation and Maintenance........................................... 4-4

Past Inspections for the Engine and the Marine Gear................... 4-14

Special Service Tools .................................................................... 4-15

Measuring instruments .................................................................. 4-19

Standard Tools .............................................................................. 4-20

Torque Chart ................................................................................. 4-21

Marine Gear Component identification.......................................... 4-22

Marine Gear Sectional View.......................................................... 4-24Case Plate Component Identification ............................................ 4-26

Preparing for Overhaul .................................................................. 4-28

Disassembly of Marine Gear ......................................................... 4-28

Draining Transmission Oil ....................................................... 4-29Removal of Oil Filter ................................................................ 4-30Removal of Dipstick................................................................. 4-30Removal of Output Coupling ................................................... 4-30Removal of Hydraulic Oil Pump............................................... 4-31Removal of Case Plate ............................................................ 4-31Removal of Valves................................................................... 4-32

Removal of Mounting Feet ...................................................... 4-33Removal of Oil Seals ............................................................... 4-37Removal of Tapered Roller Bearings ...................................... 4-38Removal of Clutch pack........................................................... 4-39

Cleaning Of Marine Gear .............................................................. 4-42


34/98

OVERHAUL



Inspection of Marine Gear............................................................. 4-42

Cases ...................................................................................... 4-42Bearings .................................................................................. 4-42Shafts and Gears .................................................................... 4-42

Reassembly of Marine Gear.......................................................... 4-43Reassembly of Input Shaft and Support Shaft ........................ 4-43Reassembly of Pinion Gear Assemblies ................................. 4-45Reassembly of Thrust Collars ................................................. 4-45Reassembly of Tapered Roller Bearings OntoInput and Support Shafts......................................................... 4-46Reassembly of Seal Rings ...................................................... 4-47Reassembly of Tapered Roller Bearing Onto Output Shaft .... 4-47Adjustment of Gear Backlash.................................................. 4-48Reassembly of Taper Roller Bearing OuterRaces Into Case B .................................................................. 4-49Reassembly of Oil Suction Cover (If Removed Earlier) .......... 4-50

Reassembly of Oil Seals ......................................................... 4-50Measuring Bearing Clearance / Adjusting Bearing Preload .... 4-51Reassembly of Gear Set Into Housing .................................... 4-52Reassembly of Tapered Roller Bearings OuterRaces Into Case A .................................................................. 4-52Final Assembly of Cases......................................................... 4-53Reassembly of Mounting Flange............................................. 4-54Reassembly of Valves............................................................. 4-54Reassembly of Case Plate ...................................................... 4-55Reinstall Oil Filter .................................................................... 4-55Reinstall Hydraulic Oil Pump................................................... 4-56Reassembly of Output Coupling.............................................. 4-56

Filling Marine Gear With Oil .......................................................... 4-57

Checking Oil Level ........................................................................ 4-58

Trial Run........................................................................................ 4-59


35/98

OVERHAULBefore You Begin Servicing



This section of the Service Manualdescribes theproceduresfor proper repair of the marine gear.

BEFORE YOU BEGINSERVICING

Before You Operate

CAUTION

NEVER permit anyone to install oroperate the marine gear without propertraining.

Read and understand this ServiceManual before you operate or servicethe marine gear to ensure that youfollow safe servicing practices andmaintenance procedures.

Safety signs and labels are additionalreminders for safe service andmaintenance techniques.

See your authorized Tuff Torq marinedealer or distributor for yourinstallation, service and trainingneeds.

0000002enTransSMTT


36/98

OVERHAUL Before You Begin Servicing



During Operation and Maintenance

ADANGER

CRUSH HAZARD!

Always use lifting equipment withsufficient capacity to lift marine gear.

Have a helper assist you attaching themarine gear to the hoist.

NEVER stand under hoisted marinegear. If the hoist mechanism fails, themarine gear will fall on you, causingserious injury or death.

NEVER support marine gear withequipment not designed to supportthe weight of the marine gear such aswooden pieces, blocks or by onlyusing a jack.


0000008enTransSM

ADANGER

FIRE HAZARD!

ALWAYS keep fire extinguishershandy in case of fire. Clearly indicatethe location of the fire extinguisherswith a safety sign.

ALWAYS ensure that the type of fireextinguishers are appropriate formaterial that might catch fire. Checkwith local authorities.

ALWAYS have all fire extinguisherschecked periodically for properoperation and / or readiness.

ALWAYS post evacuation routesprominently. Periodically conduct firedrills.

ALWAYS ensure that appropriate firedetection and extinguishingequipment are installed and checkedperiodically for proper operation.Check with local authorities.


