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TTM 60-61 Service Manual

1. a 2 4 Before You ServiCe cccccccccceceeceseceeeceeeeseceeeeeeeseseuneeeeeeesnaees 2 4 Precautions for Safe 2 4 TUFF TTM60A TTM61A Service Manual 2 1 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission SAFETY This Page Intentionally Left Blank 2 2 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Tuff Torq is concerned for your safety and the condition of your marine gear Safety statements are one of the primary ways to call your attention to the potential hazards associated with Tuff Torq marine gear Follow the precautions listed throughout the manual before operation during operation and during periodic maintenance procedures for your safety the safety of others and to protect the performance of your marine gear Keep the labels from becoming dirty or torn and replace them if they are lost or damaged Also if you need to replace a part that has a label attached to it make sure you order the new part and label at the same time This safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it ind
2. 3 8 Hydraulic Diagram irissen rinn 3 10 Shifti g PreSS p ae ane p 3 11 Function Test a 3 11 Required 3 11 TUFF TORE TTM60A TTM61A Service Manual 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission GENERAL SERVICE INFORMATION This Page Intentionally Left Blank 3 2 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission This marine gear has a built in wet type multi disc clutch and is operated by the oil pressure of the hydraulic pump The major components are damper input shaft assembly support shaft assembly output shaft assembly hydraulic pump housing The lube oil for each of the parts is distributed by the hydraulic pump in a forced lubrication system When the forward reverse changing valve lever is moved oil pressure is applied to move the clutch to the FORWARD or REVERSE position The clutch for clockwise rotation of O P is fitted to the input shaft and the clutch for counterclockwise rotation of O P is fitted to the support shaft The marine gear oil lube oil is cooled by a multi pipe marine gear oil cooler TUFF TTM60A TTM61A Service Manual GENERAL SERVICE INFORMATION 3 3 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission
3. 4 52 Final Assembly of Cases 4 53 Reassembly of Mounting 4 54 Reassembly of 4 54 Reassembly of Case 4 55 Reinstall Oil Filter 4 55 Reinstall Hydraulic Oil Pump 4 56 Reassembly of Output Coupling 4 56 Filling Marine Gear With 4 57 Checking Oil Level sese 4 58 I A 4 59 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Before You Begin Servicing This section of the Service Manual describes the procedures for proper repair of the marine gear TUFF TORM rTrueoA 11614 Service Manual OVERHAUL BEFORE YOU BEGIN SERVICING Before You Operate x NEVER permit anyone to install or operate the marine gear without proper training Read and understand this Service Manual before you operate or service the marine gear to ensure that you follow safe servicing practices and maintenance procedures Safety signs and labels are additional reminders for safe service and maintenance techniques See your authorized Tuff Torq marine dealer
4. Failure to comply could result in death or serious injury 0000021en SEVER HAZARD If the vessel has more than one engine NEVER service a marine gear if either of the engines are running In multi engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running Failure to comply could result in death or serious injury 0000022en 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL SUDDEN MOVEMENT HAZARD Shift the marine gear into the NEUTRAL position any time the engine is at idle Failure to comply could result in death or serious injury 0000023en YA BURN HAZARD Keep your hands and other body parts away from hot engine and marine gear surfaces such as the muffler exhaust pipe turbocharger if equipped engine block and marine gear chassis during operation and shortly after you shut down the engine These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015enTrans Before You Begin Servicing 9 i gt FUME BURN HAZARD e ALWAYS read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers e Failure to comply could result in death or serious inj
5. Stop the engine WAIT AT LEAST 10 MINUTES for the oil to drain back into the sump TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL 5 Check oil level If necessary add oil until the level reaches the upper mark on the dipstick Check the oil level again after operating the marine gear for a short period of time 4 59 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Trial Run This Page Intentionally Left Blank 4 60 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Section 5 TROUBLESHOOTING Problem The subsequent tables will assist you in troubleshooting Possible Cause Countermeasure In case of trouble check first if all items of the mounting and operating instructions have been completed Transmission cannot be shifted Shifting lever is loose Tighten clamping bolt on shifting lever Remote control does not permit lever travel required for testing Lift remote control off if gears can be shifted by hand correct remote control Remote control faulty Repair remote control No shifting pressure available Refer to No 7 Delayed shift time Shift linkage misadjusted not allowing full engagement Lift remote control off if gears can be shifted by hand correct remote control If the transmission cannot be shifted correctly by hand replace the control bl
6. Oil leakage at joints Bolts are not tight Tighten bolts with prescribed torque Seals on bolts have been damaged Replace seals tighten bolts used several times with prescribed torque Mating faces are contaminated no surface seal applied Unscrew housing half finish mating faces with oilstone or finishing file apply surface seal Assemble transmission tighten bolts to prescribed torque 5 4 Transmission noise becomes louder Cil level too low so that pump sucks in air Top up with oil to marking on dipstick Damage starting on flexible coupling due to misalignment between engine and transmission Replace flexible coupling Check alignment between engine and transmission Beginning damage of bearings in transmission e g due to torsional vibrations running without oil overload wrong alignment of transmission excessive engine output Disassemble transmission replace bearings of damaged and other faulty parts Find causes and remedy Beginning damage of gearings e g due to torsional vibrations running without oil overload Disassemble transmission remove faulty parts Oil suction cover in transmission has come loose TTM60A TTM61A Service Manual TUFF TORR Disassemble transmission secure oil suction cover 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Problem Possible Cause TROUBLESHOOTING Cou
7. 4 54 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Reassembly of Marine Gear Reassembly of Case Plate 1 2 Remove repair stand install the mounting feet Install parallel pins Figure 4 57 1 with large chamfer end facing case plate Place lubricating pressure relief Figure 4 57 2 valve on housing not shown in line drawing Replace gasket Figure 4 57 3 on housing Slide case plate carefully onto input shaft and support shaft Install and tighten bolts to specified torque 1 00019248 4 57 TUFF rTrueoA 11614 Service Manual OVERHAUL Reinstall Oil Filter 1 Check seal for damage and filter for wear Replace if necessary 2 The oil filter Figure 4 58 1 must be washed with clean oil whenever the oil is changed 3 Install strainer spring gasket and cover with 3 M8x40 bolts 4 E Z SL 27 70917 4 j xO j ie yo Js OP 9 gt zh WAL y d fe 1 V 1 0002011A Figure 4 58 4 55 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Reassembly of Marine Gear Reinstall Hydraulic Oil Pump 1 Install oil pump Figure 4 59 2 2 Install 4 M8x65 hex head bolts Figure 4 59 1 0001923 Figure 4 59 Reassembly of Output Coupling 1 Remove O ring from coupling before heat
8. Disassembly of Marine Gear 0003510 Figure 4 13 Remove cover for HO relief valve with O ring Figure 4 13 2 Remove modulating valve Figure 4 13 3 Remove springs Figure 4 13 4 Remove HO relief valve with shims Figure 4 13 5 Remove cover for reducing valve with O ring Figure 4 13 6 Remove pilot valve Figure 4 13 7 Remove throttle valve Figure 4 13 8 Remove spring Figure 4 13 9 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Disassembly of Marine Gear OVERHAUL Removal of Mounting Feet Removal of Mounting Flange 1 Remove two mounting feet Figure 4 14 1 1 Remove ten M10x35 hex head bolts 2 Install repair stand Figure 4 14 2 to Figure 4 19 00 win Dmm Socket wrench housing 2 Remove two locating pins Figure 4 15 2 0001925 Figure 4 14 0001926 Figure 4 15 TUFF TORM rTrueoA 11614 Service Manual 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission 4 33 OVERHAUL Disassembly of Marine Gear Disassembly of Cases 1 Loosen and remove all 15 M8 hex bolts and lock washers Figure 4 16 2 and 3 using both 12 mm and 13 mm socket wrenches Note the location of two recessed bolts near input shaft and four stainless steel bolts at lower side of housing Figure 4 17 1 2 Lightly tap case A Figure 4 16 4 with plastic hammer Prying with sharp to
9. Figure 4 39 0001941 Figure 4 38 Reassembly of Tapered Roller Bearings Onto Input and Support Shafts 1 Heat inner race of tapered bearing to approximately 120 C 250 F fi Er EN BURN HAZARD Handle heated tapered roller bearings with heat resistant gloves Failure to comply could result in death or serious injury 0000104en 4 46 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Reassembly of Marine Gear Reassembly of Seal Rings 1 Lubricate seal rings Figure 4 40 1 with grease 2 Install seal rings onto input shaft and support shaft 0001943 Figure 4 40 Reassembly of Tapered Roller Bearing Onto Output Shaft 1 If previously removed reinstall tapered roller bearing onto output shaft 2 Heatinner race of tapered bearing to approximately 120 C 250 F warning _ 29 YA BURN HAZARD Handle heated tapered roller bearings with heat resistant gloves Failure to comply could result in death or serious injury 0000104en 3 Carefully press inner race Figure 4 41 1 onto the output shaft until inner race butts against the shoulder of shaft Figure 4 41 2 TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL 0002006 Figure 4 41 4 47 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Adjustment of Gear Backlash This procedure is required only when a gea
