Service manual
Contents
1. TN 97 Rosetta UN 6592 14x28 2 46004 2 98 Vite UNI 5931 MKx100 46545 99 Dado autobloccante UNI 7473 M4 11 46 100 Rosetta elastica UNI 7214 0527 16 semo 10 Vite 150 4017 46531 102 ondulata DIN 37 461208 103 Vite TE ISO 407 M8x30 4658 SAIL DRIVE SP 60 SHOP MANUAL PREASSEMBLY OF CLUTCH GROUP Put shim ref n 3 into the shaft ref n 1 until it hits the splined part of the shaft Put shim ref n 4 all the way down into the shaft woo nx E Warm the ring ref n 5 up to 120 C put the ring into shaft ref n 1 as per picture with the help of a cylindrical stopper if necessary Put the two cages ref n 6 into the ring ref n 5 ocu Put on the clutch gear ref n 7 E Put the clutch body ref n 2 into the sahft ref n 1 make sure it has enough play to the spline and it moves freely Put on the opposition spring ref n 12 Put on shim ref n 4 all the down H 7 Ad i d j i Lal 3 Warm up ring ref n 5 up to 120 C position it all the way down into the shaft Insert the two cages ref n 6 Put on the clutch gear ref n 7 Position the bearing housing ref n 8 Insert and tighten the fixing nut ref n 9 Secure the clutch group in a vise with the proper tool tool SP 60 01 to avoid to damage2. 463008 38 telecomando Sea Prop 0 1 2004036 00 40 Vite TE ISO 407 6 11 465274 41 Guamizione in gomma sensore Sea Prop 60 1 2012176 00 42 Guarnizione in gomma Sea Prop O 11 201215 00 43 Rosetta UN 6592 4 4 GAS 11 460902 4 amp 4 lapp CAS 1 45 Supporto inferiore gruppo frizione 11 2030077 00 46 Guornizione OR 208 2 4590064 47 Guornizione OR f 4960 4B Rosetta ondulata DIN 17 B d O inox A2 18 4424 49 Vite TCEI UNI S931 0 40 8 46159800 50 Flanga chiusura membrana Sea Prop 60 1 2043032 00 351 Tappo 24 2 con OR 0040 11 458820 TargheHa olio ATF per invertitori 2028012 00 53 Rosetta UN 6592 x O 4609 _ 25 oio Sea Pron 60 11 2070060 O00 56 Toppo TE DIN 7604 480000 57 STE UN 593 09 1 458900 59 Scola inferiore Sea Prop 0 200955 00 60 comando Sea Prop 6 11 20267 00 61 Gheradiboccaggo O 1 1 203808 00 62 32005 25x47x15 4622000 63 Giunto Sea Prop 60 11 2062327 00 6 amp Seeger 019 UN 74337 71 60099 0 2 65 Guarnizione OR 4325 O Z O 1 459800 66 Cuscinetto 32007X 35 62 181 11 4622040 68 Pigno
3. 450 WHERE TO ADJUST Add shims between bearing and case where shown by the HOW TO ADJUST Remove tool n 3 Remove the temporary nut Remove the gear moving the shaft vertically and tooling 4 Replace the bowl FAKE 1 with the final one adding the shims for first NOTE The theoretical tolerance with be from 0 to 0 025 STRECHU REGISTRO POSE Ion HAS 2 18 LA prie da fma of yadro Seer quark Hericre appi FALSA T de sussherfic nus armpons e be pam Pens Wi feeder gl delle corone SITE ACCOR l on rer pore Cohen ae ex umm goa d semp h xen nonus 90 merger labaran 3 drar ion Ln gases efus 1 B Faber GuAMTO 9 REGISTRA 0 SESE ll EPRPE 28 950 24 56 5150 0 50 9 Sere 1 ST fup duin CREADA Toge obero d Tab kr rH Bene Gh xxr cba ngang lux moore l aioars giuria la compo CF ELA 13 enn quella dais quc Cw Eigen da 0 a nns coo fibro pun Put the bearing bowl ref n 66 on its location Detect gear ref n 68 measurement as per scheme n 3 Put the bearin
4. single gear To assemble the gear use induction frequency heater for bearings like STAR 220 Z serial 900601 6 To assemble the gear it must be set at 150 C for 300 seconds To assemble the bearing it must be set at 120 C for 220 seconds NOTE before to assemble the bearing wait for the gear to cool down Detect the measurement shown by the drawing and write it down on the form or on the item Assemble the bearing on the gear paying attention at the correct position all the way down Measurement to be taken 24 5 51 5 the measurement defines the real distance from the generating PREPARAZIONE INGRANAGGI MONTAGGIO SCARPONE Ful eot Ad a wen quid porin rir cums ego Bure dex xr d nonc Ree Dei Buono Gn UP dea Re s CLIE CURES Per i diee Peo chive corn TRO STAR 2 Par o DIT prega 300 Par ronaki Od menat WOLE tian 1979 271 Sec Pira d morie caeruleo clendaw cha haaay ui ska raffraddclo in queis rw dong naqnerkn s gu Feria 1 casei Sul rgeareagge cuore aio n balli amelbrenin ADJUSTMENT OF THE OUTPUT SHAFT Scheme n 1 Adjustment position gear Z 22 Assem
