Home

TWIN DISC

1. 11 Safety and General Precautions 12 Preventative Maintenance 13 Ordering Parts and Obtaining Services 14 Source of Service Information 15 Rebuilding Service 16 Warranty 16 Description Specifications 17 General uu una a T E 17 Construction Features 18 Drive Lubrication Features 19 Torque Values for Fasteners 20 21 General y A E T 21 Thrust Unit Installation 25 Trim Cylinder Installation 33 Steering Cylinder Installation 37 Driveline Installation J 40 Lubrication
2. 102 Thrust Bearing Shimming Procedure 106 Seal Installation 109 Input Shaft and Socket Assembly 115 Removal and Replacement of Thrust Socket Packing amp O Ring 122 Installation of Thrust Tube Into Thrust 123 ell ALON 131 Fin Reattachimeritiuk 132 Attaching Thrust Unit to Transom 134 Hydraulic Cylinder 135 Servicing the Steering amp Cylinders 135 Steering Cylinder Service 136 PREMIO Wal E 136 Disassembly and Inspection 138 ee ere 139 Trim Cylinder Service 142 Removal S SS su aaa 142 Disassembly amp Inspection 144 191 1 145 Arneson Surface Drive Service Manual 1022808 9 Table of Conte
3. 165 1017817 ASD12B1LU Drive Assembly Parts Drawing Double Seal uuu 166 1022907 ASD12B1LU Drive Assembly Parts Drawing 167 1017592 ASD 12B1LU Drive Installation Drawing 168 1009236 Steering Cylinder 169 1007432 Steering Cylinder VRVT electronic position indication 170 1009234 Trim Cylinder 171 1007340 Cylinder VRVT electronic position indication 172 1006786 Tie Bar Assembly 173 1023448 Aft Seal Conversion Diagram Double Seal to Triple Seal 174 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc model ASD 12B1LU Arneson Surface Drive Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wisconsin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and application of the material in this manual will result
4. 145 38 5 14 5 1954 H15N3 1 3 I8V19VA 71149 5 3 118431 33 19 13 1 11993 aje 149 5 1 NOSSNAV H AALLISOd Uso we Figure 20 Examples of Proper and Improper Alignment 45 Arneson Surface Drive Service Manual 1022808 Installation Twin Disc Incorporated Lubrication Arneson Surface Drives are supplied with an internal lubrication system that can be serviced inside the vessel Anon pressurized type of lubrication system is standard equipment on an Arneson Surface Drive and is described below Internal Lube Kit The Internal Lube Kit supplied by Twin Disc Incorporated for ASD 12 drives is shown in Figure 21 It includes an oil reservoir hose clamps hose fittings and plugs The customer provides the necessary support brackets for the reservoir All components are to be internally clean to prevent oil contamination Reservoir Mounting Mount reservoir 254 mm 10 in or higher above surface drive centerline as shown in Figure 21 Support reservoir on bottom or under flange and secure to the vessel s structure Connect 1 2 in hose as shown in Figure 21 OPERATION CHANGING OF SYSTEM OIL REQUIRES THE USE OF AN EXTERNAL PUMP NOT PART OF THIS SUPPLY DO NO
5. 1 ROD RING TUBE 2916 1 RING s 588 Z f AE NAANA NS Ly 97 SZ A 7 a AX 4 1006051 lt N 2 2 1 25 E M 2 52 2916 1 1084 1 RING n SCREW 1084 1 M2026AD 1 2 SCREW SCREW 1006060 1 een SCREW RETRACTED LENGTH 2 SHEET 1 ASSEMBLY DRAWING SHEET 2 MANUFACTURING DRAWING THIRD ANGLE PROJECTION SIMILAR TO r zz 27271 T T TL RS TE SOA 6 14 93 m zs TWIN DISE 0 005 1 1 5 RACINE WI 53403 USA x 5171 2 sss OF Cr W sn 0 e _ amp 29 45 4 n 6 23 05 nonce intennen ma 1009256 A 24759 Ph27 ss e 1 amp 0 GQ NEY OR HMI RIGHTS y rev owe mv steer zone OR OTHERS BY CONTRACT CYLINDER 55 STEERING D B A PERFORMANCE TEST REQUIREMENTS SSS VIEW A A THE FOLLOWING ARE PERFORMANCE amp DIMENSIONAL CHECKS FOR EACH CYLINDER TO BE SUMMARIZED IN REPORT FORM THE PERFORMANCE TEST SHOULD BE DONE IN THE
6. 7 gt SCREW 1007461 2 COLLAR 1007470 0 RETAINER 1007468 2 SEAL RETAINER 7 gt gt 0227 277777797 1007474 D SPACER 1007462 0 BEARING 1007466 D BEARING 1048 0 RETAINER NUT LOCK 1007489 D WASHER SESS 1005249 2 PLUG 1005912 1 RETAINER 1010876 PACKING 1005430 0 RING D SHIM 5 SHIM 5 1009223 020 gt SHIM AS NOTES 1 APPLY SHIMS TO THRUST BEARINGS ALLOWING FROM 002 INCH TO 005 INCH 1 CLEARANCE IN THE BEARING SET CHECK THE CLEARANCE BY ATTACHING A DIAL INDICATOR TO THE PROPELLER SHAFT THEN PUSH AND PULL ON THE PROPELLER SHAFT COMPARE INDICATOR READINGS DETERMINE THE END CLEARANCE 2 DURING INSTALLATION OF THE SHAFTS INTO THE HOUSINGS APPLY LUBRICANT ON AND BETWEEN LIP SEALS AND ON THE INPUT SHAFT AND THE PROPELLER SHAFT THE GREASE LUBRICANT USED ON THE LIP SEALS AND ELSEWHERE IN THIS SURFACE DRIVE MUST BE A MARINE GRADE LITHIUM GREASE FORMULATED FOR USE IN SALT WATER TWIN DISC RECOMMENDS RED LITHIUM GREASE AVAILABLE FROM ZEP MANUFACTURING CO ATLANTA GEORGIA USA OR AN EQUIVELENT PRODUCT 3 TORQUE VALUES FOR FASTENERS DESCRIPTION 10047 SCREW 20 maes 2260 Nem 1or0402 SCREW 2 LOCK THRUST BRG gt 0 FT LBS MIN 140 N
7. 0 020 11 Round to 0 50 mm Replace the retainer and subtract the shim thickness removed from Retighten the retainer until the distance between the aft end of the retainer and the aft end of the socket is the new If the retainer contacts the ball before is reached stop tightening the ring and go back to step 9 Repeat this step as necessary until there is 3 mm 1 8 in compression on the packing and less than 0 05 mm 0 002 in of gap between the retainer and thrust ball The aft retainer should be very tight at this point Note There is no torque setting specified for the final installation of the aft retaining ring When both the desired aft retainer projection and 0 05 mm 0 002 in or less gap between thrust ball and aft retainer have been reached disconnect the press apparatus Check that the U joint has clearance in all directions by gently angling the thrust tube to the extreme right left up and down positions Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Do not allow the thrust ball to contact against the thrust socket 12 13 14 Rotate prop shaft at every extreme position to check for smooth operation and absence of binding If there is any binding or roughness when spinning the shaft contact your local distributor or the factory for instructions socket is attached to transom reinstall the two mounting bolts removed ea
8. SS 1 POSITION THE ASD UNIT THE APROXIMATE CENTER OF THE VERTICLE AND HOIZONTAL AXIS 2 USING THE GAUGE CHECK THE CLEARANCE 12 00 AND 6 00 O CLOCK POSITION ADJUST THE TRIM SO THE CLEARANCE IS THE SAME ON TOP AND BOTTOM 3 USING THE GAUGE CHECK THE CLEARANCE AT 3 00 AND 9 00 O CLOCK POSITION ADJUST THE STEERING SO THE CLEARANCE IS THE SAME ON EACH SIDE Figure 13 Center the Thrust Ball in the Socket 35 Arneson Surface Drive Service Manual 1022808 Installation Twin Disc Incorporated 5 Transfer the trim bracket hole pattern and drill four 20 mm 0 78 in and two 15 5 0 61 in diameter holes as shown in Figure 14 and drawings 1017597 1 and 2 Mount the trim cylinder bracket with its backing plate and stainless steel 3 4 in diameter bolts nuts and washers Torque nuts to 122 N m 90 ft lbs Apply a generous layer of marine transom sealant under the bracket and in the fastener holes in the transom to prevent water leakage Do not turn the bolts when tightening them Hold the bolts in place and only turn the nuts If this procedure is not followed leaks can develop in the holes NOTE 1 THIS DRAWING IS TO BE USED AS A GUIDE ONLY REFER TO THE INSTRUCTIONS IN THIS MANUAL FOR INSTALLATION OF THE DRIVES AND CYLINDERS 2 BACKING PLATES OF SAME APPROXIMATE DIMENSIONS AS SHOWN FOR EQUIPMENT FOOTPRINT ARE SUPPLIED ADEQUATE CLEARANCE INSIDE VESSEL TRANSOM SHOULD BE PROVIDED 3 DRILL ALL
9. CAUTION SEVERE DAMAGE DRIVE WILL RESULT FROM ALLOWING CONTACT AS SHOWN Figure 3 Protect Ball from Damage 26 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Locate a vertical line s the transom through the intended drive centerline s as follows For twin drive installations it is recommended that drive centerlines be located in line with the engine centerlines For applications requiring offset drive mounting contact Twin Disc Incorporated for recommendations If at all possible drive mounting holes should avoid stringers and other hull fittings that preclude the use of through bolts See Figure 4 Template 1019886E duplicates the cross section of the thrust socket and wedge if applicable and is used to locate the drive centerline for 1 in socket clearance Note When transom angle is other than 6 degrees to the vessel baseline and a wedge is to be used to mount the drive Template 1019886E should be applied to the wedge and not directly to the transom Twin Disc Incorporated may advise distance to be larger DRIVE CENTERLINE LOCATION DUAL ENGINE 2 LOCATE DRIVE VERTICAL 1 LOCATE TRANSOM CENTELINE CENTERLINE FROM TRANSOM VERTICAL TRANSOM Figure 4 Drive Centerline Location Arneson Surface Drive Service Manual 1022808 27 Installation 3 4 A 4 STERN VIEW DUAL A 1 0 IN STRAIGHTEDGE DUAL INSTALLATI
10. TYP 3 PLCS 5 960 015 HOLE CIRCLE R 25 2 PLCS 12 45 CHAM BOTH INSIDE EDGES NOTES 2 ORIENT 1006101 1006090 AND 1006798 1 OF POSITION SHOWN 3 BREAK ALL SHARP EDGES 06 4 REMOVE ALL WELD SLAG AND SHOT PEEN STEEL PLATE 1 ASTM A36 COMMERCIAL QUALITY STEEL PLATE 22 00 23 62 DRILL THRU 3 PLCS AS SHOWN Arneson Surface Drive Service Manual 1022808 150 Twin Disc Incorporated Special Tools T 18050 579 Thrust amp Socket Roller Bearing Driver 1 8 x 45 416 HEAVY KNURL 1 32 x 45 1 8 x 45 P Arneson Surface Drive Service Manual 1022808 151 Special Tools Twin Disc Incorporated T 18050 640 Inner Bearing Cup Driver 4 40 9 00 8 25 HEAVY KNURL 3 50 0 50 lt gt OK XXX T 1 8 0 0 6 4 0 T 18050 640 125 45 4 60 152 Arneson Surface Drive Service Manual 1022808 Special Tools Twin Disc Incorporated PART PART DESCRIPTION REMARKS 1 T 21085 2 1 PLATE 2 21085 4 1 ASSM 3 21085 3 1 PLATE 4 2 GUSSET 7 75 x 6 75 X 375 C R STEEL 15 06 21085 Assembly Stand BOTH SIDES 153 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Sp
11. FINISH UNLESS OTHERWISE NOTED 2 ROUND ALL SHARP EDGES 157 R1 75 BLEND 0 38 4 83 3 08 8 10 REF 1 00 640 4 REF 125 X 45 350 C C C C ITEM1 Se 2 REQ D Was k 3 SIDES TYP 0 63 6 10 125 45 CHAM 8 PLCS 5 5 5 2 3 50 T 21085 4 Assembly Stand Component ITEM 2 Arneson Surface Drive Service Manual 1022808 Special Tools Twin Disc Incorporated T 21172 2 Lifting Fixture STAMP TOOL AND MODEL HERE DRILL AND TAP THRU 5 8 11 UNC DRILL AND TAP 1 3 4 10 UNS 2A DESCRIPTION STOCK SIZE HOIST 02 38 x 3 81 CNTR PULL SWIVEL HOIST RING TECO 23415 158 Arneson Surface Drive Service Manual 1022808 Special Tools Twin Disc Incorporated T 21549 11 Indicator Holder Propeller 060 675 10 1 MYVIN 9290 15 Se NYHL 1680 690 1195 880 040 x ONN 91 8 6 18 0 2160 1 1 71 dL NYHL 127 0 G 159 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Tightener T 21549 12 Drive Special Tools 68 47 earn 345906 vw Arneson Surface Drive
12. Note Do not order parts from the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number on the unit s nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Introduction Source of Service Information For the latest service information on Twin Disc products contact any Twin Disc distributor or service dealer This can be done on the Twin Disc corporate web site found at http www twindisc com Provide your model number serial number and bill of material number to obtain information on your unit If necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com Arneson Surface Drive Service Manual 1022808 15 Introduction Twin Disc Incorporated Rebuilding Service Twin Disc may provide a comple
13. Installing Inner Seal right The garter spring of the forward seal the first to be installed into the block must face forward The garter spring of the aft seal must face aft 110 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 4 Install spacer Figure 65 Installing Spacer 5 Install second lip seal using special tool T 18050 804 Garter spring on the second seal faces aft Figure 66 Installing Outer Seal left Using Seal Driver right Arneson Surface Drive Service Manual 1022808 111 Assembly Twin Disc Incorporated 6 Install the seal cover onto the rear of the thrust tube housing Clean the threaded holes with denatured alcohol Coat the clean capscrew threads with Loctite 242 or similar semi permanent threadlocker and install six 8 32 x 3 8 socket head capscrews Torque the capscrews to 2 26 N m 20 in lbs Figure 67 Install Seal Carrier 7 Spin the propeller shaft by hand to assure smooth operation The shaft should spin smoothly There should be sufficient drag caused by the two lip seals Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Triple Seal Drives after February 1 2007 1 Rotate the thrust tube in the assembly stand with the propeller end end with smaller housing diameter facing up 2 Liberally coat inside and outside of the seals with water resistant lithium grease 9 Install inner lip seal using
14. M2012N NUT LOCK M2013AN D SEE NOTE 3 SEE NOTE 1 BEARING SPACER 1018021 SPACER NOTES 1 APPLY SHIMS TO THRUST BEARINGS ALLOWING FROM 002 INCH 005 INCH 05 13 CLEARANCE IN THE BEARING SET CHECK THE CLEARANCE BY ATTACHING A DIAL INDICATOR DETAIL A MEW OF ALTERNATE INPUT SHAFT BEARING AND ASSOCIATED SPACERS TO THE PROPELLER SHAFT THEN PUSH AND PULL ON THE PROPELLER SHAFT COMPARE INDICATOR READINGS DETERMINE THE END CLEARANCE DURING INSTALLATION OF THE SHAFTS INTO THE HOUSINGS APPLY LUBRICANT ON AND BETWEEN LIP SEALS AND ON THE INPUT SHAFT AND THE PROPELLER SHAFT THE GREASE LUBRICANT USED ON THE LIP SEALS AND ELSEWHERE IN THIS SURFACE DRIVE MUST BE A MARINE GRADE LITHIUM GREASE FORMULATED FOR USE IN SALT WATER TWIN DISC RECOMMENDS RED LITHIUM GREASE AVAILABLE FROM ZEP MANUFACTURING CD ATLANTA GEORGIA USA OR AN EQUIVELENT PRODUCT 6 AT ASSEMBLY COAT PROPELLER AND INPUT SHAFTS AND THE BEARINGS AND SLEEVE 1 0 WHERE THEY ARE IN CONTACT DOW CORNING CORP 37 ASSEMBLY PASTE OR EQUAL PRODUCT APPLY A THIN EVEN COATING OF PASTE ONTO COMPONENT SURFACES RUB THOROUGHLY INTO SURFACES WITH A CLEAN LINT FREE CLOTH LEAVING A COATING DEPTH OF ABOUT 0001 IN 003 mm EXCESSIVE COATING DEPTH WLL RESULT IN SLEEVE AND BEARING DISTORTION AND MAY PREVENT BEARING ASSEMBLY AND REDUCE BEARING LIFE AFTER INSTALLING PROPELLER BEARING RACE AND PR
15. Figure 47 Bolts and Collars holding the U joint to the Input Shaft 3 Stand the input shaft on the bench with the forward end down Remove the seal wear sleeve It may be necessary to use an acetylene or butane torch to quickly heat the sleeve Figure 48 Seal Sleeve 90 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Disassembly 4 Remove roller bearing by using heat or by cutting the bearings off the shaft 4 bearing with heat first break the bearing cage witha chisel on both sides of the rollers Stand shaft vertically with the propeller end up and quickly heat inner races with an acetylene torch until the races drop off Handle the components with care The heated parts are extremely HOT Do not overheat race when removing from shaft Race should not be heated above 121 C 250 F Excessive heat will damage or distort the shaft 4b cut bearings off use a cutoff wheel with a carbide or composition wheel Cut through roller cage Separate the cage and rollers from the inner race Cut groove in inner race until half through the race Split race with chisel and slide off shaft Use extreme caution when cutting the bearing away from the shaft Do not cut or scratch the shaft Damage to the shaft will cause loss of press fit on race bearing or seal surface and will weaken the shaft 5 Clean and Inspect Clean all parts and inspect for damage If the seal sleeve is to be re
16. Propeller Installation Routine Maintenance 1 Apply a thin coat of anti seize lubricating compound to the propeller shaft as shown in Figure 22 The anti seize should not contain graphite or molbdenum disulfide such as Loctite White anti seize 2 Install the propeller thrust washer propeller nut lock nut on the shaft as shown in Figure 22 Torque the propeller nut to 640 710 N m 450 500 ft lbs Torque the jam lock to 500 570 350 400 ft lbs Approach the lower value then continue until a cotter pin slot in the nut aligns with the hole in the shaft Install the cotter pin Note The propeller nut must be re torqued per the following schedule PROPELLER INSTALLATION PROPELLER THRUST TUBE BLUE THIS AREA FOR PROP FIT PROP SHAFT SPACER COTTER JAM LOCK NUT PROPELLER NUT OLD APPLY ANTI SEIZE TO THIS AREA ONLY Figure 22 Propeller Installation 3 The propeller nut and lock nut must be checked for torque retention to the above values after initial use or within 10 hours of operation Arneson Surface Drive Service Manual 1022808 49 Installation Twin Disc Incorporated Propeller Installation New Applications 50 First time installation of new propellers will require a check to verify proper mating of the tapered shoulder on the propeller with the tapered shoulder on the shaft Mismatched tapers may result in a
17. RING 0 1007485 RING D 1007486 0 RING wo tll SCREW COVER 1007469 lt 3 SEAL 1007470 0 RING RETAINING 1007462 1 BEARING 39 RETAINER 1004794 lt 2 X SCREW Ea THRUST 1004963 gt 1007461 2 ema o 1007349 D COLLAR 0 a TUBE THRUST D 1005073 D SHAFT NC W saw sty DETAIL h ZZ pa a iii 277 S 1007467 D UNIVERSAL JOINT 1005098 3 PLUG 1007473 0 RETAINER ML731P SEAL RETAINER SHAFT 7 COMPANION FLANGE SHOWN FOR REFERENCE ONLY DETAIL j aS Ar Z lt lt 1010402 16 SCREW 1007463 lt gt BEARING M2686AJ lt 1 SLEEVE 1007464 0 CUP BEARING 1009209 lt 1 MASESFU lt D CONE BEARING FIN MASSOBA D MDD 1007487 2 RING 107 PROPELLER SPLINE 2 5 PITCH 9 REF PROPELLER HUB 1007150 NOTE 8 1007474 SPACER i D LOCK 2 1005249 2 PLUG WASHER LOCK RETAINER 1010876 2 PACKING CUP BEARING 1005430 RING 0 SHIM REQ D SHIM CAS KAS REQ D SHIM REQ SHIM 5 _REQ D 1009223 020 SHIM CAS
18. between the seals and the aft cover had a pilot that protruded into the thrust tube The shaft sleeve did not protrude past the aft cover See the Double Seal Drives instructions for installation procedures After February 1st 2007 ASD12B1LU drives were shipped with three aft seals one to seal oil in and two to seal oil out The spacer was not used in between the seals and the aft cover changed to a flat plate The shaft sleeve was made longer and protrudes under the aft cover The seals did not change during this conversion See the Triple Seal Drive instructions for installation procedures ASD12B1LU retrofit kit is available to convert double seal drives to triple seal See Aft Seal Conversion Diagram in Engineering Drawings Contact the factory for details Arneson Surface Drive Service Manual 1022808 109 Assembly Twin Disc Incorporated Double Seal Drives before February 1 2007 1 Rotate the thrust tube in the assembly stand with the propeller end end with smaller housing diameter facing up 2 Liberally coat inside and outside of the seals including the spacer with water resistant lithium grease 3 Install lip seal and spacer Seals are installed back to back with a spacer between them using special tool seal driver T 18050 804 Cover the shaft splines to protect the seals as they are pushed into the housing with the driver Garter spring on first seal faces the thrust ball Figure 64 Seal Pack left
