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Service Manual Arneson

1. FULL THREAD I TIRE RE NO LLLA i de uw ge 63 3 PLCS _ ___ _ 502 STAMP TOOL HER 5 913 i BUR RING HOIST THD 578 11 4000 LBS 23414 LOAD CAPACITY 1 1 CRS BLICK LIFTING 2953 x 1565 DESCRIPTIUN STHCK SIZE 39 5 79612 1 4 UNT UIML 5100 12 4 Special Tools Jacking Tool T 21570 1 of 2 180 Twin Disc Incorporated 24 60 3 Arneson Surface Drive Service Manual 1020619 6190201 e eung 181 516 4 STAMP LEFT SIDE HERE 2 06 THR PLCS R 50 PLCS DETAIL 2 5 2 n 18 3 Pur 800 THREADED 2 1 LEFT SIDE PLATE RIGHT SIDE PLATE DET REG DESCRIPTION STOCK SIZE 1 80 STAMP RIGHT SIDE HERE 1 T iD i Qu 1 a 25 1 1 DETAIL 4 85 00 THRU 2106 THRU 2 PLCS 10 01912 1 1001 poyeiodioouy 96101 5100 12 4 Special Tools Twin Disc Incorpora
2. i Je 5 Eier Ds 22 x Y ri _ DEPTH AND LENGTH OF ides CLEARANCE 8 00 WIDTH 176 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Special Tools Stand Setup ASD 15A1S 21089 50 201 2 eue 44 4012 REF Arneson Surface Drive Service Manual 1020619 177 871 8 Ds BREAK ALL SHARP EDGES 100 25 40 6 12251 28 0 12203 20 S STAMP dza Pa 0197 5 001 j N STAM HERE 38 JIU NIIT VU 6190 01 enuen 291135 ET Lo cae d Gy 1 emp N DRILL 90248 THRU 0 472 0 394 10 00 e 1 PUR 6 1 0 SHCS 25mm LENGTH 2 1 1 ALUMINUM HDLDER GAGE 98 00 x 1 00 DET JREQ DESCRIPTIUN STOCK SIZE 5100 212 4 82 6 912 1 J9pIoH 1016 eys 6190201 eoi ajos 621 M64x 6l Ee Aure TI
3. gt PAPA N 1 d 1 QJ 7 74 ad 32 5 x x Q D Y 4 Y 3 59580 r 935480 B4 Arneson Surface Drive Service Manual 1020619 163 Special Tools Twin Disc Incorporated Input Socket Shaft Bearing Cup Driver T 18050 775 2 lt gt 1 i5 lt L QJ lt gt m 55 50 gt 2 1 17 o 0 4 0 KNURI 52 e Wi 27 7 2 27 2 2 gt 73 2 2 lt 2 5 S 24 00 e ANN 2 e o L 2 zd 164 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Special Tools Thrust Bearing Cup Driver T 18050 776 Y pe e N 2 N F 0 1 S N 09 tcv bp L 25 S m C2 47 819 Lu 77 809 gt 4 22 N 1 2 6 828 020 WA 0 50 REF MN 1 N NL N N 7 N 2 800 Y N 9 N BIL N N N N 3 V N 2 N 2 10 50 23 50 0 03 0 50 a 165 Arneson Surface Drive Service Manual
4. 2 COTTER PIN CUTTER PIN 1 5 N JAM LOCK NUT lt PROPELLER N INL Y N N N Figure 102 Propeller Installation 3 The propeller nut and lock nut must be checked for torque retention to the above values after initial use or within 10 hours of operation 156 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 4 The propeller nut torque MUST be checked in the following operational interval A The propeller nut torque must be checked in accordance with step 2 after an additional 250 hours of operation If the torque is correct go to step B If the torque is incorrect re torque the nut and repeat step A The propeller nut torque must be checked in accordance with step 2 after an additional 500 hours of operation If the torque is correct go to step C If the torque is incorrect re torque the nut and repeat step B The propeller nut torque must be checked in accordance with step 2 after an additional 1000 hours of operation If the torque is correct go to step D If the torque is incorrect re torque the nut and repeat step C The propeller nut torque must be checked in accordance with step 2 after an additional 1500 hours of operation If the torque is correct go to step E If the torque is incorrect re torque the nut and repeat step D Continue to increase the interval in increments of 1500 hours until the regular haulout interval of the
5. 23 Prior to Removal 23 Removal of Thrust Tube While Thrust Socket Remains Mounted 24 Complete Removal of Surface Drive from Transom 29 Arneson Surface Drive Service Manual 1020619 7 Table of Contents Twin Disc Incorporated DEVS NEO me n 33 tlg Me 33 Hus d igdiu im 37 Tnm Cylinder Installation 46 Steering Cylinder Installation 52 Driveline 58 Cli 63 Propeller Installation Routine 66 Propeller Installation New Applications 68 Corrosion Protectio EI UITIUM 70 Ant fouling 72 Troubles 73 Periodic Visual Inspection 74 spun 75 GENET A Y J 75 Pror Y Y 75 Surface Drive 75 Preventative Maintenance
6. TRANSOM RANSOM TEMPLATE 10198860 TEMPLATE 41019886G Nee 0 900 2 Bi 4 x 2 STRAIGHTEDGE 2 STRAIGHTEDGE HULL BOTTOM JUAL INSTALLATIO DUA Figure 14 Mark Hull using Template 1019886G 40 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation C Drill a pilot hole through the intended drive centerline Point C This pilot hole will be used for locating the actual drive through hole and should be sized for the hole saw to be used in Step D The hole should be drilled at an angle to the transom that will make it parallel to the socket centerline Template 1019886G can be used to orient the drill as shown in Figure 15 TRANSUM BUT TUM L DR 3 MUS j HULL PERPENDICULAR TRANSOM DUAI j eps E CLIR laS Me Figure 15 Drill Holes D Follow the pilot hole with a 305 mm 12 in hole saw at the same angle used in Step C Arneson Surface Drive Service Manual 1020619 41 Installation Twin Disc Incorporated E Hold the thrust unit in place and verify 1 clearance from the edge of the thrust socket to the plane of the vessel s bottom See Figure 16 Verify that the drive flange hole pattern matches the hole pattern marked on the transom from Template 1020306 Note T
7. 1020242 1007541 PLATE 1009583 CLEVIS 1020241 PIN 1009584 2 4 NUT 1020297 PIN 1007541 PIN 1020296 TUBE ASSEMBLY SEE CHART NUT 1020297 WASHER 1020298 WASHER 1020298 1020294 2 1020295 NUT 1020295 I Hee es Ss 2077 mM d EI 7 Za 2 1 d DL oa LSS EX a NX NS VE EN 7 JH vod Po so E 2 RAT y pd Pe X xL i 20 95 mm 20 95 mm p an ES 0 80 3 75 in 0 80 3 75 in REF REF SCREW 1006351 SCREW 1006351 SIDE OF PIN OPPOSITE SIDE OF PIN WASHER MA1039H WASHER MA1039H 1 7 1048 1048 ON A 1007534 5 1007534 THIRD ANGLE PROJECTION SIMILAR TO 1007424 1 1 01 NOTICE THIS PRINT CONTAINS WS DISE PROPRIETARY INFORMATION AND IS 60 kg ARE QU eg 17 1 _____ BE USED IN ANY MANNER 3248s X 1578 INCORPORATE 3 _________________________________ TWIN DISC INCURPDRATED 2 ASSY 2 1 0 41 5 16 02 Qe SUE THIS NOTICE IS NOT INTENDED LIFY OR LIMIT RIGHTS OVERNMENT _ 8 5 10 02 2 0 EE 5 10345 8 23 01 PREV 20 ma
8. zero clearance is achieved the thrust tube should be tilted left right forward and back a resistance to movement will be felt to fully seat the ball The thrust tube assembly should remain attached to the overhead hoist during this procedure as a safety measure Do not allow the thrust ball to pivot against the edge of the installed retainer cover If the thrust tube drops against the socket damage may occur 12 Move the thrust tube back to the vertical position and recheck for clearance between the thrust ball and rear retainer wear sleeve Remove shims if necessary to obtain zero clearance between the thrust ball and the rear retainer wear sleeve Figure 77 Use Feeler Gauge and Obtain Zero Clearance Between Ball and Retainer 130 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 13 Whenzero clearance is obtained measure the gap between the socket housing and the cover The distance measured is equal to the thickness of the shims that must be removed from between the rear output end retainer and the cover to maintain the desired zero clearance between the ball and rear retainer wear sleeve Figure 78 Use Feeler Gauge to Obtain Average Gap Between Cover and Housing Arneson Surface Drive Service Manual 1020619 131 Assembly Twin Disc Incorporated 14 Remove the cover and remove the amount of shims equivalent to or the next size larger than the gap measured Exampl
9. 1982 1 2 0 1 1 po DRIVE ASS A THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT D Io e em _ _ OUTLINE OF TRANSOM 3 1925 SHEET 1 PARTS DRAWING SHEET 2 ASSEMBLY NOTES SHEET 3 INSTALLATION INTERFACE SHEET 4 INBOARD STEERING CYLINDER ARRANGEMENT DRIVE SS 71020120 d Tio ANGE STEERING CYLINDER GROUP 1020325 ES PROJECTION 1 TRIM CYLINDER GROUP 1020324 MATERIAL WEIGHT we UNLESS OTHERWISE SPECIFIED DATE Sata TWIN DISC 1 HEAT TREAT FIRST USE 1025 0 2521 00 RACINE 53403 USA ASSY ALL ANGULAR TOLERANCES 31 ASD 15 GEOMETRIC TOLERANCING D MEYERS MODEL PER ANSI 14 5 1982 CHK SURFACE TREATMENT NAME DRIVE ASS Y FN SHEET 4 OF 4 REV NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF 1 TWIN DISC INCORPORATED RACINE 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT CYLINDER SPECIFICATIONS 101 6 4 00 IN ROD DIA 50 77 2 00 IN STROKE 361 9 14 25 IN MEDIA STD HYD OIL OP
10. 2 s iem c N k OA NUT 1020216 a BALL 1020261 _ WASHER MA1039H N L SCREW MA1133D 3 _ NUT 1048 L PIN 1007534 uonejeisu 9554 UML Twin Disc Incorporated Figure 27 Steering Cylinder Arneson Surface Drive Service Manual 1020619 M2643 ING ABOVE o Installation 55 Installation Twin Disc Incorporated 7 Position the holes for the thru hull hydraulic fittings as shown A CAUTION Minor adjustments in location are allowed to clear framing however the hoses must be free to move without stress for the full range of horizontal and vertical drive movement Excessive stress on the hoses will lead to hydraulic failure and void the warranty The hoses provided have a minimum bend radius of 90mm 3 50 in for both steering and trim cylinders 8 Once the hole locations are established drill 48mm 1 875 in through holes Apply a generous amount of marine sealant when installing the thru hull fittings Install the fittings with the threaded ends inboard and the flanged ends against the outside of the transom Torque the nuts to 75 50 ft lb Connect the hoses and fittings as shown 9 A steering tie bar is required for twin drive installations When ordering the tie bar specify drive centerline to centerline distance Installation of the t