10. 35 Case Plate 36 Spring Retainer 37 2nd Relief Seat 38 Spring 39 Spring Pin 40 2nd Relief Valve 41 Mounting Foot 42 Breather 43 Dipstick 44 Gasket 45 Parallel Pin 46 Bolt 47 Coupling Plate 48 O ring 49 Output Coupling 50 Cil Seal 51 Plug TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL 52 Case B 53 Name Plate 54 Cover Suction 55 Baffle Plate 56 Seal Ring 57 Bearing 58 Ball 59 Support Shaft 60 Driven Gear 61 Hydraulic Cylinder 62 Seal Ring 63 Seal Ring 64 Spring 65 Spring Retainer 66 Ring 67 Thrust Collar 68 Support Pinion 69 Bushing 70 Friction Disc 71 Steel Plate 72 Friction Disc Retainer 73 Thrust Collar 74 Ring outer retaining 75 Bearing 76 Ring inner retaining 77 Shims 0 1 0 3 0 5 and 1 0 mm 4 23 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Marine Gear Sectional View MARINE GEAR SECTIONAL VIEW Nr S 0001972 Figure 4 2 4 24 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Marine Gear Sectional View OVERHAUL 1 Case A 2 Case B 3 Baffle Plate 4 Suction Cover 5 Shim 6 Shim 7 Shim 8 Shim 9 Mounting Flange 10 Parallel Pin 11 Case Plate 12 Gasket 13 PTO Cover 14 Gasket 15 Input Shaft 16 Drive Gea
11. Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL 1 Position a container under the marine gear to collect the waste oil 2 Remove the drain plug Figure 4 4 1 with seal using a 24 mm socket wrench 3 Check the drain seal for damage Replace if necessary Vi 0002000A Figure 4 4 4 29 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Removal of Oil Filter 1 Remove the three M8x40 bolts Figure 4 5 2 of lock washers with 12 mm socket wrench 2 Remove the filter cover Figure 4 5 3 gasket strainer spring Figure 4 5 4 and oil filter Figure 4 5 1 3 Check the gasket for damage Replace if necessary Note The oil filter Figure 4 5 1 must be washed with clean oil whenever the oil is changed 1 4 bi 0002001A Figure 4 5 4 30 Disassembly of Marine Gear Removal of Dipstick 1 Remove dipstick Figure 4 6 1 0002002A Figure 4 6 Removal of Output Coupling 1 Lock output coupling in
12. GENERAL SERVICE INFORMATION Marine Gear System MARINE GEAR SYSTEM Marine gear rotation with shift lever in position A Damper 1 Input Shaft 2 Drive Gear 3 Input Shaft Clutch 5 Input Pinion 6 Output Gear 7 Output Shaft 8 Output Coupling 9 Marine gear rotation with shift lever in position B Damper 1 Input Shaft 2 Drive Gear 3 Driven Gear 4 Support Shaft Clutch 10 Support Pinion 11 Output Gear 7 Output Shaft 8 Output Coupling 9 TTA 4 0001947 3 1 3 4 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Specifications SPECIFICATIONS Items GENERAL SERVICE INFORMATION TTM60A TTM61A Remarks Type Down Angle Hydraulic Angle 8 Maximum Input Torque 960 N m 708 ft lb 1070 N m 789 ft lb Input Speed 700 3300 min rpm Reduction Ratio F R 2 43 2 43 2 04 2 04 1 557 1 55 I P Counterclockwise Direction of Rotation O P Clockwise Recommended or Counterclockwise Viewed from Stern Shift Mechanical Cable Electrical Lubrication Forced Lubrication Oil Type API American Petroleum Institute Service Grade Class CF Viscosity SAE 30 Never use multi grade oil or mix oil types Single grade oil must be used Oil Quantity Effectiv
13. Grease lip of oil seals Reassembly of Input Shaft and Support Shaft Reassembly of Friction Assembly 1 Lubricate and install two new seal rings on input shaft piston Do not stretch seal rings when installing 2 Install piston Figure 4 34 3 into clutch housing being careful not to damage seal rings Install return spring Figure 4 34 2 inner retaining ring Figure 4 34 1 and snap ring Figure 4 34 5 by applying pressure with return spring compression tool Figure 4 34 4 Be sure inner retaining ring is locked into second groove on shaft with chamfered side facing up 4 43 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL 0003513 Figure 4 34 3 Install thrust collar 4 Lubricate steel plates and friction discs Install steel plates Figure 4 35 1 and discs Figure 4 35 2 beginning and ending with a Steel plate Note Refer to Parts Catalog for exact quantity of steel plates and friction discs 4 44 Reassembly of Marine Gear 0001939 Figure 4 35 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Reassembly of Marine Gear 5 Install friction disc retainer Figure 4 36 1 Install and seat outer retaining ring Figure 4 36 2 into groove on shaft with chamfer side of ring facing up Check for friction disc retainer alignment and full engagement 0001935B Figur
14. PRESSURE GAUGE M10 x 1 0 T CONNECTION Modulating Valve LO and HO Relief Valve NPTF 3 8 Hydraulic Oil ai Pump Strainer 150 Mesh J Clutch F HO Press J Clutch R HO Press PRESSURE GAUGE M10 x 1 0 CONNECTION Hydraulic Oil P Strainer 150 Mesh LO Relief Valve E lt at 4 1 t TEMPERATURE GAUGE CONNECTION IMECHANICAL SHIFT VERSION LO Press Modulating Valve LO Cooler r i LO Relief Valve HO Relief Valve NpTE 3 8 TEMPERATURE GAUGE L CONNECTION ELECTRICAL SHIFT VERSION 0001969 Figure 3 4 Hydraulic Diagram TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Shifting Pressure SHIFTING PRESSURE GENERAL SERVICE INFORMATION Shifting pressure is hydraulic pressure Shifting pressure must be between min and max line in the below performance graph at any time If not See Troubleshooting on page 5 1 6 Bee ee 5 LELELLC Shifting Pressure MPa Co 2000 3000 4000 Input Speed min 0002015TT Figure 3 5 FUNCTION TEST Perform a function test after servicing the marine gear Be sure the marine gear is filled with oil This test can be performed on a bench test rig or in a boat If a marine gear oil cooler is not installed conn
15. Someone may accidentally start the engine and not realize you are servicing it This could result in a Failure to comply could result in death serious injury or serious injury Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean If you must service the marine gear while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts 0000009en Failure to comply could result in death or serious injury 0000010enTrans j BURN HAZARD f you must drain the marine gear oil while it is still hot stay clear of the hot marine gear oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 000001 1enTrans TUFF TTM60A TTM61A Service Manual 2 7 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission SAFETY Safety Precautions SUDDEN MOVEMENT HAZARD Shift the marine gear into the AN NEUTRAL position any time the engine is at idle BURN HAZARD Failure to comply could result in death ALWAYS wait until the engine cools or serious injury before you drain the engine coolant 0000023en Hot engine coolant may splash and cause burns Failure to comply could result in death AWwARNNG or serious in
16. TTM60A TTM61A Service Manual 3 7 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission GENERAL SERVICE INFORMATION Case Plate Component Location CASE PLATE COMPONENT LOCATION 11 Section B B Mating Surface of Pump 13 15 17 19 21 Section E E 0001974 Figure 3 3 3 8 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Case Plate Component Location GENERAL SERVICE INFORMATION 1 Pin 2 Bearing 3 Pump Drive Gear 4 Bearing 5 Pump Driven Gear 6 Pump Cover 7 Pump Body 8 Bearing 9 O ring 10 O ring 11 O ring 12 Clamp 13 Wire Bracket 14 Switch Support 15 Safety Switch 16 Ball Joint 17 Shifting Lever 18 Parallel Pin 19 Spring 20 Ball 21 Pin 22 Parallel Pin 23 O ring 24 Cover 25 O ring 26 Spring 27 Modulating Valve 28 Spring 29 Shim 30 HO Relief Valve 31 Cover 32 Parallel Pin 33 Parallel Pin 34 Bolt 35 Shifting Valve 36 V ring 37 O ring 38 O ring 39 Cover 40 Pilot Valve 41 Throttle Valve 42 Spring TUFF TTM61A Service Manual 3 9 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission GENERAL SERVICE INFORMATION HYDRAULIC DIAGRAM 3 10 r LO Press H Clutch F He HO Press z LO Press 1 Clutch R HO Press
17. or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enTrans TUFF TORM rTrueoA TTM61A Service Manual 4 5 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL fh i d a D e Mx EXPOSURE HAZARD ALWAYS wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a cooling fan flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the alert signals Failure to comply could result in death or serious injury 0000005en 4 6 Before You Begin Servicing r SHOCK HAZARD ALWAYS turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en TTM60A TTM61A Service Manual TUFF TORR 2008 Tuf
18. pump Spring in shifting pressure Replace spring relief valve is broken Throttle valve for shifting Replace throttle valve pressure is broken 8 Excessive oil temperature Excessive oil in transmission Remove excessive oil with commercial suction pump Oil cooler is dirty on water Clean oil cooler on water side side Worn oil pump Replace oil pump Seal rings on input shaft or Remove case plate replace support shaft are faulty seal ring If case plate is worn replace likewise Clutch is slipping Refer to No 3 Clutch does not open Dismount transmission and completely due to worn disc coupling support Replace inner disc support and or clutch 9 Water in the oil oil looks milky Oil cooler faulty Repair leakage at cooler or replace cooler High water level in engine compartment water entering through output shaft seal TUFF TORM 1160 T1614 Service Manual Remedy cause for water level in engine compartment change transmission 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission TROUBLESHOOTING Problem Possible Cause Countermeasure Oil leakage at output shaft Breather clogged with paint or dirt Remove paint or dirt from breather Shaft seal faulty Disassemble transmission Replace seal If seal location on output shaft is worn seal lip should be mounted offset Oil leakage at breather Excessive oil in transmission Pump out excessive oil
19. swivel flame with flange stabilizing wrench Figure 4 7 2 2 Remove M20x60 hex head bolt Figure 4 7 1 with 30 mm socket wrench 3 Remove coupling plate Figure 4 8 1 and O ring Figure 4 8 2 4 Using a gear puller remove output coupling Figure 4 9 1 326232 1 i 2 0001921 Figure 4 7 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Disassembly of Marine Gear OVERHAUL Removal of Hydraulic Oil Pump 1 Remove four M8x65 hex head bolts Figure 4 10 1 2 Remove oil pump Figure 4 10 2 2 1 0003508 Figure 4 10 Removal of Case Plate 1 Loosen and remove all 10 M8 hex head bolts and lock washers Figure 4 11 2 amp 3 with 12 mm socket wrench 2 Using a plastic hammer lightly tap the split line of the case plate surface to break the seal 3 Remove case plate Figure 4 11 4 and lubricating pressure relief valve Figure 4 11 5 4 Remove parallel pins Figure 4 11 1 0001922A 0002003 Figure 4 9 TUFF TORM rTrueoA TTM61A Service Manual 4 31 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL 2 3 0001924A Figure 4 11 Removal of Valves 1 Loosen and remove four hex bolts Figure 4 12 1 2 Remove wire bracket Figure 4 12 2 1 2 0003509 Figure 4 12 3 Remove shifting valve Figure 4 13 1 4 32