0000018en

AWARNING


When you install the emergency nutthe boat will move forward as soon asyou start the engine! Make sure the

area is clear before you start theengine.


0000025en


37/98




AWARNING

SEVER HAZARD!

Keep hands and other body partsaway from moving / rotating partssuch as the flywheel or PTO shaft.

Wear tight-fitting clothing and keepyour hair short or tie it back while theengine is running.

Remove all jewelry before you operate

or service the marine gear. NEVER start the engine in gear.

Sudden movement of the engineand / or vessel could cause death orserious personal injury.

NEVER operate the marine gearwithout the guards in place.

Before you start the engine make surethat all bystanders are clear of thearea.

Keep children and pets away while theengine is operating.

Check before starting the engine thatany tools or shop rags used duringmaintenance have been removed fromthe area.


0000002enTrans

AWARNING

ALCOHOL AND DRUG HAZARD!

NEVER operate the vessel while youare under the influence of alcohol ordrugs.

NEVER operate the vessel when youare feeling ill.


0000004enTrans


38/98




AWARNING

EXPOSURE HAZARD!

ALWAYS wear personal protectiveequipment such as gloves, workshoes, eye and hearing protection asrequired by the task at hand.

NEVER wear jewelry, unbuttonedcuffs, ties or loose-fitting clothingwhen you are working near

moving / rotating parts such as thecooling fan, flywheel or PTO shaft.

ALWAYS tie back long hair when youare working near moving / rotatingparts such as a cooling fan, flywheel,or PTO shaft.

NEVER operate the engine whilewearing a headset to listen to music orradio because it will be difficult to hearthe alert signals.


or serious injury.0000005en

AWARNING

SHOCK HAZARD!

ALWAYS turn off the battery switch (ifequipped) or disconnect the negativebattery cable before servicing theelectrical system.

Check the electrical harnesses forcracks, abrasions, and damaged orcorroded connectors. ALWAYS keep

the connectors and terminals clean.


0000009en


39/98




AWARNING

SEVER HAZARD!

Stop the engine before you begin toservice the marine gear.

Secure the propeller so it will not turnbefore you service the marine gear.

NEVER leave the key in the key switchwhen you are servicing the marinegear. Someone may accidentally start

the engine and not realize you areservicing it. This could result in aserious injury.

If you must service the marine gearwhile it is operating, remove alljewelry, tie back long hair, and keepyour hands, other body parts andclothing away from moving / rotatingparts.


0000010enTrans

AWARNING

BURN HAZARD!

If you must drain the marine gear oil

while it is still hot, stay clear of the hotmarine gear oil to avoid being burned.



0000011enTrans

AWARNING

BURN HAZARD!

ALWAYS wait until the engine coolsbefore you drain the engine coolant.Hot engine coolant may splash andcause burns.


0000016en

AWARNING

SEVER HAZARD!

NEVER service the marine gear whileunder tow or if the engine is running atidle speed. The propeller may rotateunder these circumstances.


0000021en

AWARNING

SEVER HAZARD!

If the vessel has more than oneengine, NEVER service a marine gearif either of the engines are running. Inmulti-engine configurations thepropeller for an engine that is shutdown may rotate if any of the otherengines are running.


0000022en


40/98




AWARNING


Shift the marine gear into the

NEUTRAL position any time theengine is at idle.


0000023en

AWARNING

BURN HAZARD!

Keep your hands, and other bodyparts, away from hot engine andmarine gear surfaces such as themuffler, exhaust pipe, turbocharger (ifequipped), engine block and marinegear chassis during operation andshortly after you shut down theengine. These surfaces are extremely

hot while the engine is operating andcould seriously burn you.


0000015enTrans

AWARNING

FUME / BURN HAZARD!

ALWAYS read and follow safetyrelated precautions found oncontainers of hazardous substanceslike parts cleaners, primers, sealantsand sealant removers.


0000014en

ACAUTION

COOLANT HAZARD!

Wear eye protection and rubber gloves

when you handle long life or extendedlife engine coolant. If contact with theeyes or skin should occur, flush eyesand wash immediately with cleanwater.


0000005en


41/98




ACAUTION




0000003enTrans

ACAUTION

SLIPPING AND TRIPPING

HAZARD!

Ensure that adequate floor space isset aside for servicing marine gear.The floor space must be flat and freeof holes.

Keep floor free of dust, mud, spilledliquids and parts to help preventslipping and tripping.

Failure to comply may result in minor or

moderate injury.0000022en

ACAUTION

POOR LIGHTING HAZARD!