19. check to make sure there is no movement in the pivoting joint 9 Using a 1 4 drill bit drill 1 8 into the retainer threads through the setscrew hole This creates a spot for the setscrew to lock the retainer nut CAUTION Do not let the drill bit contact the setscrew hole threads Figure 99 Drill 1 8 into the retainer threads 10 Clean the hole of metal chips and hardened threadlocker thoroughly 11 Reinstall the setscrew using Loctite 242 or similar semi permanent threadlocker Torque setscrew to 8 N m 6 ft lbs Arneson Surface Drive Manual 1022808 143 Hydraulic Cylinder Service Twin Disc Incorporated Disassembly amp Inspection 1 9 Remove the capscrew from the tube near the point where the rod protrudes out of the cylinder Hold the cylinder tube using strap wrench or suitable split blocks Loosen the rod guide using a suitable wrench Thread the rod guide out and slide the entire rod piston assembly from the tube The guide and piston will stay on the rod at this point Remove the setscrew in the side of the piston and using a suitable wrench carefully thread the piston off the rod Remove the guide from the rod Remove all O rings seals and the wiper Using a cleaning solvent clean the tube bore rod guide and piston Inspect the bore of the cylinder tube and the working area of the rod for scratches nicks and other surface defects If necessary use a 400 grit or finer
20. Arneson Surface Drive Service Manual 1022808 164 Twin Disc Incorporated List of Engineering Drawings Engineering Drawings Engineering Drawings The following pages include the engineering drawings that are specific to this model The engineering drawings included are listed below Note Any part numbers listed in the following engineering drawings are for reference only Please refer to your bill of material for part numbers specific to your model 1017817 1022907 1017592 1009236 1007432 1009234 1007340 1006786 1023448 Arneson Surface Drive Service Manual 1022808 ASD 12B1LU Drive Assembly Parts Drawing Double Aft Seal ASD 12B1LU Drive Assembly Parts Drawing Triple Aft Seal ASD 12B1LU Drive Installation Drawing Steering Cylinder Steering Cylinder VRVT electronic position indication Trim Cylinder Trim Cylinder VRVT electronic position indication Tie Bar Assembly Aft Seal Conversion Diagram Double Seal to Triple Seal 165 Engineering Drawings Twin Disc Incorporated 166 Arneson Surface Drive Service Manual 1022808 BEARING SPACER 1018021 SPACER DETAIL VIEW OF ALTERNATE INPUT SHAFT BEARING AND ASSOCIATED SPACERS COMPANION FLANGE SHOWN FOR REFERENCE ONLY 77 5 nrVn n rm r r 2970 1007467 lt 0 UNIVERSAL 1005098 3 PLUG 1007473 D
21. Arneson Surface Drive Service Manual 1022808 17 Description and Specifications Twin Disc Incorporated Construction Features Arrangement Arneson Surface Drives are arranged as two major subassemblies the thrust socket assembly and the thrust tube assembly The thrust socket assembly is fixed to the vessel s transom and the thrust tube pivots on the socket Housings Arneson Surface Drives are comprised of three housings the thrust tube the thrust ball and the thrust socket All three are made of nickel aluminum bronze alloy material Bearings The input engine driven shaft is supported and located by a cylindrical roller bearing on the input end and a ball bearing on the output end The propeller shaft is supported by two tapered roller bearings on the input end and by a cylindrical roller bearing on the output end The bearing clearance on the two tapered roller bearings is controlled by the use of a single shim pack between the thrust ball and the forward bearing cup Shafts Both of the shafts are heat treated stainless steel material U joint Assembly The U joint assembly is a constant velocity universal joint assembly that is spline connected to the input shaft and the propeller shaft It is located and retained to the input shaft to prevent axial float The output spline is sized to slip freely on the propeller shaft allowing relative axial movement at the universal joint output end only W
22. FITTING 1008282 1 1007814 1 cune TING 1006108 1 1005408 2 1006352 2 Mico PISTON 1 1009847 1 PLUG YOKE TRIM w NPT PORTS SPACER RING 2 PLCS SEE CHART 1 1005951 1 ROD THREADED PLUG 2 lt gt Sy lt lt WS lt momo TT BRACKET TRIM 222222222222222 222222 7227272274222222222 2 gt gt ZZZ 2 ey KAA 1008027 2 RING 0 1008012 1 RING CAD FILE 1009234 1 PARTS SCREW SET RETRACTED LENGTH PARTS DRAWNG SHEET 2 MANUFACTURING DRAWING 116 7 THIRD ANGLE PROJECTION 1005494 1 P WIPER 1005521 1 SEAL 1008282 1 Emas tis contans 1 PROPRIETARY INFORMATION IS 012 130185 MACHINED DIMENSIONS 7 28 93 TJIN 58 GUIDE 1008022 E 1 021 Not ro BE USED N ANY WANNER RING IN CORPORATE 2 wow w sss usa 1004792 27570 RACINE 53405 USA pm ASD12 4 1009234 1 24755 12 13 93 11 1 e2 SCREW SET THIS NOTICE IS NOT INTENDED TREATWENT rra GAM 25196 l CYLINDER ASSEMBLY TRIM
23. HOLES PERPEDICULAR TO TRANSOM 625 5 8 16 mm THRU 4 PLACES 781 25 32 20 mm THRU 4 PLACES 3 88 531 17 32 13 5 mm THRU 4 PLACES 1 125 1 1 8 28 5 THRU 2 PLACES 233 8508 1 125 1 1 8 28 5 THRU 7 PLACES ON 15 15 625 5 8 16 mm THRU 2 PLACES 7 80 FOR CLEARANCE DEADRISE SHOWN 0 a 2963 n 8 27 FOR 6 TRANSOM oe al END VIEW DIMENSIONS ARE PARALLEL WITH TRANSOM 6 6 STEERING CYLINDER PIVOT POINT NOTE A RANGE OF STEERING CYLINDER BRACKET POSITIONS IS SHOWN TO OPTIONAL RANGE FOR STEERING ALLOW FOR VARYING DEADRISE ANGLES CYLINDER LOCATION Figure 14 Transom Layout Dual Drive 36 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Steering Cylinder Installation The following installation procedure positions the steering cylinders to allow maximum steering capability without damage to the drive The steering cylinders should reach both travel limits just prior to the ball thrust tube contacting the socket at all trim cylinder positions ils On single drive installations the steering cylinder must be located to offset the effects of the propeller torque If propeller rotation is clockwise as viewed from the rear the cylinder must be located on the starboard side The cylinder must be on the port side for counterclockwise rotati
24. Jonel OR O GAM PERFORMANCE TEST REQUIREMENTS MILWAUKEE CYLINDER SPECIFICATIONS REFER TO FOLLOWING PERFORMANCE amp FUNCTION CHECKS AND SUMMERIZE A REPORT FORM STYLE HYD OIL FOR EACH CYLINDER THE PERFORMANCE TEST SHOULD BE DONE IN THE FOLLING LISTED ORDER BORE 2 1 4 OPER PRESS 20500 P S I A gt CYCLE TEST 1007805 lt 2 STROKE 448 CYCLE CYLINDER WITH 1000 PSI INTERNAL FITTING ROD DIA 1 3 4 HYDRAULIC LOAD FOR 250 CYCLES 1005216 NOTE 1 MILW CYL STD TOLERANCES B BREAKING FORCE FITTING APPLY TO ALL DIMENSIONS RECORD BREAKING FORCE INITATE CYLINDER S P 1607926 TRANSLATION WITH NO EXTERNAL SIDE LOAD PICH TWIN DISC PART NO 1007940 RECORD THIS FORCE AT THE FULLY RETRACTED amp MID STROKE POSITIONS TO ROD END CAP pss ee KA PART OF SERVICE KIT 1007310 HARDWARE PART OF SERVICE 1007311 SEALS NO LEAKS ALLOWED FOR ALL STATIC O RING SEALS AT 2500 PSI OPERATING PRESSURE DYNAMIC SEALS RECORD LEAKAGE PAST THE PISTON SEALS PER TIME PERIOD NO LEAKAGE ALLOWED PAST ROD GUIDE SEAL AT 2500 PSI OPERATING PRESSURE DIMENSIONAL CHECK RECORD EXTENDED amp RETRACTED CYLINDER LENGTHS 1006256 SEE NOTE 4 HOSE 55 SEAL ais SEE NOTE 4 1006087 RING 0 D PIN a 4 HOSE 55 WIPER 1 pe
25. OTHER THAN 6 DEGREES STEERING CYLINDER 4 PLACES BACKING PLATES OF SAME APPROXIMATE DIMENSIONS 5 SHOWN FOR EQUIPMENT FOOTPRINT ARE SUPPLIED ADEQUATE CLEARANCE INSIDE VESSEL TRANSOM SHOULD BE PROVIDED DRILL ALL HOLES PERPENDICULAR TRANSOM ee 917 32 13 51 THRU 4 PLACES 1 1 8 28 5 THRU PLACES 95 84161 THRU 2 PLACES CLEARANCE TOP VIEW SHOWN NUMBER OF TEETH 27 PITCH DIA d 675 827 DIA 58457 lt FOR 6 TRANSOM Cee TOLERANCE 9H END VIEW DIMENSIONS ARE PARALLEL WITH TRANSOM PETWEEN Mae 62376 1009234 TRIM_CYLINDER 11 12 UNF 2A STEERING CYLINDER PIVOT POINT INPUT SHAFT DETAIL SCALE 21 OPTIONAL RANGE FOR STEERING CYLINDER LOCATION 62 52 SIDE VIEW SHOWN 6 TRANSOM REF 002374 1006974 NOTICE THIS PRINT CONTAINS MATERIAL UNLESS OTHERWISE SPECIFIED 1 PROT TD USED IN ANY MANNER mgs 9119 97 SCALE DETRIMENTAL TO THE INTERESTS OF 22000 tai usa Ei 0 005 TWIN DISC INCORPORATED 7 PST USE ALL ANGULAR TOLERANCES DRN RACINE 53403 USA ee ASD 12L GEOMETRIC 1 0 1 7 5 2 THIS NOTICE IS NOT INTENDED E Nystrom 2 20 07 F Nystrom 51 14 5 1982 URFACE TREATMENT NAME E Pe INSTALLATION OTHERS Bv CONTRACT NOTE 1 APPL
26. SPECIFIED MACHINED DIMENSIONS TWIN DISE PROJECTION INCORPORATED DATE 10 18 95 SCALE RACINE 1 53403 USA amea 1007432 APPD SHEET 1 DF 2 REV A ALL ANGULAR TOLERANCES 1 Too ee TREAT FIRST USE ASSY ASD 12 SURFACE TREATMENT ASSM P TT L cH no nare 204 pate TUBE SPACER ROD THREADED PLUG RETRACTED LENGTH STROKE TRIM CYLINDER 1009234 12301E 1 1009799 1006112 1009350 1006068 1007050 2 1009336 14301E 1 1009797 1006111 1009349 1006068 1006077 2 1005559 002270 002 1009799 1006112 1009350 1005587 34 68 1008190 002270 003 1009797 100611 1009349 1005587 40 18 1 APPLY LUBRICANT BETWEEN MATING EXTERNAL SURFACES SUCH AS BALL BRACKET LUBRICANT TO BE MARINE GRADE LITHIUM GREASE WITH PROPERTIES FOR SALT WATER ENVIRONMENT SUCH AS ZEP RED LITHIUM GREASE SOLD BY ZEP MANUFACTURING CO ATLANTA GA USA 30301 1 008076 2 2 TORQUE VALUES P N DESCRIPTION TORQUE VALUES 3 COAT THE MARKED THREADS THREAD LOCKER 242 BLUE SEMI PERMANENT 4 COAT THE MARKED THREADS WITH THREAD LOCKER 270 RED PERMANENT 5 USE PIPE SEALANT ON THREADS OF HYDRAULIC FITTINGS 1006254 1 HOSE 1006351 1 1006257 1 73 SCREW SET HOSE 1007805 2 FITTING 1009932 1 2 2 1006071 1 1005222 1 NUT LOCK
27. Service Manual 1022808 160 Special Tools Twin Disc Incorporated T 18050 804 Seal Driver DETAIL 1 Nxt SK DETAIL 2 s cea 8 z 3 129 2 3 xs 3 134 2 DETAIL 2 LABEL T 18050 804 DET 2 6 00 LABEL T 18050 804 DET 1 3 513 23 508 2 R 06 i 22722727277 63 160 3155 06 0259 23 505 I T 3 500 5 15 DETAIL LABEL 18050 804 DET 3 DETAIL SSS py 27224242627 DLA DETAIL 1 EN SA e 161 Arneson Surface Drive Service Manual 1022808 ve Driver T 18050 805 Wear Slee 908 090801 1 Z ZZZZzZZZZZ sss 22222222 Special Tools Twin Disc Incorporated T 21549 32 Trim Cylinder Seal Protector 163 1 508 1 747 2 1 502 1 627 1 746 2 626 2 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Special Tools T 21549 33 Steering Cylinder Thread and Seal Protector 1 247 lt 1 064 246 8 063
28. Thrust Bearing Shimming Procedure Note Shimming to the correct bearing endplay is extremely important to the proper operation of the Arneson Surface Drive 1 Install the thrust ball onto the thrust tube Align slots in thrust ball with case slots in thrust tube Secure the thrust ball using four of the eight 1 2 13 x 2 12 socket head capscrews evenly spaced Torque the capscrews to 135 N m 100 ft lbs 2 Turn the thrust tube assembly over so that the output end is facing up Install a dial indicator using special tool T 21549 11 onto the prop shaft Figure 61 Lower Ball Secure with Four Capscrews left and Turn Over and Install Dial Indicator T 21549 11 right 106 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 9 Use a hoist and special tool T 21172 2 to lift up on the prop shaft with force of approximately 300 Ibs Rotate the shaft several turns and zero the dial indicator Mark the angular location of the indicator stem on the housing Lower the prop shaft rotate several turns stopping on the mark and read the indicator The clearance must be 0 05 0 13 mm 0 002 0 005 in If the indicated reading is out of tolerance turn the thrust tube over so that the forward end of the tube is facing up Mark the thrust ball to ensure placement of the thrust ball in the same location after placing necessary shims Remove the thrust ball and add the required amount of shims to
29. exceed the recommendation of the driveline manufacturer Most drivelines should not be run in a straight line where the transmission output shaft and surface drive input shaft are perfectly in line The angular offset between the transmission output shaft centerline and the driveline centerline must be within one half degree of the angular offset between the driveline centerline and the surface drive input shaft centerline 2 Both ends of a two piece driveline must be in phase with each other The correct orientation of the yoke arms on each end of the driveline is for them to be parallel to each other Most drivelines contain a slip spline between the two ends and the male and female sides of the slip spline may be capable of assembly at random angular positions It is very important to maintain the two yoke ends parallel when reassembling the driveline after service 3 Examples of proper and improper alignment are shown in Figure 20 Arneson Surface Drive Service Manual 1022808 41 Installation 42 Twin Disc Incorporated A method of alignment is listed here to aid in proper alignment or checking an existing installation for proper alignment The surface drive input shaft centerline will be fixed as it is located and bolted to the vessel s transom The engine and marine transmission must be adjusted so that the output shaft centerline is parallel to the surface drive input shaft centerline and the offset angle is within the
30. input shaft spines or threads upon removal of unit from transom Place Arneson Surface Drive unit on suitable blocks or stands Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Disassembly Disassembly Disassembly Overview The disassembly instructions that follow are separated into major sub assemblies u Disassembly ofthe thrust socket from the thrust tube Thrust tube disassembly Propeller shaft disassembly Thrust socket disassembly oO UD U joint input shaft disassembly Note It is highly recommended to replace all bearings seals and o rings that are accessible when servicing the drive Arneson Surface Drive Service Manual 1022808 75 Disassembly Twin Disc Incorporated Disassembly of Thrust Socket from Thrust Tube If complete ASD unit was removed from the transom Special Tools e Wrench Special Tool 1009229 provided with new surface drives 1 Disassemble socket from thrust tube by first loosening band clamps on boot and push boot back over thrust tube Figure 33 Boot Secured With Three Circle Clamps 76 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Disassembly 2 Using a micrometer depth gauge or other accurate method measure exact distance that face of aft retainer projects from face of thrust socket This will allow for accurate reinstallation when thrust tube is reinstalled Record this measurement for use when reassembling
31. is rough Inspect bearings for corrosion and for indication of wear of balls or rollers Inspect for scored scratched cracked pitted or chipped races Replace the bearing if you find one of these defects Inspect bearing bores and shafts for grooved burred or galled conditions that would indicate the bearing has been turning in its housing or on its shaft If you cannot repair the damage with a 400 grit or finer emery cloth replace the part Arneson Surface Drive Service Manual 1022808 95 Cleaning and Inspection Twin Disc Incorporated 96 Bushings and Sleeves Inspect bushings and sleeves for size and out of roundness Inspect for scores burrs sharp edges and evidence of overheating Remove scores with a 400 grit or finer emery cloth If the bushing or sleeve is out of round deeply scored or excessively worn replace it If there is any question replace Spacers Inspect spacers for distortion scores burrs and wear Rework or replace any defective spacers Splined Parts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with 400 grit or finer emery cloth or a soft stone Replace the part if other defects are found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses Anodes Replace anodes before they are 50 of their original size Inspect anodes both drive and transom mounted to see if they are still secured tig
32. proper limits 1 Fabricate pointer plates that can be mounted to the same transmission output flange adapter that the driveline will connect to and to the surface drive input flange that the driveline will connect to Fabricate inner hollow tubes and outer hollow tubes and weld pointers indicator ends onto inner shafts Drill a hole in same length outer tube and then weld a nut to the tube This will be used as the retention device for the inner tube once the inner tube is slid into the outer tube Weld the tube assemblies to the plates making sure that the tube to plate runout is zero This will allow for adjustment of both shafts to identical lengths Make sure there is a tight fit between the outer tube and inner tube the closer the fit the more accurate the alignment will be See Figures 18 and 19 Arneson Surface Drive Service Manual 1022808 Installation Twin Disc Incorporated Bolt one pointer onto the transmission output shaft flange Bolt the other pointer onto the surface drive input shaft flange These pointers are an extension of the shaft centerlines on which they are mounted If the installation requires that the transmission output shaft centerline is not parallel to the surface drive input shaft centerline adjust both pointers to the same lengths so the pointed end indicator reference end of the inner shafts are in close proximity to each other Once this is completed use a dial indicator making su
33. special tool seal driver T 18050 804 Cover the shaft splines to protect the seals as they are pushed into the housing with the driver Garter spring on first seal faces the thrust ball Figure 68 Installing Inner Seal The garter spring of the forward seal the first to be installed into the block must face forward The garter spring of the two aft seals must face aft Arneson Surface Drive Service Manual 1022808 113 Twin Disc Incorporated 4 Install second and third lip seals one at a time using special tool T 18050 804 Garter spring on second and third seals face aft Figure 69 Installing Outer Seals left Using Seal Driver right 5 Install the seal cover onto the rear the thrust tube housing Clean the threaded holes with denatured alcohol Coat the clean capscrew threads with Loctite 242 or similar semi permanent threadlocker and install six 8 32 x 3 8 socket head capscrews Torque the capscrews to 2 26 N m 20 in lbs Figure 70 Install Seal Carrier 6 Spin the propeller shaft by hand to assure smooth operation The shaft should spin smoothly There should be sufficient drag caused by the two lip seals 114 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Input Shaft and Socket Assembly Freeze the following parts to a temperature of 29 C 20 F e Roller Bearing AWARNING Handle the components with care The frozen parts are extremel
34. the drive Figure 34 Measuring the Gap Between Thrust Ball and Aft Retainer Arneson Surface Drive Service Manual 1022808 77 Disassembly Twin Disc Incorporated Note Place a container under thrust socket to catch normal oil spillage as the unit comes apart 3 Unscrew and remove safety clip around aft retainer Figure 35 Aft Retainer Ring Lock Clip in the Notch Locking Tab 78 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Disassembly 4 Using wrench Special Tool 1009229 unscrew aft retainer counterclockwise If retainer is seized or moves with great difficulty gently and evenly heat the outside of the socket near the aft retainer with a butane or propane torch Do not overheat housings Excessive heat may damage or distort casting Socket housing should not be heated above 121 C 250 F Figure 36 Removing the Aft Retainer using Special Wrench 5 Remove thrust tube from socket with caution taking care that ball comes out of the socket evenly Protect ball and socket with plastic bags to avoid contamination by dirt and dust Do not let ball contact the threaded edges of the socket Severe damage to the ball and socket could result 6 Store thrust tube securely without anything touching the ball Arneson Surface Drive Service Manual 1022808 79 Disassembly Twin Disc Incorporated Disassembly of the Thrust Tube Special Tools Assembly Stand Fixture T 21085 Not requ