11. BEARING SLEEVE MA996D CREW COMPANION FLANGE 75 APPROACH LOWER TORQUE VALUE THEN CONTINUE UNTIL COTTER PIN SLOT IN NUT ALIGNS WITH HOLE IN SHAFT 0 fROMTOP OF PLUG TO O D OF YOKE NOT LESS THAN 2 2 DO NOT EXCEED LISTED TORQUE Arneson Surface Drive Service Manual 1020619 21 Description and Specifications Twin Disc Incorporated 22 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Removal from Vessel Removal from Vessel Prior to Removal Removal and disassembly should not begin until the drive unit exterior and work area have been thoroughly cleaned Detailed illustrations of special tools are located in Special Tools References will be made when a special tool is required As parts are disassembled inspect for damage wear and burrs See Cleaning and Inspection for details Note There are two methods to service an ASD 15A1S 1 The first method as described below explains the removal of the thrust tube assembly while keeping the thrust socket mounted to the transom This method is used when service is required on the thrust tube section and no major repairs are required in the thrust socket assembly 2 The second method that follows covers the removal of the surface drive from the transom followed by the disassembly of the thrust tube from the thrust socket Arneson Surface Drive Service Manual 1020619 23 Removal from Vessel Twin Disc Incorporated Remova
12. INSTALL CAP O RING PISTON SEALS AND WEAR RINGS LIGHTLY OIL O RING PISTON SEALS WEAR RING AND TUBE BORE ASSEMBLE CAP WITH PISTON INTO TUBE UNTIL HAND TIGHT ALIGN SET SCREW HOLES IN TUBE WITH PREVIOUSLY DRILLED DIMPLES IN CAP APPLY SET SCREWS MA1133D AND TORQUE AS SPECIFIED 7 TORQUE VALUES DESCRIPTION TORQUE VALUES 1020217 BALL 215 285 N m 150 200 FT LB MA960R SCREW 15 10 FT LB 1020204 YOKE SEE NOTE 4 1020206 SEE NOTE 5 11330 SET SCREW 7 5 FT LB 15 10 FT LB 1020211 RoD 15 10 FT LB 8 COAT THE MARKED THREADS WITH LOCKTITE THREAD LOCKER 242 142 BLUE SEMI PERMANENT 9 COAT THE MARKED THREADS WITH LOCKTITE THREAD LOCKER T70 RED PERMANENT 10 USE PIPE SEALANT ON HYDRAULIC FITTING THREADS 11 HYDRAULIC FITTINGS SHALL BE SCREWED HAND TIGHT AND WRENCHED AN ADDITIONAL 1 5 2 5 TURNS UNTIL ALIGNED 05 PIPE SEALANT SPARINGL Y SLEEVE MA1 SEAL MA1129D 2 CYLINDER SPECIFICATIONS BORE 123 83 4 875 ROD DIA 60 00 2 362 IN STROKE 127 00 5 00 OPER MEDIA STD HYD OIL OPER PRESS 1500 P S I MAX 2000 P S I SYSTEM RELIEF VALVE HYDRAULIC PORT THREAD SIZE 3 8 18 130B 2 TUBE ASS Y 1020256 PIN 1020218 YOKE 1020204 TUBE 1020205 SCREW MA960R 4 CAP 1020206 SCREW MA1133C 2 BALL 1020217 SCREW MA113 SCREW MA1133D 3 PISTON ASS Y O RING A2916LM O RING A2
13. ROUND ALL SHARP EDGES Arneson Surface Drive Service Manual 1020619 173 Special Tools Twin Disc Incorporated Assembly Stand Adapter T 21089 5C 1 of 2 7125 16 098 uas 8 047 pe 80 531 THRU pr esce 2 PLCS f 29 9 s Pd TD 8 PLCS 58 SHOWN 109 FLA 3 gt PLCS N NO Xd 1 1417 5 7 R7 911 06 755 S p 125 i 3 _ 16 x 3 A _ 2013 e 50 RO S0 BOTH SIDES 2 PLCS 1 00 STOCK DETAIL 6 el d i N i N ES NG N a N N X 8 00 BASE BRACKET 6 80 x 450 x 63 DETAIL 1 PLATE UPPER SUPPOR 8 00 x 1713 x 1 00 BRACKET 6 31 450 x 1 00 8 00 x 10 0 x 375 STUCK SIZE 174 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Special Tools Assembly Stand Adapter T 21089 5C 2 of 2 100 STUCK 20 25 1 40 xe 13 45 4 50 DETAIL 3 63 STOCK i 80 N 13 x 45 8 PLCS eta S AS SH WN 8 80 REF 6 80 Arneson Surface Drive Service Manual 1020619 175 Special Tools Twin Disc Incorporated Stand Setup ASD 15 15 21089 50 1 of 2
14. and Install Eye Bolt Into Prop Shaft right 5 Install the assembled propeller shaft into the thrust tube by inserting the shaft rear end first into the forward end of the thrust tube Take care not to damage the bearings or races while inserting the shaft into the housing Seat the shaft firmly in the thrust tube E Figure 58 Lower the Prop Shaft Assembly left and Seat the Shaft In the Bearing Race right Arneson Surface Drive Service Manual 1020619 113 Assembly Twin Disc Incorporated 6 Install the frozen front bearing cup into the thrust tube and raise the shaft approximately 0 030 inch to ensure that there will be end play in the bearing set Keep the shaft raised until the rear bearing race stays in place when the shaft is lowered Figure 59 Install the Chilled Rear Bearing Cup left and Raise the Shaft to Ensure End Play right Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 7 Install the thrust ball onto the thrust tube Secure the thrust ball using four M16 2 0 x 50 socket head capscrews evenly spaced Torque the capscrews to 170 N m 125 ft lbs 8 Turn the thrust tube assembly over so that the output end is facing up Install a dial indicator using special tool T 21549 28 onto the prop shaft T 21549 28 Figure 60 Lower Ball Secure with Four Capscrews left and Turn Over and Install Dial Indicator T 21549 28 right 9 Use a hoist and sp
15. 1 4 full when cold with the drive stopped to allow for expansion from agitation during operation A milky appearance could be an indication that water has been ingested Do not operate the drive for extended periods with contaminated oil Periodic oil sample analysis can be helpful in identifying the presence of water or other contaminants that could indicate impending failure Oil should be changed after the first 200 hours of operation and every 500 hours or twelve months whichever comes first thereafter When the vessel is waterborne drain the lubrication oil by removing the lower hose that is attached to the drive inside the vessel Drain and vent ports are provided on the drive to assist draining when the vessel is dry docked Arneson Surface Drive Service Manual 1020619 77 Preventative Maintenance Twin Disc Incorporated Steering and Trim Hydraulic Oil System Oil Level The oil level should be checked daily or every 10 hours Oil and Filter Change Interval The oil filter if equipped in the Steering System should be changed whenever the engine filters are changed The oil should be changed if contaminated An oil analysis can be helpful in avoiding problems from continued operation with contaminated oil Type Oil Recommended See Description and Specifications 78 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Preventative Maintenance Overhaul Interval A complete overhaul of the unit sh
16. Bar Arneson Surface Drive Service Manual 1020619 31 Removal from Vessel 32 Twin Disc Incorporated Disconnect the driveline companion flange Remove the retainer washer bolts and the retainer washer from the end of the surface drive input shaft Additional removal of driveline components may be required to allow access to the companion flange retainer washer Do not cradle the surface drive on the prop shaft or input shaft Damage to the unit could result 7 Properly support both the socket and thrust tube to prevent the surface drive from falling upon removal of the mounting bolts Remove the socket mounting nuts washers backing plate and bolts The surface drive should now slide away from the transom Take care not to damage the input shaft spines during the removal of the surface drive Place surface drive on suitable blocks or stands Make sure to support both the socket and thrust tube Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Installation General Note For Reinstallation of repaired units to the transom from which it was removed see the instructions at the end of Assembly in this manual Note Please read this Installation Manual all the way through and become thoroughly familiar with its contents before commencing installation procedures Installation Requirements The installation of the surface drive must comply with all prevailing manufacturer s
17. Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Introduction Source of Service Information For the latest service information on Twin Disc products contact any Twin Disc distributor or service dealer This can be done on the Twin Disc corporate web site found at http www twindisc com Provide your model number serial number and bill of material number to obtain information on your unit necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com Arneson Surface Drive Service Manual 1020619 15 Introduction Twin Disc Incorporated Rebuilding Service Twin Disc may provide a complete rebuilding service for surface drives and hydraulic cylinders Call or write Twin Disc Incorporated for information on services pricing and scheduling Twin Disc Incorporated 1328 Racine Street Racine Wisconsin 53403 USA Telephone 262 638 4000 Fax 262 638 4480 Warranty Equipment for which this manual was written has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual For details of the warranty contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Inc Racine Wisconsin U S A 16 Arneson Su