20. using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003enTrans Notes Be sure to replace the parts which upon inspection and measurement are faulty whose measurements are outside the prescribed limits or have exceeded the prescribed period of use Parts which still meet the standard measurements and prescribed period of use but which are expected to fall below the standard before the next inspection should also be replaced DISASSEMBLY OF MARINE GEAR If necessary make alignment marks on parts to make reassembly easier As each part is removed check its condition and appearance for changes in shape damage and scratches Disassemble the parts in an orderly manner separating parts which can be used from those which need to be replaced TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Disassembly of Marine Gear Draining Transmission Oil A meti p BURN HAZARD f you must drain the marine gear oil while it is still hot stay clear of the hot marine gear oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011enTrans caution 9 9 ALWAYS be environmentally responsible
21. 5 C 113 F the marine gear may overheat and cause the marine gear oil to break down If the ambient temperature falls below 15 5 F rubber components such as gaskets and seals will harden causing premature marine gear wear and damage Contact your authorized Tuff Torq marine dealer or distributor if the marine gear will be operated in either temperature extreme 0000065enKMH60A Only use the marine gear oil specified Other marine gear oils may affect warranty coverage cause internal marine gear components to seize and or shorten marine gear life Prevent dirt and debris from contaminating marine gear oil Carefully clean the oil plug and dipstick and the surrounding area before you remove either one NEVER mix different types of marine gear oil This may adversely affect the lubricating properties of the marine gear oil NEVER overfill Overfilling may result in internal damage 0000005enTrans TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Before You Begin Servicing The correct level of marine gear oil is very important for proper marine gear function Check the marine gear for the proper amount of marine gear oil before you start the engine for the first time Running the engine with insufficient oil level in the marine gear will cause damage to internal marine gear components NEVER overfill the marine g
22. 9 O ring 30 Pin 31 Cover 32 V ring 33 Wire Bracket 34 Shifting Lever 35 Ball Joint 36 Bolt 37 Switch Support 38 Clamp 39 O ring 40 Spring 41 Ball 42 O ring 43 Cover 44 Modulating Valve 45 Spring 46 Spring 47 Shim 48 HO Relief Valve 49 Shim 50 O ring 51 Cover TUFF TTM61A Service Manual 4 27 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL PREPARING FOR OVERHAUL Prepare for the disassembly of the marine gear as follows 1 Secure the marine gear on a level base A DANGER AA m CRUSH HAZARD Always use lifting equipment with sufficient capacity to lift marine gear Have a helper assist you attaching the marine gear to the hoist NEVER stand under hoisted marine gear If the hoist mechanism fails the marine gear will fall on you causing serious injury or death NEVER support marine gear with equipment not designed to support the weight of the marine gear such as wooden pieces blocks or by only using a jack Failure to comply will result in death or serious injury 0000008enTransSM 2 Clean off any dirt oil or dust on the marine gear with detergent air or steam Note Be careful not to get any dust inside the marine gear during operation 4 28 Preparing for Overhaul FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing marine gear and when
23. TTM60A TITM61A SERVICE MANUAL P N M2 77624 3010 This Service Manual has been developed for the exclusive use of service and repair professionals such as Tuff Torq authorized Distributors and Tuff Torq authorized Dealers It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non professional to perform the service or repair properly and or safely Please contact an authorized Tuff Torq repair or service professional before working on your Tuff Torq product Disclaimers All information illustrations and specifications in this manual are based on the latest information available at the time of publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any time without notice Tuff Torq by Kanzaki TUFF TORQ and TUFF TORR are registered trademarks of Tuff Torq Corporation in the United States and Y KAN or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the w
24. TUFF TORM rTrueoA TTM61A Service Manual 4 57 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL CHECKING OIL LEVEL Always check oil level before operating the marine gear Marine gear oil level may be checked in cold SEVER HAZARD NEVER service the marine gear while under tow or if the engine is running at idle speed The propeller may rotate under these circumstances Failure to comply could result in death or serious injury 0000021en Only use the marine gear oil specified Other marine gear oils may affect warranty coverage cause internal marine gear components to seize and or shorten marine gear life Prevent dirt and debris from contaminating marine gear oil Carefully clean the oil plug and dipstick and the surrounding area before you remove either one NEVER mix different types of marine gear oil This may adversely affect the lubricating properties of the marine gear oil NEVER overfill Overfilling may result in internal damage 0000005enTrans or hot condition 1 2 Fully reinsert dipstick 3 Remove dipstick The oil level should be between the upper Figure 4 63 2 and lower Figure 4 63 1 lines on dipstick 4 58 Remove dipstick Figure 4 62 1 and wipe with clean cloth Checking Oil Level 4 Fully reinsert dipstick 0001587C 0001598A Figure 4 63 5 Move the shift lever to NEUTRAL position 6 Sta
25. VERHAUL Tool Name Special Service Tools Applicable model and tool size Illustration Protector For Disassembly of Bearing Cup Part No 177524 09710 4 18 Gear Steady For Measuring of Backlash Part No 177524 09730 i TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Measuring instruments MEASURING INSTRUMENTS Instrument Name Application OVERHAUL Illustration Micrometer Measuring gauge from 0 25 mm Accuracy of reading 1 100 mm Y 0000834 Dial Indicator Gauge Dial indicator gauge with arm type support 0001993 Dial Gauge TUFF TORM rTrueoA 11614 Service Manual 0000831 4 19 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Standard Tools STANDARD TOOLS Tool Name Application Illustration Wrench For hexagon bolts 8 mm 12 mm 14 mm 17 mm 24 mm 3 0001994 Allen Wrench 6 mm 8 mm 0001995 Hexagon Socket Wrench 12 mm 13 mm 17 mm 24 mm 30 mm Torque Wrench Adjustable up to 450 N m Plastic Hammer 1000 g and Sturdy Screwdriver Extractor Minimum diameter of 130 mm 0001999 Hexagon Bit Sockets 6 mm 8 mm Rolling Head Pry Bars Rc ni 0003506 Slide Hammer Bearing Puller 0003507 4 20 TTM60A TTM61A Service TUFF TORR 2008 Tuff To
26. ance techniques See your authorized Tuff Torq marine dealer or distributor for your installation service and training needs 0000002enTransSMTT 2 4 NK CRUSH HAZARD Always use lifting equipment with sufficient capacity to lift marine gear Have a helper assist you attaching the marine gear to the hoist NEVER stand under hoisted marine gear If the hoist mechanism fails the marine gear will fall on you causing serious injury or death NEVER support marine gear with equipment not designed to support the weight of the marine gear such as wooden pieces blocks or by only using a jack Failure to comply will result in death or serious injury 0000008enTransSM TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Safety Precautions DANGER T FIRE HAZARD ALWAYS keep fire extinguishers handy in case of fire Clearly indicate the location of the fire extinguishers with a safety sign ALWAYS ensure that the type of fire extinguishers are appropriate for material that might catch fire Check with local authorities ALWAYS have all fire extinguishers checked periodically for proper operation and or readiness ALWAYS post evacuation routes prominently Periodically conduct fire drills ALWAYS ensure that appropriate fire detection and extinguishing equipment are installed and checked periodically f
27. and Gears Check all gears bearings piston rings on the input shaft and support shaft for signs of wear or failure If any of the gears are damaged or showing signs of excessive wear Tuff Torq recommends replacing the complete gear set To check for correct clutch operation rotate the gears on the input shaft Inspect clutch for excessive wear replace clutch as required by feeling of smooth rotating only Friction Disc Standard Limit 1 65 1 75 mm 1 55 mm 0 065 0 069 0 061 in Stepped Wear Friction Disc TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Reassembly of Marine Gear Thrust Collars 1 2 HHL 0001942 Figure 4 33 Stepped Wear Standard Limit j i 4 85 4 95 mm 4 65 mm Engine Side 0 191 0 195 0 183 in Propeller Side 4 90 5 00 mm 4 70 mm p 0 193 0 197 in 0 185 in TUFF TORM rTrueoA 11614 Service Manual OVERHAUL REASSEMBLY OF MARINE GEAR Be sure to use genuine parts for replacements including new gaskets seals O rings piston rings and seal rings Use the correct parts and assemble them in the correct manner to specified standards tightening torque adjustment values etc Also grease the important bolts and nuts as specified Depending upon the placement of the packing grease the seal packing Oil or grease moving parts
28. and the marine gear breather and raise the operating temperature considerably ALWAYS keep the oil level between upper and lower lines on the dipstick 0000089enKMH60AOM If the marine gear oil temperature is too high stop engine immediately and check the marine gear oil level and check the oil cooler for proper coolant and water flow Have the marine gear serviced by an authorized Tuff Torq marine dealer or distributor before you start the engine again 0000074enTT After you add marine gear oil run the engine for several minutes and shut it down Wait at least 10 minutes to check the marine gear oil level This allows the oil to drain back into the sump otherwise you may overfill the marine gear with oil 0000075enKMH60AOM 2 12 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Safety Precautions SAFETY New Marine Gear Break In engine to idle for approximately 15 minutes while you check for proper marine gear function and marine gear oil leaks On the initial engine start up allow the 4 9 ALWAYS be environmentally responsible During the break in period carefully observe marine gear indicators if any for proper marine gear function Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous During the break in period check the materials such a