5. the spline on the shaft proceed screwing both nuts on the end of the shaft 1n Tk Measure the height of the clutch group the value must be 83 02 mm If it is not increase or decrease the thickness by adding or removing some shims ref n 3 the fixing nuts ref n 9 Warm the bearings ref n 10 up to 120 C put them on the bearing housing ref n 8 screw the fixing nuts ref n 9 tighten and rivet the thread with a punch the position of the markings on the thread AWE SIME S WEE d Position the preassembled clutch group with the thrust blocks of the respective bearings PREASSEMBLY OF THE INPUT GEAR GROUP Warm up bearing ref n 19 up to 120 Put it as per picture all the way down into the shaft ref n 17 Insert the drag pin of the oil pump ref n 20 Put in the rotor of the oil pump ref n 21 Put on O ring ref n 18 Put the bearing bowl ref 19 and 22 into the bearing housing ref n 14 all the way down Put on the previously assembled shaft internally to the bearing housing Put bearing ref n 22 onto the bearing housing ref n 23 Put the bearing all the way down into the shaft Insert and tighten the fixing nut ref n 24 Rivet the thread using a pin to avoid its unscrewing in two opposite locations UE IT iE an Put the oil seal ref n 25 in its position adding grease in its locat
6. LAU SIL Poa ZA H rani 2 i SEZIONE a7 4 era 2 87 N lt S NM 4 MN M NS YA zA 4 2 f 1 UI NS 5 bd Piet me A e A XA PARE ASSN 7 Y lt ME E S SIL A NND DER gt NS S 2 qs AS i QE AUN ee e V 5 d 2 SS Fil E eb cm AM T KI N SEN ES S DETTAGLIO D SCALA 1 1 o ae RES LI LI Sed prop 80 codice n Os Er c 19 22 Zag 2081692 2061691 1013180 Lx eoe 2 14 2061694 2061693 1013181 37 TR bi SSE wE N DETTAGLIO d me m Lau P 9 SCALA 1 1 s Albero secondario S 2021516 00 2 Corpo frizione Sea Prop 60 205651 00 3 Spessore registro bero sec Sea Prop 60 4 201375 00 4 Rasamento su secondario TMC 40 2 20604 00 5 Anello interno FAG JR25x30x265 2 4584020 6 rullini FAG 0 57 4 46040544 7 Ingranaggio c
7. Service manual Sea Prop 60 USE OF THE MANUAL Consignee gt Operator gt 4 Maintenance The good functioning and the efficiency of the mechanical components mainly depend on a constant and correct maintenance TAKING VISION OF THE ENTIRE MANUAL allows to properly perform the operations of ordinary and extraordinary maintenance The lack of the recommended operations can compromise the lifetime and the integrity of the transmission and bring to failure or injury to the operator In the event of breakdown or anomaly the prompt reaction from the specialized personnel will guarantee a higher lifetime of the assembly preventing further damage in the years GENERAL SAFETY RECOMMENDATIONS IMPORTANT LL Safety precautions Before starting any operation read this paragraph carefully The correct use and the correct repair of the assembly and its components are very important for security and reliability The recommended procedures that are listed on this service manual have been tested as operative ways to act Strictly follow each procedure making use both of writings and illustrations Some of these procedures show the usage of pertinent tools designed to perform every operation clearly and correctly Some specific tools must be used where necessary to perform some proper operations It is impossible to manage every working procedure or all the possible methods with their own risks therefor