18. Keep the wrapper on new bearings until they are installed Do not expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Sealed Joints Scrape surfaces to remove old gasket material on previously sealed joints Wipe off cured sealant with gel type paint remover containing methylene chloride Do not get paint or gasket remover on painted surfaces Clean surfaces with denatured alcohol or clean solvent to remove oil and grease residue Test for clean surfaces by applying a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface in a film If the water puddles or forms beads use fresh solvent and reclean Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Cleaning and Inspection Inspection Housings Cast Parts and Machined Surfaces Bearin Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will cause loss of press of bearings or races Inspect oil and grease passages for obstructions If you find an obstruction remove it with compressed air or work a wire back and forth through the passage and flush it with solvent Inspect machined surfaces for burrs scratches nicks and for
19. MA1052C 2 SLEEVE M26964 COLLAR 1020138 2 7777771 1039 3 gt z SCREW MA996D 3 MID A 25522 N No 22222247 22222774 27770 lt 78 1504 2 5 1020124 BEARING 1120 2 SLEEVE 1020139 SEAL MA1125 2 KIT 1020247 SHIM 1020222 as req d SHIM 10202224 as req d SHIM 10202228 as req d SCREW MA1052K 6 PARTS SHIPPED LOOSE GREASE FITTING M268 TEE FITTING MA711H ADAPTER FITTING MA1053P 0 FD 2717 Mar SN AD O RING 1008017 PLUG MA1038H 4 PIN MA1035C 2 U JOINT 1020123 1020135 1008064 2 1020248 5 1020142 SHIM 1020142A as req d SHIM 1020142B as req d SHIM 1020142C as req d RETAINER 1020136 EZ 5 KKK NIS CLAMP 1020180 2 COVER 1020137 SCREW 1124 24 BUSHING 1020174 BUSHING 1020172 2 HOUSING GROUP 1020129 THRUST TUBE 1020097 SLEEVE 1020131 PIN MA1035K 2 SLEEVE 1020130 PIN MA1035J 2 INSERT MA1064H 12 INSERT MA1064F 18 INSERT MA1064G 8 PLUG 1038 RING M2078CD ISOLATOR 1020146 NUT MA1127A CLAMP 1020181 2 PLUG 1005982 2 PLUG 2051 5 SEAL 1126 3 2
20. Remove Nut Washer and Spacer 2 Remove the lock washer and spacer Discard the lock washer 3 The tapered bearings can be removed with heat or by cutting the bearings off the shaft A CAUTION Use extreme caution when cutting bearings away from the shaft Do not cut or scratch the shaft Damage to the shaft will cause the loss of press fit on the races bearings or seal surfaces and will weaken the shaft 94 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly A To Remove Bearings with Heat To remove the bearings with heat first break the bearing cages with a chisel and remove it with the tapered rollers Stand the shaft vertically with the propeller end up and quickly heat the inner races with an acetylene torch until the races drop off B To Remove Bearings by Cutting To cut bearings off use a cutoff wheel with a carbide or composition wheel Cut through the bearing cages Remove the cages and the tapered rollers Cut a groove in the inner race that is approximately half way through the race Split the race with a chisel and slide the race off the shaft Figure 43 Use Chisel to Cut Bearing Cage to Remove Rollers 4 On the propeller end of the shaft remove the seal sleeve bearing and spacer by using a split bearing puller to pull on the spacer 55 Clean and inspect the shaft for damage on critical dimension surfaces See Cleaning and Inspection Arneson Surface Drive Ser
21. Twin Disc Incorporated List of Special Tools Special Tools Special Tools The following pages include the special tool drawings that are specific to this model The special tool drawings included are listed below and continue on the following page D D D DO DO DO D UD Arneson Surface Drive Service Manual 1020619 18050 774 1 18050 7 75 18050 776 18050 777 18050 780 18050 780 18050 781 21089 5 21089 5 T 21089 5B T 21089 5B T 21089 5C T 21089 5C T 21089 5D T 21089 5D T 21549 28 T 21567 Input Socket Shaft Wear Sleeve Driver Input Socket Shaft Bearing Cup Driver Thrust Bearing Cup Driver Propeller Shaft Seal Sleeve Driver Propeller Shaft Seal Driver Assembly Detail 1 Propeller Shaft Seal Driver Assembly Detail 2 Input Socket Shaft Seal Driver Assembly Stand Adapter 1 of 2 Assembly Stand Adapter 2 of 2 Assembly Stand Adapter 1 of 2 Assembly Stand Adapter 2 of 2 Assembly Stand Adapter 1 of 2 Assembly Stand Adapter 2 of 2 Stand Setup ASD 15 15 1 of 2 Stand Setup ASD 15 15 2 of 2 Shaft Indicator Holder Lifting Fixture 161 Special Tools Twin Disc Incorporated 9 21570 Jacking Tool 1 of 2 21570 Jacking Tool 2 of 2 162 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Special Tools Input Socket Shaft Wear Sleeve Driver T 18050 774
22. Twin Disc Incorporated Installation Lubrication The ASD 15A1S is supplied with an internal lubrication system that can be serviced inside the vessel A non pressurized type of lubrication system is standard equipment on the ASD 15 15 and is described below Internal Lube Kit The Internal Lube Kit is used for the ASD 15 15 drives This kit shown in the schematic diagram of Figure 32 includes an oil reservoir hose clamps and necessary hose fittings and plugs supplied by Twin Disc Incorporated The customer provides the necessary support brackets for the reservoir All components are to be internally clean to prevent oil contamination Reservoir mounting Mount reservoir 254mm 10 in or higher above surface drive centerline as shown in Figure 32 Support reservoir on bottom and secure to the vessel s structure Connect 19mm 0 75 in hose as shown in Figure 32 Before starting the lubrication filling process lower drive unit by extending the trim cylinder This will aid in bleeding air from thrust tube Remove the top plug from the thrust socket Fill the drive unit with proper oil until approximately 4 from top outside opening in thrust socket Allow 5 minutes for air to escape recheck oil level Note Similarly the drive can be filled through the upper hose inside the vessel Fill reservoir to the level to about half full leaving some tank air space for oil expansion Replace all fill plugs and check the fittings The
23. WASHER 2013 SCREW MA1124C 8 SPACER 1020157 SLEEVE 1020132 1020182 5 gt 222229 1020183 1020184 42 2 wm 22227 1 m 548 22 7777777722222221222 68 63 gt 222 ee 55 7777 2 2 2222222227 2 2226 4 T A COVER 1020141 07998 222 SHAFT 1020262 SPACER 1020255 MA585DV 2 O RING A2916AH 2 590 2 O RING A2916LL 2 KIT 1020249 PLUG MA1038H 2 SHIM 1020140 as req d BEARING 1005104A SHIM 1020140A as req d SHIM 1020140B as req d O RING A2916GQ 2 SCREW MA1124A 18 SCREW 1123 12 BOOT 1020143 BALL 1020134 KIT 1020246 3 SHIM 1020145 as SHIM 1020145 as req d SHIM 10201458 req d 1020144 SHEET 1 PARTS DRAWING SHEET 2 ASSEMBLY NOTES SHEET 3 INSTALLATION INTERFACE SHEET 4 INBOARD STEERING CYLINDER ARRANGEMENT meas PROJECTION 1 SIMILAR TO 1018683 REF B O M 1020120 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm 19 1216 MACHINED DIMENSIONS RUE GR FIRST USE 20 29 53403 USA ALL ANGULAR TOLERANCES 1 i cz ncs PE Be 1 02011 9 5 DRIVE ASS Y SHEET 1 4 FEATURES STAINLESS STEEL
24. and support it on the thrust tube Figure 80 Remove the Retainer or Wear Sleeve left and Install Packing Shim Pack right 16 Install a shim pack of the packing shims measuring approximately 3 8 mm 0 150 in in thickness These are placed on top of the packing material The packing will be deliberately over shimmed 17 Install the rear retainer wear sleeve followed by the shim pack and cover Install every third M12 1 75 x 35 socket head capscrew retaining the cover to the socket Evenly torque the screws to 34 N m 25 Ib ft Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 18 gt Measure the gap between the thrust socket housing and the cover in several positions around the diameter of the thrust socket Average these measurements and label this average as A tight retainer bolts Note that if there is no gap more shims will need to be added on the packing material Figure 81 Use Feeler Gauge to Obtain Average Gap Between Cover and Housing Gap A 19 Loosenthe cover retaining screws and allow the packing and o ring to relax 20 Measure the gap between the thrust socket housing and the cover in several positions around the diameter of the thrust socket Average these measurements and label this average as B loose retainer bolts Figure 82 Use Feeler Gauge to Obtain Average Gap Between Cover and Housing Gap B Arneson Surface Drive Service Manual 1020619 135 As
25. small diameter end is facing up and attach a dial indicator and special tool T 21549 28 to the forward end of the input shaft Install a swivel eyebolt into the input end of the shaft Rotate the shaft several turns and zero the indicator Mark the angular location of the indicator stem on the socket Use a hoist to lift on the input end of the shaft rotate several turns while lifting stop with the indicator stem on the mark and note the end play reading on the indicator The indicated end play should be larger than 0 05 mm 0 002 in The desired final end play is 0 05 mm to 0 127 mm 002 in to 005 in Turn the assembly over with the large end up Figure 71 Install Four Capscrews to Retain Sleeve left and Turn Over and Measure End Play right 14 Remove or add shims between the housing and the bearing sleeve to adjust the bearing clearance and repeat steps 12 through 14 until the shaft end play is within tolerance Shims must be removed not added to reduce end play Remove the guide studs and install the remaining M10 1 5 x 30 socket head capscrews and torque to 55 N m 40 ft lbs Rotate the shaft by hand to assure smooth operation and recheck the final end play Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 16 Turn the assembly over with the input shaft up Lubricate the seal surfaces and use special tool T 18050 781 to press the seals back to back into the seal carrier