29. arts P 3 y y conditions Failure to comply may result in minor Avoid operating in the presence of or moderate injury chemical gases or fumes 0000024en 0000003enTrans Observe the following environmental operating conditions to maintain marine gear performance and avoid premature marine gear wear If any problem is noted during the visual check ALWAYS take the necessary corrective action before you operate the engine 0000021en NEVER run the marine gear if the ambient temperature is above 45 C 113 F or below 15 C 5 F If the ambient temperature exceeds NEVER hold the key in the START position for longer than 15 seconds or 45 C 113 F the marine gear may the starter motor will overheat overheat and cause the marine gear oil to break down 0000007en If the ambient temperature falls below 15 5 F rubber components such CAUTION as gaskets and seals will harden The illustrations and descriptions of causing premature marine gear wear optional equipment in this manual such and damage as the operator s console are for a Contact your authorized Tuff Torq typical marine gear installation Refer to marine dealer or distributor if the the documentation supplied by the marine gear will be operated in either optional equipment manufacturer for temperature extreme specific operation and maintenance instructions 0000065e
30. ases by heating the cases in an oven to approximately 120 C 250 F Put the housing in the oven upside down so the outer races will fall out The case can be heated by using other methods such as a torch or heat gun Be sure to keep the shims together with the same outer races from where they were removed Properly identify shims and outer races 4 36 Disassembly of Marine Gear TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Disassembly of Marine Gear OVERHAUL Removal of Oil Seals Removal of Baffle Plate and Oil Suction I Cover 1 Remove and discard input oil seal Figure 4 21 1 1 Remove baffle plate Figure 4 23 1 and oil suction cover Figure 4 23 2 from case B Note The oil suction cover removal is optional 2 Protect the housing Be sure to keep any dirt out of housing 0001932 4 23 Removal of Seal Rings 2 Remove and discard output oil seal 1 Remove seal rings Figure 4 24 1 from input Figure 4 22 1 shaft and support shaft Figure 4 24 0001931A Figure 4 22 TUFF TORM rTrueoA TTM61A Service Manual 4 37 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Disassembly of Marine Gear Removal of Tapered Roller Bearings Check for failed bearings or excessive bearing wear If bearings are damaged replace both the outer bearing race and i
31. description or omissions Contact an authorized Tuff Torq marine dealer or distributor for any questions you have regarding this Service Manual TUFF TORM rTrueoA TTM61A Service Manual 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission INTRODUCTION REVISION HISTORY This manual is a living document Periodic manual revisions are published to document product improvements and changes This practice ensures the manual has the most current information As manual revisions become necessary individual pages are prepared and sent to those who need the information If a page or number of pages should be replaced the replacement information is sent along with a revised Revision Control Table Discard the older obsolete information Revision Control Table Revision Date Revision Number JAN 2008 Rev 00 New Page Numbers Involved Revision History At times the revision involves inserting additional pages in one or more sections Insert the new information and only the Revision Control Table should be replaced This method of revision control represents the most cost effective solution to providing fresh updated information as needed Remarks New Manual 1 2 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Section 2 SAFETY Page Safety Precautions
32. e 2 8 L 0 5 L 3 0 qt 0 5 qt 286 0 mm 11 3 in Dimensions 145 4 mm 5 7 in 390 mm 15 4 in Clutch Size SAE 11 5 in Marine Gear 58 0 kg 127 9 Ib Without Mounting Feet Marine Gear Oil Cooler Damper Mounting Feet 2 3 x 2 kg 5 x 4 Ib Marine Gear Oil Cooler 7 0 kg 15 4 Ib 8 0 kg 17 64 Ib With Bracket Hoses Fittings Damper 7 5 kg 16 5 Ib TUFF TTM60A TTM61A Service Manual 3 5 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission GENERAL SERVICE INFORMATION Marine Gear Component Location MARINE GEAR COMPONENT LOCATION 7 8 9 10 17 14 15 Section A A uns s Figure 3 2 TTM60A TTM61A Service Manual TUFF TORR 3 6 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Marine Gear Component Location GENERAL SERVICE INFORMATION 1 Plug 2 Mounting Foot 3 Upper Cover 4 Gasket 5 Plug 6 O ring Dipstick 8 Parallel Pin 9 Breather 10 Mounting Foot 11 Magnet Plug 12 Seal Washer 13 Spring Pin 14 Spring Retainer 15 Spring 16 2nd Relief Sheet 17 2nd Relief Valve TUFF
33. e operation Determine the cause and repair the problem before you continue to operate the engine 0000029en Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the marine gear s safety and performance characteristics shorten the marine gear s life and may affect the warranty coverage on your marine gear 0000024enKMH60AOM If you have more than one engine you cannot shift the marine gear into the B position after you install the emergency nut 0000077en TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Before You Begin Servicing It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the marine gear 0000060enTrans Only use replacement parts specified Other replacement parts may affect warranty coverage cause internal marine gear components to seize or shorten marine gear life 0000147en Always tighten to the specified torque Loose parts can cause equipment damage or cause it to operate improperly 0000148en TUFF TORM rTrueoA 11614 Service Manual OVERHAUL 4 13 2008 Tuff Torq by Kanzaki Por
34. e 4 36 6 Repeat same procedure for support shaft Reassembly of Pinion Gear Assemblies 1 Lubricate and slide pinion gear assembly Figure 4 37 1 onto the shaft 2 Secure pinion gear assembly with retaining ring Figure 4 37 2 TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL 0001940 Figure 4 37 3 Repeat same procedure for support shaft Reassembly of Thrust Collars 1 Heat thrust collars to 120 C 250 F Z 7 p BURN HAZARD Handle heated thrust collars with heat resistant gloves Failure to comply could result in death or serious injury 0000103en Press thrust collars Figure 4 38 1 onto both the input and support shafts The engine side thrust collar must be installed with lining facing down The propeller side thrust collar must be installed with the lining facing up 4 45 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Reassembly of Marine Gear 3 Make sure thrust collars are fully pressed on 2 Carefully press inner race Figure 4 39 1 shaft and have a clearance of 0 25 1 05 mm onto the shaft until inner race is against thrust 0 010 0 041 in between thrust collar and top collar Figure 4 39 2 Be careful not to of pinion gear assembly damage roller cage when installing the inner 4 Verify that the thrust collars are not bent after race installing _ 1 lio 0002005
35. e marine gear and cause it to operate improperly 0000149en 4 52 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Reassembly of Marine Gear OVERHAUL Final Assembly of Cases 1 Align tabs and install baffle Figure 4 53 1 2 Using Shell Alvania Grease or equivalent fill space between seal and dust lips of shaft seal rings 3 Apply a thin coat of Threebond 1215 or equivalent on mating face of case B Figure 4 53 2 4 Install parallel pins Figure 4 53 3 with large chamfer end facing up 0001946 Figure 4 52 0001927B Figure 4 53 TUFF TORM rTrueoA 11614 Service Manual 4 53 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Reassembly of Marine Gear Reassembly of Mounting Flange Reassembly of Valves 1 Install 2 locating pins Figure 4 54 2 1 Install valves to case plate Figure 4 55 2 Install 10 M10x35 hex head bolts Figure 4 54 1 with 14 mm socket wrench m EN EU cod EK v 2 0003516 Figure 4 55 2 Ifitis necessary adjust the shifting pressure by increasing or decreasing shims increasing the shim thickness by 0 1 mm 0 0039 in shifting pressure rise by about 0 7 MPa 101 5 psi 3 Installbracket Figure 4 56 1 0001926 Figure 4 54 2 1 0003517 Figure 4 56 4 Install and tighten four hex bolts Figure 4 56 2
36. ear with marine gear oil An excessive oil level may cause leakage at the shaft seals and the marine gear breather and raise the operating temperature considerably ALWAYS keep the oil level between upper and lower lines on the dipstick 0000089enKMH60AOM Before operating the engine check marine gear oil level 0000072enKMH60AOM During normal operation the marine gear should only be shifted with the engine at idle Shifting at higher engine speed will damage the marine gear 0000073en TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL If the marine gear oil temperature is too high stop engine immediately and check the marine gear oil level and check the oil cooler for proper coolant and water flow Have the marine gear serviced by an authorized Tuff Torq marine dealer or distributor before you start the engine again 0000074enTT After you add marine gear oil run the engine for several minutes and shut it down Wait at least 10 minutes to check the marine gear oil level This allows the oil to drain back into the sump otherwise you may overfill the marine gear with oil 0000075enKMH60AOM New Marine Gear Break In On the initial engine start up allow the engine to idle for approximately 15 minutes while you check for proper marine gear function and marine gear oil leaks During the break in period carefully observe marine gear indicators