Ensure that the work area is

adequately illuminated.

Use task lighting to illuminate areasthat need additional illumination.

Always place wire cage on portablesafety lamps.


0000023en

ACAUTIONTOOL HAZARD!

Use tools appropriate for the task athand.

Use the correct size tool for looseningor tightening machine parts.


0000024en

CAUTION

If any problem is noted during the visualcheck, ALWAYS take the necessarycorrective action before you operate theengine.

0000021en

CAUTION

NEVER hold the key in the START

position for longer than 15 seconds orthe starter motor will overheat.

0000007en


42/98




CAUTION

The illustrations and descriptions ofoptional equipment in this manual, such

as the operators console, are for atypical marine gear installation. Refer tothe documentation supplied by theoptional equipment manufacturer forspecific operation and maintenanceinstructions.

0000018enTrans

CAUTION



Avoid operating in extremely dustyconditions.

Avoid operating in the presence ofchemical gases or fumes.

0000003enTrans

CAUTION



NEVER run the marine gear if theambient temperature is above +45C(+113F) or below -15C (+5F).

If the ambient temperature exceeds+45C (+113F) the marine gear mayoverheat and cause the marine gear oilto break down.

If the ambient temperature falls below -15C (+5F) rubber components such

as gaskets and seals will hardencausing premature marine gear wearand damage.

Contact your authorized Tuff Torqmarine dealer or distributor if themarine gear will be operated in eithertemperature extreme.

0000065enKMH60A

CAUTION

Only use the marine gear oil specified.Other marine gear oils may affectwarranty coverage, cause internalmarine gear components to seize and /or shorten marine gear life.

Prevent dirt and debris fromcontaminating marine gear oil.Carefully clean the oil plug anddipstick and the surrounding areabefore you remove either one.

NEVER mix different types of marine

gear oil. This may adversely affect thelubricating properties of the marinegear oil.

NEVER overfill. Overfilling may resultin internal damage.

0000005enTrans


43/98




CAUTION

The correct level of marine gear oil isvery important for proper marine gear

function: Check the marine gear for the proper

amount of marine gear oil before youstart the engine for the first time.

Running the engine with insufficientoil level in the marine gear will causedamage to internal marine gearcomponents.

NEVER overfill the marine gear withmarine gear oil. An excessive oil levelmay cause leakage at the shaft seals

and the marine gear breather, andraise the operating temperatureconsiderably.

ALWAYS keep the oil level betweenupper and lower lines on the dipstick.

0000089enKMH60AOM

CAUTION

Before operating the engine, checkmarine gear oil level.

0000072enKMH60AOM

CAUTION

During normal operation, the marinegear should only be shifted with theengine at idle.

Shifting at higher engine speed willdamage the marine gear.

0000073en

CAUTION

If the marine gear oil temperature is toohigh, stop engine immediately and

check the marine gear oil level andcheck the oil cooler for proper coolantand water flow.

Have the marine gear serviced by anauthorized Tuff Torq marine dealer ordistributor before you start the engineagain.

0000074enTT

CAUTION

After you add marine gear oil, run theengine for several minutes and shut itdown. Wait at least 10 minutes to checkthe marine gear oil level. This allows theoil to drain back into the sump,otherwise, you may overfill the marinegear with oil.

0000075enKMH60AOM

CAUTION

New Marine Gear Break-In:

On the initial engine start-up, allow theengine to idle for approximately 15minutes while you check for propermarine gear function and marine gearoil leaks.

During the break-in period, carefullyobserve marine gear indicators (if any)for proper marine gear function.

During the break-in period, check themarine gear oil levels frequently.

0000011enTrans


44/98




CAUTION

NEVER engage the starter motor whilethe engine is running. This may damage

the starter motor pinion and / or ringgear.

0000012en

CAUTION

NEVER attempt to modify the marinegears design or safety features.

Failure to comply may impair themarine gears safety and performancecharacteristics and shorten the marine

gears life. Any alterations to thismarine gear may affect the warrantycoverage of your marine gear.

0000044enKMH60AOM

CAUTION



NEVER dispose of hazardousmaterials irresponsibly by dumping

them into a sewer, on the ground, orinto ground water or waterways.


0000013en

CAUTION

Protect the electric components fromdamage when you use steam or use

high-pressure water to clean the engineor marine gear.

0000014enTrans

CAUTION

ALWAYS stop the engine immediately ifany indicator illuminates during engineoperation. Determine the cause andrepair the problem before you continueto operate the engine.