26. tapered roller bearings One 1 spherical roller bearing One 1 seal sleeve with two o rings in place the inner diameter 2 Support the shaft in a horizontal position on blocks allowing enough radial clearance for installation of the bearings Apply a thin coat of Molykote P37 Ultra Pure High Temperature Paste to the shaft on the surfaces where the bearings will seat as an anti seize compound Application Instructions Apply a thin even coating of paste onto component surfaces Rub thoroughly into surfaces with a clean lint free cloth leaving a coating depth less than 0 003 mm 0 0001 in Excessive coating depth will result in sleeve and bearing distortion and may prevent bearing assembly and reduce bearing life E e Figure 50 Propeller Shaft left and Engine End Propeller End right 108 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly Install a heated tapered roller bearing on the forward universal joint end of the shaft with the smaller diameter end toward the propeller end ofthe shaft and seated against the shoulder Install the second tapered roller bearing with the large diameter end against the large diameter end of the first one Be sure to maintain pressure on the bearings as they cool until they take hold spacer Figure 51 Install Bearings left Followed by the Spacer right Install the spacer followed by the washer with the tabs pointing toward the
27. 242 blue or similar liquid thread locker Lower the thrust ball onto the thrust tube taking care that the o rings and isolator remain in the proper location The fill vent plug in the thrust ball must be located at the top of the thrusttube This is opposite the fin mounting surface Figure 61 O ring On Thrust Tube left and Use Grease to Hold O ring in Thrust Ball Groove right Thrust ball 1 Thrust tube Figure 62 Place Isolator Over Thrust Tube left and Lower Thrust Ball Onto Thrust Tube right Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 13 Coat the clean capscrew threads with Loctite 242 blue or similar liquid thread locker and install the twelve M16 2 0 x 50 socket head capscrews Torque the capscrews to 170 N m 125 ft lbs Figure 63 Install Capscrews to Secure Ball to Thrust Tube 14 Turnthe thrust tube over so that the rear end is facing up Arneson Surface Drive Service Manual 1020619 117 Assembly Twin Disc Incorporated 15 Place the seal cover rope guard with the opening facing up Use special tool T 18050 780 to press a seal into the rear seal cover with the lip opening rear down toward the rear of the cover Install the spacer followed by another seal with the lip opening rear down toward the rear of the cover Install the third seal with the lip opening facing up followed by the snap ring Install two o rings in the
28. 77 General 77 sunl 79 Periodic Visual 79 Propeller Torque 81 83 Treubleshooling Chart 83 8 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Table of Contents f 85 aiara 85 Disassembly of the Thrust Socket from Thrust Tube 86 Thrust Tube Disassembly 89 Prop Shaft Disassembly 94 Thrust Socket 96 U joint Input Shaft 99 Cleaning and Inspection 103 103 e 105 107 Assembly OVCIVIEW sinis il be bibe L1 PER VOR din 107 Propeller Shaft 108 Thrust Tube Assembly iiec 112 Thr
29. Drive Service Manual 1020619 145 Assembly Twin Disc Incorporated 22 gt Measure the gap between the thrust socket housing and the cover in several positions around the diameter of the thrust socket Average these measurements and label this average as A tight retainer bolts Note that if there is no gap more shims will need to be added on the packing material Figure 93 Use Feeler Gauge to Obtain Average Gap Between Cover and Housing Gap A 146 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 23 Loosen cover retaining screws and allow the packing and o ring to relax 24 gt Measure the gap between the thrust socket housing and the cover in several positions around the diameter of the thrust socket Average these measurements and label this average as B loose retainer bolts Figure 94 Use Feeler Gauge to Obtain Average Gap Between Cover and Housing Gap B Arneson Surface Drive Service Manual 1020619 147 Assembly 148 25 26 27 Twin Disc Incorporated Subtract A tight retainer bolts from B loose retainer bolts Record the difference as C actual compression C represents the actual compression that results from the packing and o ring being compressed with 150 in 3 81 mm thickness of packing shims Subtract the specified amount of compression 1 25 mm 25 mm 0 050 010 in from C the actual compression Record this new calculation as D
30. FROM m THREADS PLACE BRACKET OVER THREADED END OF CAP 8 170 28 2 E PROJECTION ENSURE BALL AND CAP THREADS ARE CLEAN THEN THREAD BALL ONTO CAP USING LOCKTITE AS SPECIFIED TORQUE TO SIMI ER SPECIFIED VALUE INSERT SET SCREWS MA1133D INTO BALL 9 USE PIPE SEALANT ON HYDRAULIC FITTING THREADS TORQUE AS SPECIFIED REF BOM 1020233 1009545 NUT 1020216 BALL 1020261 32 12 2 UNLESS OTHERWISE SPECIFIED DATE SCREW MA1133D 3 PROPRIETARY INFORMATION IS i MACHINE DIMENSIONS wo uu DISE _1 _ Not to USED IN ANY MANNER 147 Ibs x ee iN CORPORATE p ouo CHE seme 2008 01 1 FIRST USE 25 SCR RACINE W 53403 USA L q T T ej D5 tcw05335 1 02 Racine 5403 USA 103 6 29 01 ANS 14 5 1982 1020254 THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS ewessde 19 0 12000105 Rev SHEET Zone paw REV SHEET ZONE NO DATE i FN SHEET or 2 D B 5 55 mm in FITTING CYLINDER GROUP BOM ow 9 o ms HOSE 1020336 N SEE CHART NUT 1005999 SPACER 1009585 2 FITTING M2483CQ 1007031 FITTING 26435 2 P FITTING M2483CP STEERING CYLINDER ASS Y SPACE
31. IN THIS WILL CREATE A LINE FIT TO SLIGHTLY LOOSE BETWEEN THE AFT RETAINER AND THE BALL THE AFT RETAINER HAS NOW BEEN SHIMMED PROPERLY TO THE BALL 2 SEAL AND PACKING d REMOVE THE THRUST BALL FROM THE SOCKET INSTALL THE PACKING O RING AND THEN PACKING OVER THE FORWARD RETAINER NEXT SHIMS ARE REQUIRED BETWEEN THE AFT RETAINER AND PACKINC THE GOAL IS TO OBTAIN THE PROPER SQUEEZE ON THE O RING THE PACKING IS NOT A RESILIENT MATERIAL THEREFORE ONCE COMPRESSED WILL MAINTAIN ITS SHAPE PROPER SQUEEZE ON THE O RING IS 10 15 OF THE CROSS SECTION WHICH 15 1 0 TO 1 5mm 04 TO 06 IN BEN S wn s A 224 ESSN Ze 1043 888 A 244 BALL 22 11 2 Z 2 22 22 LLY fpr 540 9 b INITIALLY 5 THE PACKING MATERIAL BY INSERTING 3 8mm 150 IN OF SHIMS INSTALL THE AFT RETAINER RETAINER COVER AND BOLTS TORQUE EVENLY TO 36 25 FT LB BECAUSE THE PACKING WAS OVER SHIMMED GAP WILL EXIST BETWEEN THE RETAINER COVER AND THE SOCKET HOUSING MEASURE THIS GAP TAKE SEVERAL READINGS AROUND THE UNIT AND AVERAGE THE VALUES c LOOSEN THE BOLTS ON THE RETAINER COVER ALLOW THE O RING TO RELAX AGAIN MEASURE THIS GAP TAKE SEVERAL READINGS AROUND THE UNIT AND AVERAGE THE VALUES THE DIFFERENCE BETWEEN THESE TWO READINGS IS THE SQUEEZE ON THE O RING EXAMPLE A 3 8mm 150
32. IN SHIMS ON THE PACKING RETAINER BOLTS TORQUED TO 25 FT LBS B LOOSEN RETAINER BOLTS C SQUEEZE ON O RING GAP 2 75mm 110IN AVG SQUEEZE 2mm 08 IN THE O RING SQUEEZE SHOULD BE BETWEEN 1 0 TO 1 5mm 040 060 IN THIS EXAMPLE 0 75 mm 0 030 IN OF SHIM MATERIAL SHOULD BE REMOVED 7 LUBRICANT RECOMMENDATIONS SAE 30 WITH EMULSIFYING PROPERTIES MIN VISCOSITY 100 CST 6 100 F FILL DRIVE UNTIL EXTERNAL RESERVOIR IS ONE THIRD FULL 8 TORQUE JAM NUT 860 1000 600 700 FT LB APPROACH LOWER TORQUE VALUE THEN CONTINUE UNTIL COTTER PIN SLOT IN NUT ALIGNS WITH HOLE IN SHAFT 9 FROM OF PLUG 0 0 OF NOT LESS THAN 2 2mm TORQUE NOT TO EXCEED 42 30 FT LBS HANDLE CAREFULLY TO AVOID DAMAGING PAINT TOUCH UP CHIPPED PAINT WITH A TWO PART MARINE EPOXY PRIMER SUCH AS PETTIT 46455 METAL PRIMER FOLLOWED 4700 AND 4701 HIGH BUILD EPOXY PRIMER OR EQUAL THE MINIMUM THICKNESS FOR CURED PRIMER IS 0 15mm 006 IN 10 11 AFTER DRIVE IS INSTALLED REMOVE SHIPPING PLUG MA1040C AND REPLACE WITH LUBE OIL SYSTEM ADAPTER FITTINGS MA1053P AND SEE TWIN DISC SERVICE MANUAL FOR ALL OTHER PROCEDURES AND SPECIFICATIONS 12 22241 77 2 25 22 4 GAP 0 75mm 030 AVG 1987 NOTICE 5 PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DI
33. If the packing and o ring must be replaced due to leakage remove the ball and thrust tube assembly from the socket and follow the complete instructions for assembly of the thrust tube to the socket while attached to the e transom as shown in the previous section Boot Installation Note The bootis not intended to keep water out Its purpose is to protect the drive from marine growth and debris The fin must be removed to install the boot Clean the interior of the boot with a clean cloth and cleaning solvents Holding the boot with the large end facing forward pass the boot over the prop shaft and slide down and over the thrust socket Make sure that the grooves in the thrust socket housing match up with the ridges on the boot Secure the boot to the thrust socket with two circle clamps Make sure that the clamp screws are on the top of the unit They create a drag if positioned on the bottom or in the water Apply anti seize lubricating compound on the clamp threads Position the output end of the boot over the thrust tube so that the flat portion of the boot is just behind the thrust tube to ball joint Secure the boot with two circle clamps Make sure that the screws are on top of the unit THRUST TUBE SMOOTH Figure 96 Install Boot Over Output Placing Ribs In Boot In Socket Grooves Arneson Surface Drive Service Manual 1020619 149 Assembly Twin Disc Incorporated Fin Reattachment 150 Remove any rough