8. ampana frizione Sea Prop 0 2 2061695 00 8 Supporto cuscinetto albero sec Sea Prop 60 2 2030072 0 9 Dado fissaggio albero sec Sea Prop 0 2 2038030 00 10 Cuscinetto 30208A 40x80x19 75 12 462200 13 Scatola superiore Sea Prop 0 1 2009053 00 14 Coperchio albero ingresso Sea Prop 60 1 2010365 00 f5 5 registra albero ing Sea Prop 60 2 20374 00 EINE EN Em 17 Albero ingresso rapp 049 Sea Prop 0 11 2021606 05 eoe ee eed 19 Cuscinetto 32009X 45x75x20 12 46220600 20 Vite ICE UNI 5931 11 4 21 pompa Sea Prop 60 1 20560550 00 22 Cuscinetto 32008XA 40x68x19 171 4622050 29 Supporto cuscinetto ingr Sea Prop 60 1 2030080 00 24 Dado bloccaggio albero ing Sea Prop 60 1 20380531 00 25 Anelo di tenutu 55x72x8 viton 11 49970872 26 DN 7980 82 68 4601508 27 Vite ICELUN 5931 30 16 46520 29 Anelpditentu 25 35 4595083 30 Guarnizione OR 39837 11 4945 32 Spina d ferm albero comndo 11 2035004 00 33 Spina Elastica UN 6874 3x20 4613034 34 Mola carica pattino IMC 50 0 11 2020068 00 36 Vite STEI 8 40 UN 5923 19 1 45807 37 Dado gutefrenante UNI 77738
9. ble tool 1 fixing it with the vertical tension rod Assemble the bushing 2 replacing the pilot bearing on the lower cover group Temporarily close the support to the lower cover group With dial gauge measure the axial play C i e 0 26 HOW MUCH TO ADJUST 59 75 X X shims to add 23 49 36 25 59 75 0 01 0 01 0 26 0 25 WHERE ADJUST Add shims between support and bearing as shown by the HOW TO ADJUST Remove the outer bowl of the bearing from its bearing housing Add as many shims as necessary part number 2013000 Reassemble the bowl making sure it is in the correct position all the way down NOTE shims must be added in a tolerance range between 0 025 and 0 025 PLAY DETECTED ON A SHAFT WITH DIAL GAUGE C 23 49 fixed measurement tool A 36 25 measurement to be detected on each item as B measurement SAL ST AL iF ses PESTA POSERTE HORAMASGD 2 22 EP emn 1 fonts yerkos Morrie aus Goel eel dal urort Chiudi hpa 1 aupra aio RLEVARE oon L omin IC PE garh 2D duara REGISTRA 26 K Soe do mra 322 9001 1 02 IDE PEGE Sees du maxxrib s com ra 55 3 PESTA 5 lt acris del dolo nau umm nore pi pari cee 2019900 oppa aseriran
10. don cha nd n MOTALA space ord deve aere crus n ur campo d pio d 1 25 Measure gear ref n 74 as shown by scheme 1 Insert tool SP60 04 securing it as shown by the scheme Put the gear ref n 74 on shaft ref n 73 Insert bearing ref n 82 with the help of a stopper if necessary tool SP60 05 Put the bearing bowl ref n 82 into the lower cover group Insert the output gear group already preassembled Put the bearing bowl ref n 19 into the bearing housing ref n 78 Insert the support and use the bolts to fix it On the end of the shaft screw the proper tool for bearings adjustment tool SP60 06 With a gauge measure the shifting of the output shaft Adjust the bearings adding shims rif n 75 81 as shown by scheme 1 ADJUSTMENT OF THE VERTICAL TRANSMISSION SHAFT Scheme n 3 ADJUSTMENT POSITION GEAR Z 19 First operation is to check the thickness of gear C measurement Mount bowl FAKE 1 of the bearing on the lower cover group and the internal part ACTUAL 2 on gear Z 19 Recall that the gears are coupled Place gear bearing in postion Couple the gear to the shaft and lock it temporarily with a nut Holding the axis vertically fit the tooling 3 Then fit tool 4 to put the shaft in line With the dial gauge in position check play B moving the shaft vertically HOW MUCH TO ADJUST B C D shims to add Example 26 600 0 850 24 5 51 50 0