35. the nuts If this procedure is not followed leaks can develop in the holes Re attach both the steering and trim cylinders The trim cylinder yoke pin should be re attached first followed by re attaching the steering cylinder clevis pin to the trim yoke Reconnect all hoses Refill the steering and trim cylinders with power steering fluid or Automatic Transmission Fluid ATF Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated List of Special Tools Special Tools Special Tools The following pages include the special tool drawings that are specific to this model The special tool drawings included are listed below and continue on the following page Arneson Surface Drive Service Manual 1022808 1009229 T 18050 579 T 18050 640 T 21085 T 21085 1 T 21085 2 T 21085 3 T 21085 4 T 21172 2 T 21549 11 T 21549 12 T 18050 804 T 18050 805 T 21549 32 T 21549 33 Wrench Thrust amp Socket Roller Bearing Driver Inner Bearing Cup Driver Assembly Stand Assembly Stand Component Assembly Stand Component Assembly Stand Component Assembly Stand Component Lifting Fixture Indicator Holder Propeller Drive Tightener Seal Driver Wear Sleeve Driver Trim Cylinder Seal Protector Steering Cylinder Thread and Seal Protector 149 Twin Disc Incorporated Special Tools 1009229 Wrench R 65 38
36. the top of the front bearing cup to reduce the bearing clearance into tolerance Figure 62 Thrust Ball Location Mark 4 Repeat step 3 until the bearing clearance is in tolerance Note The correct bearing end play is extremely important to the proper operation of the surface drive 5 Remove the thrust ball Arneson Surface Drive Service Manual 1022808 107 Assembly Twin Disc Incorporated 6 Grease O ring with water resistant lithium grease and install in groove located to the outside of the bolt holes on the forward face of the thrust tube housing Clean bolt holes and bolts with denatured alcohol to prepare for thread locking compound 7 Lower thrust ball into thrust tube If re shimming was done align the marks on the thrust ball and thrust tube from the shimming procedure If re shimming was not done align slots in thrust ball pilot with cast slots in thrust tube Coat the bolt threads with Loctite 242 or similar semi permanent threadlocker and install the eight 12 point bolts Torque bolts to 136 N m 100 ft lbs Figure 63 Case Slot left Thrust Ball Slot right 108 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Aft Seal Installation Aft Lip Seal Note There are two different aft sealing arrangements on the ASD12B1LU Before February 1st 2007 ASD12B1LU drives were shipped with two aft seals one to seal oil in and one to seal oil out There was a spacer placed in
37. transom e Press Apparatus T 21549 12 e Wrench 1009229 provided with original package Seal Driver T 18050 804 To assure correct sealing of thrust ball O ring and packing when changing thrust tube assembly the aft threaded retainer must exert the correct pressure on the packing A3 mm 1 8 in press on the packing material ensures adequate pressure When correctly installed there should be less than a 0 05 mm 0 002 in clearance between thrust ball and the aft retainer Check this dimension with a standard feeler gauge tool When placing aft retainer into thrust socket assembly a shim pack may be required Support thrust tube with block and tackle forklift or other system capable of carrying its weight This will assist ina smooth insertion and avoid damage to unit Do not let ball contact the threaded edges of the socket Severe damage to the ball and socket could result 1 Coat entire spherical surface of thrust ball with water resistant lithium grease Arneson Surface Drive Service Manual 1022808 123 Assembly 124 Twin Disc Incorporated If the socket is attached to the transom 2a Place approximately 4 mm 0 15 in shims in socket on top of packing Coat U joint yoke splines with lubricating oil to assist in installation of yoke onto propeller shaft Insert thrust tube into socket with caution taking care that the ball enters socket evenly and firmly U joint is engaging smoothly and that the packi
38. u 46 Propeller Installation Routine Maintenancoes 49 Propeller Installation New Applications 50 Corrosio Prolteellpoh u u IU UI sassa ass 52 Anti fouling Protection 53 Periodic Visual Inspection 54 Operation J J 55 General S S u u a a aaa 55 Prior 55 Surface Drive Operation 56 Arneson Surface Drive Service Manual 1022808 7 Table of Contents Twin Disc Incorporated Preventative Maintenance 57 General 57 Overhaul Interval 59 Periodic Visual Inspection 60 Propeller Torque 62 Troubleshooting 63 Troubles
39. used examine it for scratches on the seal mating surfaces and clean the area with a 400 grit or finer emery cloth Inspect the yoke splines for burrs and remove if present See Cleaning and Inspection Use extreme caution when removing rough edges or burrs from critical shaft surfaces Removing excess material will cause the loss of press on races bearings or seal surfaces Arneson Surface Drive Service Manual 1022808 91 Disassembly Twin Disc Incorporated NOTES 92 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Cleaning and Inspection Cleaning and Inspection Cleaning Note Replace all oil seals gaskets O rings packing retaining snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents or by steam cleaning Parts must he dried and oiled immediately Bearings should not be exposed to moisture Examine all parts carefully for grit dirt and abrasives and reclean them if necessary Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent to flush oil pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher scre
40. with just heat insert a long drift or rod into the forward end of tube through to rear Tap rod evenly around bearing circumference with mallet or hammer until bearing is free Discard this bearing inserted into forward end of tube Figure 40 Inserting drift into thrust tube to remove aft bearing 13 Rotate thrust tube so the aft end is facing up Remove bearing cup from forward end of thrust tube by heating housing around cup with a butane or propane torch and inserting a long drift or rod from rear of tube Tap rod evenly around cup with a mallet until cup is free Discard cup 14 At this point thrust tube should be flushed out using clean solvent to remove dirt or other materials trapped inside All components such as shafts retainer rings etc should also be cleaned at this point prior to reassembly as described in Cleaning and Inspection Arneson Surface Drive Service Manual 1022808 83 Disassembly Twin Disc Incorporated Disassembly of the Propeller Shaft 1 On the forward end of the propeller shaft remove threaded lock that holds tapered bearing in place by tapping lightly with hammer and drift tool Lock nut is retained by lock washer with fold over tab Tab must be bent away from lock nut to spin freely off shaft Threaded lock nut spins counterclockwise for removal Remove lock washer and spacer Discard lock washer Figure 41 Bending Fold Over Tab to Remove Lock Nut 2 Remo
41. 8 23 Installation Twin Disc Incorporated Mounting Hardware All mounting hardware used other than that supplied by Twin Disc Incorporated must be of stainless steel and must meet Twin Disc Incorporated standards Flat washers must be used under all nuts and bolt heads Thread lubricant must be used with all mounting hardware to prevent galling and or seizing All bolt holes through fiberglass material should be cleaned to prevent seizing by glass fiber residue All through hull fittings and bolts gaskets and mating flanges must be installed using recommended amounts of marine transom sealant Brand 5200 marine sealant or equivalent is recommended Follow manufacturer s instructions with regard to surface cleaning and preparation Note Twin Disc Incorporated recommends that accepted standard installation and construction practices for marine components be followed throughout The American Boat and Yacht Council publication Safety Standards for Small Craft provides useful general guidelines This publication may be obtained from The American Boat and Yacht Council 613 Third Street Suite 10 Annapolis MD 21403 USA www abycinc org 24 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Thrust Unit Installation In order to maximize drive efficiency the lower 50 of the propeller should be immersed in the water when running at planing speeds Because the flow pattern from a plan
42. 808 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting Chart The following chart is intended as a guide for determining the cause of problems that could be encountered and the corrective actions for those difficulties The surface drive is one part of a complete power package Problems in the input power system engine or the output power delivery components transmission and driveline can cause problems that may be erroneously interpreted as being surface drive related It is important that the entire power package and control systems be considered when problems are encountered The Troubleshooting Chart is shown on the following page Arneson Surface Drive Service Manual 1022808 63 Troubleshooting Propeller does not turn Trim steering function failure Excessive drive noise or vibration Water in drive oil The oil looks milky and brown Anodes are significantly corroded after a short period of time in the water Anodes are not corroding or corroding extremely slowly Twin Disc Incorporated Table 3 Troubleshooting Chart Probable Cause Transmission malfunction Broken transmission coupling Broken drive coupling Broken internal U joint Low hydraulic oil Pump belt broken Leak in hydraulic line Leak in cylinder Trim control switch failure Trim control solenoid failure Hydraulic pump failure Steering helm malfunction Misaligned inboard driveline Propeller d
43. Cylinder Service Twin Disc Incorporated Trim Cylinder Service Removal l Make sure the battery cables are still disconnected and the key is notin the ignition 2 If needed support the drive with block and tackle forklift or other system capable of carrying the weight of the surface drive Do not allow the thrust tube to angle down to the point where the ball thrust tube assembly makes contact against the thrust socket 3 Remove trim cylinder yoke pin to disconnect the cylinder from the drive Protective Cover Figure 98 Trim Cylinder 4 Disconnect and plug both hoses at the cylinder Manually cycle the cylinder to remove the oil in it Use a container to catch the oil 5 Check the amount of play in transom mounting bracket If there is any play indicating that the ball joint is loose in the bracket the bracket must be serviced by following the directions below If there is no play in the ball joint skip to the next section Disassembly amp Inspection 6 While supporting the cylinder remove the four 4 transom bracket mounting bolts nuts and washers 142 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Hydraulic Cylinder Service 7 Remove the trim cylinder from the vessel 8 Remove the transom bracket setscrew closest to the hose fittings and tighten the large retaining nut inside the bracket to 75N m 55 ft Ibs Use a 1 2 hex bit socket to tighten the nut After tightening
44. Drive Service Manual 1022808 Twin Disc Incorporated Hydraulic Cylinder Service 5 Insert the setscrew to lock the piston on the piston rod Coat the threads with Loctite 242 or similar semi permanent threadlocker Tighten setscrew to 8 N m 6 ft lbs Figure 105 Tighten the setscrew 6 Insert the piston rod assembly back into the tube being careful not to damage the piston O rings or the tube threads Figure 106 Insert the piston rod assembly into the tube Arneson Surface Drive Manual 1022808 147 Hydraulic Cylinder Service Twin Disc Incorporated 148 Tighten the guide until the guide is tight against the tube and the socket head capscrew holes on the guide and on the tube are in alignment Strap Wrench Figure 107 Tighten the guide 8 Remove any threadlocker compound still present in the hole from previous capscrew installation Replace the socket head capscrew using Loctite 242 or similar semi permanent threadlocker Tighten to 8 N m 6 ft Ibs If the cylinder was removed from the transom mount the trim cylinder bracket with its backing plate and stainless steel 3 4 inch diameter bolts nuts and washers Torque nuts to 122 N m 90 ft lbs Use thread lubricating compound to prevent seizing Apply a generous layer of marine transom sealant under the bracket and in the fastener holes to prevent water leakage Do not turn the bolts when tightening them Hold the bolts in place and only turn
45. EAL CONVERSION rNystrow Z 1 of 1 FY B 1022808 08 07 TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
46. ER NUT lt 5 VRVT SHIELDED 1004803 lt 2 2 12777774 6 57 ASS CANA Sot 7460 355552 2 4 Z lt S 1007444 bD PISTON SPRING 1 SEE NOTE 4 RING RETAINER 1 RING RETAINER 1 SEE NOTE 3 RING 0 1 1006652 1 TRANSDUCER SEE NOTE 4 SCREW lt TO ELECTRONIC MODULE ELECTRONIC MODULE SPECIFICTIONS SUPPLIER PENNY amp GILES CONTROLS 163 PLEASANT STREET ATTLEBORO MA TRANSDUCER MODEL_VRVT100 1 5 320 1 15 POTTED SHIELDED CABLE INPUT SUPPLY VOLTAGE 22 to 26Vdc OUTPUT OUTPUT VOLTAGE Vo 5Vdc POLARITY ZERO ADJUST 100 TEMPERATURE RANGE 30 C TO 80 C MODULE HOUSING ALUMINUM ALLOY ELASTOMER ISOLATORS FOR VIBRATION CONTROL EH 027 2 7 4 L 7 P 72227471 rd A OE EOL 4 69 HOSE_ASSEMBLY RING WEAR SEAL 2 BOLT WASHER CLEVIS 1006436 2 WASHER 1005225 FITTING 1 4 PORT 2 PORTS AS SHOWN 1 1 8 ACROSS FLATS gt Ww Sem KUN gt SEE NOTE 3 RING WEAR 1 RING 2 SCREW D SEAL 1 WIPER 1 1007301 GUIDE 3 5 0 0 1004996 WASHER 1006509 lt 1 NUT VENDOR MILWAUKEE CYLINDER CUDAHY WI REF D 13680 THIRD ANGLE UNLESS OTHERWISE
47. FOLLOWING LISTED ORDER A CYCLE TES SEE NOTE 4 PLUG 1 HOSE ARRANGEMENT 1007432 CYCLE CYLINDER AGAINST 1000 PSI INTERNAL HYDRAULIC LOAD FOR 250 CYCLES gt BREAKAWAY FORCE RECORD BREAK FORCE TO INITATE CYLINDER TRANSLATION WITH NO EXTERNAL SIDE LOAD RECORD THIS FORCE AT THE FULLY RETRACTED amp MID STROKE POSITIONS LEAK TEST 1 STATIC SEALS VISUAL NO LEAKS ALLOWED FOR ALL STATIC O RING SEALS AT 2500 PSI OPERATING PRESSURE 2 DYNAMIC SEALS RECORD LEAKAGE PAST THE PISTON SEALS PER TIME PERIOD NO LEAKAGE ALLOWED PAST ROD GUIDE SEAL AT 2500 PSI OPERATING PRESSURE PENNY 2 4 7 SEE NDTE 4 IRE WRAPPING SEE NDTE 4 FITTING lt D SEE NDTE 4 CLAMP 1 D gt RECORD EXTENDED amp RETRACTED CYLINDER LENGTHS 1004775 MILWAUKEE CYLINDER SPECIFICATIONS NONE STD HYD OIL 2500 P S I MODEL D 13680 MOUNTING STYLE_____ H 62 S BORE 2 1 2 STROKE 12 1 2 ROD DIA 11 4 CUSHIONS OPER MEDIA OPER PRESS 1007432S amp GILES VRVT SHIELDED CABLE NOTE 1 MILW CYL STD TOLERANCES APPLY TO ALL DIMENSIONS ETCH TWIN DISC PART No 1007432 amp MCC S N TO BLIND END CAP PART OF 1007304 SERVICE KIT SEALS PART OF 1007305 SERVICE KIT HARDWARE TUBE 1 316 5 5 WITH XYLAN COATING ON THREADS 2 HOSE ASSEMBLY 1006680 8 1 1004779 HOSE ASSEMBLY 1005216 FITTING 9 1007812 FITTING FITTING WASH
48. IOR 1018018 BEARING 1018021 1 SPACER 1018019 D SPACER TO INSTALLING SLEEVE 1007458A CLEAN EXCESS 37 3 TORQUE VALUES FOR FASTENERS PASTE FROM PROPELLER SHAFT DESCRIPTION 1004785 SCREW COVER 20 IN LBS_ 2260 1010402 SCREW FN 257148 35 DO HOT a TORQUE NUT LOCK THRUST BRG 100 FT LBS MIN 140 N m MIN 9 SEE DISC SERVICE MANUAL 1020481 FOR 450 500_FT LBS PROPELLER AND NUT TORQUEING SCHEDULE 7 SCREW U JOINT gt 10 PLEASE TWN DISC SERVICE MANUAL FORALL OTHER PROCEDURES AND SPECIFICATIONS SCREWS M1731P MUST REUSED AFTER REMOVAL ALTERNATELY TORQUE NEW SCREWS 45 185 65 TORQUE LOCKNUT 1006069 TO 350 400 FT LBS 500 570 APPROACH LOWER VALUE IF SLOT DOES NOT ALIGN WITH HOLE IN DETAIL VIEW OF ALTERNATE PROPELLER BEARING AND ASSOCIATED SPACERS FEATURES STAINLESS STEEL PROPELLER AND INPUT SHAFTS BRONZE HOUSINGS TRIPLE PROPELLER SHAFT SEALS 4 RECOMMENDED LUBRICATING OIL API SERVICE CATEGORY CF OR HIGHER SAE 30 W THROUGH SAE 90W OIL FILL DRIVE UNTIL EXTERNAL RESERVOIR 15 ONE THIRD FULL APPROXIMATE CAPACITY 20 22 QUARTS 19 19 3 4 LITERS SUPPORTING DOCUMENTATION INSTALLATION DRAWING 1017592 INSTALLATION MANUAL 1020480 SERVICE MANUAL 1020481 MASS ELASTIC SYSTEM DWG B3504AL BI
49. LL OF MATERIAL BOM 1022906 LOCTITE INSTRUCTIONS USE ALL APPLICABLE SOLVENTS PRIMERS AND ACTIVATORS 5 COAT THE MARKED THREADS WTH LOCTITE THREAD LOCKING COMPOUND 242 BLUE 5A COAT THE MARKED THREADS WITH LOCTITE THREAD LOCKING COMPOUND NO 270 RED PERMANENT 5B COAT PIPE THREADS WTH LOCTITE NO 545 PURPLE ANGLE maar 1004856 MATERIAL VEIGHT UNLESS OTHERWISE SPECIFIED DATE 600 Las MACHINED DIMENSIONS DIS 1 273 20030 HEAT TREAT FIRST USE 0 005 RACINE 83403 ASD 12L SURFACE TREATMENT 1 2 2 9 PORIVE ASSEMBLY NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE 53403 USA THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT Turk PER ANSI 145 1982 NOTES 1 THIS DRAWING IS BE USED AS GUIDE ONLY 05 8 16 THRU PLEASE REFER TO THE TWIN DISC INSTALLATION 4 PLACES y MANUAL FOR INSTALLING THE DRIVE AND CYLINDERS TRANSOM ANGLE FOR ASD UNITS 6 DEGREES TO VERTICAL PLUS OR MINUS 1 DEGREE AS SHOWN IN THE SIDE VIEW MOUNTING WEDGE IS REQUIRED 1009536 25732 C20 THRU FOR TRANSOM ANGLES
50. NT LOCKING BOLTS ADJUSTABLE SHAFTS ON BOTH SIDES LENGTHS MUST BE SET EQUAL RUNOUT IN THIS AREA IS NO GREATER THAN 1 59MM 0625 INCH BOTH SIDES PRIOR TO ALIGNMENT ROTATE BOTH SHAFTS TO VERIFY WITHIN SPECIFICATION ARNESON INPUT SHAFT DRIVELINE FLANGE Figure 19 Remote or Island Mounted Alignment Tool Shafts Parallel Arneson Surface Drive Service Manual 1022808 Installation Twin Disc Incorporated SSNV1d 1371192194 NO Ld3VHS 1 NOS3NAY OL LAVHS LNdLAD NOISSIWSNVSL LON 349 149 5 LNdNI SNVAL SHL 5 Id 1411 54 OL 149 58 LAdLAO NOISSIWSNYNL LON 3 y NdLNO NOISSIWSNVaL JHL HS LN N3 LN 0150 9 31 23184 914 L NI NOSANS8 3 1 NOSSNaV NV 1934405 LSAW 149 5 1 583 1 9 3495 JHL 35 38 IWSNVaL LAVYHS 0 1 4 5 149 5 15 LAVHS 5 10 9 31 31 14 9 NOS3 1238500 84350 1 5 1954 9 31 31 9184 Y 714 53 849 ANY 149 5 NOISSIWSNVaL S3NV d 1411 4 9 15 8 3015 01
51. ON Twin Disc Incorporated Use Template 1019886E to locate and mark drive centerline s as shown in Figure 5 For single drive installations position centerline of Template 1019886E on transom centerline Locate Point C on transom using template 1017597 page 1 Mark centers for mount holes 7 and lubrication holes 2 For twin drive installations locate and match Point C on transom using template 1019886E Rotate template until cutaway area on the thrust socket flange is parallel to the hull deadrise as shown in Figure 5 Locate and mark centers for mount bolts 7 and lubrication holes 2 SIDE VIEW TRANSOM TRANSOM TEMPLATE TEMPLATE 1019886E 1019886E nF r STRAIGHTEDGE HULL BOTTOM HULL BOTTOM DUAL Figure 5 Mark Hull using Template 1019886E 28 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation 5 Drill a pilot hole through the intended drive centerline Point This pilot hole will be used for locating the actual drive through hole and should be sized for the hole saw to be used in Step D The hole should be drilled at an angle to the transom that will make it parallel to the socket centerline Template 1019886E can be used to orient the drill as shown in Figure 6 TRANSOM TEMPLATE 1019886E HULL BOTTOM DRILL BIT MUST BE PERPENDICULAR TO TRANSOM OR TO THE WEDGE IF USED Figure 6 Drill Holes Arneso