0000029en

CAUTION

Establish a periodic maintenance planaccording to the engine application andmake sure you perform the requiredperiodic maintenance at intervalsindicated. Failure to follow theseguidelines will impair the marine gearssafety and performance characteristics,shorten the marine gears life and may

affect the warranty coverage on yourmarine gear.

0000024enKMH60AOM

CAUTION

If you have more than one engine, youcannot shift the marine gear into the Bposition after you install theemergency nut.

0000077en


45/98




CAUTION

It is important to perform daily checks.

Periodic maintenance prevents

unexpected downtime, reduces thenumber of accidents due to poormachine performance and helps extendthe life of the marine gear.

0000060enTrans

CAUTION

Only use replacement parts specified.Other replacement parts may affectwarranty coverage, cause internal

marine gear components to seize, orshorten marine gear life.

0000147en

CAUTION

Always tighten to the specified torque.Loose parts can cause equipmentdamage or cause it to operateimproperly.

0000148en


46/98

OVERHAUL Past Inspections for the Engine and the Marine Gear



PAST INSPECTIONS FOR THEENGINE AND THE MARINEGEAR

For precise, high-quality operation, preparation isnecessary. Check the customer management filefor the past performance of the engine and marinegear.

When was the last maintenance done?

How much has the marine gear been used(length of time / hours of use) since the lastmaintenance work?

What problems were found at the lastinspection, and what maintenance work was

performed? Are the parts needed for replacement during

maintenance on hand?

Is there a check sheet for the maintenancework?


47/98

OVERHAULSpecial Service Tools



SPECIAL SERVICE TOOLS

No Tool Name Applicable model and tool size Illustration

1 Base

(For Disassemblyof Shaft

Assembly)Part No. 177524-09210

2 Repair Stand

Part No. 177524-09110

3 Spacer A

Part No. 177524-09320

4 Spring Pusher

Part No. 177524-09310

5 Shaft Stand

Part No. 177524-09240

6 Spacer B

Part No. 177524-09240

0001977

0001978

0001979

0001980

0001981

0001982


48/98

OVERHAUL Special Service Tools



7 Bearing Extractor

(For Bearing and

Collar on Engine

Side)Part No. 177524-09350

8 Thrust Collar

Extractor

(For Collar on

Propeller Side) Part No. 177524-09380

9 Wrench

(For OutputCoupling)

Part No. 177524-09160

10 Master-Case A

(Input Shaft)

(For Shim

Adjustment ofInput Shaft and

Support Shaft)

Part No. 177524-09510

11 Master-Case A

(Output Shaft)

(For Shim

Adjustment of

Output Shaft

Assembly) Part No. 177524-09520


0001983

0001984

0001986

0001987

0001988


49/98

OVERHAULSpecial Service Tools



12 Master-Case B

(Input Shaft)

(For Shim

Adjustment of

Input Shaft

Assembly)

Part No. 177524-09540

13 Master-Case B

(Output Shaft)

(For Shim

Adjustment of

Output Shaft

Assembly)

Part No. 177524-09550

14 Master-Case A(For Shim

Adjustment of

Case A)Part No. 177524-09610

15 Master-Case B

(For Shim

Adjustment of

Case B) Part No. 177524-09620

16 Spring Press Tool

(For Assembly of

Shaft Assembly)Part No. 177524-09010

17 Arm Kit (For

Disassembly of

Shaft Assembly)Part No. 177524-09200


0001989

0001990

0001991

0001992

0003502

0003503


50/98

OVERHAUL Special Service Tools



18 Protector (For

Disassembly of

Bearing Cup)Part No. 177524-09710

19 Gear Steady (For

Measuring of

Backlash)Part No. 177524-09730


0003504

0003505


51/98

OVERHAULMeasuring instruments



MEASURING INSTRUMENTS

No. Instrument Name Application Illustration

1 Micrometer Measuring gauge from 0-25 mm. Accuracy of

reading 1/100 mm

2 Dial Indicator Gauge Dial indicator gauge with arm-type support

3 Dial Gauge

0000834

0001993

0000831


52/98

OVERHAUL Standard Tools



STANDARD TOOLS

No. Tool Name Application Illustration

1 Wrench For hexagon bolts

(8 mm, 12 mm, 14 mm, 17 mm, 24 mm)