34. Incorporated 9 Remove thrust tube from socket with caution taking care that the ball comes out of the socket evenly Protect ball and socket with plastic bags to avoid contamination by dirt and dust 10 Theforward thrust ball retainer may come out of the socket along with the thrust ball Do not drop the forward thrust ball retainer The forward retainer can be reused if itis not damaged or worn Forward Thrust Ball Figure 7 Inner forward Thrust Ball Retainer with Packing 11 Store thrust tube securely without anything touching the ball 28 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Removal from Vessel Complete Removal of Surface Drive from Transom Always disconnect the battery cables and remove the key from the ignition before beginning this procedure CAUTION Support the surface drive with block and tackle forklift or other system capable of carrying the weight of the surface drive Do not allow the thrust tube to angle down to the point where the ball thrust tube assembly makes contact against the thrust socket Severe damage to the ball and the socket could result Arneson Surface Drive Service Manual 1020619 29 Removal from Vessel Twin Disc Incorporated 1 Remove the battery cables and remove the key from the ignition 2 Support the drive with a block and tackle forklift or other system capable of carrying the weight of the surface drive Do not allow the thrust tub
35. SHAFTINC TRIPLE PROPELLER SHAFT SEALS ALUMINUM HOUSING NOTICE THIS PRINT CONTAINS MATERIAL EE us 121 8 22 13 E ME 5 1285 S wor 102808 29 0 Rev sweet zone par Rev sheer zone No part PROPRIETARY INFORMATION AND IS T TO BE US HEAT TREAT SURFACE TREATMENT GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT DESCRIPTION DRY TORQUE VALUE MA1124C SCREW COVER 4 0 3 0 FT LB 1124 SCREW FIN 17 N m 12 FT LB 1123 SCREW BALL 170 N m 125 FT LB 11248 SCREW RETAINER COVER 60 N m 40 FT LB 1140 1285 N m 800 900 FT LB TAPER PIPE FITTINGS SHALL BE SCREWED HAND TIGHT AND WRENCHED AN ADDITIONAL 1 5 2 0 TURNS USE PIPE SEALANT SPARINGLY 720 SS dee S 2444 2 2 20 5 1 PACKING QTY 2 1250mm 49 17IN LENGTH EACH IS REQUIRED 2 STACK SHIMS SO THAT 0 05 0 13mm 002 TO 005 IN BEARING END PLAY IS ACHIEVED APPLY LUBRICANT ON AND BETWEEN SEALS LUBRICANT SHALL BE A MARINE GRADE LITHIUM GREASE WITH PROPERTIES FOR SALT WATER ENVIRONMENT SUCH AS ZEP BRAND RED LITHIUM GREASE 3b THE PROPELLER SHAFT SEALS ARE PROVIDED WITH A LUBRICATION PORT T
36. THE NUT UNTIL PIN 1020219 CAN BE FULLY INSERTED THREADED PARTS WITH LOCTITE AS SPECIFIED IN THESE NOTES TORQUE SCREWS 9608 TO SPECIFIED VALUE SCREW MA960R 4 CLEAN THREADS PRIOR TO APPLYING LOCTITE 6 TORQUE VALUES 2 INSTALL LIGHTLY OILED SEAL WEAR RING AND SCRAPER IN ROD CAP LIGHTLY OIL ROD AND INSERT ROD THROUGH END CAP DESCRIPTION TORQUE VALUES INSERT PREVIOUSLY LUBRICATED PIVOT PIN INTO CLEVIS AND 1020261 BALL 215 285 150 200 FT LB THREAD IT ONTO ROD TORQUE AS SPECIFIED DIMPLE THE ROD MA960R SCREW 15 N m 10 FT LB THROUGH THE M8 PIVOT PIN HOLE THE SMALLER OF THE TWO 1020237 NOTE 3 EE 2 1020238 stt NOTE 3 11330 SET SCREW 7 5 FT LB SHEET 1 3 INSTALL CAP O RINGS PISTON SEALS AND WEAR RING 1020258 PISTON SEE NOTES CYLINDER LIGHTLY OIL PISTON SEALS WEAR RING AND TUBE BORE 1020240 110 140 75 100 FT LB ASSEMBLE CAPS 1020236 AND 1020237 DO LUBRICATE 11338 SET SCREW 15 10 FT LB THREADS TO TUBE UNTIL HAND TIGHT ALIGN SET SCREW HOLES MA1048F 57 40 FT LB IN TUBE WITH PREVIOUSLY DRILLED DIMPLES IN CAPS CLEAN SET 1020216 70 N m 50 FT LB HOSE amp FITTING SCREW THREADS APPLY SET SCREWS MA1133D AND TORQUE AS ARRANGEMENT SPECIFIED 7 COAT THE MARKED THREADS WITH LOCKTITE THREAD LOCKER 242 742 BLUE SEMI PERMANENT F E 4 LIGHTLY LUBRICATE SPHERICAL SURFACES OF BALL AND BRACKET USING ABOVE GREASE KEEP GREASE AWAY
37. and support the shaft with the input end down Support the u joint with the hoist Remove the bolts and collars holding the U joint to the input shaft Raise the u joint assembly off the input shaft Another technique is to clamp the U joint s H shaped center coupling in a vise The U joint should be positioned so it looks like an H on its side with the bottom leg of the H in a vise 2 Slide the shaft out of the splines of the yoke taking care that the loose bearing sleeve is restrained to prevent damage ws 5 0 f 070 60i 656 3 2 les 11 15 4 m Bearing Sleeve Figure 47 Stand Shaft Assembly and Support Remove Bolts Raise U joint Arneson Surface Drive Service Manual 1020619 99 Disassembly Twin Disc Incorporated 3 Remove the bearing cup from the bearing sleeve The bearing cup is a light press fit in the sleeve and should slide out of the sleeve with little effort If necessary tap against the bearing lip to assist in removal or apply even heating to the sleeve outer diameter Figure 48 Remove Bearing Cup from the Bearing Sleeve 4 Remove the rear input bearing from the input shaft using a split type bearing puller If necessary see Propeller Shaft Disassembly for removal by heat Input Seal Figure 49 Input Shaft with Bearings and Seal Wear Sleeve 5 Stand the input shaft on the bench with the forward end down on the bench Remove the seal wear sle
38. capacity of the reservoir drive system is approximately 10 15 gallons Arneson Surface Drive Service Manual 1020619 63 79 6190 01 enuen enS 16 ze LUBE OIL RESERVOIR Y PUMPING RATING VESS THA 15 15 5 OIL DRAINING uonejeisu peie10d402u 95101 Twin Disc Incorporated Installation Lubricants Recommended oil is SAE 30 or SAE 40 meeting API Service Category CF or higher certified by the vendor to meet Caterpillar Test TO 4 specifications During operation the lube oil level will rise in the oil reservoir due to the displacement of oil from within the drive unit into the reservoir This is normal The oil level will return to the original levels when the unit is not running or idling Arneson Surface Drive Service Manual 1020619 65 Installation Twin Disc Incorporated Propeller Installation Routine Maintenance 1 Apply a thin coat of anti seize lubricating compound to the propeller shaft as shown in Figure 33 2 Install the propeller thrust washer propeller nut lock nut on the shaft as shown in Figure 25 Torque the propeller nut to 1220 N m 900 ft Ibs Torque the jam lock nut to 860 to 1000 N m 634 to 738 ft Ibs Approach the lower value then continue until a cotter pin slot in the nut aligns with the hole in the shaft Insta
39. edges or burrs from the mating surfaces of the thrust tube and fin pad Repair any paint damage that results Clean the flat surfaces and threaded holes with alcohol Spread a thin layer of waterproof marine grade silicone sealer on the thrust tube fin pad using care to keep silicone out of the threaded holes Coat the clean capscrew threads with Loctite 242 blue or similar liquid thread locker Place the fin on the fin pad and install the eighteen M10 1 5x 35 socket head capscrews If necessary tap the fin with a plastic mallet to align the fin on the base Tighten all screws evenly squeezing excessive sealer to the outside Torque the capscrews to 17 N m 12 ft lbs Continue re torquing until the capscrews no longer turn as the sealer is squeezed out Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 4 Clean the excess sealer from the seam Figure 97 Apply Silicone to Thrust Tube Surface left Put Pin In Place and Install Bolts right Figure 98 Torque Capscrews left Remove Excess Silicone from Tube right Arneson Surface Drive Service Manual 1020619 151 Twin Disc Incorporated Assembly Attaching Thrust Unit to Transom Note A review of the Installation Section of this manual could be very helpful for properly installing the surface drive 1 Using suitable lifting device cradle the unit into place against the transom with the input shaft installed into the hole in trans
40. in Special Tools 2 Remove the cover rope guard screws and the cover and seal assembly Gently force a thin plastic blade or equivalent between the flange and thrust tube Remove evenly to avoid jamming the cover assembly within the bore Avoid chipping or scratching the thrust tube paint Figure 38 Remove Cover Rope Guard Remove Retaining Ring Seals Spacer and O rings 3 Remove retaining ring and remove seals and o rings from cover and discard Do not discard the spacer Arneson Surface Drive Service Manual 1020619 89 Disassembly Twin Disc Incorporated 4 Rotate the thrust tube in the assembly stand so that the input end is facing up If a stand is not available a suitable support should be made Thrust Ball Figure 39 Rotate Thrust Tube Assembly so Ball is Up Remove 12 point Capscrews 90 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly Remove the screws holding the thrust ball to the thrust tube Use a 16mm 12 point socket wrench Note A lifting device can be fabricated using a length of channel material that is longer than the inner opening of the ball that is slightly shorter than the inner diameter of the ball Drill a hole in the center of the channel material for an eyebolt hole This device is shown being used in the picture below Slide the thrust ball out of the thrust tube Remove the o ring from the bottom of the thrust ball When sliding the thrust