52. P 37 ASSEMBLY PASTE OR EQUAL PRODUCT APPLY A THIN EVEN COATING OF PASTE ONTO COMPONENT SURFACES RUB THOROUGHLY INTO SURFACES WITH A CLEAN LINT FREE CLOTH LEAVING A COATING DEPTH OF ABOUT 0001 IN 003 mm EXCESSIVE COATING DEPTH WLL RESULT IN SLEEVE AND BEARING DISTORTION AND MAY PREVENT BEARING ASSEMBLY AND REDUCE BEARING LIFE AFTER INSTALLING PROPELLER BEARING RACE AND PRIOR TO INSTALLING SLEEVE 1007458A CLEAN EXCESS 37 PASTE FROM PROPELLER SHAFT SCREWS M1731P MUST BE REUSED AFTER REMOVAL ALTERNATELY TORQUE NEW SCREWS 45 1 5 65 TORQUE LOCKNUT 1006069 TO 350 400 FT LBS 500 570 APPROACH LOWER VALUE IF SLOT DOES NOT ALIGN WITH HOLE IN SHAFT INCREASE TORQUE UNTIL THE HOLE ALIGNS 00 EXCEED MAXIMUM TORQUE 9 SEE TWIN DISC SERVICE MANUAL NO 1020481 FOR PROPELLER AND NUT TORQUEING SCHEDULE 10 PLEASE SEE TWIN DISC SERVICE MANUAL FOR ALL OTHER PROCEDURES AND SPECIFICATIONS 1 NOTICE THIS PRINT CONTAINS 1007486 1 1005152 RING 0 PIN COTTER 1006069 D SCREW NUT COVER NUT an SPACER 1007470 0 1007484 0 RING RETAINING RING O 1007462 1007485 D BEARING RING D 1007349 gt TUBE THRUST 1005073 gt 5 DETAIL 2 ZX RS OSs 1007487 RING D SLEEVE 1007474 lt 0 SPACER 1009209 lt 0 FIN SEE NOTE 3 SE
53. Paint and Coating every six months Clean any blemishes or corrosion and coat with antifouling paint Do not apply paint or other coatings to sacrificial anodes Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Preventative Maintenance Table 2 Maintenance Checklist Location and Action Beginning After first First 500 hours of 2000 hours operation but not to exceed a 12 reservoir fluid level Check visually Hydraulic oil filter Replacement Propeller Check for damage Propeller nut Torque See Propeller Torque Schedule on next page check Socket trim cylinder steering cylinder Check transom fasteners Hydraulic system Perform manual and indicated b ana SiS Hydraulic and drive system oil Check for leakage oben ff lock to lock ring Check that it is tight Arneson Surface Drive Service Manual 1022808 61 Preventative Maintenance Twin Disc Incorporated Propeller Torque Maintenance 62 Note The propeller nut should be re torqued according to the following schedule Torque the propeller nut to 640 710 Nm 450 500 ft lbs Torque the jam lock nut to 500 570 Nm 350 400 ft lbs Approach the lower value then continue until a cotter pin slot in the nut aligns with the hole in the shaft Install the cotter pin 1 The propeller nut and lock nut must be checked for torque retention to the above values after initial use or
54. RVICE ONLY OBSOLETE FOR PRODUCTION SUPERCEDED BY ASSEMBLY 1022907 BOM 1022906 REFER TO KIT 1023571 FOR SEAL CONVERSION FEATURES STAINLESS STEEL PROPELLER AND INPUT SHAFTS BRONZE HOUSINGS SUPPORTING DOCUMENTATION INSTALLATION DRAWING 1017592 INSTALLATION MANUAL 1020480 SERVICE MANUAL 1020481 MASS ELASTIC SYSTEM DWG B3504AL BILL OF MATERIAL BOM 1017817 PROPELLER SPLINE 2 5 PITCH REF PROPELLER HUB 1007150 NOTE 8 1018018 BEARING 1018021 0 SPACER 1018019 O SPACER DETAIL B VIEW ALTERNATE PROPELLER BEARING AND ASSOCIATED SPACERS ANGLE PROPRIETARY INFORMATION AND IS 3 27 07 Not T USED IN MANNER 29 04 DETRIMENTAL TO THE INTERESTS OF CS TWIN DISC INCORPORATED O j kEcvn253 2 19 03 RACINE 53405 USA 28702 7 31 98 THIS NOTICE 15 NOT INTENDED OI GRANTED TD THE US GOVERNMENT OR OTHERS BY CONTRACT MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED SS 275 20010 HEAT TREAT FIRST USE 0 005 assy ALL ANGULAR TOLERANCES 21 SURFACE TREATMENT ASSEMBLY HK FN Pio e 97 TOON DISC INCORPORATED RACINE WI 53403 USA 1017817 ere 77 5 m I na Ds o alas a70 PT 1005152 1 PIN COTTER 1006069 1 NUT 1010401 GD NUT 1007457 0 SPACER 1007484 1
55. T EXCEED 5 PSI VACUUM INTO ASD AND RESERVOIR DURING OIL DRAINING L CAN BE FILLED TO BOTH THE ASD UNIT AND RESERVOIR BY PUMPING OIL IN REVERSE ORDER F DRAINING PROCEDURE DO EXCEED 5 PSI INTO ASD AND RESERVOIR DURING OIL FILLING OTHER INSTALL OIL LINES IN SUCH A WAY AS NOT TO TRAP AIR OIL LEVEL IN RESERVOIR SHOULD BE MAINTAINED TO ABOUT ONE THIRD FULL TO ALLOW FOR EXPANSION OF OIL WHILE OPERATING VESSEL 1 2 1 0 HOSE AND FITTINGS SUPPLIED BY TWIN DISC INC WITH RESERVIOR INSTALLER TO CUT HOSES TO LENGTH AND ASSEMBLE WITH FITTINGS Figure 21 Lubrication System 46 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation To Fill the Unit See the Drive Lubrication Features section for a listing of proper oils to be used for filling the drive and reservoir 1 Trim the drive all the way down by extending the trim cylinder 2 If the vessel is out of the water A Remove the plug on the top of the socket and the plug at the forward end on top of the thrust tube B Fill the drive as much as possible through the open thrust tube plug hole Plug that hole C Continue filling as much as possible through the open socket plug hole Plug that hole D Finish filling the drive through the top of the reservoir until the reservoir is one third full Replace all fill plugs and check fittings Check this level after 24 hours and after the first vessel
56. TWIN DISC INCORPORATED Service Manual Arneson Surface Drive Model ASD12B1LU Document Number 1022808 Twin Disc Incorporated makes no warranty or guaranty of any kind expressed implied or otherwise with regard to the information contained within this manual Twin Disc Incorporated has developed this manual through research and testing of the information contained therein Twin Disc Incorporated assumes no responsibility for any errors that may appear in this manual and shall not be liable under any circumstances for incidental consequential or punitive damages in connection with or arising out of the use of this manual The information contained within this manual is subject to change without notice Document Number 1022808 August 2007 Arneson Surface Drive Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE TRANSMISSION SURFACE DRIVE and ELECTRONIC CONTROL SYSTEMS A Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of shipment by Twin Disc Incorporated to original customer but not to exceed twelve 12 month
57. Twin Disc Incorporated 9 Slide spacer on forward end of shaft positioning it against the bearing Figure 51 Spacer positioning 4 Slide lock washer and threaded lock nut onto the shaft Tighten threaded lock nut with a hook spanner wrench Torque lock nut to 136 N m 100 ft lbs Ensure the bearings are firmly seated against shaft shoulder Figure 52 Thread Lock Nut 5 Secure lock nut by bending a locking tab into a slot the nut Figure 53 Securing Lock Nut by Bending Locking Tab 100 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 6 Slide the heated bearing race followed by the seal sleeve onto the aft end of the shaft long spline end using special tool T 18050 805 Handle the components with care The heated parts are extremely HOT Figure 54 Sliding the Heated Bearing Race on the Shaft 7 Set this assembly aside Place plastic bags over bearings and similarly protect rear race and splines Do not allow dust or debris to settle on bearings or components Arneson Surface Drive Service Manual 1022808 101 Assembly Twin Disc Incorporated Thrust Tube Assembly Special Tools e Assembly Stand T 21085 1 2 20 UNF Eyebolt e Thrust Tube amp Socket Roller Bearing Driver 18050 579 Inner Bearing Cup Driver 18050 640 Seal Driver 18050 804 e Wear Sleeve Driver T 18050 805 e Shaft Endplay Indicator Holder T 21549 11 e Lifting Fixture T 21172 2 e Six M
58. URE RANGE 30 C TO 80 C jf 1007313 LBs IN DISE LU 4 TREAT FIRST USE RACINE MT 83802 TUSA MODULE HOUSING CAST ALUMINUM ALLOY _ ELASTOMER ISOLATORS FOR VIBRATION CONTROL GEDMETRIC TOLERANCING 10 0 7 3 4 0 L TWIN DISC INCORPORATED SURFACE TREATMENT NAME eee CYLINDER D C B A STEERING INBOARD STEERING TIE BAR 455 TUBE ASSY DRIVE CENTER DIM DRIVE CENTER DIM NOTES INCHES INCHES INCHES INCHES EQUAL THREADED ROD LENGTH 37 40 41 44 245 275 40 43 44 47 275 305 43 46 47 50 305 335 46 49 50 53 335 365 45 52 53 56 365 395 52 55 56 59 395 485 55 58 59 62 425 455 61 64 65 68 485 515 64 67 68 71 67 70 71 74 70 73 74 77 73 76 77 60 76 79 80 83 79 82 83 86 51 5 54 5 54 5 57 5 57 5 60 5 60 5 63 5 63 5 66 5 66 5 69 5 1006793 1006781 58 61 46 12 49 12 62 65 45 5 48 5 Ar 1006089 CLEVIS ROD 1006075 10786 2 TUBE 455 1078 lt MA801H SCREW SET SCREW MA1081P 2 REF 1 12 2 62 WASHER Q lt B TH SIDES M2026AD OUTBOARD STEERING NUT 2050 COTTER PIN REF 80 2 30 BOTH SIDES OUTBOARD STEERING 4229753 TWIN DISC VEIG T USE FULL INC TED a i s m m
59. WASHERS EE ed RETAINER lt Bod N c 555 BETWEEN CLEVIS Z AND CYLINDER YOKE NUT TORQUE TO SCREW COTTER PIN 57 Nm 40 68 NOTE 1 APPLY A THIN COAT OF LUBRICANT BETWEEN MATING SURFACES OF CLEVIS BOLT CLEVIS AND TRIM CYLINDER YOKE LUBRICANT TYPE TO BE A MARINE GRADE LITHIUM GREASE WITH PROPERTIES FOR SALT WATER ENVIRONMENT SUCH AS ZEP RED LITHIUM GREASE UNLESS OTHERWISE STATED DO NOT LUBRICATE COMPONENT THREADS Figure 16 Steering Cylinder tie bar is required for twin drive installations on mono hull vessels When ordering the tie bar specify drive centerline to centerline Arneson Surface Drive Service Manual 1022808 39 Installation Twin Disc Incorporated hardware provided Comply with all requirements and torque values shown in Figure 17 Adjust the length of the tie bar as required to make the drive thrust housings parallel Torque tie bar jam nuts 8 Once the trim cylinders steering cylinders and tie bar are installed cycle the units in all directions to check all the clearances at the thrust ball cylinder transom mounting brackets steering cylinder clevis and tie bar clevis to assure no contact is made between the pivoting and stationary components Critical positions to check are when the drives are steered fully to port and fully to starboard with the drives trimmed both fully up and fully down four total check positions 9 Slip the thrust ball boot back over th
60. Y LUBRICANT BETWEEN MATING EXTERNAL SURFACES SUCH AS BALL BRACKET AND PIVOT CLEMIS STEERING CYL ROD TUBE PISTON HOSE LENGTH LUBRICANT TO MARINE GRADE LITHIUM P N P N P N P N GREASE WITH PROPERTIES FOR SALT WATER ENVIRONMENT 1009236 12302E 1009247 1009866 1005823 1006263 28 34 SUCH AS ZEP RED LITHIUM GREASE 1009237 12302 2 1009246 1006127 1005823 1006263 30 47 2 TORQUE VALUES 1009343 14302E 1005946 1009863 1005947 1004779 36 27 1007392 1007393 1009866 1005823 1006263 27 95 DESCRIPTION TORQUE VALUES 1018057 1018062 1009866 1005823 1006263 27 55 1006051 RETAINER e 55 1018059 1018063 1009863 1005947 1004779 35 48 12 4 1005830 150 FT LB M2060Q 75 FT LB MA1084C SCREW 6 M2026AD 40 FT LB 3 COAT THE MARKED THREADS WITH THREAD LOCKER 242 T42 BLUE SEMI PERMANENT 4 COAT THE MARKED THREADS WITH THREAD LOCKER SEE CHART 1 T70 RED PERMANENT HOSE 1006260 1 5 USE PIPE SEALANT ON THREADS OF HYDRAULIC HOSE 1 FITTINGS OPPOSITE SIDE OF PI SCREW FITTING SCREW 70078720 1005611 1 1006126 1 100781 SEE CHART 1 GUIDE CLEVIS 1008069 1 1006075 1 1078 1 PISTON 1007811 2 SEAL PIVOT FITTING SCREW A2916FF 1 1005492 1 MA8OIH 1 1008994 1 1005830 1 RING 0 4 18 NPT PORTS WIPER SCREW BRACKET BALL RING 0 M20699 2 PLCS SEE CHART 1 1006073 1 CAP 0 A2916FF 1
61. aded rods should pass through the 1 inch holes on either side of the center hole of the plate Secure the plate with nuts Go to Step 5 If the socket has been removed from the transom 2b 3b Ab Position the socket in socket bench with larger diameter end facing up Coat U joint yoke splines with lubricating oil to assist in installation of yoke onto propeller shaft Place approximately 4mm 0 15 in shims in socket on top of packing Lift thrust tube and position above thrust socket Slowly lower thrust tube into socket Inspect aft retainer for any nicks scratches or burrs Smooth with 400 grit or finer emery cloth and clean thoroughly with alcohol or cleaning solvent Coat threads of aft retainer with anti seize that does not contain graphite or molbdenum disulfide such as Loctite White Anti Seize Slip ring over thrust tube and position around thrust ball Place the unit horizontally in the assembly stand Position the socket so the flat end of its mounting flange is facing the same direction as the fin mount on the thrust tube Install the threaded rods of press apparatus special tool T 21549 12 through the mounting plate bolt holes in the o clock and 9 o clock positions Attach nuts on the forward end of the threaded rods Pass the threaded rods through the 1 inch bolt holes in the press apparatus plate Attach nuts to the aft end of the threaded rod Go to Step 5 Arneson Surface Drive Se
62. allow housing temperature to exceed 121 C 250 F 4 Clean and inspect shaft for damage on critical dimension surfaces as directed in Cleaning and Inspection Arneson Surface Drive Service Manual 1022808 85 Disassembly Twin Disc Incorporated Disassembly of the Thrust Socket Special Tools Two eyebolts with 1 inch threaded shank Socket Bench This should be an assembly bench capable of supporting a minimum of 454 Kg 1000 Ibs The bench should have a hole in the center approximately 216 mm 8 1 2 in in diameter and two 29 mm 1 1 8 in bolt holes 180 apart outside of the center hole The bolt holes should have a 432 mm 17 in bolt hole center When working at the bench secure thrust socket to bench with two 1 in bolts 1 Before disassembly of thrust socket can be accomplished remove the thrust tube ball assembly from thrust socket using instructions in the Disassembly of Thrust Socket from Thrust Tube section 2 Remove socket shaft U joint bearing and inner race by first placing thrust socket on socket bench with smaller diameter end through hole in bench 3 Remove shims O ring and packing Remove forward retainer Note cutouts in socket lip in three places to use as lifting points on retainer Forward retainer is a slip fit and should slide out of socket with little effort Figure 43 Removing Shims O ring Packing and Forward Retainer 86 Arneson Surface Drive Service Manual 1022808 Twin D
63. ally and may fail Contact Twin Disc if the taper contact pattern is not in accordance with Figure 23 Once the contact is confirmed to be acceptable clean the dye from the tapers with the above solvent and reinstall the propeller as outlined in the previous section Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Acceptable Unacceptable cote enn b o 8 S 0 w w a Small Spots Large Spots and Streaks Large Gaps in Pattern Mostly Large Spots 80 on Top Not Enough Total Contact Area Figure 23 Dye Contact Pattern Samples Arneson Surface Drive Service Manual 1022808 51 Installation Twin Disc Incorporated Corrosion Protection As with any marine outdrive a cathodic corrosion protection system should be installed Follow American Boat and Yacht Council ABYC recommendations found in Project E2 All electrically isolated components have been supplied with tapped holes to facilitate installation of a bonding system Twin Disc Incorporated recommends the usage of the proper Anode Kit for cathodic protection Reference instructions are available from Twin Disc Incorporated for system installation and details 52 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Anti fouling Protection It is recommended that a suitable antifouling paint be applied to min
64. amaged Low drive oil level Failed bearing or U joint Air in trim cylinders Leak in thrust ball socket seal Leak in thrust tube aft oil seal Loose oil fill and or drain plug Electrical fault on vessel Stray current from marina or another vesel Not enough anodes Too much uncoated more noble metals No problem Anodes not connected to bonding system Poor quality anodes Anodes are covered with paint tape etc Repair or replace Repair or replace Repair or replace Repair or replace Check for leak Repair or service the system Replace Replace Repair Replace Replace Repair or replace Repair or replace Repair or replace Check for leak Repair or service the system Remove drive and repair Bleed hydraulic system Tighten aft threaded retainer ring Remove and replace packing and o ring Remove and replace aft oil seals and o rings Repair or replace shaft sleeve if damaged Tighten or remove and replace the plug Repair elecrical fault check bonding system and replace anodes Install galvanic isolator and or check that it is working If problem continues investigate installing a polarization transformer Install additional anodes Coat the more noble metals i e stainless steels brasses bronzes etc No remedy needed Ensure that the anodes have less than 1 0 Ohm resistance with all metals they are protecting Use anodes made per the proper MIL specific
65. and O ring into thrust socket See following instructions Removal and Replacement of Thrust Socket Packing and O Ring Arneson Surface Drive Service Manual 1022808 121 Assembly Twin Disc Incorporated Removal and Replacement of Thrust Socket Packing amp O Ring 1 Remove old packing and O ring from socket discard 2 Place layer of new packing around inside of socket at packing groove taking care notto twist out of square shape Butt 45 angle cuts together The ideal position of packing joints is at the 10 o clock and 2 o clock position in relation to top of the drive unit Work excess packing around until it lies flat against socket wall If necessary trim packing to achieve proper fit 3 Place O ring against first layer of packing Smooth flat against socket wall 4 Place second layer of new packing around inside of socket as in step 3 and press down to keep O ring in place Make sure second butted packing joint is rotated at least 90 in relation to the first Figure 79 Replacement of Thrust Socket Packing and O Ring 5 Coat retaining ring packing and O ring with water resistant lithium grease Lubricate universal joint with lubricating oil 6 The socket is now ready for installation of thrust tube 122 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Installation of Thrust Tube Into Thrust Socket Special Tools e Assembly Stand T 21085 if socket has been removed from
66. and retainer becomes zero before is reached DO NOT tighten the retainer any more Doing so may damage the thrust ball and or retaining ring Remove the retainer and add the smallest plastic shim available to the shim pack Before installing the new shim measure it s thickness in three places Add the average value to Tighten the retainer again until the distance between the aft end of the retainer and the aft end of the socket is the new Note Shims may be cut in one place to aid in assembly Make sure to place cut shims underneath an uncut shim so that the retainer does not contact them Repeat this step as necessary Figure 82 Measuring the Gap Between Thrust Ball and Aft Retainer Arneson Surface Drive Service Manual 1022808 127 Assembly 128 10 Twin Disc Incorporated Measure the gap between the aft retainer and the thrust ball It should be no more than 0 05 mm 0 002 in If the gap is greater than that remove the retainer and 0 25 mm 0 010 in of shims for every 0 08 mm 0 003 in of extra gap For example If the measured gap is 0 20 0 008 remove the retainer and 0 50 mm 0 020 in of shims Table 4 Shim Calculation Example Required Extra Gap 020mm 00mm 015 Thickness of 0 008 0 002in 0 006 shims to ExtaGap remove 0 5 025mm 008 0 47mm 0 006 0010 0 003