37. ect a hydraulic hose between the inlet and outlet of the hydraulic pump Required measuring instruments Pressure gauge 0 5 MPa 0 750 psi with connecting thread M10 x 1 25 e Temperature gauge 0 120 C 0 250 F connecting thread 3 8 18 NPTF See Hydraulic Diagram on page 3 10 for pressure and temperature gauge location TUFF TTM61A Service Manual Required Tests 1 Fluid leaks Noise emission Direction of rotation LH RH Lube oil temperature Shifting pressure Neutral performance Shifting performance 3 11 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission GENERAL SERVICE INFORMATION The function test should be carried out as follows Engine Speed Shift Lever Position A Lever is raised B Lever is lowered Function Test Duration Test 800 1000 rpm neutral 1 2 600 800 rpm idling speed A lt gt B position repeatedly 1 2 3 6 7 1500 2500 rpm B position 1 2 4 600 800 rpm idling speed A lt gt B position repeatedly 1 2 3 6 7 idling maximum speed A position 1 2 5 600 800 rpm idling speed A gt B position 1 2 idling maximum speed B position 1 2 5 Until oil temperature of 75 80 C 167 176 F has been reached At different speeds Note See Shifting Pressure on page 3 11 and Standard Valve of Performance bel
38. esult in minor or moderate injury 0000005en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing marine gear and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003enTrans 2 10 SLIPPING AND TRIPPING HAZARD Ensure that adequate floor space is set aside for servicing marine gear The floor space must be flat and free of holes Keep floor free of dust mud spilled liquids and parts to help prevent slipping and tripping Failure to comply may result in minor or moderate injury 0000022en POOR LIGHTING HAZARD Ensure that the work area is adequately illuminated Use task lighting to illuminate areas that need additional illumination e Always place wire cage on portable safety lamps Failure to comply may result in minor or moderate injury 0000023en TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Safety Precautions SAFETY TOOL HAZARD Observe the following environmental operating conditions to maintain marine gear performance and avoid premature marine gear wear Use tools appropriate for the task at hand Use the correct size tool for loosening Avoid operating in extremely dust or tightening machine p
39. f Torq by Kanzaki Portions Reproduced with Permission Before You Begin Servicing E SEVER HAZARD Stop the engine before you begin to service the marine gear Secure the propeller so it will not turn before you service the marine gear NEVER leave the key in the key switch when you are servicing the marine gear Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury f you must service the marine gear while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010enTrans j BURN HAZARD f you must drain the marine gear oil while it is still hot stay clear of the hot marine gear oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 000001 1enTrans TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL j BURN HAZARD ALWAYS wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and cause burns Failure to comply could result in death or serious injury 0000016en SEVER HAZARD NEVER service the marine gear while under tow or if the engine is running at idle speed The propeller may rotate under these circumstances
40. from disassembly FUME BURN HAZARD ALWAYS read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en Use EPA OSHA approved solvents Parts must be dried and oiled immediately after cleaning Be sure parts are free from grit dirt and abrasives Only use clean solvent to flush valves Be sure to flush all hoses and the heat exchanger Do not remove packing grease from new bearings Thoroughly wash used bearings Do not use compressed air to dry the bearings Remove all old sealant from sealed joints Thoroughly clean the surfaces to remove old sealant and grease 4 42 Cleaning Of Marine Gear INSPECTION OF MARINE GEAR Cases Replace any case that is cracked Inspect machined surfaces and bores for wear grooves or scratches Only use crocus cloth or a soft stone to remove scratches and burrs Repair any damaged threads using the correct size tap or thread repair kit Bearings Replace any bearing that was removed by using a service tool Replace bearings that show signs of corrosion and wear such as scoring scratching cracked pitting or chipping Replace bearing if its rotation is rough Inspect bearing bores and shafts for grooves burrs or galling Replace the part if crocus cloth can not repair the damage Shafts
41. h heat resistant gloves related precautions found on 9 ilii containers of hazardous substances Failure to comply could result in death like parts cleaners primers sealants or serious injury and sealant removers 0000104en Failure to comply could result in death or serious injury 0000014en Use heat resistant gloves when handling the hot housing halves and outer races BURN HAZARD 0000102en Handle heated tapered roller bearing outer races with heat resistant gloves AWwARNNG Failure to comply could result in death or serious injury 2 0000105 WI BURN HAZARD Handle heated thrust collars with heat resistant gloves jfi 6 Failure to comply could result in death or serious injury BURN HAZARD 0000103en Handle heated output coupling with heat resistant gloves j p Failure to comply could result in death or serious injury 0000106en TUFF TTM60A TTM61A Service Manual 2 9 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission SAFETY Safety Precautions e COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may r
42. his value is determined by parts accuracy and can not be adjusted e If backlash is 0 08 0 16 mm 0 003 0 006 in go to step 6 f backlash is less than 0 08 mm 0 003 in decrease the shim thickness of input shaft shims Decreasing the shim thickness by 0 1 mm 0 004 in increases backlash by 0 008 mm 0 0003 in f backlash is greater than 0 16 mm 0 006 in increase the shim thickness of output shaft shims Increasing the shim thickness by 0 1 mm 0 004 in decreases backlash decreases by 0 008 mm 0 0003 in 7 Remove output shaft from case B Reinstall the output shaft in case B with baffle plate TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL Reassembly of Taper Roller Bearing Outer Races Into Case B 1 Heat case B in an oven or other way to approximately 120 C 250 F or cool outer races with dry ice or liquid nitrogen A p BURN HAZARD Handle heated tapered roller bearing outer races with heat resistant gloves Failure to comply could result in death or serious injury 0000105en 2 Install outer races Figure 4 46 1 into case B 3 When case B has cooled down to ambient temperature carefully finish installing outer races using a copper brass punch 0001944 Figure 4 46 4 49 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Reassembly of Marine Gear Reassembly of Oil Suction Cover If Removed Earlie
43. icates an imminently hazardous situation which if not avoided will result in death or serious injury Danger is limited to the most extreme situations 0000001en Warning the word WARNING is in black letters with an orange rectangle behind it indicates a potentially hazardous situation which if not avoided could result in death or serious injury 0000001en TUFF TTM60A TTM61A Service Manual SAFETY Caution the word CAUTION is in black letters with a yellow rectangle behind it indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury 0000001en Caution without the safety alert symbol indicates a potentially hazardous situation that can cause damage to the marine gear personal property and or the environment or cause the marine gear to operate improperly 0000001enTrans 2 3 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission SAFETY SAFETY PRECAUTIONS Before You Service Safety Precautions Precautions for Safe Servicing DANGER x NEVER permit anyone to install or operate the marine gear without proper training Read and understand this Service Manual before you operate or service the marine gear to ensure that you follow safe servicing practices and maintenance procedures Safety signs and labels are additional reminders for safe service and mainten
44. if any for proper marine gear function During the break in period check the marine gear oil levels frequently 000001 1enTrans 4 11 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Before You Begin Servicing NEVER engage the starter motor while the engine is running This may damage the starter motor pinion and or ring gear 0000012en NEVER attempt to modify the marine gear s design or safety features Failure to comply may impair the marine gear s safety and performance characteristics and shorten the marine gear s life Any alterations to this marine gear may affect the warranty coverage of your marine gear 0000044enKMH60AOM ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en 4 12 Protect the electric components from damage when you use steam or use high pressure water to clean the engine or marine gear 0000014enTrans ALWAYS stop the engine immediately if any indicator illuminates during engin
45. igure 4 50 5 3 Set the special tool Figure 4 51 1 2 3 amp 4 on case B 4 Using a dial gauge measure the depth B of each individual master Figure 4 51 5 5 Calculate the required shim thickness T using the following formula T A B 0 05 mm T A B 0 05 mm T A B 0 0 1mm Input Shaft Support Shaft Output Shaft 0002009A Figure 4 50 4 51 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Reassembly of Marine Gear Reassembly of Tapered Roller Bearings Outer Races Into Case A 1 Use the required shim thickness Figure 4 52 2 determined in Bearing Preload Play Adjustment and Bearing Clearance Adjustment 2 Heat case A engine side case in an oven or other way to approximately 120 C 250 F or cool outer races with dry ice or liquid nitrogen wA 4 D BURN HAZARD Handle heated tapered roller bearing outer races with heat resistant gloves Failure to comply could result in death or serious injury 0000105en 0002010A Figure 4 51 3 Insert shims and outer races Figure 4 52 1 into case Reassembly of Gear Set Into Housing 4 When case has cooled down to ambient 1 Install baffle temperature carefully finish installing outer 2 Clean housing mating surfaces with an oilstone races using a copper brass punch Keep dirt out of marine gear housing Dirt may shorten the life of th