2 Allen Wrench (6 mm, 8 mm)

3 Hexagon Socket Wrench (12 mm, 13 mm, 17 mm, 24 mm, 30 mm)

4 Torque Wrench Adjustable up to 450 Nm

5 Plastic Hammer (1000 g) and Sturdy

Screwdriver

6 Extractor Minimum diameter of 130 mm

7 Hexagon Bit Sockets (6 mm, 8 mm)

8 Rolling Head Pry Bars

9 Slide Hammer Bearing Puller

0001994

0001995

0001996

0001997

0001998

0001999

0002910

0003506

0003507


53/98

OVERHAULTorque Chart



TORQUE CHART

Item Size Torques

Transmission Assembly Bolts

M8 18.6 - 22.6 Nm 13.7 - 16.7 ft-lb

M10 37.2 - 41.2 Nm 27.5 - 30.4 ft-lb

M12 65.7 - 75.5 Nm 48.5 - 55.7 ft-lb

Output Coupling Bolt M20 401 - 441 Nm 296 - 326 ft-lb

Dipstick Hand Tight

Breather Hand Tight


54/98

OVERHAUL Marine Gear Component identification



MARINE GEAR COMPONENT IDENTIFICATION

Figure 4-1

0001970

5

12

13

1415

16

17

18

20

21

22

2324

25

2627

28

29

30

31

32

33

3435

36

3738

3940

41

42

43

44

45

46

47

48

49

50

51

52

56

5758

59

60

6162

63

6465

6667

68

69

5453

71

55

70

11

10

9

8

7

6

4

3 72

73

7574

76

77

1

2

19


55/98

OVERHAULMarine Gear Component identification



1 Parallel Pin

2 Case A3 Mounting Flange4 Oil Seal

5 Parallel Pin

6 Shims (0.1, 0.3, 0.5, and 1.0 mm)7 Bearing8 Output Gear9 Output Shaft

10 Bearing11 Shims (0.1, 0.3, 0.5, and 1.0 mm)

12 Shims (0.1, 0.3, 0.5, and 1.0 mm)13 Bearing14 Thrust Collar

15Ring16Ring

17 Friction Disc Retainer18 Friction Disc19 Steel Plate

20 Bushing21 Input Pinion

22 Thrust Collar23Ring24 Spring Retainer

25 Return Spring26Ring

27Ring28 Hydraulic Cylinder29 Drive Gear

30 Input Shaft

31Ball32 Bearing33 Seal Ring34 Shims (0.1, 0.3, 0.5, and 1.0 mm)

35 Case Plate36 Spring Retainer

37 2nd Relief Seat38 Spring39 Spring Pin

40 2nd Relief Valve41 Mounting Foot

42 Breather43 Dipstick

44Gasket45 Parallel Pin46Bolt

47 Coupling Plate48 O-ring49 Output Coupling

50 Oil Seal51Plug

52 Case B

53 Name Plate54 Cover Suction55 Baffle Plate

56 Seal Ring

57 Bearing58Ball59 Support Shaft60 Driven Gear

61 Hydraulic Cylinder62 Seal Ring

63 Seal Ring64 Spring65 Spring Retainer

66Ring67 Thrust Collar

68 Support Pinion69 Bushing70 Friction Disc

71 Steel Plate72 Friction Disc Retainer

73 Thrust Collar74 Ring (outer retaining)75 Bearing

76 Ring (inner retaining)77 Shims (0.1, 0.3, 0.5, and 1.0 mm)


56/98

OVERHAUL Marine Gear Sectional View



MARINE GEAR SECTIONAL VIEW

Figure 4-2

1018 27 32 6 50 1538 8 45

39

3

44

7

51

43

41

42

40

9

1

35

36

2

19

26

21

27

25

20

24

23

28

29

22

16

12

11

31 5 30 17 14 13

63227

1

35

36

2

19

27

26

21

20

25

23

24

28

22

34

29

31

30 17

4

48

49

47

46

0001972


57/98

OVERHAULMarine Gear Sectional View



1 Case A

2 Case B3 Baffle Plate4 Suction Cover

5 Shim

6 Shim7 Shim8 Shim9 Mounting Flange

10 Parallel Pin11 Case Plate

12Gasket13 PTO Cover14Gasket

15 Input Shaft16 Drive Gear

17Ball18 Thrust Collar Eng.19 Thrust Collar Prop.