67. ane IFIRST USI MATERIAI USA e INCH ewer Ge L al 1006786 j j C 5 24823 1 20 94 TWIN DISC INCORPORATE rev on ne pave sneer zoe cn wax TIE ASSEMBLY D C B 1007469 SEAL 0 1007474 SPACER 1007456 COVER 1007458A SLEEVE lt lt aa LLL X eS Z v 2 DOUBLE AFT SEAL ARRANGEMENT pot Tess ameeurse FIRST USE mae 0 030 XXXX 0005 NOTICE THIS PRINT CONTAINS PROPIETARY INFORMATION AND IS NOT TO BE ANGULAR TOLERANCES CETS USED IN ANY MANNER DETRIMENTAL THE INTEREST OF THIS NOTICE 15 NOT INTENDED NULLIFY OR LIMIT RIGHTS GRANTED TO SHEET ZONE DATE PER ASME 14 5 1994 THE U S GOVERNMENT UR OTHERS BY CONTRACT 1007469 SEAL 3 M2686AJ SLEEVE 1022991 COVER 72222222271 LUI WY Z S 22 lt lt lt TRIPLE AFT SEAL ARRANGEMENT CCONVERT FROM DOUBLE SEAL WITH KIT 1023571 NEW COVER AND NEW WEAR SLEEVE THIN DISS INCORPORATED MATERIAL HEAT TREAT FULL RACINE 53403 USA SIMILAR THIRD ANGLE D 1 R A M strom PROJECTION D ca AFT S
68. asis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit April 19 2007 TDWP10098 rev 2007 FLAT RATE HOUR ALLOWANCE COMMERCIAL MARINE SURFACE DRIVE Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated j 000504 40404008408 and test for leaks 0 eee P r s 5 sol Replace thrust tube 6 s EAA e sin 8 eee FLAT RATE HOUR ALLOWANCE COMMERCIAL MARINE ELECTRONIC CONTROL SYSTEMS Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated Travel and related expenses are not included as a part of Twin Disc Electronic Control Warranty Description of Flat Rate Labor hours allowed for function to the right gt External Sensor Removal Removal and Reinstallation and Test Reinstallation and Test Electronic Control there no serviceable internal components April 19 2007 TDWP10098B rev 2007 Twin Disc Incorporated Table of Contents Table of Contents Iniroduction 11 General Information
69. ation Remove any coatings on the anodes surfaces the Driveline alignment in the Installation Chapter 64 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Removal from Vessel Removal from Vessel Prior to Removal Removal and disassembly should not begin until the drive unit exterior and work area have been thoroughly cleaned Detailed illustrations of special tools are located in Special Tools References will be made when a special tool is required As parts are disassembled inspect for damage wear and burrs See Cleaning and Inspection for details Note There are two methods to service an Arneson Surface Drive 1 The first method as described below explains the removal of the thrust tube assembly while keeping the thrust socket mounted to the transom This method is used when service is required on the thrust tube section and no major repairs are required in the thrust socket assembly 2 The second method that follows covers the removal of the surface drive from the transom followed by the disassembly of the thrust tube from the thrust socket Arneson Surface Drive Service Manual 1022808 65 Removal from Vessel Twin Disc Incorporated Removal of Thrust Tube While Thrust Socket Remains Mounted to Transom Special Tools Wrench Special Tool 1009229 provided with new surface drives Always disconnect the battery cables and remove the key from the ignition before beginn
70. cate the fin in the vertical plane PIN PIN COTTER 2 SPACER SPACER 2 Figure 11 Trim Cylinder Mount Arneson Surface Drive Service Manual 1022808 33 Installation Twin Disc Incorporated 3 Position the drive unit at the center trim height This is determined by setting the drive unit ball joint in the exact center of the socket Determine this measurement using the Thrust Ball Centering Gauge supplied with the package See Figures 12 and 13 Lay the tool against the ball shoulder and adjust the unit so that the tool fits evenly all the way around the circumference of the socket This assures that the unit is in line with the socket and input shaft so that the entire unit is in a straight line This is referred to as the neutral running angle 120 REF 2 38 cldSV 97690601 6 63 0 50 1 88 ee Figure 12 Drive Centering Template 1020624E 34 Arneson Surface Drive Service Manual 1022808 Installation Twin Disc Incorporated After the neutral running angle is determined lay the trim cylinder bracket against the transom 4 making sure that the cylinder is at the center travel location The center of the transom bracket should be aligned with the drive centerline TO ENSURE DRIVE IS CENTERED THIS DISTANCE MUST BE EQUAL ON TOP BOTTOM LEFT AND RIGHT OF DRIVE FULLY SEATED 1020624E ASD12 SOCKET ON
71. d steering trim that need proper maintenance Lubrication oil is contained in a closed system that is comprised of a reservoir that is connected to the front of the drive Oil fills the area inside the drive and surrounds the propeller shaft the input shaft and the constant velocity universal joint that connects the two shafts The hydraulic steering and trim is a self contained system It is used to operate the trim cylinder and the steering cylinders of the surface drive Proper maintenance of the cathodic protection system anodes bonding system etc is very important in preventing deterioration of the Arneson Surface Drives Lubrication Lubrication oil should be checked daily The reservoir should be approximately 1 3 full when cold with the drive stopped to allow for expansion from heat and agitation during operation milky appearance is usually an indication that water has been ingested Do not operate the drive for extended periods with contaminated oil Periodic oil sample analysis can be helpful in identifying the presence of water or other contaminants that could indicate impending failure When the vessel is waterborne drain the lubrication oil by removing the lower hose that is attached to the drive inside the vessel Drain and vent ports are provided on the drive to assist draining when the vessel is dry docked See the Maintenance Checklist table in this section for the recommended oil change intervals Arneso
72. damaged or broken propeller shaft and a lost propeller Follow the procedure below to check the propeller to shaft fit 1 Clean the taper on the forward end of the propeller hub and the tapered shoulder of the shaft with alcohol or other cleaner and wipe dry Apply a layout dye to the shaft taper as follows Use a machinist s layout dye such as Dykem Steel Layout Blue Dykem part number DX100 marketed by ITW Dymon Company 805 E Old 56 Highway Olathe KS 66061 USA Apply the layout fluid to the shaft taper as thinly and evenly as possible over the entire tapered surface The more evenly the dye is applied the more accurate will be the reading Allow the dye to dry completely before proceeding Slide the propeller onto the shaft until the male and female tapers touch Install the propeller nut and torque the nut to 200 N m 150 ft lbs Verify that the propeller is securely seated on the shaft taper Remove the propeller nut and slide the propeller away from the shaft being careful not to disturb the layout dye on the shaft and on the propeller hub internal female taper Evaluate the contact pattern on both tapers See Figure 23 for guidance on acceptable contact patterns The surfaces should match approximately 80 of the total tapered area Note It is important that the contact should be biased toward the larger diameter end of both tapers If contact is predominant at the small end the shaft may be overstressed loc
73. de positive steering and a means for adjusting the depth of the surface piercing propeller while under way Prior to Daily Use Verify that the surface drive has adequate lubrication and that the hydraulic steering reservoir and trim pump reservoir are properly filled The lube oil reservoir must not be filled more than 1 3 full when cold with the drive stopped The level will rise during operation due to temperature increase and rotation of internal parts Arneson Surface Drive Service Manual 1022808 55 Operation Twin Disc Incorporated Surface Drive Operation 56 For optimum performance the surface drive should be trimmed so that the center of the propeller hub is at the waterline under operating conditions Under way adjustments may be required when the vessel trim changes due to fuel consumption loading etc The surface drive should not be trimmed up to such a degree that the engine is allowed to operate higher than the maximum speed recommended by the engine manufacturer A change in trim while underway may cause a change in steering direction Transmission forward reverse shifting should be accomplished at engine idling speed to avoid unnecessary impact loads that could damage the surface drive Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance General Maintenance There are two hydraulic systems on Arneson Surface Drives lubrication an
74. e ee SEE 3 4 e FITTING 1006351 lt 3 1007514 FITTING RING 40 SCREW SET FITTING i SEE NOTE 3 1009847 D SCREW SET 2 YOKE 1004773 1 1007550 1006076 lt SASS lt NN SS n 77 22222022224 BRACKET PEP 17777 1006649 SS 72 LOCK WOK WASHER X 222222222222 F SSS SIIN 1006076 SCREW 1007309 D 3 CONNECTOR 1 BALL SEE NOTE 4 1006646 D RING WEAR lt 1 pra 1007358 lt D PISTON TRANSDUCER 1006647 lt 1006651 lt gt gt SEE SPACER 1007308 NIE 3 RING 0 2 1006077 lt gt GUIDE SEE NOTE 4 SPRING D DTE PIN COTTER SEE 3 RING 0 1007550 gt A SCREW 2 SEE 3 1007359 lt gt RING RETAINING 1 TUBE SEE 3 RING RETAINING 1 32 40 RETRACTED LENGTH 36 58 RETRACTED LENGTH VENDOR MILWAUKEE CYLINDER ELECTRONIC MODULE SPECIFACTIONS CUDAHY SUPPLIER NOTE UNLESS OTHERWISE SPECIFIED ALL PARTS SUPPLIED STREET T AND INSTALLED BY MILWAUKEE CYLINDER ATTLEBORO MA TRANSDUCER MODEL VRVT100 1 S 130 EM 1B 15 FT CABLE INPUT SUPPLY VOLTAGE Vs 22Vdc to 26Vdc THIRD ANGLE POLARITY ZERD ADJUST 100 OT T 7 am nar UNLESS SPECIFIED TY nS TEMPERT
75. e socket and tighten the boot clamps Verify that the boot is not twisted F DIM A CLEVIS TUBE ASSEMBLY BOLT WASHERS VV USED TO FILL GAP BETWEEN CLEVIS AND TRIM CYLINDER REF 1 12 2 62 YOKE BOTH SIDES OUTBOARD STEERING NUT TORQUE TO REF 80 2 30 57 Nm 40 ft lbs BOTH SIDES INBOARD STEERING NOTES 1 APPLY A THIN COAT OF LUBRICANT BETWEEN MATING SURFACES OF PINS AND CLEVIS LUBRICANT TYPE MUST BE A MARINE GRADE LITHIUM GREASE WITH PROPERTIES FOR SALT WATER ENVIRONMENT SUCH AS ZEP RED LITHIUM GREASE 2 LUBRICATE THREADS WITH AN ANTI SEIZE THAT DOES NOT CONTAIN GRAPHITE OR MOLYBDENUM DISULFIDE SUCH AS LOCTITE WHITE HI TEMP ANTI SEIZE 3 CENTER TUBE ASSEMBLY TO EQUALIZE LENGTH OF EXPOSED THREADED ROD Figure 17 Tie Bar Assembly 40 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Driveline Installation The driveline between the transmission output shaft and the surface drive input shaft must be properly aligned for maximum life and minimum vibration 1 The transmission output shaft centerline must be parallel to the surface drive input shaft centerline or if offset the angle between the transmission output shaft centerline and the driveline must equal the angle between the driveline and the surface drive input shaft centerline The angular offset between the transmission output shaft centerline and the driveline centerline must not
76. e the piston on to the rod again being careful notto damage seals or rod threads Figure 95 Slide the piston on to the rod 4 The used flexloc nut should be discarded and replaced with a new one Tighten to 100 N m 75 ft Ibs Figure 96 Tighten the flexloc nut 5 Insert the piston rod assembly back into the tube being careful not to damage the piston O rings or the tube threads Figure 97 Insert the piston rod assembly into the tube 140 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Hydraulic Cylinder Service Tighten the guide until it is tight against the tube and the socket head capscrew holes on the guide and on the tube are in alignment Remove any threadlocker compound still present in the hole from previous capscrew installation Replace the socket head capscrew using Loctite 242 or similar semi permanent threadlocker Tighten to 8 N m 6 ft Ibs If the cylinder was removed from the transom mount the steering cylinder bracket with its backing plate and stainless steel 1 2 inch diameter nuts bolts and washers Torque nuts to 60 N m 45 ft lbs Apply a generous layer of marine transom sealant under the bracket and in the fastener holes to prevent water leakage Do not turn the bolts when tightening them Hold the bolts in place and only turn the nuts If this procedure is not followed leaks can develop in the holes Arneson Surface Drive Manual 1022808 141 Hydraulic
77. easurement Shims 0 254 mm 010 in Freeze the following parts to a temperature of 29 C 20 F e Roller Bearing Two 2 Bearing Cups AWARNING Handle the components with care The frozen parts are extremely COLD 1 Heat the thrust tube bearing housing to 121 C 250 F Handle the components with care The heated parts are extremely HOT Place thrust tube vertically in assembly stand with propeller end end with smaller housing diameter facing up Heat thrust tube bearing housing area Slide frozen roller bearing into aft bore of thrust tube Seat bearing against shoulder with special tool T 18050 579 if necessary Figure 55 Installing Aft Thrust Tube Bearing 102 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 9 Install bearing spiral lock retainer ring into aft end of thrust tube Figure 56 Installing Rear Bearing Spiral Lock Retainer Ring 4 Rotate the thrust tube in the assembly stand so the forward end of the tube end with larger diameter is facing up Heat thrust tube bearing housing area Slide the first frozen bearing cup into the forward end of the tube Open end of the cup should face up Seat cup firmly against shoulder with special tool T 18050 640 Handle the components with care The frozen parts are extremely COLD Figure 57 Installing First Bearing Cup Arneson Surface Drive Service Manual 1022808 103 Assembly Twin Disc Incorporated 5 Lubr
78. ecial Tools MOOLS 001 T 21085 1 Assembly Stand Component SAIS HLOG eld 0676 NMOHS SV 5 LES 001 080 d 0001 099 S3903 TIY ANNOY 2 ASIMYSHLO SSJINN HSIN neg OL SAOV4YNS 11 L LON Gel Arneson Surface Drive Service Manual 1022808 154 Special Tools Twin Disc Incorporated T 21085 2 Assembly Stand Component NOTE 1 ALL SURFACES HAVE MIN 250 FINISH UNLESS OTHERWISE NOTED 2 ROUND ALL SHARP EDGES 19 50 12 50 F 7 56 1 00 15 11 9 422 DRILL 2 0 DP 1 2 13 UNC 2B TAP 1 5 DP 2 PLCS AS SHOWN 1 06 5 Ag 155 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Special Tools T 21085 3 Assembly Stand Component 5 6 lez 065 lez 1 0961 lez 065 NMOHS SV o g 92 62 Y NO q3SvdS 35919 9 30 1 9 0015 69 gL 00771 S3903 17 ANNOY Q31ON ASIMYSHLO SSJINN HSINId NIN 1530 6 1 ALON Arneson Surface Drive Service Manual 1022808 156 Special Tools Twin Disc Incorporated 1 00 STOCK 61 56 NOTE 250 1 ALL SURFACES TO HAVE MIN
79. eeve Driver T 18050 805 Heat the following parts to 121 C 250 F e Two 2 Tapered Bearings Cones e Bearing Race e Seal Sleeve Handle the components with care The heated parts are extremely HOT 1 Support the shaft in a horizontal position on blocks allowing enough radial clearance for installation of the bearings Apply a thin coat of anti seize that does not contain graphite or molbdenum disulfide such as Loctite White Anti Seize to the shaft on the surfaces where the bearings will seat Application Instructions Apply a thin even coating of paste onto component surfaces Rub thoroughly into surfaces with a clean lint free cloth leaving a coating depth less than 0 003 mm 0 0001 in Excessive coating depth will result in sleeve and bearing distortion and may prevent bearing assembly which will reduce bearing life 98 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 2 Lubricate propeller shaft and tapered bearings with prior to assembly Slip heated tapered bearings on forward end of propeller shaft short spline end one at a time The bearings should be positioned back to back with small diameter ends facing out Figure 49 Propeller Shaft Propeller End left Forward End right Handle the components with care The heated parts are extremely HOT Figure 50 Install Tapered Roller Bearings Arneson Surface Drive Service Manual 1022808 99 Assembly
80. eight The approximate dry weight of the ASD12B1LU is 356 kg 785 Ibs This includes the drive trim and steering cylinders trim pump reservoir mounting hardware and hoses 18 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Description and Specifications Drive Lubrication Features Drive Oil Capacity The approximate capacity of the drive and reservoir is 19 21 liters 5 5 5 gallons Lubrication Specifications The lubricating oil is specified as SAE 30W 40W API Service Category CF or higher certified by vendor to pass Caterpillar test TO 4 O SAE 80W 90W Hypoid EP Type API GL Grade 5 Power Steering and Trim Lubrication Specifications Hydraulic fluid such as Dexron automatic transmission fluid should be used for the power steering and power trim hydraulic systems Arneson Surface Drive Service Manual 1022808 19 Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Table 1 Torque Specifications for Fasteners used in ASD 12B1LU DRY TORQUE VALUE DESCRIPTION Screw Ball Nut Look Input Flange Nut Lock Tapered Bearings on Prop Shaft 140 N m min 100 Ib ft min Screw Ball Retainer Clip 7350 N mm 65 Ib in Nut Jam Prop 610 680 450 500 lb ft Nut Lock Prop 480 540 350 400 Ib ft Screw U Joint 45 lb ft Apply Loctite 242 or similar semi permanent threadlocker Approach lower tor
81. election are based on hull design normal operating weight and rated engine performance Twin Disc Incorporated is prepared to provide preliminary recommendations but actual propeller requirements may change in service Arneson Surface Drive Service Manual 1022808 21 Installation Twin Disc Incorporated Packing List Consult packing list and verify that all listed items have been received and are undamaged Note All internal components of the surface drive must be protected from the damaging effects of dirt grit and dust prior to installation Take care to insure these components are kept clean by the use of plastic or other clean covering Care must be taken not to damage the surface of the thrust ball trim and steering cylinder rods or exposed portion of the propeller shaft Nicks and scratches can cause premature seal failure and subsequent oil leaks Structural Strength of Mounting The vessel structure in the area of the transom and the transom itself bears the entire weight of the surface drive and the torque and thrust loads generated by the propeller s Asolid mounting base and a properly designed transom structure is essential for the successful installation of surface drives If the transom and mounting base is not sufficiently strong it is possible to damage the surface drive or the vessel itself Twin Disc Incorporated will not be responsible for surface drives that have been improperly mounted or where m