46. ing coupling 2 Heat output coupling to 120 C 250 F Figure 4 60 1 ZW BURN HAZARD Handle heated output coupling with heat resistant gloves Failure to comply could result in death or serious injury 0000106en 3 Press output coupling onto shaft using M20x60 retaining bolt Figure 4 60 4 4 56 Remove bolt When output coupling has cooled down to ambient temperature lubricate O ring Figure 4 60 2 with grease and insert into output coupling Add anti seize compound to bolt Finish tightening output coupling down on output shaft with bolt Figure 4 60 4 and coupling plate Figure 4 60 3 Tighten bolt to 401 441 N m 295 325 ft Ib 4 3 0001922B Figure 4 60 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Filling Marine Gear With Oil OVERHAUL FILLING MARINE GEAR WITH OIL Recommended Oil Type of Oil API American Petroleum Institute service grade class CD or CF Viscosity SAE 30 Note NEVER use multi grade oil or mix oil types Single grade oil must be used Capacity 2 8 L 3 0 qt 1 Remove the oil cap Figure 4 61 1 Fill with the following quantities of oil and add the amount required for cooler and pipelines 2 After filling the marine gear with oil reinstall the oil cap and hand tighten Over tightening may damage the cap 0001593A Figure 4 61
47. jury 0000016en il AWARNNG SEVER HAZARD e Keep your hands and other body NEVER service the marine gear while parts away from hot engine and under tow or if the engine is running at marine gear surfaces such as the idle speed The propeller may rotate muffler exhaust pipe turbocharger if under these circumstances equipped engine block and marine gear chassis during operation and shortly after you shut down the engine These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000021en SEVER HAZARD f the vessel has more than one engine NEVER service a marine gear if either of the engines are running In multi engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running Failure to comply could result in death or serious injury 0000015enTrans Use heat resistant gloves when handling the hot housing halves and outer races 0000102en Failure to comply could result in death or serious injury 0000022en 2 8 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Safety Precautions SAFETY D tE IN FUME BURN HAZARD iibi cac e ALWAYS read and follow safety Handle heated tapered roller bearings wit
48. marine gear corrective action before you operate the The floor space must be flat and free engine of holes 0000021en Keep floor free of dust mud spilled liquids and parts to help prevent slipping and tripping NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat Failure to comply may result in minor or moderate injury 0000022en 0000007en TUFF TORM rTrueoA TTM61A Service Manual 4 9 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL The illustrations and descriptions of optional equipment in this manual such as the operator s console are for a typical marine gear installation Refer to the documentation supplied by the optional equipment manufacturer for specific operation and maintenance instructions 0000018enTrans Observe the following environmental operating conditions to maintain marine gear performance and avoid premature marine gear wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes 0000003enTrans 4 10 Before You Begin Servicing Observe the following environmental Operating conditions to maintain marine gear performance and avoid premature marine gear wear NEVER run the marine gear if the ambient temperature is above 45 113 F or below 15 5 F If the ambient temperature exceeds 4
49. nKMH60A 0000018enTrans TUFF TTM61A Service Manual 2 11 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission SAFETY Only use the marine gear oil specified Safety Precautions Before operating the engine check Other marine gear oils may affect warranty coverage cause internal marine gear components to seize and or shorten marine gear life Prevent dirt and debris from contaminating marine gear oil Carefully clean the oil plug and dipstick and the surrounding area before you remove either one NEVER mix different types of marine gear oil This may adversely affect the lubricating properties of the marine gear oil NEVER overfill Overfilling may result in internal damage 0000005enTrans marine gear oil level 0000072enKMH60AOM During normal operation the marine gear should only be shifted with the engine at idle Shifting at higher engine speed will damage the marine gear 0000073en The correct level of marine gear oil is very important for proper marine gear function Check the marine gear for the proper amount of marine gear oil before you start the engine for the first time Running the engine with insufficient oil level in the marine gear will cause damage to internal marine gear components NEVER overfill the marine gear with marine gear oil An excessive oil level may cause leakage at the shaft seals
50. nner bearing race Removal of Taper Roller Bearings Inner Races Input Shaft and Support Shaft Engine Side Remove the engine side tapered roller bearing inner races with thrust collar by using a bearing extractor Figure 4 25 1 along with the arm and threaded rod M16 x 600 Figure 4 25 2 Be sure to pull on the thrust collar not on the bearing Note the direction that the thrust collar is installed on shaft 0001933 Figure 4 25 4 38 Input Shaft and Support Shaft Propeller Side Do not disassemble the shaft and piston housing If a bearing is damaged replace the complete bearing set TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Disassembly of Marine Gear Removal of Clutch pack Removal of Clutch Discs 1 To remove clutch discs from input shaft remove retaining ring Figure 4 26 1 0002004 Figure 4 26 2 Slide pinion gear assembly Figure 4 27 1 off input shaft 0001934 Figure 4 27 TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL Carefully remove outer retaining ring Figure 4 28 1 Remove friction disc retainer Figure 4 28 2 Remove steel plates and friction discs from the case Repeat same procedure to remove the friction disc retainer from the support shaft 0001935A Figure 4 28 4 39 2008 Tuff Torq by Kanzaki Portions Reproduced with Permi
51. ntermeasure Chattering transmission noise mainly at low engine speed The engine or propeller generate torsional vibrations in the drive unit which produce a chattering noise in the transmission Mount a specified damper between engine and transmission recommended damper Type CF R 136 011 61106 S2 by CENTA Parts No 177524 03911 Otherwise analyze the torsional vibrations to find out the proper propeller shaft and propeller refer to recommended propeller shaft and propeller in operation manual Misaligned jack shaft on input or output TUFF TORM rTrueoA 11614 Service Manual Mount and align jack shaft strictly according to instructions issued by jack shaft manufacturer 5 5 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission TROUBLESHOOTING This Page Intentionally Left Blank 5 6 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission
52. ock Clutch is slipping i e propeller speed too low for engine speed Inadmissible oil used Drain oil refill with prescribed oil flush transmission while engine runs in neutral position drain oil refill transmission Oil contains water Refer to No 9 Shifting pressure too low Refer to No 6 Wear on clutch disks Disassemble transmission replace clutch disks Piston rings in clutch are damaged TUFF TORM rTrueoA TTM61A Service Manual Disassemble transmission replace clutch 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission TROUBLESHOOTING Problem Possible Cause Countermeasure Transmission locked in gear Seal ring on input shaft or support shaft in case plate is faulty Remove case plate replace seal ring if case plate is worn replace Warped disks due to overheating of slipping clutch Refer to No 3 Plain bearings on input or support shaft have failed Disassemble transmission repair if possible or use substitute transmission Output shaft turns in neutral position Rotary valve in casing is worn Replace rotary valve Faulty plain bearing on input or support shaft Disassembly transmission and input or support shaft replace bearing concerned and other damaged parts Warped disks due to overheating of slipping clutch Refer to No 3 5 2 Shifting pressure too low Oil st
53. ols can result in damage to sealing surface leakage of oil and failure of gear 3 Remove parallel pins Figure 4 16 1 1 0001928 Figure 4 17 k 0001927A Figure 4 16 4 34 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Disassembly of Marine Gear Removal of Shafts and Gears 1 Remove gear set from case B Input shaft Figure 4 18 1 assembly Support shaft Figure 4 18 2 assembly Output shaft Figure 4 18 3 assembly 0001929 Figure 4 18 2 Ifitis needed when adjustment of shim is needed remove bearing races by using Rolling Head Pry Bars or Slide Hammer Bearing Puller 3 If you use a Rolling Head Pry Bars for removal of case A input bearing races you should use 6 protector Figure 4 19 1 and Figure 4 20 TUFF TORM 1160 T1614 Service Manual em OVERHAUL Xa re 0003511 Figure 4 19 EON d Sua N 0003512 Figure 4 20 Remove the shims from case A and case B on the input shaft Remove the shims from case A and case B on the output shaft Remove the shims from case A on the support shaft 4 35 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Removal of Tapered Roller Bearings Outer Races Use heat resistant gloves when handling the hot housing halves and outer races 0000102en Remove the tapered roller bearings outer races from the c
54. or distributor for your installation service and training needs 0000002enTransSMTT 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL During Operation and Maintenance A DANGER 84 m CRUSH HAZARD Always use lifting equipment with sufficient capacity to lift marine gear Have a helper assist you attaching the marine gear to the hoist NEVER stand under hoisted marine gear If the hoist mechanism fails the marine gear will fall on you causing serious injury or death NEVER support marine gear with equipment not designed to support the weight of the marine gear such as wooden pieces blocks or by only using a jack Failure to comply will result in death or serious injury 0000008enTransSM 4 4 Before You Begin Servicing ADANGER T FIRE HAZARD ALWAYS keep fire extinguishers handy in case of fire Clearly indicate the location of the fire extinguishers with a safety sign ALWAYS ensure that the type of fire extinguishers are appropriate for material that might catch fire Check with local authorities ALWAYS have all fire extinguishers checked periodically for proper operation and or readiness ALWAYS post evacuation routes prominently Periodically conduct fire drills ALWAYS ensure that appropriate fire detection and extinguishing equipment are installed and checked periodically for proper operation Check with local a