41. in accordance with the required torque after an additional 250 hours of operation If the torque is correct go to step B If the torque is incorrect re torque the nut and repeat step A The propeller nut torque must be checked in accordance with the required torque after an additional 500 hours of operation If the torque is correct go to step C If the torque is incorrect re torque the nut and repeat step B The propeller nut torque must be checked in accordance with the required torque after an additional 1000 hours of operation If the torque is correct go to step D If the torque is incorrect re torque the nut and repeat step C The propeller nut torque must be checked in accordance with the required torque after an additional 1500 hours of operation If the torque is correct go to step E If the torque is incorrect re torque the nut and repeat step D Continue to increase the interval in increments of 1500 hours until the regular haulout interval of the vessel is reached If at any point in steps A through the haulout interval of the vessel is reached or surpassed the torque check interval may be established to be the same as the haulout interval Record the final interval for reference Arneson Surface Drive Service Manual 1020619 81 Preventative Maintenance Twin Disc Incorporated 82 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Troubleshooting Troubleshooting Troubl
42. joint and into the threaded holes in the shaft Note thatthe holes in the shaft and the u joint are not perfectly aligned so that the tapered collar will draw and hold the u joint yoke against the bearing Note Care must be taken when assembling the collar and screw into the yoke and shaft to prevent the collar from catching its lower edge on the edge of the hole Begin by sliding the collar over the screw and into contact with the screw head The large end of the collar must face the screw head Continue to hold the collar against the screw head thread the screw into the shaft about two turns The collar should not yet be in the hold Next slide the collar into the tapered yoke hole ensuring that the collar enters the hole without catching its edge on the edge of the hole It should be possible to tilt the screw slightly to the side to allow the collar to enter the tapered hole Once the collar is started into the yoke advance the screw until it contacts the collar and then torque the screw to the final torque value Tighten the two capscrews evenly until the distance from the top of the collar to the yoke surface measures 2 2 mm 0 087 in Do not exceed a torque of 42 N m 30 ft lbs on the capscrews m 1 5 o gt Figure 68 Lower U joint Onto Spline Align the Hole with the Threads center and Install Collars right Arneson Surface Drive Service Manual 1020619 121 Assembly 122 Twin Disc In
43. lbs Follow the torque sequence shown on the next page Note Delrin isolation pads and bushings are only needed on metal vessels and vessels with graphite composite hulls 154 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated N NA Assembly D NS x GUN SAN Figure 101 Torque Sequence for Socket Installation on Hull Arneson Surface Drive Service Manual 1020619 N AX V D uA LO X 5 pe CN 155 Assembly Twin Disc Incorporated Propeller Installation Routine Maintenance 1 Apply a thin coat of anti seize lubricating compound to the propeller shaft as shown in Figure 102 A CAUTION Do not apply anti seize compound to the propeller or propeller shaft tapers Tapers must be clean and dry for assembly 2 Install the propeller thrust washer propeller nut lock nut on the shaft as shown in Figure 102 Torque the propeller nut to 1220 N m 900 ft Ibs Torque the jam lock nut to 860 to 1000 N m 634 to 738 ft Ibs Approach the lower value then continue until a cotter pin slot in the nut aligns with the hole in the shaft Install the cotter pin Note The propeller nut should be re torqued following the following schedule ER INSTALLATIO PRUPELLER
44. measurement using the Thrust Ball Centering Gauge supplied with the package See Figures 22 and 23 Lay the tool against the ball shoulder and adjust the unit so that the tool fits evenly all the way around the circumference of the socket This assures that the unit is in line with the socket and input shaft so that the entire unit is in a straight line This is referred to as the neutral running angle ALUMINUM SHARP EDGES 3 gt ALL SURFACES TO BE SMOOTH 169 00 EN 1170 45 STAMP PART HER STAMP PART _ 10206240 d NAME HERE 0 1 V M LUST BALL GAUGE gt MODEL ASD 15 10 2 PLACES Figure 22 Centering Gauge Arneson Surface Drive Service Manual 1020619 49 Installation Twin Disc Incorporated 4 After the neutral running angle is determined lay the trim cylinder bracket against the transom making sure that the cylinder is at the center travel location The center of the transom bracket should be aligned with the center of the drive centerline CLEAR SIDE AME ON EACH ex S THE V Ys YU RIV 7 Figure 23 Center the in the Socket 50 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Transfer the bracket hol
45. must be checked in accordance with step 2 after an additional 1500 hours of operation If the torque is correct go to step E If the torque is incorrect re torque the nut and repeat step D Continue to increase the interval in increments of 1500 hours until the regular haulout interval of the vessel is reached If at any point in steps A through the haulout interval of the vessel is reached or surpassed the torque check interval may be established to be the same as the haulout interval Record the final interval for reference Arneson Surface Drive Service Manual 1020619 67 Installation Twin Disc Incorporated Propeller Installation New Applications First time installation of new propellers will require a check to verify proper mating of the tapered shoulder on the propeller with the tapered shoulder on the shaft Mismatched tapers may result in a damaged or broken propeller shaft and a lost propeller Follow the procedure below to check the propeller to shaft fit 1 Clean the taper on the forward end of the propeller hub and the tapered shoulder of the shaft with alcohol or other cleaner and wipe dry 2 Apply a layout dye to the shaft taper as follows Use machinist s layout dye such as Dykem Steel Layout Blue Dykem part number DX100 marketed by ITW Dymon Company 805 E Old 56 Highway Olathe KS 66061 USA 3 Apply the layout fluid to the shaft taper as thinly and evenly as possible over the entire tape
46. or U joint Remove drive and repair Air in trim cylinders Bleed hydraulic system Water in drive oil The oil Leak in thrust ball socket Tighten threaded looks milky and brown seal retainer ring Leak in thrust tube rear oil Remove and replace seal packing and o ring Loose oil fill and or Tighten or remove and plug replace the plug See the Driveline alignment in the Installation Chapter 84 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly Disassembly Disassembly Overview The disassembly instructions that follow are separated into major sub assemblies Disassembly of the thrust socket from the thrust tube Thrust tube disassembly Propeller shaft disassembly Thrust socket disassembly D D D U joint input shaft disassembly Arneson Surface Drive Service Manual 1020619 85 Disassembly Twin Disc Incorporated Disassembly of the Thrust Socket from the Thrust Tube 1 Attach special tool T 21567 securely to the propeller shaft and use a hoist to stand the surface drive in a vertical position CAUTION Do not damage the input shaft when lifting the surface drive Use enough blocks to keep the input shaft from contacting the floor 2 Place suitable blocking under the socket and lower the socket onto the blocks Use the hoist to support the thrust tube and prevent it falling to the side 3 Remove the 18 M10 1 5 x 25 socket head capscrews and
47. propeller is securely seated on the shaft taper 5 Remove the propeller nut and slide the propeller away from the shaft being careful not to disturb the layout dye on the shaft and on the propeller hub internal female taper 6 Evaluate the contact pattern on both tapers See Figure 103 for guidance on acceptable contact patterns The surfaces should match approximately 8096 of the total tapered area Note It is important that the contact should be biased toward the larger diameter end of both tapers If contact is predominant at the small end the shaft may be over stressed locally and may fail Contact Twin Disc if the taper contact pattern is not in accordance with Figure 103 8 Once the contact is confirmed to be acceptable clean the dye from the tapers with the above solvent and re install the propeller as outlined in the previous section 158 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly Acceptable Unacceptable TEDAN E 2 2 62 amp 4 Vo Da 2 EU E Small Spots Large Spots and Streaks Large Gaps in Pattern Mostly Large Spots 8096 on Top Not Enough Total Contact Area Figure 103 Dye Contact Pattern Samples Figure 104 Propeller Retaining Parts Propeller Installed Arneson Surface Drive Service Manual 1020619 159 Assembly Twin Disc Incorporated 160 Arneson Surface Drive Service Manual 1020619