82. emery cloth to smooth the defects Contact your local Twin Disc Distributor if either component is excessively damaged If damaged repair the rod threads and clean the rod again CAUTION Do not remove excessive material or create flat spots This could cause leakage past the seals Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Hydraulic Cylinder Service Assembly 1 Replace all the rod guide and piston O rings seals and the wiper Lubricate all of these components to aid in re assembly Note When replacing the polypak seal in the guide the O ring portion of the polypak seal should face into the cylinder Figure 100 Install the polypak seal into the guide followed by the wiper 2 Slide the guide back on the rod being careful not to damage the seals or the rod threads Figure 101 Slide the guide on to the rod Arneson Surface Drive Manual 1022808 145 Hydraulic Cylinder Service Twin Disc Incorporated Note Special tool T 21549 32 should be used to protect the guide seals Figure 102 Special tool T 21549 32 3 Thread the piston back on to the rod and tighten it using a suitable wrench Figure 103 Thread the piston back on to the rod 4 Using 1 4 drill bit drill 1 8 into the rod threads through the setscrew hole This creates a spot for the setscrew to lock the piston on the rod Figure 104 Drill 1 8 into the retainer threads 146 Arneson Surface
83. et head screws starting with the two lower two upper screws If necessary tap fin with plastic mallet to align fin on base then continue installing the remaining screws Torque to 35 N m 25 ft lbs Clean excess sealer from seam Figure 88 Installing Fin Bolts Arneson Surface Drive Service Manual 1022808 133 Assembly Twin Disc Incorporated Attaching Thrust Unit to Transom 1 Using suitable lifting device cradle unit into place against transom with input shaft protruding through the hole in transom Align mounting bolt holes Coat each bolt with marine transom sealant 3M Brand 5200 marine sealant or equivalent is recommended to prevent leakage Place a 1 inch A N washer under the bolt head and install 1 inch diameter mount bolts 3 Install nuts and washers inside transom and torque to 175 200 N m 130 150 ft Ibs 134 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Hydraulic Cylinder Service Hydraulic Cylinder Service Servicing the Steering amp Trim Cylinders Special Tools 1 2 hex bit socket T 21549 33 steering cylinder thread and seal protector T 21549 32 trim cylinder seal protector Propeller steering and propeller trim are achieved through the use of hydraulic cylinders located outside the vessel as shown below Trim linders Steering CY DENS Cylinder j Steering Cylinder Figure 89 View of Dual Installat
84. guide out and slide the entire rod piston assembly from the tube The guide will stay on the rod as will the piston at this point Remove the flexloc nut and slide the piston and guide off the rod Remove all O rings seals and the wiper Using a cleaning solvent clean the tube bore rod guide and piston Inspect the bore of the cylinder tube and the working area of the rod for scratches nicks and other surface defects If necessary use a 400 grit or finer emery cloth to smooth the defects Contact your local Twin Disc Distributor if either component is excessively damaged CAUTION Do not remove excessive material or create flat spots This could cause leakage past the seals Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Hydraulic Cylinder Service Assembly 1 Replace all the rod guide and piston O rings seals and the wiper Lubricate all of these components to aid in re assembly Note When replacing the polypak seal in the guide the O ring portion of the polypak seal should face into the cylinder Figure 93 Install the polypak seal into the guide followed by the wiper 2 Slide the guide back on the rod being careful not to damage the seals or the rod threads Note Special tool T 21549 33 should be used to protect the rod guide seals Figure 94 Slide the guide on to the rod Arneson Surface Drive Manual 1022808 139 Hydraulic Cylinder Service Twin Disc Incorporated 3 Slid
85. hooting Chal J J J J J 63 Removal from Vessel 65 Prior to Removal 65 Removal of Thrust Tube While Thrust Socket Remains Mounted to Transom 66 Removal of Complete Arneson Surface Drive Unit From Transom 71 TS AS SOY uuu xu yaaa 75 Disassembly OVERVIEW T 75 Disassembly of Thrust Socket from Thrust Tube If complete ASD unit was removed from the transom 76 Disassembly of the Thrust 80 Disassembly of the Propeller 84 Disassembly of the Thrust Socket 86 Disassembly of the U Joint Input Shat t 90 Cleaning and Inspection 93 93 SPECON A 95 8 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Table of Contents PS SOON 97 Assembly Overview 97 Propeller Shaft Assembly 98 Thrust Tube Assembly
86. htly If loose tighten or replace the anodes Inspect for marine growth coatings tape etc covering anodes Replace if they cover more than 10 of the anode surface area Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Assembly Assembly Overview Note See Special Tools section for detailed tool drawings References to special tool numbers are made when required Note See Engineering Drawings for the location and description of the referenced components Note Refer to Description and Specifications Troubleshooting and Preventative Maintenance for all lubrication specifications Handle the heated and frozen components with care The heated parts are extremely HOT The frozen parts are extremely COLD Note Heat Shrink Assembly Methods When using heat shrink methods of assembly components should be installed by hand Occasionally when performing this procedure a or bearing may become misaligned in a housing or on a shaft and will not slide properly into place Always have standby tools such as a drift and plastic mallet available to tap components into place Use light taps only when trying to realign a component Note It is highly recommended to replace all bearings seals and o rings that are accessible when servicing the drive Arneson Surface Drive Service Manual 1022808 97 Assembly Twin Disc Incorporated Propeller Shaft Assembly Special Tools e Wear Sl
87. icate bearings and race with oil to prepare for installation into thrust tube Thread 1 2 20 UNF eyebolt into tapped hole on the forward end of propeller shaft Attach hoist to eye bolt Figure 58 Install Eye Bolt 6 Lower assembled propeller shaft aft end first into forward end of thrust tube Take care not to damage propeller bearing while inserting shaft into housing Seat shaft firmly into the thrust tube Figure 59 Installing Propeller Shaft Assembly into Thrust Tube 104 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 7 Visually check that the propeller bearing has not been damaged Note If using a new shaft thrust bearing thrust tube or thrust ball you must re shim the thrust bearing endplay 8 Install second frozen thrust bearing cup into the forward end of the thrust tube Open end of the cup faces down If re shimming is necessary immediately raise the shaft 0 76 mm 0 030 in to ensure there will be end play in the bearing set Keep the shaft raised until the front bearing cup stays in place when the shaft is lowered Figure 60 Install the Chilled Front Bearing Cup left and Raise the Shaft to Ensure End Play right Arneson Surface Drive Service Manual 1022808 105 Assembly Twin Disc Incorporated Thrust Bearing Shimming Procedure Note If re shimming is not necessary install the used shim pack on top of the thrust bearing cup and go to step 7 skipping the
88. ice Manual 1022808 Twin Disc Incorporated Removal from Vessel Removal of Complete Arneson Surface Drive Unit From Transom Always disconnect the battery cables and remove the key from the ignition before beginning this procedure l Remove the cotter pin and jam nut Loosen the propeller nut until it is flush with the end of the shaft to prevent damage when the propeller moves from the tapered pilot Remove the propeller from the splined shaft using suitable pullers soft blocks and mallets as necessary allowing the propeller to stop against the spacer and propeller nut Remove the propeller nut spacer and propeller from the rear end of the propeller shaft Jam Nut Propaller Hut Figure 30 Propeller Retaining Parts left and Propeller Installed right Arneson Surface Drive Service Manual 1022808 71 Removal from Vessel Twin Disc Incorporated 2 Drain oil from unit through drain holes in housings or from lower oil reservoir hose inside the boat Remove trim yoke pin s from trim yoke s disconnecting steering cylinder and or tie bar from thrust tube ty Trim Cylinders Steering Cylinder 7 Tie Bar Steering Cylinder Figure 31 Rear View of Dual Installation Showing Cylinders and Tie Bar Support the thrust tube with a block and tackle forklift or other system capable of carrying the weight of the thrust tube Do not allow the thrust tube t
89. imize marine growth Care must be taken to keep anti fouling away from pivoting joints cylinder rods output shaft anodes bonding wires and anywhere else the anti fouling could interfere with the proper operation of the drive Arneson Surface Drive Service Manual 1022808 53 Installation Twin Disc Incorporated Periodic Visual Inspection 54 Check the propeller for any signs of damage daily Repair or replace as necessary Check the Cathodic Protection frequently on new vessels once a week for a month and at least once a month thereafter Possible corrosion problems can be detected and solved by checking the anodes often Replace anodes when eroded to one half of full size Check all bonding wires and fittings Replace if required Inspect the oil lines for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Operation General Operation The following information is intended for use by the vessel operator It will help the operator understand the operation of Arneson Surface Drives and applies to the surface drives only The vessel s operator manual must be referred to for procedures applicable to other vessel functions and for the operation of the control system for this drive Arneson Surface Drives provi
90. in consistent performance from the unit and help reduce downtime Arneson Surface Drive Service Manual 1022808 11 Introduction Twin Disc Incorporated Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Incorporated will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unaccepted maintenance working practices Important Safety Notice 12 Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure safe operations under prevailing conditions Proper guards and other safety devices that may be specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Inc To prevent accidental starting of the engine when performing routine maintenance disconnect the battery cables from the battery and remove ignition key from the switch Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete
91. ing this procedure 1 Remove the cotter pin and jam nut Loosen the propeller nut until it is flush with the end of the shaft to prevent damage when the propeller moves from the tapered pilot Remove the propeller from the splined shaft using suitable pullers soft blocks and mallets as necessary allowing the propeller to stop against the spacer and propeller nut Remove the propeller nut spacer and propeller from the rear end of the propeller shaft Jam Nut Propaller Hut Figure 24 Propeller Retaining Parts left and Propeller Installed right 66 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Removal from Vessel Support the thrust tube with a block and tackle forklift or other system capable of carrying the weight of the thrust tube Do not allow the thrust tube to angle down to the point where the ball thrust tube assembly makes contact against the thrust socket Severe damage to the ball and the socket could result SOCKET BALL CLEARANCE CAUTION SUPPORT END OF PROPELLER SHAFT TO PREVENT SEVERE DAMAGE TO DRIVE SSS es 22 2222 CAUTION SEVERE DAMAGE TO DRIVE WILL RESULT FROM ALLOWING CONTACT AS SHOWN Figure 25 Protect Ball from Damage Arneson Surface Drive Service Manual 1022808 67 Removal from Vessel Twin Disc Incorporated 2 Drain oil from unit through drain holes in housings or from lower oil reservoir hose inside the boat Rem
92. ion Showing Cylinders and Tie Bar The cylinders are mounted on the boat s transom with ball joints The trim cylinder is connected directly to the drive at the top of the thrust tube The steering cylinder is connected directly to the drive either through the trim cylinder yoke when the steering cylinders are mounted outboard or through the trim yoke pin when the steering cylinders are mounted inboard Arneson Surface Drive Manual 1022808 135 Hydraulic Cylinder Service Twin Disc Incorporated Steering Cylinder Service 136 Removal 1 2 Remove the battery cables and remove the key from the ignition If necessary support the drive with block and tackle forklift or other system capable of carrying the weight of the surface drive Do not allow the thrust tube to angle down to the point where the ball thrust tube assembly makes contact against the thrust socket Remove the steering cylinder clevis pin Fitting Guide Leeking Capecrew Figure 90 Steering Cylinder 4 Disconnect and plug both hoses at the cylinder Manually cycle the cylinder to remove the oil in it Use a container to catch the oil Check the amount of play in transom mounting bracket If there is any play indicating that the ball joint is loose in the bracket the bracket must be serviced by following the directions below If there is no play in the ball joint skip to the next section Disassembly amp I
93. ired but very helpful stand is not available a suitable support should be made Eyebolt with 1 2 20 UNF screw Note It is highly recommended to replace all bearings seals and o rings that are accessible when servicing the drive Once thrust tube assembly has been removed from socket section begin disassembly by placing the thrust tube vertically in the assembly stand special tool T 21085 with input end facing up Thrust Ball Figure 37 Rotate Thrust Tube Assembly so Ball is Up Remove 12 point Capscrews 2 Remove the screws holding the thrust ball to the thrust tube Use a 1 2 12 point socket wrench 3 Lift thrust ball out of thrust tube Note When lifting thrust ball out of thrust tube watch for the shim pack located between thrust ball shoulder and thrust bearings Upon ball removal shims may stick to ball shoulder 80 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated D Disassembly Place ball aside and inspect for scratches dents or rough edges Smooth ball surface with fine emery cloth or similar material Do not create flat spots on the ball s outside surface Remove O ring from face of thrust tube housing and check inside for remaining shims located against the thrust bearings If original bearings will be used in reassembly save these shims If original bearings will not be used in reassembly the shim pack will change Remove propeller shaft from housi
94. isc Incorporated Disassembly 4 Remove retaining ring from groove next to the ball bearing Figure 44 Removing Retaining Ring Arneson Surface Drive Service Manual 1022808 87 Disassembly 88 Twin Disc Incorporated Remove the screws holding socket assembly to the bench Support the assembly about 15 cm 6 in above the bench top with wooden blocks It should be high enough to allow space for a butane or propane torch Lift U joint with hoist with just enough lifting force to suspend socket Heat housing around large ball bearing until U joint assembly lifts out Be careful not to damage shaft and U joint because these items may be reused Assembly Butane or Propane Torch Figure 45 Heating Housing to Remove U Joint Assembly Handle the components with care The heated parts are extremely HOT Do not overheat housings Excessive heat will damage or distort the casting Socket housing should not be heated above 121 C 250 F 6 Rest thrust socket on its side and remove seal retaining ring from small diameter end of socket Remove oil seals and bearing retaining ring Do not damage retaining rings as these items may be reused Seals should be replaced with new parts Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Disassembly 7 Remove roller bearing outer race from smaller diameter end of the housing by first threading two 1 in lifting eye bolts on opposite
95. ld the bolts in place and only turn the nuts If this procedure is not followed leaks can develop in the holes Note The backing plate must be oriented with the spot faced holes outward and with the stamped top upward Spot faced holes are only on backing plates for drives with wedges BACKING PLATE 7 QTY WASHER 7 QTY NYLOCK NUT DRIVE INSTALLATION SOCKET TRANSOM Figure 8 Drive Installation Arneson Surface Drive Service Manual 1022808 31 Installation Twin Disc Incorporated 10 Install the input flange companion flange onto the input shaft See Figure 10 Torque the flange retainer bolts to 100 75 ft lbs Figure 9 Torque Sequence for Socket to Hull INPUT FLANGE REMOVAL amp INSTALLATION INBOARD DRIVESHAFT INPUT SHAFT TRANSOM Figure 10 Input Flange Removal and Installation 32 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Trim Cylinder Installation The trim cylinder provides the capability to position the drive at differing trim angles depending on operating conditions The following procedure sets the trim cylinder at mid travel See Figure 11 for assembly instructions for the cylinder yoke i Connect the trim cylinder to the thrust tube using the supplied mounting hardware See Figure 11 2 Loosen the hose clamps on one end of the drive unit protective boot and rotate the thrust tube housing as required to lo
96. m MIN 450 500 FT LBS 640 70 SCREW pip 45 4 RECOMMENDED LUBRICATING OIL API SERVICE CATEGORY CF OR HIGHER SAE 30 OIL MIN VISCOSITY 100 CST 100 F SAE 40 OIL MIN VISCOSITY 141 CST 100 F FILL DRIVE UNTIL EXTERNAL RESERVOIR 15 ONE THIRD FULL APPROXIMATE CAPACITY 20 22 QUARTS 19 19 3 4 LITERS LOCTITE INSTRUCTIONS USE ALL APPLICABLE SOLVENTS PRIMERS AND ACTIVATORS 5 COAT THE MARKED THREADS WTH LOCTITE THREAD LOCKING COMPOUND NO 242 BLUE SEMI PERMANENT 5A COAT THE MARKED THREADS WITH LOCTITE THREAD LOCKING COMPOUND NO 270 RED PERMANENT 58 COAT PIPE THREADS LOCTITE NO 545 PURPLE 22222 222 Z gt 72 1007439 lt CLAMP 1005949 D CLIP RETAINER 1004794 2 SCREW 1005913 D RETAINER 1009208 BOOT 1009201 D BALL THRUST 1004963 gt SCREW 1008008 D RING 0 1007440 CLAMP 1007239 D Zw AG ee w SSS SSSI 1010402 16 SCREW 1007463 lt gt CONE BEARING 1007464 CUP BEARING MON NEMEN MAS85FU 1 CONE BEARING M2013AN lt D 59 1 WASHER LOC CUP BEARING 1007483 5 SPACER SHIM lt AS_REQ D IM_CAS_REQ D SHIM 5 0 1 6 ASSEMBLY COAT PROPELLER AND INPUT SHAFTS AND THE BEARINGS AND SLEEVE 1 0 WHERE THEY ARE IN CONTACT DOW CORNING COR
97. n Surface Drive Service Manual 1022808 29 Installation Twin Disc Incorporated Follow the pilot hole with a 198 mm 7 8 in hole saw at the same angle used in Step C Hold the thrust unit in place and verify 1 clearance from the edge of the thrust socket to the plane of the vessel s bottom See Figure 7 Verify that the drive flange hole pattern matches the hole pattern marked on the transom from template 1017597 page 1 Note The cutaway area on the thrust socket flange should be aligned parallel with the hull deadrise 1 in clearance must be with the main drive boot in place TRANSOM STRAIGHTEDGE HULL BOTTOM HULL BOTTOM DUAL Figure 7 Measure for Clearance 30 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Remove the drive unit and drill 7 28 5 mm 1 12 in diameter holes and 2 28 5 mm 1 12 in lubrication holes using template 1017597 page 1 Holes should be drilled perpendicular to the transom Mount the basic drive unit trim and steering cylinders not installed using the backing plate and 1 in diameter stainless steel bolts nylock nuts and washers as shown in Figure 8 Uniformly torque the nuts to 175 200 N m 130 150 ft lbs using the tightening sequence on Figure 9 Apply a generous layer of marine transom sealant under the bracket and in the fastener holes to prevent water leakage Do not turn the bolts when tightening them Ho