55. or proper operation Check with local authorities Failure to comply will result in death or serious injury 0000018en SUDDEN MOVEMENT HAZARD When you install the emergency nut the boat will move forward as soon as you start the engine Make sure the area is clear before you start the engine Failure to comply could result in death or serious injury 0000025en TUFF TTM60A TTM61A Service Manual SAFETY 2e SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the marine gear NEVER start the engine in gear Sudden movement of the engine and or vessel could cause death or serious personal injury NEVER operate the marine gear without the guards in place Before you start the engine make sure that all bystanders are clear of the area Keep children and pets away while the engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enTrans 2 5 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission SAFETY 2 6 e ALCOHOL AND DRUG HAZARD NEVER operate the ves
56. ow Standard Value of Performance Items TTM60A TTM61A Remarks Neutral Performance Time Until Stopping Oil Temperature 30 C lt 20 seconds 86 F Idling Speed Shifting Oil Temperature 30 C lt 1 0 seconds 86 F Idling Speed Time to Engage Oi Temperature lt 90 C 194 F Oil Pressure 3 12 lt 4 09 MPa lt 4 82 MPa 593 psi 699 psi 3 72 0 05 MPa 4 38 x 0 05 MPa 539 7 psi 635 7 psi gt 1 86 MPa gt 2 19 270 psi 318 psi Oil Temperature 30 C 86 F 3300 rpm Oil Temperature 60 140 F 3300 rpm Oil Temperature 60 C 140 F 700 rpm Maximum Setting Minimum lt 0 30 MPa lt 0 65 MPa 44 psi 94 psi 0 25 0 05 MPa 0 60 0 05 MPa 36 7 psi 87 7 psi Oil Temperature 30 86 F 3300 rpm Oil Temperature 60 140 F 3300 rpm Oil Temperature 60 140 F 700 rpm Maximum Setting 2 0 01 MPa Minimum 1 5 psi TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Section 4 OVERHAUL Page Before You Begin Servicing 4 3 Before You 4 3 During Operation and 4 4 Past Inspections for the Engine and the Marine Gear 4 14 Special Se
57. r 1 Apply a thin coat of Threebond 1215 or equivalent to suction cover location on case B 2 Place suction cover Figure 4 47 1 onto case B 3 Install and tighten 5 M8 suction cover bolts Figure 4 47 2 0001930B 0001945 Figure 4 47 Figure sa Reassembly of Oil Seals 1 Apply Shell Alvania Grease or equivalent to lips of input oil seal Figure 4 48 1 and output oil seal Figure 4 49 1 2 Install the seals until seal is flush with case 4 50 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Reassembly of Marine Gear 0001931B Figure 4 49 Measuring Bearing Clearance Adjusting Bearing Preload This procedure is required when a gear ratio or the shaft assembly is changed The required preload play of bearings of the individual shafts in the housing is obtained by using shims of different thickness under the outer races of the tapered roller bearings Shims which have been removed during disassembly may be reused Adjustment of Bearing Preload Play Input Support Output 0 05mm Preload 0 05mm Preload 0 10mm Preload 0 05mm Play 0 05mm Play 0 00mm Play TUFF TORM rTrueoA TTM61A Service Manual OVERHAUL Adjustment of Bearing Clearance 1 Setthe special tool Figure 4 50 1 2 3 amp 4 on case A 2 Using a dial gauge measure the depth A of each individual master F
58. r 17 Ball 18 Thrust Collar Eng 19 Thrust Collar Prop 20 Spring Retainer 21 Friction Disc Retainer 22 Hydraulic Cylinder 23 Return Spring 24 Friction Disc 25 Steel Plate 26 Ring 27 Ring 28 Ring 29 Ring 30 Ring 31 Bearing 32 Bearing 33 Support Shaft 34 Driven Gear 35 Input Pinion 36 Bushing 37 Support Pinion 38 Output Shaft 39 Output Gear 40 Output Coupling 41 Coupling Plate 42 Bolt 43 O ring 44 Bearing 45 Bearing 46 Strainer Cover 47 Gasket 48 Filter 49 Strainer Spring 50 Cil Seal TUFF TTM61A Service Manual 4 25 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Case Plate Component Identification CASE PLATE COMPONENT IDENTIFICATION 36 0001971 Figure 4 3 4 26 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Case Plate Component Identification OVERHAUL 1 Plug 52 Pilot Valve 2 O ring 53 Throttle Valve 3 Upper Cover 54 Spring 4 Gasket 5 Case Plate 6 Plug 7 Cap 8 Gasket 9 PTO Cover 10 O ring 11 O ring 12 Pump Body 13 Bearing 14 Pump Driven Gear 15 Bearing 16 Pump Cover 17 Bearing 18 Pump Drive Gear 19 Bearing 20 Pin 21 O ring 22 O ring 23 Strainer Cover 24 Gasket 25 Strainer Spring 26 Filter 27 Shifting Valve 28 Pin 2
59. r ratio is changed Notes The propeller side shim is for adjusting gear backlash The engine side shim is for adjusting bearing side clearance Use the following procedure to adjust gear backlash 1 Install input shaft assembly in case B with a 0 9 mm shim behind outer race of bearing Figure 4 42 1 3 0002007A Figure 4 42 2 Install support shaft assembly in case B A shim is not required Figure 4 42 2 3 Install output shaft assembly in case B with a 0 9 mm shim behind the outer race of bearing Figure 4 42 3 4 Setthe special tool Figure 4 43 1 Place outer race of each bearing onto each individual shaft Figure 4 43 2 4 48 Reassembly of Marine Gear 0002008A Figure 4 43 5 Fixthe output gear by gear steady Figure 4 44 1 0003514 Figure 4 44 6 Seta dial gauge on case B with tip of dial indicator gauge touching either the input pinion or support pinion Carefully rotate shafts and measure the backlash between output gear and input shaft pinion and output gear and support shaft pinion Standard backlash is 0 08 0 16 mm 0 00314 0 0063 in Figure 4 44 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Reassembly of Marine Gear aN 0003515 Figure 4 45 Note The backlash measurement between output gear and support pinion is only for confirmation T
60. rTrueoA TTM61A Service Manual 4 1 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL 4 2 Inspection of Marine Gear 4 42 SCEII DUERME 4 42 B alilds cese Ede DI EP MEDECIN 4 42 Shafts and Gears sse ener 4 42 Reassembly of Marine 4 43 Reassembly of Input Shaft and Support Shaft 4 43 Reassembly of Pinion Gear Assemblies 4 45 Reassembly of Thrust Collars 4 45 Reassembly of Tapered Roller Bearings Onto Input and Support Shatfts 4 46 Reassembly of Seal Rings esses 4 47 Reassembly of Tapered Roller Bearing Onto Output Shaft 4 47 Adjustment of Gear 4 48 Reassembly of Taper Roller Bearing Outer Races Into Case B 4 49 Reassembly of Oil Suction Cover If Removed Earlier 4 50 Reassembly of Oil Seals 4 50 Measuring Bearing Clearance Adjusting Bearing Preload 4 51 Reassembly of Gear Set Into Housing 4 52 Reassembly of Tapered Roller Bearings Outer Races Into Case A
61. rainer clogged Wash strainer or replace fine one Oil level in transmission Top up with oil In case of oil loss check transmission cooler and pipelines for leakage and remedy in the same way also refer to No 10 through No 13 Oil pump is worn out Replace oil pump Spring in shifting pressure relief valve is broken Replace spring Seal rings on input shaft or support shaft are faulty Remove case plate replace seal ring if case plate is worn replace likewise Throttle valve for shifting pressure is broken Replace throttle valve Piston rings in clutch are faulty Disassemble transmission Replace clutch Choke port at modulator valve obstructed by contamination TTM60A TTM61A Service Manual TUFF TORR Wash the modulator valve 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission TROUBLESHOOTING No Problem Possible Cause Countermeasure 7 No shifting pressure available Direction of engine rotation Replace with engine of correct does not agree with arrow on rotation transmission No oil in the transmission Refill with oil Strainer is dirty Replace fine strainer Oil level in transmission is too Top up with oil In case of oil low loss check transmission cooler and pipelines for leakage and remedy in the same way Also refer to No 10 through No 13 Oil pump is worn out Replace oil
62. ritten permission of Tuff Torq 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission 808 ii TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Section TABLE OF CONTENTS nteger Tercer 1 1 Safelyusu MM 2 1 General Service Information 3 1 Overhaul enne eene 4 1 Troubleshooting U 5 1 TUFF TORM rTrueoA 11614 Service Manual 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission TABLE OF CONTENTS This Page Intentionally Left Blank iv TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Section 1 INTRODUCTION This manual gives specific instructions for the proper repair on T TM transmissions Please follow the procedures carefully to ensure quality service Tuff Torq recommends that you read this Service Manual completely before starting with repairs as some of the procedures described are rather complex Along with standard tools Tuff Torq recommends the use of special tools necessary to perform repairs correctly Tuff Torq products are continuously undergoing improvement This Service Manual has been checked carefully in order to avoid errors However Tuff Torq is not liable for any misrepresentations errors of
63. rm the required damage or cause it to operate periodic maintenance at intervals improperly indicated Failure to follow these 6600134881 guidelines will impair the marine gear s safety and performance characteristics shorten the marine gear s life and may affect the warranty coverage on your marine gear Keep dirt out of marine gear housing Dirt may shorten the life of the marine REDIMI GOAONE gear and cause it to operate improperly 0000149en If you have more than one engine you cannot shift the marine gear into the B position after you install the emergency nut 0000077en It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the marine gear 0000060enTrans Only use replacement parts specified Other replacement parts may affect warranty coverage cause internal marine gear components to seize or shorten marine gear life 0000147en 2 14 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Section 3 GENERAL SERVICE INFORMATION Page Marine Gear System a 3 4 Specifications HE 3 5 Marine Gear Component Location 3 6 Case Plate Component
64. rq by Kanzaki Portions Reproduced with Permission Torque Chart TORQUE CHART Item OVERHAUL Torques Transmission Assembly Bolts 18 6 22 6 N m 13 7 16 7 ft Ib 37 2 41 2 N m 27 5 30 4 ft Ib 65 7 75 5 Nm 48 5 55 7 ft Ib Output Coupling Bolt 401 441 N m 296 326 ft lb Dipstick Hand Tight Breather TUFF TORM rTrueoA 11614 Service Manual Hand Tight 4 21 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Marine Gear Component identification MARINE GEAR COMPONENT IDENTIFICATION 0001970 Figure 4 1 4 22 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Marine Gear Component identification 1 Parallel Pin 2 Case A 3 Mounting Flange 4 Oil Seal 5 Parallel Pin 6 Shims 0 1 0 3 0 5 and 1 0 mm 7 Bearing 8 Output Gear 9 Output Shaft 10 Bearing 11 Shims 0 1 0 3 0 5 and 1 0 mm 12 Shims 0 1 0 3 0 5 and 1 0 mm 13 Bearing 14 Thrust Collar 15 Ring 16 Ring 17 Friction Disc Retainer 18 Friction Disc 19 Steel Plate 20 Bushing 21 Input Pinion 22 Thrust Collar 23 Ring 24 Spring Retainer 25 Return Spring 26 Ring 27 Ring 28 Hydraulic Cylinder 29 Drive Gear 30 Input Shaft 31 Ball 32 Bearing 33 Seal Ring 34 Shims 0 1 0 3 0 5 and 1 0 mm