11. e whoever uses not recommended tools must be aware that the safety of the operator and the boat will be endangered Recall icons OPERATION REQUIRING PARTICULAR ATTENTION AND PRECISION FROM THE OPERATOR OPERATION DAMAGING THE COMPONENT OR PRODUCT IF NOT PERFORMED CORRECTLY SS 5 The procedure for assembly disassembly of the transmission allows to perform the complete overhaul of the group and is assisted with photos for a complete and safe guide for each operation It is assumed that the transmission has been removed from the vessel The deep knowledge of the assembly allows the correct estimate of the kind of procedure to be followed which may only require the disassemble of a few components operating on a part of the transmission only Recommended tightening torque based to the screw type Filettatu ra 8 8 8G 10 9 10K 12 9 12K vite Nm Nm Nm M2 0 37 0 52 0 63 M 2 3 0 60 0 84 1 01 M 2 6 0 86 1 21 1 45 M3 1 34 1 88 2 26 M 3 5 2 06 2 89 3 48 M4 3 04 4 31 5 15 M5 6 03 8 48 10 2 6 10 3 14 71 17 65 M7 17 16 24 52 28 44 8 25 50 35 30 42 17 10 50 01 70 61 85 32 12 87 28 122 58 147 10 14 138 27 194 17 235 36 16 210 84 299 1 357 94 18 289 3 411 88 490 34 20 411 88 578 50 696 28 22 558 98 784 54 941 44 24 710 99 1000 28 1196 42 27 1049 32 1480 81 1775 01 30 1421 97 2010 38 2402 64 funi kp 2 25 4 F 1 gt T
12. g ref n 66 on the gear insert transmission shaft rif n 60 assemble the gear and screw the lock nut rif n 70 Insert bearing rif n 62 insert and screw lock nut rif n 61 With the proper tool tool SP60 07 hold steady the shaft in order to prevent its spin screw lock nut rif n 70 and rif n 61 On the end of shaft assemble dial gauge and detect the axial shifting as per scheme n 3 Go ahead with the gear adjustment by adding shims rif n 67 vec 7 gii gg gend vil nk 02100 Disassemble the adjustment tooling position the shims reassemble the components as shown previously when reassembling the nut rif n 70 use drops of thread locker Put oil seals ref n 79 in the support ref n 78 as shown by the cross section drawing Assemble the O rings rif n 80 and grease their surface to make their assembly easier Position the support all the way down Put in the fixing screws rif n 83 applying a drop of thread locker Tighten and fit the helicoil rif n 90 Assemble the zinc rif n 84 and tighten with screws rif n 91 Manually check the shaft spin and the play between the tapered pairs There should be no crawling during the spinning Put the o ring rif n 65 in its location apply grease to make the assembly easier Insert the retaining ring rif n 50 Join the upper part with the lowe part
13. ion to make the assembly easier Position the oil seal with a stopper PREASSEMBLY OF THE DRIVE GROUP Put on the oil seal ref n 29 internally to the support of the drive group ref n 28 Grease the oil seal location to make easier the insertion put it down using a stopper if necessary End up the preassembly inserting Drive shaft ref n 31 stop pin ref n 31 pin ref n 33 opposition spring ref n 34 sliding block drive ref n 35 adjusting pin ref n 36 lock nut ref n 37 O ring pos 30 drive lever ref n 39 PREASSEMBLY OF THE DRIVE COVER GROUP Put the bearing bowl ref n 10 into the cover group ref n 11 Put on the clutch group previously preassembled Insert the tooling tool SP 60 02 to center the clutch group into the cover upper assy Tighten it with the two screws Inserit the gear group previously preassembled apply tooling tool SP 60 03 as per the picture on the input shaft ocrew the centre pin until the gear gets the position Verify the measurement on the top the shaft with a depth gauge Disassemble tool SP 60 02 remove the gear group remove the clutch group Adjust the bearings applying a 0 05 mm preload dividing the shims into equel parts under the thrust blocks of the bearings ref n 10 Put the o rings ref n 45 on their locations of the lower support apply some grease Insert the preassembled clutch group Put the slee