48. remove the fin and set it aside 4 To disassemble the socket from the thrust tube remove the forward pair of circle clamps on the rubber boot and push the boot up over the thrust tube Figure 35 Remove Clamps and Raise Boot Up Onto Thrust Tube 86 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly 5 Remove the retainer wear sleeve cover bolts Figure 36 Remove Capscrews from Cover Arneson Surface Drive Service Manual 1020619 87 Disassembly 88 Twin Disc Incorporated Remove the retainer wear sleeve cover shims and retainer wear Sleeve Remove thrust tube from socket with caution taking care that the ball comes out of the socket evenly The forward thrust ball retainer may come out of the socket along with the thrust ball Do not drop the forward thrust ball retainer The forward retainer can be reused if itis not damaged or worn Figure 37 Remove Cover Shims Retainer and Raise Thrust Ball Assembly 10 Store thrust tube securely without anything touching the ball Protect the spherical surface of the ball from scratches and dents Cover the socket assembly the thrust tube and ball to protect from moisture and dirt Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly Thrust Tube Disassembly 1 Place the thrust tube vertically in the assembly stand with the output end facing up See special tool T 21089 5D Stand Setup
49. that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure safe operations under prevailing conditions Proper guards and other safety devices that may be specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Inc To prevent accidental starting of the engine when performing routine maintenance disconnect the battery cables from the battery and remove ignition key from the switch Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these points could cause failure at the lift point or points and result in damage or personal injury A CAUTION Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Introduction Preventative Maintenance Frequent reference to the information provided in this manual regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended main
50. threaded portion of the shaft Install the nut with the slanted end toward the washer If a proper spanner is not available tighten the threaded lock nut by placing a drift in the lock nut notch and tapping the drift with a mallet Torque the lock nut to at least 100 ft lbs 136 N m to firmly seat the bearings against the shaft shoulder Secure the lock nut by bending a locking tab on the lock washer into the aligning slot on the lock nut Figure 52 Install Washer and Locking Nut left Tighten Nut center and Bend Tab Into Slot right Arneson Surface Drive Service Manual 1020619 109 Assembly 110 Twin Disc Incorporated 5 Install the bearing spacer onto the propeller end of the shaft with the larger opening over the shoulder on the shaft Install the heated spherical bearing onto the shaft against the spacer Figure 53 Place Spacer Over Shaft left Place Spacer Over Shoulder center and Install Spherical Bearing right Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 6 Confirm that the two o rings are in the grooves in the inside diameter of the seal sleeve Install the heated seal sleeve onto the propeller shaft Use special tool T18050 777 to seat the sleeve against the spherical bearing As the sleeve cools re seat the sleeve making sure it remains tight against the bearing Figure 54 O rings Shown In Sleeve left and Place Sleeve Onto the S
51. to reduce marine growth Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Several recommended Marine Paint suppliers are listed as follows Hycote 151 Somay Products Inc 4301 N W 35th Street Miami Florida 33142 4382 USA Phone 001 305 633 6333 Fax 001 305 638 5524 www somay com Pettit Marine Paint Kop Coat Marine Group 36 Fine Street Rockaway New Jersey 07866 USA Phone 001 800 221 4466 www kop coat com www petitprod com International Coatings Ltd Interlux 24 30 Canute Road Southampton Hampshire SO14 3PB UK Phone 44 0 23 8022 6722 44 0 23 8022 2090 yacht uk yachtpaint com Arneson Surface Drive Service Manual 1020619 71 Installation Twin Disc Incorporated Anti fouling Protection Itis recommended that a suitable antifouling paint be applied to minimize marine growth 72 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Troubleshooting Table 2 Troubleshooting Probable Cause Propeller does not turn Transmission malfunction Repair or replace Broken transmission Repair or replace coupling Broken drive coupling Repair or replace Broken internal U joint Repair or replace Trim steering function Low hydraulic oil Check for leak in the failure hydraulic system Leak in hydraulic line Replace Leak in cylinder Replace Trim control switch failure Replace Trimcontrol solenoid failure
52. 0 2 00 DETAIL 168 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Special Tools Input Socket Shaft Seal Driver T 18050 781 2 4 N da A NZA y N ANN NI X VT 1 1 Ze 1 1 1 lt L 9 m m 44 993 J in 94988 3 950 B 23925 5 Meier urs dE 19 SY i 40 150 P Y 0 06 x 450 e PLCS SS D I 5 SS 26 00 Arneson Surface Drive Service Manual 1020619 169 Special Tools Twin Disc Incorporated Assembly Stand Adapter T 21089 5A 1 of 2 so V As NI 1 p T 1 7 8 ay m S vi 137 X 1 S t EA E x 7 Ro 1 1 i 1 SRN ASS NS SON 170 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Special Tools Assembly Stand Adapter T 21089 5A 2 of 2 ASSEMBLY ST 93 00 140 8 SRS PIN RETAINING nu SEE SHEE 6 80 x 450 x 63 7 CRS 3AS SEE SHEET 3 8 00 x 1713 x 100 6 1 CRS PLATE U
53. 1020619 Special Tools Twin Disc Incorporated Propeller Shaft Seal Sleeve Driver T 18050 777 1 tv N we a m 5 wo yh Y lt 09 e p N 10 2 D g A N N NIIT N N 23 9362 85 00 N N 166 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Special Tools Propeller Shaft Seal Driver Assembly T 18050 780 Detail 1 41 12 O E a 888 CY D gt disc E 1 N QJ NUN _ o Uo 2 2 27 1 H SZ 7 7 7 7 2 lt I 1 22 IO Y m lt 2 bed gt Lil EN F3 lt Y VY 1 i Y e N 7 9 40 gt x Arneson Surface Drive Service Manual 1020619 167 Special Tools Twin Disc Incorporated Propeller Shaft Seal Driver Assembly T 18050 780 Detail 2 ARK TOOL AND DETAIL 2 0 03 x 45 006 45 1 0 03 x 45 Y i a 22422225 203 Oa 4040 Dx Dus 2223 47227 006 x 457 003 457 1 0
54. 15 285 1 18 15 10 FT LB ACE BRACKET OVER THREADED SEE NOTE 4 20D ENSURE BALL AN CLEAN THEN SEE NOTE 5 BALL ONTO ROD TORQL ALUE 7 5 SCREWS MA1133D INTO BALL TORQUE NE NOTE 1 70 50 MAX T IN BALL 10 FT LB 8 AND TO S m 10 FT LB LUBRICATE NUT 1 18 FT LB NUT INTO BRACKET UNTIL HAND BACK THE NUT E FULLY INSERTED ORQU VALUE YDRAULIC FITTINGS SHALL BE SCREWED HAND TIGHT AND 4 COAT THE M BEADS WHE LOBE UREA LOCKER NCHED AN ADDITIONAL 1 5 2 5 TURNS UNTIL ALIGNED USI SEALANT SPARINGLY 242 142 BLU PERMANENT E MARKED THREAD PERMANENT TH LOCKTITE THREAD LOCKER HYDRAULIC PORT THREAD SIZE 3 8 18 6 USE PIPE SEALANT ON HYDRAULIC FITTING THREADS BRACKET 1020215 1020217 1 UIML 5 Installation RU DRILL 48 lt Figure 21 Trim Cylinder HOS M2483CN G TING 4 Twin Disc Incorporated Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated NOTES 12 MATERIA 2 BREAK A Installation Position the drive unit at the center trim height This is determined by setting the drive unit ball joint in the exact center of the socket Determine this
55. 3403 USA A a 480 15 75 in 5 55 mm in GROUP BOM 13 5 1007020 1020324 1875 n 38 15 1007020 1020324 50 _ 20 10070204 10203244 75 _ 30 10070208 10203244 102 40 10070208 10203248 M5 45 10070208 10203248 140 5 5 1007020 10203240 __165 65 205 HOSE 1020356 FITTING M2483CQ VIEW FITTING M2483CN 3 gt N HOSE 1007031 SEE CHART NUT 1005999 SPACER 1009585 2 2 SHEET 1 CYLINDER ARRANGEMENT SHEET 2 HOSE amp FITTING FITTING M2643S 2 TRIM CYLINDER ASS Y b M TR wy 3 27 ER THIRD ANGLE SPACER 1009585 2 eX ps SIMILAR TO ES 1009234 SEE CHART A N REF BOM 1020202 E NOTICE THIS PRINT CONTAINS MATERIAE WEIGHT WR 138 kg UNLESS OTHERWISE SPECIFIED DATE 1 X PROPRIETARY INFORMATION AND IS 5 16 01 20 1536 1005999 S X NOT TO BE USED IN ANY MANNER 305 LBS X 30 75 SCALE INCORPORATED DETRIMENTAL TO THE INTERESTS OF 05 10 8 FIRST USE THUSA TWIN DISC INCORPORATED ASSY ALL ANGULAR TOLERANCES 417 RACINE WI 53403 USA GEOMETRIC TOLERANCING D MEYERS ASD 15 PER ANSI Y14 5M 1982 CHK aT MEC menam rN GRANTED TO THE U S G
56. 916BP 2 PEUG 1020210 3D 2 1020257 ROD 1020207 PISTON 1020208 1056 A2616LK 5 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF E 3 7 02 29 01 ponozsde 19 01 Rev SHEET ZONE CH DATE sheet ZONE CH paw D TWIN DISC INCORPORATED RACINE 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT O RING A2916FS PIN 102021 SCREW MA996 O RING A2916BP 2916 ou CAP 1020209 ROD 1020211 SLEEVE 1020212 PLATE 9 1020220 AK 4 ec SIMILAR TO 1009234 REF BOM 1020202 MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED 138 kg DIMENSIONS ARE mm 2 MACHINED DIMENSIONS 305 Ibs N m 50 75 40 25 FIRST USE X XX 0 13 ASSY ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING ASD 15 PER ANSI Y14 5M 1982 B THIRD ANGLE PROJECTION DATE 5 16 01 0 5 1 0 DRN CHK APPD SHEET 1 CYLINDER ARRANGEMENT SHEET 2 HOSE amp FITTING ARRANGEMENT TIN 2456 INCORPORATED RACINE WI 5