65. rt the engine Let the engine run at idle with the shift lever in the NEUTRAL position for several minutes This will ensure the oil is distributed to all pipelines oil cooler and marine gear oil passages TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Trial Run After you add marine gear oil run the engine for several minutes and shut it down Wait at least 10 minutes to check the marine gear oil level This allows the oil to drain back into the sump otherwise you may overfill the marine gear with oil 0000075enKMH60AOM Stop the engine WAIT AT LEAST 10 MINUTES for the oil to drain back into the sump Check the oil level If necessary add oil until the level reaches the upper mark on the dipstick Check the oil level again after operating the marine gear for a short period of time TRIAL RUN 1 Perform a trial run after filling marine gear with oil Move the shift lever to the NEUTRAL position Start the engine Let the engine idle with the shift lever in the NEUTRAL position for several minutes This will ensure the oil is distributed to all pipelines and the oil cooler After you add marine gear oil run the engine for several minutes and shut it down Wait at least 10 minutes to check the marine gear oil level This allows the oil to drain back into the sump otherwise you may overfill the marine gear with oil 0000075enKMH60AOM
66. rvice 4 15 Measuring instruments 4 19 Standard Su u SD uu ses 4 20 Torque Chalrlt a 4 21 Marine Gear Component identification 4 22 Marine Gear Sectional View 4 24 Case Plate Component Identification 4 26 Preparing for Overhaul a 4 28 Disassembly of Marine 4 28 Draining Transmission Oil a 4 29 Removal of Oil Filter 4 30 Removal of Dipstick sss 4 30 Removal of Output Coupling 4 30 Removal of Hydraulic Oil Pump 4 31 Removal of Case Plate a 4 31 Removal of 4 32 Removal of Mounting Feet a 4 33 Removal of Oil Seals 4 37 Removal of Tapered Roller Bearings 4 38 Removal of Clutch 4 39 Cleaning Of Marine Rt 4 42 TUFF TORM
67. s engine oil diesel marine gear oil levels frequently fuel and engine coolant Consult the 0000011enTrans local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping NEVER engage the starter motor while them into a sewer on the ground or the engine is running This may damage into ground water or waterways the starter motor pinion and or ring Failure to follow these procedures may seriously harm the environment 0000013en gear 0000012en NEVER attempt to modify the marine gear s design or safety features Protect the electric components from damage when you use steam or use Failure to comply may impair the high pressure water to clean the engine marine gear s safety and performance or marine gear characteristics and shorten the marine Dono deni gear s life Any alterations to this marine gear may affect the warranty aac al ALWAYS stop the engine immediately if any indicator illuminates during engine operation Determine the cause and repair the problem before you continue to operate the engine 0000029en TUFF TTM60A TTM61A Service Manual 2 13 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission SAFETY Safety Precautions Establish a periodic maintenance plan Always tighten to the specified torque according to the engine application and Loose parts can cause equipment make sure you perfo
68. sel while you are under the influence of alcohol or drugs NEVER operate the vessel when you are feeling ill Failure to comply could result in death or serious injury 0000004enTrans Safety Precautions lt f P a a us e aM EXPOSURE HAZARD ALWAYS wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a cooling fan flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the alert signals Failure to comply could result in death or serious injury 0000005en TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Safety Precautions SAFETY m SEVER HAZARD SHOCK HAZARD Stop the engine before you begin to ALWAYS turn off the battery switch if service the marine gear equipped or disconnect the negative battery cable before servicing the electrical system Secure the propeller so it will not turn before you service the marine gear NEVER leave the key in the key switch when you are servicing the marine gear
69. ssion OVERHAUL Removal of Clutch Pistons 1 To remove clutch pistons from input shaft remove thrust collar Figure 4 29 1 by using an extractor Figure 4 29 2 Note Make sure to observe the direction the thrust collar is mounted to the shaft M8x300 2 0001936 Figure 4 29 2 Using a spring compressor Figure 4 30 2 compress the spring no more than 5 mm 3 Remove snap ring Figure 4 30 1 4 Remove inner retaining ring Figure 4 31 1 from groove 4 40 Disassembly of Marine Gear 0001937 Figure 4 30 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Disassembly of Marine Gear OVERHAUL 5 Remove the spring retainer return spring Figure 4 31 2 and hydraulic cylinder Figure 4 31 3 This may require application of low pressure air to opening in end of shaft to remove piston 1 Note Make sure to observe the direction the retaining ring is installed on the shaft chamber facing up 6 Repeat same procedure for support shaft 2 0002699 Figure 4 32 0001938 Figure 4 31 TUFF TORM rTrueoA TTM61A Service Manual 4 41 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL CLEANING OF MARINE GEAR Note Discard all gaskets seals O rings piston rings and seal rings Replace any part that was damaged
70. tions Reproduced with Permission OVERHAUL Past Inspections for the Engine and the Marine Gear PAST INSPECTIONS FOR THE ENGINE AND THE MARINE GEAR For precise high quality operation preparation is necessary Check the customer management file for the past performance of the engine and marine gear When was the last maintenance done How much has the marine gear been used length of time hours of use since the last maintenance work What problems were found at the last inspection and what maintenance work was performed Are the parts needed for replacement during maintenance on hand Is there a check sheet for the maintenance WOrk 4 14 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Special Service Tools SPECIAL SERVICE TOOLS Tool Name Applicable model and tool size OVERHAUL Illustration Base For Disassembly of Shaft Assembly Part No 177524 09210 Repair Stand Part No 177524 09110 4 0001978 Spacer A Part No 177524 09320 0001979 Spring Pusher Part No 177524 09310 Shaft Stand Part No 177524 09240 Spacer B Part No 177524 09240 TUFF TORM rTrueoA TTM61A Service Manual E 0001982 4 15 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission OVERHAUL Tool Name Special Service Tools Applicable model and tool size Ill
71. ury 0000014en COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en 4 8 TTM60A TTM61A Service TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Before You Begin Servicing OVERHAUL POOR LIGHTING HAZARD Ensure that the work area is adequately illuminated Use task lighting to illuminate areas that need additional illumination FLYING OBJECT HAZARD Always place wire cage on portable ALWAYS wear eye protection when safety lamps servicing marine gear and when using Failure to comply may result in minor compressed air or high pressure or moderate injury water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor caution or moderate injury TOOL HAZARD 0000003enTrans 0000023en Use tools appropriate for the task at hand or tightening machine parts e Failure to comply may result in minor or moderate injury 0000024en SLIPPING AND TRIPPING HAZARD If any problem is noted during the visual Ensure that adequate floor space is check ALWAYS take the necessary set aside for servicing
72. ustration Bearing Extractor For Bearing and Collar on Engine Side Part No 177524 09350 Thrust Collar Extractor For Collar on Propeller Side Part No 177524 09380 Wrench For Output Coupling Part No 177524 09160 0001986 Master Case A Input Shaft For Shim Adjustment of Input Shaft and Support Shaft Part No 177524 09510 0001987 4 16 Master Case A Output Shaft For Shim Adjustment of Output Shaft Assembly Part No 177524 09520 0001988 TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Special Service Tools Tool Name Applicable model and tool size OVERHAUL Illustration Master Case B Input Shaft For Shim Adjustment of Input Shaft Assembly 177524 09540 f i Ar A Z 0001989 Master Case B Output Shaft For Shim Adjustment of Output Shaft Assembly Part No 177524 09550 0001990 Master Case A For Shim Adjustment of Case A Part No 177524 09610 0001991 Master Case B For Shim Adjustment of Case B 177524 09620 Spring Press Tool For Assembly of Shaft Assembly Part No 177524 09010 Arm Kit For Disassembly of Shaft Assembly Part No 177524 09200 TUFF TORM rTrueoA TTM61A Service Manual 0003503 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission O
73. uthorities Failure to comply will result in death or serious injury 0000018en SUDDEN MOVEMENT HAZARD When you install the emergency nut the boat will move forward as soon as you start the engine Make sure the area is clear before you start the engine Failure to comply could result in death or serious injury 0000025en TTM60A TTM61A Service Manual TUFF TORR 2008 Tuff Torq by Kanzaki Portions Reproduced with Permission Before You Begin Servicing OVERHAUL SS SEVER HAZARD Keep hands and other body parts ALCOHOL AND DRUG HAZARD away from moving rotating parts NEVER operate the vessel while you such as the flywheel or PTO shaft are under the influence of alcohol or drugs Wear tight fitting clothing and keep 3 your hair short or tie it back while the P NEVER operate the vessel when you engine is running are feeling ill Remove all jewelry before you operate Failure to comply could result in death or service the marine gear or serious injury 0000004enTrans NEVER start the engine in gear Sudden movement of the engine and or vessel could cause death or serious personal injury NEVER operate the marine gear without the guards in place Before you start the engine make sure that all bystanders are clear of the area Keep children and pets away while the engine is operating Check before starting the engine that any tools

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