98. n Surface Drive Service Manual 1022808 57 Preventative Maintenance Twin Disc Incorporated Steering and Trim Hydraulic Oil System Oil Level The oil level should be checked daily or every 10 hours of operation Oil and Filter Change Interval The oil filter if equipped in the Steering System should be changed whenever the engine filters are changed and when the oil is changed The oil should be changed if contaminated An oil analysis can be helpful in avoiding problems from continued operation with contaminated oil Type Oil Recommended See Description and Specifications 58 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Preventative Maintenance Overhaul Interval Acomplete overhaul of the unit should be made at the same time that the engine is overhauled Arneson Surface Drive Service Manual 1022808 59 Preventative Maintenance Twin Disc Incorporated Periodic Visual Inspection 60 Check the propeller for signs of damage daily Repair or replace as necessary Check the Cathodic Protection System at least every month Replace anodes when 50 consumed or if excessive corrosion is seen Check all bonding wires and fittings Replace if required Inspect the oil lines for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required Check the condition of the
99. ng and O ring material remain in place Note U joint can be positioned by running a rope or wire through upper fill hole of thrust socket Thread a loop between the front U joint yoke and the shaped piece Next loop that end around the outer diameter of the U joint s front spline This can then be pulled tight to hold U joint yoke in place to assist in thrust tube insertion Once splines are engaged remove rope or wire by pulling it out through the hole Figure 80 Support U Joint During Installation of Thrust Tube into Thrust Socket 3a Inspect aft retainer for any nicks scratches or burrs Smooth with 400 grit or finer emery cloth and clean thoroughly with alcohol or cleaning solvent Coat threads of aft retainer with anti seize that does not contain graphite or molbdenum disulfide such as Loctite White Anti Seize Slip ring over thrust tube and position around thrust ball Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated 4a Assembly Remove two of the drive unit s mounting bolts Bolts to remove will be directly across from each other 180 apart at approximately the 3 o clock and 9 o clock positions Install the threaded rods of press apparatus special tool T 21549 12 into each hole and attach nuts to the inside of transom to secure rods Place the plate of the press apparatus over the propeller shaft to rest against the aft end of the thrust tube The thre
100. ng by first threading a 1 2 20 UNF eyebolt into tapped hole on forward end of propeller shaft Attach hoist to eyebolt Heat thrust tube housing at the forward bearing area with a butane or propane torch Handle the components with care The heated parts are extremely HOT Do not allow housing temperature to exceed 121 C 250 F Figure 38 Remove propeller shaft Arneson Surface Drive Service Manual 1022808 81 Disassembly Twin Disc Incorporated 82 7 As housing is heated apply just enough lifting force to suspend drive Apply heat slowly until bearing cup frees itself Place the propeller shaft assembly aside 8 Rotate thrust tube in assembly stand so aft end is facing up Remove six retaining screws located on the face of the rear seal block assembly Remove the seal housing Figure 39 Seal Carrier 9 Remove the seals and bearing retaining ring Do not scratch or damage shaft when removing components If damaged yet repairable use a fine emery cloth to smooth the surface 10 Rotate the thrust tube so that the forward end is facing 11 Remove aft bearing by heating housing around bearing with a butane or propane torch The bearing may fall out Handle the components with care The heated parts are extremely HOT Do not allow housing temperature to exceed 121 C 250 F Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Disassembly 12 Ifthe bearing does not fall out
101. ning hull tends to move upward several inches from transom to the output end of the drive a straight edge running aft from the hull bottom to the propeller will normally be even with or for the larger drives below the lower of the thrust tube at its aft end The thrust socket ball must be positioned out of the water under planing conditions which is the intent of these installation procedures All through transom holes must be drilled perpendicular to the transom outer surface to allow the mounting bolts washers to seat flush against the drive flange The drive unit must be supported as shown in Figure 2 at all times prior to trim cylinder final installation Do not allow the ball joint thrust tube to bottom against the thrust socket as shown in Figure 3 as this can cause damage to the ball and socket bearings The supporting mechanism must be capable of carrying the unit s weight approximately 600 pounds Note When transom angle is other than 6 degrees to the vessel baseline and a wedge is to be used to mount the drive Template 1019886E should be applied to the wedge and not directly to the transom Arneson Surface Drive Service Manual 1022808 25 Installation Twin Disc Incorporated TRANSOM SUPPORT UNDER SUPPORT PROPELLER SHAFT UNDER BALL Figure 2 Support Unit for Installation SOCKET BALL CLEARANCE eee SSS CAUTION SUPPORT END OF PROPELLER SHAFT TO PREVENT SEVERE DAMAGE TO DRIVE
102. nspection While supporting the cylinder remove the four 4 transom bracket mounting bolts nuts and washers Remove the steering cylinder from the vessel Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Hydraulic Cylinder Service 8 Remove the transom bracket setscrew closest to the hose fittings and tighten the large retaining nut inside the bracket to 75N m 55 ft lbs Use a 1 2 hex bit socket to tighten the nut After tightening check to make sure there is no movement in the pivoting joint Figure 91 Use 1 2 bit socket to tighten the large retaining nut 9 Using a 1 4 drill bit drill 1 8 into the retainer threads through the setscrew hole This creates a spot for the setscrew to lock the retainer nut Do not let the drill bit contact the setscrew hole threads Figure 92 Drill 1 8 into the retainer threads 10 Clean the hole of metal chips and hardened threadlocker thoroughly 11 Reinstall the setscrew using Loctite 242 or similar semi permanent threadlocker Torque setscrew to 8 N m 6 ft lbs Arneson Surface Drive Manual 1022808 137 Hydraulic Cylinder Service Twin Disc Incorporated 138 Disassembly and Inspection 1 Remove the capscrew from the tube near the point where the rod protrudes out of the cylinder Hold the cylinder tube using strap wrench or suitable split blocks Loosen the bronze rod guide using a suitable wrench Thread the rod
103. ntical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated C As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment D Only a Twin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated E Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials F failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge b
104. nts Twin Disc Incorporated Special JU LLULLU uuu 149 List of Special Tools u 149 1009229 Wrenigli IA aaa Zaa sasa 150 T 18050 579 Thrust amp Socket Roller Bearing Driver 151 T 18050 640 Inner Bearing Cup Driver 152 1 21085 Assembly Stand J 153 T 21085 1 Assembly Stand Component 154 T 21085 2 Assembly Stand Component 155 T 21085 3 Assembly Stand Component 156 T 21085 4 Assembly Stand Component 157 T 21172 2 Lifting Fixturpre UU 158 T 21549 11 Indicator Holder Propeller 159 T 21549 12 Drive Tightener 160 T 18050 804 Driver 161 T 18050 805 Wear Sleeve 162 T 21549 32 Cylinder Seal Protector 163 T 21549 33 Steering Cylinder Thread and Seal Protector 164 Engineering Drawings 165 List of Engineering Drawings
105. o angle down to the point where the ball thrust tube assembly makes contact against the thrust socket Severe damage to the ball and the socket could result 72 Arneson Surface Drive Service Manual 1022808 Removal from Vessel Twin Disc Incorporated SOCKET BALL CLEARANCE S CAUTION SUPPORT END OF PROPELLER SHAFT TO PREVENT SEVERE DAMAGE TO DRIVE CAUTION SEVERE DAMAGE TO DRIVE WILL RESULT FROM ALLOWING CONTACT AS SHOWN Figure 32 Protect Ball from Damage Arneson Surface Drive Service Manual 1022808 73 Removal from Vessel 74 Twin Disc Incorporated Disconnect driveline companion flange at input shaft and remove center flex lock nut and thrust washer on drive input shaft Note Additional removal of driveline components may be required to allow access to companion flange center flex nut Support Arneson Surface Drive unit properly to prevent Arneson Surface Drive from falling when the mounting bolts are removed Do not cradle the Arneson Surface Drive unit on the propeller shaft or input shaft Damage to the unit could result 6 Remove socket mounting bolts nuts and washers Cut or scrape as much sealant as possible from the edges of the socket Avoid scratching or other damage to the transom Use a blunt tool when prying the socket flange from the transom Apply force slowly and evenly at several points on the flange Drive should now slide away from transom Take care not to damage
106. o not allow temperature of housing to exceed 121 C 250 F Do not overheat races when removing from shaft Races should not be heated above 121 C 250 F Excessive heat will damage or distort the shaft Figure 73 Thrust Socket Housing Arneson Surface Drive Service Manual 1022808 117 Twin Disc Incorporated 2 Install frozen forward socket roller bearing into small diameter end of the socket Slide bearing down to shoulder in housing Seat bearing against shoulder with specialtool T 18050 579 if necessary Handle the components with care The frozen parts are extremely COLD Figure 74 Installing Frozen Forward Socket Bearing into Socket 3 Install bearing retaining ring Assure ring is seated into groove Figure 75 Installing Retaining Ring 4 Place thrust socket in socket bench with small diameter end protruding through hole in bench 118 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Input Shaft and U Joint le Before installing input shaft and U joint into socket place spiral lock retainer ring above bearing on input shaft Figure 76 Installing Input Shaft and U Joint into Socket Arneson Surface Drive Service Manual 1022808 119 Assembly Twin Disc Incorporated 2 Heatthe socket housing with a butane or propane torch to assistin the installation of U joint assembly Do not allow housing temperature to exceed 121 C 250 F Handle the com
107. on On twin drive installations each of the steering cylinders may both be inboard or both be outboard of the drives ES 66 00 minimum a gt Co OUTLINE Lc OF TRANSOM 2 er Se Figure 15 Transom with Optional Inboard Steering Arneson Surface Drive Service Manual 1022808 37 Installation 38 Twin Disc Incorporated Position the drive in the neutral trim position and parallel to the vessel centerline See Figure 13 Attach the steering cylinder clevis to the trim yoke pin with the hardware supplied See Figure 16 Torque nut to 57 N m 40 ft Ibs Set the steering cylinder to the mid travel location and position the steering cylinder mounting bracket on the transom See Figure 14 The height and orientation of the mounting bracket should be such that the mounting bracket the clevis and the rod end are as close to centered as possible For hulls with moderate deadrise this height is usually dictated by clearance from the hull bottom Note If at all possible the mounting bracket holes should avoid stringers the hull bottom and any hull fittings that preclude the use of through bolts Mark the location orientation of the mounting bracket with a straight line approximately 12 in long Slide the ball protective boot back from the thrust socket The trim cylinder should be supporting the weight of the thrust tube Remove the plastic gauge from the stee
108. operation If necessary add more oil to the reservoir until it is again one third full If the vessel is the water A Fill through the top of the reservoir until the oil sustains a one third full level in the reservoir Note Filling the drive will take longer when the vessel is in the water because the oil takes time to flow through bearings etc in the drive B Replace all fill plugs and check fittings C Check this level after 24 hours and after the first vessel operation If necessary add more oil to the reservoir until it is again one third full 4 During operation the lube oil level will rise in the oil reservoir due to heat and the displacement of oil from within the drive unit into the reservoir This is normal The oil level will return to the original levels when the unit cools and is not running or idling Arneson Surface Drive Service Manual 1022808 47 Installation Twin Disc Incorporated To Drain the Unit 1 Trim the drive all the way up by retracting the trim cylinder 2 If the vessel is out of the water remove the drain plug at the bottom of the socket Replace the drain plug after the oil has drained out If the vessel is the water drain the reservoir Connect the hose at the bottom of the reservoir to a pump and pump the oil out of the unit Reconnect the hose to the reservoir after pumping 48 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation
109. ounting is deemed to be unsafe or structurally unsound Such mounting will void all Twin Disc Incorporated warranties 22 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Mounting Requirements The Arneson Surface Drive propeller requires clean water flow to operate at a proper efficiency The bottom of the vessel hull should be clean and clear of any obstructions such as water intakes soeedometer sensors etc for an area at least 21cm 8 in each side of the propeller tips and at least 1 83 m 6 ft forward of the transom The optimum mounting angle for Arneson Surface Drive is six degrees to the vessel s baseline Correct mounting of the unit may require a supplementary wedge When ordering the Arneson Surface Drive be sure to specify existing transom angle deadrise angle of hull and whether it s a single or twin installation Application inquiries can be correctly answered only if accompanied by an Application Data Sheet that is available from the dealer or the factory Inboard and outboard surfaces of the transom must be parallel to within 6 40 mm 1 4 in Transom outboard surface must be flat to within 1 60 mm 1 16 in Transom inboard surface must be flat to within 3 18 mm 1 8 in in way of the surface drive socket If the surface drive is installed with an incorrect mounting angle serious performance deficiencies could result Arneson Surface Drive Service Manual 102280
110. ove trim yoke pin s from trim yoke s disconnecting steering cylinder and or tie bar from thrust tube Steering Cylinder Figure 26 Rear View of Dual Installation Showing Cylinders and Tie Bar 4 Loosen band clamps on boot and push back over thrust tube Te Figure 27 Band Clamps and Boot 68 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Removal from Vessel 5 Unscrew remove safety clip around aft retainer Figure 28 Removing the Safety Clip Around the Aft Retainer Arneson Surface Drive Service Manual 1022808 69 Removal from Vessel Twin Disc Incorporated 70 6 Using wrench Special Tool 1009229 unscrew aft retainer counterclockwise Note If retainer is seized or moves with great difficulty gently and evenly heat the outside of the socket near the aft retainer with a butane or propane torch Do not overheat housings Excessive heat may damage or distort casting Socket housing should not be heated above 121 C 250 F Figure 29 Unscrewing threaded Aft Retainer 7 Remove thrust tube from socket with caution taking care that ball comes out of the socket evenly Protect ball and socket with plastic bags to avoid contamination by dirt and dust Do not let ball contact the threaded edges of the socket Severe damage to the ball and socket could result 8 Store thrust tube securely without anything touching the ball Arneson Surface Drive Serv
111. ponents with care The heated parts are extremely HOT Assure shaft and bearing are kept straight as they are installed into housing Do not bind Figure 77 Installing Input Shaft and U Joint into Socket 120 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Lift the input shaft and U joint assembly above socket Lower the assembly into the thrust socket until ball bearing is above the bearing bore Align bearing to bore and once housing is heated bearing should fall into place Keep the bearing straight in housing bore When shaft is inserted into socket assure that roller bearing engages smoothly After socket shaft assembly is installed install retainer ring which was placed above the bearing before installation into the retainer ring groove Use a suitable retaining ring pliers to help compress the bearing retaining ring while installing it The retaining ring pliers may have to be modified by bending its prongs This will allow its handle avoid the u joint during installation Lubricate bearing with oil Figure 78 Installing Retaining Ring 5 Prepare the forward retainer for installation into the socket housing Inspect spherical surface of this ring for any scratches or burrs on its surface Remove rough areas by lightly sanding with emery cloth or 400 or finer grit sandpaper Thoroughly clean with alcohol Slide forward thrust retainer ring into socket housing Install packing
112. power unit Lifting excessive loads at these points could cause failure at the lift point or points and result in damage or personal injury Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Introduction Preventative Maintenance Frequent reference to the information provided in this manual regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment and if observed minimum repairs aside from normal wear will result Arneson Surface Drive Service Manual 1022808 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts 14 Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you
113. que value then continue until the cotter pin slot in nut aligns with hole in shaft Do not exceed the maximum torque value 20 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation Installation General Note For Reinstallation of repaired units to the transom from which it was removed see the instructions at the end of Assembly in this manual Note Please read this Installation Manual all the way through and become thoroughly familiar with its contents before commencing installation procedures Installation Requirements The installation of the surface drive must comply with all prevailing manufacturer s instructions and requirements as defined in this manual Twin Disc Incorporated will not be responsible for surface drives that have been improperly installed or where such installations shall be deemed to be unsafe or structurally unsound Such improper installation shall immediately void all Twin Disc Incorporated warranties Rated Capacity The ASD 12B1LU is designed for a maximum intermittent torque loading of 4800 foot pounds applied at the input shaft flange Please verify that output of the power unit to be used does not exceed this torque rating Consult Twin Disc Incorporated for applications exceeding this capacity or if the installation is intended for commercial or heavy duty use Reduction Ratio and Propeller Gearbox reduction ratio and propeller pitch diameter s