14. ne rinvio rapp 086 Sea Prop 9 171 2061692 00 69 Rosetta DN 988 17 24 4573000 70 Ghiera autobloccante M7xX O O 1 458005 O 71 Rosetta UNI 6592 105x21 inox AS J nm 72 Vite 150 4014 10 35 inox AA 218 4615805 74 Corona rinvio 0 86 Sea Prop 0 11 2061691 00 75 Spessore di registra 9 748 1 2 2013624 O00 7 6 Boccola asse elica Seu Prop 0 1 25008 00 77 Haelicoi MOx15 a 78 Supporta albero elica Sea Prop 60 amp 1 2030076 O0 Anella di tenuta 40 52 7 viton a 80 Guornizione OR 4950 1 1 2 1588085 82 Cuscinetto 32004 20x42x15 171 4622000 83 Vit UN 5931 MOx25 inox 2 4615797 84 Anoda zinco Sea Prop 60 171 205009 00 85 Distanziale x elica a fisse 1 2013778 00 86 Guarnizione OR 2031 BRENNEN 87 Toppo scarico oio Sea Prop 60 211 2059073 00 BB Vite TSPELUM 5933 0 1 KI l 90 Helicol M6x4 2d a 91 Vie TCELUN 5931 6 25 AA 1 3 465400 92 Rosetta UN 6592 T GAS 211 460903 O 93 94745 1 458875 Distanzidle aggiuntivo x elica a pale abbattibili 2013729 00 95 5101 per supporto omvironte Sen Prop 60 1 2004037 QU 96 Supporto antivibrante Sea Prop 60
15. of the gearbox place the fixing screws rif n 72 and tighten LN Put the fitting on the location of the breather plug screw the fitting all the way positioning the chamfered part as per the photo ocrew the breather plug rif n 53 Place the spacers rif n 85 on the output shaft protecting the splined part applying damping layer Finish the upper part of the gearbox applying the oil dipstick and the oil filling plug Apply and tighten the lock plug on the membrane rif n 44 Apply support rif n 95 and tighten with bolts rif n 101 Apply antivibrating bracket rif n 96 and fixing screw rif n 98 tightening it Make the adjustment of the drive system Put thread locker on the dowel pin rif n 59 With the drive lever ref n 73 in the neutral position manually spin the output axis rif n 73 screwing the dowel pin ref n 59 at the same time until you feel like the rotation of the output shaft is resisting Unscrew the dowel by 74 of a revolution and lock it in position with the lock nut
16. ve ref n 63 into the shaft Put in the two membranes ref n 41 and later ref n 42 Put on the lower support ref n 45 as shown by the picture Put them in position making sure that the rubber membranes are correctly positioned on the internal of their locations Tighten the fixing screws Put the gear group into the cover group verify the left distance between the gear group and the case Put on as shims as to add 0 05 mm to the value detected by the thickness gauge Put the o ring ref n 16 in its location add grease if necessary Put the gear group into the cover group tighten the fixing screws Put on the oil seal ref n 18 Apply layer of sealant paste as shown by the picture insert the drive group previously assembled 39 M V Put in the fixing screws ref n 88 with thread locker and tighten Put on the drive bracket ref n 38 tighten the fixing screws Out the bushing for the breather plug into the threaded hole ocrew the breather plug ref n 53 e 54 SEAPROP ASSEMBLY PDF NUMBER 1 ARRANGE GEARS FOR LOW COVER ASSEMBLY Detect the measurement shown by the drawing and note it on the form Assemble the gear on the shaft and then the internal part of the bearing on the gear 59 75 measurement showing the distance of the position of the mounting face from the generating where it is needed to position the gear plus or minus 0 05 36 25 measurement to detect on each
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