20 Spring Retainer21 Friction Disc Retainer

22 Hydraulic Cylinder23 Return Spring24 Friction Disc

25 Steel Plate26Ring

27Ring28Ring29Ring

30Ring

31 Bearing32 Bearing33 Support Shaft34 Driven Gear

35 Input Pinion36 Bushing

37 Support Pinion38 Output Shaft39 Output Gear

40 Output Coupling41 Coupling Plate

42Bolt43 O-ring

44 Bearing45 Bearing46 Strainer Cover

47Gasket48 Filter49 Strainer Spring

50 Oil Seal


58/98

OVERHAUL Case Plate Component Identification



CASE PLATE COMPONENT IDENTIFICATION

Figure 4-3

0001971

12

3 4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

1920

2122

23

24

25

26

28

27

29

3031

32

33

40 41

39

38

37

36

34

35

42

43

44

45

46

47

48

50

51

52

53

5449


59/98

OVERHAULCase Plate Component Identification



1 Plug

2 O-ring3 Upper Cover4 Gasket

5 Case Plate

6 Plug7 Cap8 Gasket9 PTO Cover

10 O-ring11 O-ring

12 Pump Body13 Bearing14 Pump Driven Gear

15 Bearing16 Pump Cover

17 Bearing18 Pump Drive Gear19 Bearing

20Pin21 O-ring

22 O-ring23 Strainer Cover24Gasket

25 Strainer Spring26 Filter

27 Shifting Valve28Pin29 O-ring

30Pin

31Cover32 V-ring33 Wire Bracket34 Shifting Lever

35 Ball Joint36Bolt

37 Switch Support38Clamp39 O-ring

40 Spring41Ball

42 O-ring43Cover

44 Modulating Valve45 Spring46 Spring

47Shim48 HO Relief Valve49Shim

50 O-ring51Cover

52 Pilot Valve

53 Throttle Valve54 Spring


60/98

OVERHAUL Preparing for Overhaul



PREPARING FOR OVERHAUL

Prepare for the disassembly of the marine gear asfollows.

1. Secure the marine gear on a level base.

2. Clean off any dirt, oil or dust on the marine gearwith detergent, air or steam.

Note: Be careful not to get any dust inside themarine gear during operation.

Notes:

Be sure to replace the parts which uponinspection and measurement are faulty, whosemeasurements are outside the prescribedlimits, or have exceeded the prescribed periodof use.

Parts which still meet the standard

measurements and prescribed period of use,but which are expected to fall below thestandard before the next inspection shouldalso be replaced.

DISASSEMBLY OF MARINEGEAR

If necessary, make alignment marks on parts tomake reassembly easier.

As each part is removed, check its condition andappearance for changes in shape, damage andscratches.

Disassemble the parts in an orderly mannerseparating parts which can be used from thosewhich need to be replaced.

ADANGER

CRUSH HAZARD!

Always use lifting equipment with

sufficient capacity to lift marine gear. Have a helper assist you attaching the

marine gear to the hoist.

NEVER stand under hoisted marinegear. If the hoist mechanism fails, themarine gear will fall on you, causingserious injury or death.

NEVER support marine gear withequipment not designed to supportthe weight of the marine gear such aswooden pieces, blocks or by only

using a jack.


0000008enTransSM

ACAUTION




0000003enTrans


61/98

OVERHAULDisassembly of Marine Gear



Draining Transmission Oil 1. Position a container under the marine gear tocollect the waste oil.

2. Remove the drain plug (Figure 4-4, (1)) withseal using a 24 mm socket wrench.

3. Check the drain seal for damage. Replace ifnecessary.

Figure 4-4

AWARNING

BURN HAZARD!

If you must drain the marine gear oilwhile it is still hot, stay clear of the hotmarine gear oil to avoid being burned.



or serious injury.0000011enTrans

CAUTION



NEVER dispose of hazardousmaterials irresponsibly by dumpingthem into a sewer, on the ground, orinto ground water or waterways.


0000013en

0002000A

(1)


62/98

OVERHAUL Disassembly of Marine Gear



Removal of Oil Filter

1. Remove the three M8x40 bolts (Figure 4-5, (2))of lock washers with 12 mm socket wrench.

2. Remove the filter cover (Figure 4-5, (3)),gasket, strainer spring (Figure 4-5, (4)) and oilfilter (Figure 4-5, (1)).

3. Check the gasket for damage. Replace ifnecessary.

Note: The oil filter (Figure 4-5, (1)) must bewashed with clean oil whenever the oil ischanged.

Figure 4-5

Removal of Dipstick

1. Remove dipstick (Figure 4-6, (1)).

Figure 4-6

Removal of Output Coupling

1. Lock output coupling in swivel flame with flangestabilizing wrench (Figure 4-7, (2)).

2. Remove M20x60 hex head bolt(Figure 4-7, (1)) with 30 mm socket wrench.

3. Remove coupling plate (Figure 4-8, (1)) and

O-ring (Figure 4-8, (2)).4. Using a gear puller, remove output coupling

(Figure 4-9, (1)).