114. re that the run out on the pointers are no greater then 1 59 mm 0625 in It will be necessary to check runout on both shafts by turning them each 360 The engine and transmission package must be adjusted so that the pointer ends meet each other TRANSMISSION OUTPUT SHAFT CENTERLINE WILL NOT BE PARALLEL TO ARNESON INPUT SHAFT CENTERLINE FABRICATED POINTERS TO BE USED IN PLACE OF DRIVE SHAFT TO COMPLETE ALIGNMENT OF TRANSMISSION OUTPUT SHAFT CENTERLINE TO ARNESON INPUT SHAFT CENTERLINE ADJUSTMENT LOCKING BOLTS ADJUSTABLE SHAFTS ON BOTH SIDES LENGTHS MUST BE SET EQUAL BOTH MUST BE 21 LESS THAN 1 59MM RUNOUT IN THIS AREA IS NO GREATER THAN 1 59MM 0625 INCH BOTH SIDES PRIOR TO ALIGNMENT ROTATE BOTH SHAFTS TO VERIFY WITHIN SPECIFICATION Figure 18 Remote or Island Mounted Alignment Tool Shafts not Parallel Arneson Surface Drive Service Manual 1022808 43 Installation TRANSMISSION OUTPUT SHAFT DRIVELINE FLANGE 44 Twin Disc Incorporated adjusted so that the two rods are parallel to each other The rods can be lengthened as long as the runout is within the allowable limits to ease in the adjustments TRANSMISSION OUTPUT SHAFT CENTERLINE WILL BE PARALLELTO ARNESON INPUT SHAFT CENTERLINE FABRICATED POINTERS TO BE USED IN PLACE OF DRIVE SHAFT TO COMPLETE ALIGNMENT OF TRANSMISSION OUTPUT SHAFT CENTERLINE TO ARNESON INPUT SHAFT CENTERLINE ADJUSTME
115. ring cylinder and compress the steering cylinder completely Push the drive in the direction of the steering cylinder allowing a 6 mm 1 4 in clearance between the thrust ball and socket Place the steering cylinder bracket against the transom and mark the location Mark the bracket outline on the transom Pivot the drive horizontally in the other direction extend the cylinder completely and repeat the procedure Let it swing with the thrust tube Mark the steering cylinder bracket outline on the transom Position the mounting bracket at the center of these two marks Transfer the steering bracket hole pattern and drill four 13 5 mm 0 53 in and Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Installation two 16 mm 0 63 in diameter holes as shown in Figure 14 and drawings 1014597 1 and 2 Mount the steering cylinder bracket with its backing plate and stainless steel 1 2 in diameter bolts nuts and washers Torque nuts to 61 N m 45 ft lbs Apply a generous layer of marine transom sealant under the bracket and in the fastener holes in the transom to prevent water leakage Do not turn the bolts when tightening them Hold the bolts in place and only turn the nuts If this procedure is not followed leaks can develop in the holes SCREW OPPOSITE SIDE OF PIN L SCREW CLEVIS PIVOT PIN FITTING BOLT 4 566 SASS A ASNN 3 lt SS
116. rlier Torque mounting bolts to 175 200 N m 130 150 ft lbs See Mounting Hardware in Installation Section Install front oil seals back to back but seperated by the spacer Install seals using special tool seal driver T 18050 804 Cover the socket shaft with the input seal protector to protect the seals as they are pushed into the housing with the driver Garter spring on first seal faces the U joint Garter spring on second seal should face forward Fill the seals and the groove between the two seals with lithium based grease to assure proper lubrication Figure 83 Installing Front Oil Seals and Spacer Arneson Surface Drive Service Manual 1022808 129 Twin Disc Incorporated 15 Install spiral retaining ring Figure 84 Installing Spiral Lock Retaining Ring 16 Place clip in the notch of the aft retainer that is positioned in front of the six bolt holes on the aft face of socket housing Clean tapped holes with alcohol and dry with compressed air Secure with two bolts that have been coated with Loctite 242 or similar semi permanent threadlocker Torque retainer clip bolts 7 3 N m 65 in lbs Figure 85 Aft Retainer Ring Lock Clip in the Notch Locking Tab 130 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Boot Installation Note The boot is not intended to keep water out its purpose is to protect the drive from marine growth and debris Clean the interior of
117. rvice Manual 1022808 125 Assembly 126 Twin Disc Incorporated Once rods are in place draw together the thrust tube and socket by tightening nuts on the rods Perform this step by evenly applying pressure to both sides of press fixture Stop tightening when nuts become extremely difficult to turn Note the distance from the front end of the socket flange to the aft end of the propeller shaft should be very close to 1590 mm 62 5 Do not attempt to pull thrust tube into thrust socket using retainer ring This can scratch the thrust ball and cause retainer ring to warp or break It can also cause a rough ball surface that will severely affect the sealing integrity of the packing and o ring arrangement Figure 81 Tightening the Aft Retainer using Special Wrench 6 Inspect shims and ensure that they are flat against the packing and will not get caught in the retainer threads Thread aft retainer into socket until contact is made and resistance is felt on packing Measure and record the distance from the aft end of the retainer to the aft end of the socket in three places The average of these values is distance Distance is equal to A minus 3 mm 1 8 in Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 9 Tighten the aft retainer until the distance from the aft end of the retainer to the aft end of the socket is If the gap between the thrust ball
118. s of service whichever occurs first This is the only warranty made by Twin Disc Incorporated and is in lieu of any and all other warranties express or implied including the warranties of merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc Incorporated The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering Twin Disc Incorporated is not responsible for any specific application installation or performance standard Any analysis program by Twin Disc Incorporated based upon customer supplied information is done solely as an accommodation to the customer and is not to be interpreted or construed as an approval for specific application or installation or a guarantee of performance B The exclusive remedy provided by Twin Disc Incorporated whether arising out of warranty within the applicable Incorporated be either the repair or replacement of any Twin Disc Incorporated part or product found by Twin Disc Incorporated to be defective and the labor to perform that work and to remove and reinstall or equivalent credit In this context labor is defined as the flat rate labor hours established by Twin Disc Incorporated in the published Twin Disc Flat Rate Schedule required to remove disassemble inspect repair reassemble reinstall and test the Twin Disc Incorporated product only Au
119. sides of the housing in the mounting bolt holes Lift socket and heat housing at the bearing area until the bearing race drops out If necessary tap lightly against bearing race with a drift to assist in removal Small Diameter End of Sockel Housing Figure 46 Heating Housing to Remove Roller Bearing from Small Diameter End Handle the components with care The heated parts are extremely HOT Do not overheat housings Excessive heat will damage or distort the casting Socket housing should not be heated above 121 C 250 F Flush thrust socket housing and components with clean solvent to remove all debris Visually inspect all parts for damage or dirt Inspect all seal and bearing contact surfaces for wear or damage Forward retainer should be free from any rough edges or burrs Smooth any rough areas with 400 grit or finer emery cloth See Cleaning and Inspection section of this manual Arneson Surface Drive Service Manual 1022808 89 Disassembly Twin Disc Incorporated Disassembly of the U Joint Input Shaft 1 Once the input shaft with the universal joint is removed from the socket housing separate the u joint from the shaft Clamp the U joint s H shaped center coupling in a vise The U joint should be positioned so it looks like an its side with the bottom leg of the H in a vise 2 Remove the bolts and collars holding the U joint to the input shaft Slide the shaft out of the splines ofthe yoke
120. t yoke against the bearing Note Care must be taken when assembling the collar and screw into the yoke and shaft to prevent the collar from catching its lower edge on the edge of the hole Begin by sliding the collar over the screw and into contact with the screw head The large end of the collar must face the screw head A Continue to hold the collar against the screw head and thread the screw into the shaft about two turns The collar should not yet be in the hold Next slide the collar into the tapered yoke hole ensuring that the collar enters the hole without catching its edge on the edge of the hole It should be possible to tilt the screw slightly to the side to allow the collar to enter the tapered hole B Once the collar is started into the yoke advance the screw until it contacts the collar and then torque the screw to the final torque value C Tighten the two capscrews evenly Do not exceed a torque of 65 N m 45 ft lbs on the capscrews Figure 72 Lower U joint Onto Spline left Install Collars right 116 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly Thrust Socket Place thrust socket assembly bench with the smaller diameter end facing up Lubricate bore and outside of forward socket bearing with lubricating oil If necessary heat the outside of the small diameter end of the socket with a butane or propane torch to assist in the installation of the roller bearing D
121. te rebuilding service for surface drives and hydraulic cylinders Call or write Twin Disc Incorporated for information on services pricing and scheduling Twin Disc Incorporated 1328 Racine Street Racine Wisconsin 53403 USA Telephone 262 638 4000 Fax 262 638 4480 Warranty Equipment for which this manual was written has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual For details of the warranty contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Incorporated Racine Wisconsin U S A 16 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Description and Specifications Description and Specifications General The ASD 12B1LU Arneson Surface Drives are in line steerable propulsion systems that support and drive a surface piercing propeller at variable depth positions Nameplate The nameplate identifies the model bill of material BOM and the serial number of the unit These numbers are necessary to identify the correct parts for the surface drive ARNESON e SURFACE DRIVE MODELNO Ld BOM NO _ SERIALNO SAE30W SAE40W API SERVICE CATEGORY CF OR HIGHER CERTIFIED BY VENDOR TO PASS CATERPILLAR TEST TO 4 SAE80W SAE90W HYPOID EP TYPE API GL GRADE 5 TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A Figure 1 Nameplate for Arneson Surface Drive
122. the boot with a clean rag and cleaning solvent Holding the boot with the large end facing forward pass the boot over the propeller shaft and slide down to the thrust socket Assure that the grooves in the thrust tube and socket housings match up with the ridges on the inner diameter of the boot Secure boot to thrust tube with small circle clamp and to the socket with two large circle clamps Assure that the clamp screws are on the top of the unit Apply anti seize that does not contain graphite or molodenum disulfide such as Loctite White Anti Seize on clamp threads Figure 86 Boot Secured With Three Circle Clamps Arneson Surface Drive Service Manual 1022808 131 Assembly Twin Disc Incorporated Fin Reattachment 1 If working on more than one unit at a time make sure that the number on the fin is the same as the number on the fin pad The number can be found on the port side of the thrust tube under the Twin Disc logo On the fin the number is located on the upper port side VA Fin Pad Number Fin Number Figure 87 Identifying Fin and Fin Pad Numbers 2 Remove any rough edges or burrs from mating surfaces of thrust tube and fin pad Clean with alcohol Spread a thin layer of waterproof marine grade silicone sealer on thrust tube fin pad 132 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Assembly 9 Place fin on fin pad and install sock
123. thorized reasonable travel and living expenses will be considered for payment on all Commercial Marine Products except on Electronic Control Systems Under no circumstances including failure of the exclusive remedy shall Twin Disc Incorporated be liable for economic loss consequential incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise ide
124. ve tapered bearings by using heat or by cutting the bearings off the shaft 2a To remove bearings with heat first break the bearing cage with achisel on both sides of the rollers Stand shaft vertically with the propeller end up and quickly heat inner races with an acetylene torch until the races drop off Handle the components with care The heated parts are extremely HOT Do not overheat races when removing from shaft Races should not be heated above 121 C 250 F Excessive heat will damage or distort the shaft 2b cut bearings off use a cutoff wheel with a carbide composition wheel Cut through roller cage Separate the cage and rollers from the inner race Cut groove in inner race until half through the race Split race with chisel and slide off shaft 84 Arneson Surface Drive Service Manual 1022808 Twin Disc Incorporated Disassembly Use extreme caution when cutting the bearings away from the shaft Do not cut or scratch the shaft Damage to the shaft will cause loss of press fit on races bearings or seal surfaces and will weaken the shaft Figure 42 Breaking Bearing Cage With a Chisel On the propeller end of the shaft remove seal sleeve spacer and rear roller bearing race by applying rapid heat with an acetylene torch Slide components off the shaft Discard the rear roller bearing race and the seal sleeve Handle the components with care The heated parts are extremely HOT ACAUTION Do not
125. w locations Cleaning Bearings Do not remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease Never dry bearings with compressed air Do not spin non lubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Arneson Surface Drive Service Manual 1022808 93 Cleaning and Inspection Twin Disc Incorporated 94 Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently itis important to keep bearings clean Do not remove grease from new bearings Keep the wrapper on new bearings until they are installed Do not expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Sealed Joints Scrape surfaces to remove old gasket material on previously sealed joints Wipe off cured sealant with gel type paint remover containing methylene chloride Clean surfaces with denatured alcohol or clean solvent to remove oil and grease residue Test for clean surfaces by applying a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface in a film If the water puddles or forms beads use fresh solvent and reclean Arneson Surface Drive Service Manual 1022808 T
126. win Disc Incorporated Cleaning and Inspection Inspection Housings Cast Parts and Machined Surfaces Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with 400 grit or finer emery cloth or a soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will cause loss of press of bearings or races Inspect oil and grease passages for obstructions If you find an obstruction remove it with compressed air or work a wire back and forth through the passage and flush it with solvent Inspect machined surfaces for burrs scratches nicks and foreign matter If you cannot remove the defect with 400 grit or finer emery cloth or a soft stone replace the part Inspect threaded openings for damaged threads Chase all threads with a thread chaser of the correct size to remove old thread locking compound Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels This applies where a matched set of parts is not involved Inspect dowel pin holes for wear due to movement between mating parts If a dowel pin hole is worn re bore and sleeve the hole when possible Otherwise replace the parts This applies where a matched set of parts is not involved Bearings Inspect bearings for roughness of rotation Replace the bearing if the rotation
127. within 10 hours of operation 2 The propeller nut torque MUST be checked in the following operational interval A The propeller nut torque must be checked in accordance with the required torque after an additional 250 hours of operation If the torque is correct go to step B If the torque is incorrect re torque the nut and repeat step A B The propeller nut torque must be checked in accordance with the required torque after an additional 500 hours of operation If the torque is correct go to step C If the torque is incorrect re torque the nut and repeat step B 2 The propeller nut torque must be checked in accordance with the required torque after an additional 1000 hours of operation If the torque is correct go to step D If the torque is incorrect re torque the nut and repeat step C D The propeller nut torque must be checked in accordance with the required torque after an additional 1500 hours of operation If the torque is correct go to step E If the torque is incorrect re torque the nut and repeat step D E Continue to increase the interval in increments of 1500 hours until the regular haulout interval of the vessel is reached F If at any point in steps A through F the haulout interval of the vessel is reached or surpassed the torque check interval may be established to be the same as the haulout interval Record the final interval for reference Arneson Surface Drive Service Manual 1022
128. y COLD 1 Heat the roller bearing and the input shaft socket end seal wear sleeve to 250 F 121 C Handle the components with care The heated parts are extremely HOT Assemble the previously heated bearing sleeve to the input end of the input shaft Figure 71 Input Shaft Seal Sleeve 3 Assemble the previously heated ball bearing onto the output universal joint end of the input shaft Be sure to hold the bearing against the shoulder of the shaft as it cools 4 Clean the threaded holes that are cross drilled in the output end spline with denatured alcohol to prepare for Loctite 242 or similar semi permanent threadlocker 5 Stand the input shaft in the vertical position with the output universal joint end up This can be identified as the spline that has a cross drilled and threaded hole through the shaft Arneson Surface Drive Service Manual 1022808 115 Assembly Twin Disc Incorporated 6 Lower the U joint assembly over the spline aligning the cross drilled holes in the shaft and u joint yoke 7 Coat the two clean 3 8 24 UNF x 1 1 2 socket head capscrew threads with Loctite 242 or similar semi permanent threadlocker and insert the capscrew through the collar Install the capscrew and collar through the holes in the u joint and into the threaded holes in the shaft Note that the holes in the shaft and the u joint are not perfectly aligned so that the tapered collar will draw and hold the u join

TWIN DISC

Contents

Download Pdf Manuals

Related Search

Related Contents