Figure 4-7

0002001A

(2)

(3)

(1) (4)

0002002A

(1)

0001921

(1)

(2)


63/98




Figure 4-8

Figure 4-9

Removal of Hydraulic Oil Pump

1. Remove four M8x65 hex head bolts(Figure 4-10, (1)).

2. Remove oil pump (Figure 4-10, (2)).

Figure 4-10

Removal of Case Plate

1. Loosen and remove all 10 M8 hex head boltsand lock washers (Figure 4-11, (2 & 3)) with12 mm socket wrench.

2. Using a plastic hammer, lightly tap the split lineof the case plate surface to break the seal.

3. Remove case plate (Figure 4-11, (4)) andlubricating pressure relief valve(Figure 4-11, (5)).

4. Remove parallel pins (Figure 4-11, (1)).

0001922A

(1)

(2)

0002003

(2) (1)0003508


64/98




Figure 4-11

Removal of Valves

1. Loosen and remove four hex bolts(Figure 4-12, (1)).

2. Remove wire bracket (Figure 4-12, (2)).

Figure 4-12

3. Remove shifting valve (Figure 4-13, (1)).

Figure 4-13

4. Remove cover for HO relief valve with O-ring(Figure 4-13, (2)).

5. Remove modulating valve (Figure 4-13, (3)).

6. Remove springs (Figure 4-13, (4)).

7. Remove HO relief valve with shims(Figure 4-13, (5)).

8. Remove cover for reducing valve with O-ring(Figure 4-13, (6)).

9. Remove pilot valve (Figure 4-13, (7)).

10. Remove throttle valve (Figure 4-13, (8)).

11. Remove spring (Figure 4-13, (9)).

0001924A

(2,3)(1)

(4) (1)

(5)

(1) (2)

0003509

(1)

(2) (3)

(4)(5)

(9)(8)

(7)(6)

0003510


65/98




Removal of Mounting Feet

1. Remove two mounting feet (Figure 4-14, (1)).

2. Install repair stand (Figure 4-14, (2)) tohousing.

Figure 4-14

Removal of Mounting Flange

1. Remove ten M10x35 hex head bolts(Figure 4-15, (1)) with 14 mm socket wrench.

2. Remove two locating pins (Figure 4-15, (2)).

Figure 4-15

0001925

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(2)

0001926

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(2)


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Disassembly of Cases

1. Loosen and remove all (15) M8 hex bolts andlock washers (Figure 4-16, (2 and 3)) usingboth 12 mm and 13 mm socket wrenches. Note

the location of two recessed bolts near inputshaft and four stainless steel bolts at lower sideof housing (Figure 4-17, (1)).

2. Lightly tap case A (Figure 4-16, (4)) with plastichammer. Prying with sharp tools can result indamage to sealing surface, leakage of oil, andfailure of gear.

3. Remove parallel pins (Figure 4-16, (1)).

Figure 4-16

Figure 4-17

(2,3)

(1)(4)

0001927A

0001928(1)


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Removal of Shafts and Gears

1. Remove gear set from case B:

Input shaft (Figure 4-18, (1)) assembly

Support shaft (Figure 4-18, (2)) assembly

Output shaft (Figure 4-18, (3)) assembly

Figure 4-18

2. If it is needed (when adjustment of shim isneeded) remove bearing races by using RollingHead Pry Bars or Slide Hammer Bearing Puller.

3. If you use a Rolling Head Pry Bars for removalof case A input bearing races, you should useprotector (Figure 4-19, (1)) and (Figure 4-20).

Figure 4-19

Figure 4-20

4. Remove the shims from case A and case B onthe input shaft.

5. Remove the shims from case A and case B onthe output shaft.

6. Remove the shims from case A on the support

shaft.

0001929

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(2)

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0003512


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Removal of Tapered Roller Bearings OuterRaces

Remove the tapered roller bearings outer racesfrom the cases by heating the cases in an oven toapproximately 120C (250F): Put the housing inthe oven upside down, so the outer races will fallout.

The case can be heated by using other

methods such as a torch or heat gun. Be sure to keep the shims together with the

same outer races from where they wereremoved. Properly identify shims and outerraces.


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Removal of Oil Seals

1. Remove and discard input oil seal(Figure 4-21, (1)).

Figure 4-21

2. Remove and discard output oil seal(Figure 4-22, (1)).

Figure 4-22

Removal of Baffle Plate and Oil SuctionCover

1. Remove baffle plate (Figure 4-23, (1)) and oilsuction cover (Figure 4-23, (2)) from case B.

Note: The oil suction cover removal is optional.

2. Protect the housing. Be sure to keep any dirtout of housing.

Figure 4-23

Removal of Seal Rings

1. Remove seal rings (Figure 4-24, (1)) from inputshaft and support shaft.

Figure 4-24

0001930A

(1)

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0001931A

0001932

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Removal of Tapered Roller Bearings

Check for failed bearings or excessive bearingwear. If bearings are damaged, replace both theouter bearing race and inner bearing race.

Removal of Taper Roller Bearings InnerRaces

Input Shaft and Support Shaft - Engine Side

Remove the engine side tapered roller bearinginner races with thrust collar by using a bearingextractor (Figure 4-25, (1)) along with the arm andthreaded rod M16 600 (Figure 4-25, (2)).

Be sure to pull on the thrust collar not on thebearing.

Note the direction that the thrust collar isinstalled on shaft.

Figure 4-25

Input Shaft and Support Shaft - Propeller Side

Do not disassemble the shaft and piston housing. Ifa bearing is damaged, replace the completebearing set.

(1)

0001933

(2)


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Removal of Clutch pack

Removal of Clutch Discs

1. To remove clutch discs from input shaft,

remove retaining ring (Figure 4-26, (1)).

Figure 4-26

2. Slide pinion gear assembly (Figure 4-27, (1))off input shaft.

Figure 4-27

3. Carefully remove outer retaining ring(Figure 4-28, (1)).

4. Remove friction disc retainer (Figure 4-28, (2)).

5. Remove steel plates and friction discs from the

case.

6. Repeat same procedure to remove the frictiondisc retainer from the support shaft.

Figure 4-28

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0001935A

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Removal of Clutch Pistons

1. To remove clutch pistons from input shaft,remove thrust collar (Figure 4-29, (1)) by usingan extractor (Figure 4-29, (2)).

Note: Make sure to observe the direction thethrust collar is mounted to the shaft.

Figure 4-29

2. Using a spring compressor (Figure 4-30, (2)),compress the spring no more than 5 mm.

3. Remove snap ring (Figure 4-30, (1)).

4. Remove inner retaining ring (Figure 4-31, (1))from groove.

Figure 4-30

0001936

(1)(2)

M8x300

M12

0001937

(1)

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5. Remove the spring retainer, return spring(Figure 4-31, (2)) and hydraulic cylinder(Figure 4-31, (3)). This may require applicationof low pressure air to opening in end of shaft toremove piston.

Note: Make sure to observe the direction theretaining ring is installed on the shaft(chamber facing up).

6. Repeat same procedure for support shaft.

Figure 4-31

Figure 4-32

0001938

(1)

(2)

(3)

(3)(2)

(1)

0002699


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OVERHAUL Cleaning Of Marine Gear



CLEANING OF MARINE GEAR

Note: Discard all gaskets, seals, O-rings, pistonrings and seal rings. Replace any partthat was damaged from disassembly.

Use EPA / OSHA approved solvents. Parts must bedried and oiled immediately after cleaning. Be sureparts are free from grit, dirt and abrasives.

Only use clean solvent to flush valves.

Be sure to flush all hoses and the heatexchanger.

Do not remove packing grease from new bearings.Thoroughly wash used bearings. Do not usecompressed air to dry the bearings.

Remove all old sealant from sealed joints.Thoroughly clean the surfaces to remove oldsealant and grease.

INSPECTION OF MARINE GEAR

Cases

Replace any case that is cracked.

Inspect machined surfaces and bores for wear,grooves or scratches. Only use crocus cloth or asoft stone to remove scratches and burrs.

Repair any damaged threads using the correct sizetap or thread repair kit.

Bearings

Replace any bearing that was removed by using aservice tool.

Replace bearings that show signs of corrosion andwear such as scoring, scratching, cracked pitting orchipping.

Replace bearing if its rotation is rough.

Inspect bearing bores and shafts for grooves, burrsor galling. Replace the part if crocus cloth can notrepair the damage.

Shafts and Gears

Check all gears, bearings, piston rings on the inputshaft and support shaft for signs of wear or failure.

If any of the gears are damaged or showing signsof excessive wear, Tuff Torq recommendsreplacing the complete gear set.

To check for correct clutch operation, rotate thegears on the input shaft.

Inspect clutch for excessive wear, replace clutch asrequired by feeling of smooth rotating only.

Friction Disc

AWARNING

FUME / BURN HAZARD!

ALWAYS read and follow safetyrelated precautions found on

containers of hazardous substanceslike parts cleaners, primers, sealantsand sealant removers.


TTM60 61A Service Manual

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