57. E PONENT THREADS INSTALL THREADED OCTITE BRACKET UNTIL HAND TIGHT SPECIFIED VALUE CIFIED IN THESE NOTES CLEAN THREADS PRIOR TO BACK THE NUT UNTIL PIN 1020219 CAN BE FULLY INSERTED LOCTITE TORQUE SCREWS MA960R TO SPECIFIED VALUE 2 INSERT PREVIOUSLY LUBRICATED PIVOT PIN INTO Em THREAD IT ONTO ROD TORQUE AS SPECIFIED DIM Oy TORQUE VALJES THE 8 PIVOT PIN HOLE THE SMAL TORQUE A MM DRILL DIMPLE MUST MA1133B TORQUE AS SPECIFIED 7 n 3 LIGHTLY LUBRICATE SPHERICA BALL AND CAP BRACKET USING ABOVE GREAS AWAY FROM SET SCREW THREADS PLACE BRACKET OVER ND OF CAP PISTON ENSURE BALL AND CAP THREADS ARE THEN THREA ET PIN 00 FT LB BALL ONTO CAP USING LOCKTITE AS SPECIFIED TORQUE ES 00 ET LE SPECIFIED VALUE INSERT SET SCREWS 11330 INTO BALL PAN SET SC TORQUE AS SPECIFIED 3 NU 0 LB MAX T THE MARKED THREADS OCTITE THREAD LOCKER 42 142 BLUE SEMI PERMANENT WITH LOCTITE THREAD LOCKER AT THE MARKED THREA T70 RED PERMANENT 1 8 USE PIPE SEALANT ON HYDRAULIC F MAQ6OR 4 BOLT 1020242 ni Fi 7 Mes
58. ER PRESS 1500 P S I MAX 2000 P S I SYSTEM RELIEF VALVE HYDRAULIC PORT THREAD SIZE 3 8 18 6 RING MA1130A SEAL 1129 SEAL MA1129B 2 O RING A2916JD WIPER 1152 TUBE ASS Y 1020258 TUBE 10292325 SETSCREW MA1133D 4 CAP 1020256 x 1020237 PIN 1020240 BOLT 1020242 O RING A2916JD 5 LT AA IL 7 LS LEM ee ee ee eS eS eS ey NN 2 4124 LT YF RS SCREW MA1133B 5 ASS Y 1020173 4 5 1020238 PIN M 1036J CLEVIS 1020241 O RING A2916LN RING 1131 WASHER MA1039H ROD 1020239 NUT MA1048F 1005754 0 STEERING ANGLE 485 BRACKET 1020215 67 kg ASSEMBLY NOTES j PIN 1020219 1 APPLY A THIN COAT OF LUBRICANT BETWEEN MATING SURFACES OF BALL BRACKET NUT PIVOT PIN CLEVIS AND CLEVIS PIN CLEVIS 5 ALIGN SLOT IN BALL WITH HOLE IN BRACKET INSTALL PIN PLUG MA1038J 2 LUBRICANT TYPE MUST A MARINE GRADE LITHIUM GREASE WITH 1020218 AND TORQUE SCREWS MA960R SPECIFIED VALUE PROPERTIES FOR SALT WATER ENVIRONMENT SUCH AS RED LITHIUM LUBRICATE NUT THREADS 1020216 AND SCREW NUT INTO PIN 1020218 GREASE MARKETED BY THE ZEP CORP ATLANTA GA USA UNLESS BRACKET UNTIL HAND TIGHT TORQUE TO SPECIFIED VALUE OTHERWISE STATED DO NOT LUBRICATE COMPONENT THREADS INSTALL BACK
59. ION A change in trim while underway may cause a change in steering direction Transmission forward reverse shifting should be accomplished at engine idling speed to avoid unnecessary impact loads that could damage the surface drive Arneson Surface Drive Service Manual 1020619 75 Operation Twin Disc Incorporated 76 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance General Maintenance There are two oil systems on the ASD 15 15 Lubrication oil is contained in closed system that is comprised of a reservoir that is connected to the front of the drive Oil fills the area inside the drive and surrounds the propeller shaft the input shaft and the constant velocity universal joint that connects the two shafts Oil is maintained in the reservoir at a level that allows for expansion due to agitation by the rotating shafts The hydraulic steering and trim oil system is a self contained hydraulic system supplied by others It is used to operate the trim cylinder and the steering cylinders of the surface drive Proper maintenance of the Cathodic protection system is very important in preventing deterioration of the ASD 15 15 Periodic clean up and maintenance of all painted or coated surfaces is also very important in obtaining long service life from the surface drive Lubrication Lubrication oil should be checked daily The reservoir should be approximately
60. ION OUTPUT SHAFT AND THE ARNESON INPUT SHAFT USE THE SAME PLANE IN THIS TOP VIEW A VARIAB NGTH UNIVERSAL SHAFT MUST BE USE DU PDSITIVE NEGATIVE INCLINATION NOSE DOW INPUT AND ARNESON OPER ALIGNMENT ELT BETWEEN THE TRANSMISSION OUTPUT SHAFT OTE THE TRANSMISSION SHAFT INPUT SHAFT ARE NOT ON PARALLEL PLANES TU SHAFT CONDITION Y uonejeisu SIDE VIEW _ 22225 gn amp Hi ALIGNMENT USING PARALLEL PLANES EN TRANSMISSION QUTPUT SHAFT AND ARNESON I SHAFT VARIABLE LENGTH UNIVERSAL SHAFT MUST BE USED CORRECT ALIGNMENT BETWEEN TRANSMISSION OUTPUT AND ARNESON INPUT THE RANSMISSIUN OUTPUT AND THE ARNESON INPUT SHAFT USE THE SAME PLANE IN THIS TOP VIEW A VARIABLE LENGTH UNIVERSAL SHAFT MUST USED IMPROPER ALIGNMENT BETWEEN THE TRANSMISSION OUTPUT SHAFT ARNESON SHAK NOTE TRANSMISSION OUTPUT SHAFT AND ARNESON INPUT SHAF ARE NOT ON PARALLEL PLANES peie10d402u 95101
61. O LUBRICATE THE SEALS REMOVE THE PIPE PLUG AND INSERT THE GREASE FITTING THAT IS PROVIDED WITH THE DRIVE USE ZEP BRAND RED LITHIUM GREASE OR EQUAL AS ABOVE PUMP GREASE UNTIL CLEAN GREASE EMERGES UNDER THE EDGE OF THE COVER ROPE GUARD 4 APPLY MARINE GRADE SILICONE NON HARDENING ON THE FIN PAD SURFACE PRIOR TO INSTALLATION 5a COAT THE MARKED THREADS WITH THREAD LOCKING COMPOUND 242 742 BLUE SEMI PERMANENT USE ALL APPLICABLE SOLVENTS PRIMERS AND ACTIVATORS 5b COAT ALL TAPER PIPE THREADS WITH A PIPE THREAD SEALANT USE SPARINGLY 6 SHIM PROCEDURE AFT RETAINER d PLACE FORWARD RETAINER 1020135 INTO SOCKET HOUSING ENSURE THE RETAINER IS SEATED FIRMLY AGAINST THE SHOULDER IN THE SOCKET b THIS PROCEDURE IS TO SHIM THE AFT RETAINER 1020136 TO THE THRUST BALL 1020134 PLACE THE THRUST BALL INTO THE FORWARD RETAINER INSTALL ENOUGH SHIMS OVER SHIM THE RETAINER COVER 1020137 AS TO CREATE A BETWEEN THE COVER AND THE SOCKET HOUSING THE WEIGHT OF THE RETAINER COVER WILL CAUSE THE TO SEAT AS A LINE FIT TO THE BALL BECAUSE THE COVER WAS OVER SHIMMED A GAP WILL EXIST BETWEEN THE COVER AND THE SOCKET HOUSING MEASURE THIS GAP TAKE SEVERAL READINGS AROUND THE UNIT AND AVERAGE THE VALUES REMOVE THE AMOUNT OF SHIMS EQUIVALENT TO OR THE NEXT SIZE LARGER THAN THE GAP MEASURED FOR EXAMPLE IF THE GAP MEASURED IS 2 92mm 115 IN INCHES REMOVE 3 05mm 120
62. OVERNMENT DER ASS Y RIM APPD OR OTHERS BY CONTRACT SHEET 2 oF 2 REV C_ 1 APPLY THIN COAT OF LUBRICANT BETWEEN SURFACES OF PINS AND CLEVIS LUBRICANT TYPE MUST BE A MARINE GRADE LITHIUM GREASE WITH PROPERTIES FOR SALT WATER ENVIRONMENT SUCH AS RED LITHIUM GREASE SOLD BY ZEP MANUFACTURING CO ATLANTA GA USA UNLESS OTHERWISE STATED DO NOT LUBRICATE COMPONENT THREADS TORQUE VALUES NUT MA1048F 57 Nm 40 LB FT SCREW MA1133E 15 Nm 10 LB FT NUT 1020295 285 Nm 200 LB FI BAR TE BAR ASSEMBLY ASSEMBLY BOM DRIVE CENTER DISTANCE mm in DIMENSION TUBE ASSEMBLY 1020290 1020290 1750 1900 68 90 74 80 1184 1334 46 61 52 52 1020291 1020290 1020290 1900 2050 74 80 80 71 1334 1484 52 52 58 43 1020291 10202908 10292808 1600 1750 63 00 68 90 1034 1184 40 71 46 61 102029 TB 6 10202900 1020290 2050 2200 80 71 86 60 1484 1634 58 45 64 50 1020291C 2 LUBRICATE THREADS PINS 1020296 1020296 AND 1020242 3 CENTER TUBE ASSEMBLY EQUALIZE LENGTH OF EXPOSED THREADED ROD 1020294 4 APPLY LOCTITE THREAD LOCKING COMPUND 242 BLUE OR EQUAL TO PARTS MARKED WITH 5 APPLY LOCTITE WICKING COMPOUND 290 GREEN OR EQUAL TO PARIS MARKED WITH 6 INSTALL 1006351 FLUSH WITH END OF PIVOT PIN 1020240 SCREW MA1133E SCREW MA1133E PIN 1020242 PIN 1020240 PIN 1020240 CLEVIS 1020241 1020296
63. PPER SUPPORT SEE SHEE 5 gt PUR 2 13 UNC x x 1 00 4 CRS PLA SE SHEE 6 31 4 50 3 2 CRS BRACKE SEE SHEE 0 0 2 CRS PLATE 2 8 00 x 100 375 1 2 CRS GUSS MENS SE SHEE DET R DESCRIPTION STOCK SIZE Arneson Surface Drive Service Manual 1020619 171 Special Tools Twin Disc Incorporated Assembly Stand Adapter T 21089 5B 1 of 2 STAMP TOOL AND DET 8 7 02090 DA 94 X 30 1 DRILL u 5 25 8 23 00 75 STDCK i 1 2069 THRU 8 6 PLCS EQUALLY SPACED 5 81 00 9925 HC AS SHOWN 6 PLCS i _ H EM M Te V4 A D S Z 1 STAMP TOOL 8 HER 1 3 00 172 ND Al SHARP EDGES Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly Stand Adapter T 21089 5B 2 of 2 93 00 X 140 8 1 5 4 1 CRS 2 1 CRS DET REG 830 x 115 x 100 230 x 230 x 0 75 STUCK SIZE Special Tools 23 00 DRILL 1 06 1 00 LCS stock DRILL 0 422 200 DEEP 1 2 13 UNC 8B 150 DEEP N N 4 4 Li i I vx i 1 l N 8 N g T 8 886 ASSEMBLY STAND ADAPTER
64. PPLIED ADEQUATE CLEARANCE INSIDE VESSEL TRANSOM SHOULD BE 4 DRILL ALL HOLES PERPENDICULAR TO TRANSOM 200 0 MIN METRIC EXTERNAL INVOLUTE SPLINE MEASURED BASIC 95 045 94 982 Dm 5 0 PINS 94 907 2X SCALE TRANSOM DETAIL INPUT SHAFT 4 584 0 866 15 20 0 9 THRU 4 PLACES 6 26 5 13 PLACES 20 0 THRU 480 0 4 PLACES ET M 5 975 74 44444444 4 STEERING PIVOT POINT 5 RANGE OF STEERING CYLINDER BRACKET POSITIONS 15 SHOWN TO ALLOW FOR VARYING DEADRISE ANGLES OP TIONAL RANGE FOR STEERING 2 CYLINDER LOCATION SHEET 1 PARTS DRAWING SHEET 2 ASSEMBLY NOTES SHEET 3 INSTALLATION INTERFACE SHEET 4 INBOARD STEERING CYLINDER ARRANGEMENT METRIC DRIVE 1020120 PROJECTION 1 AR TO STEERING CYLINDER GROUP 1020325 TRIM CYLINDER GROUP 1020324 en TWIN DISC NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT PROPRIETARY INFORMATION AND IS BE USED MANNER DETRIMENTAL TO THE INTERESTS OF HEAT TREAT FIRST USE TWIN DISC INCORPORATED assy ASD 15 RACINE 53403 USA MODEL MACHINED DIMENSIONS INCORPORATED 0 25 3 16 RACINE 53403 USA 0 XXX 0 13 DRN ALL ANGULAR TOLERANCES 1 0 MEYERS GEOMETRIC TOLERANGING D MEYERS ISURFACE TREATMENT NAME P
65. R 1009585 2 VIEW FROM ABOVE V E SEE CHART NUT 1005999 X 2 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT DRILL THRU 48 9 1 875 in 5 90 in mas PROJECTION SIMILAR TO 1009545 REF BOM 10202355 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS 0 75 WEIGHT 61 75 kg 136 Ibs HEAT TREAT FIRST USE ASSY ASD 15 PER ANSI 14 5 1982 CHK SURFACE TREATMENT NAME CYLINDER ASS Y STEERING B MATERIAL WR N 2 ALL ANGULAR TOLERANCES 41 TOLERANCING 6 5 gt h 10 1 4 VIEW SHEET 1 CYLINDER ARRANGEMENT SHEET 2 HOSE amp FITTING ARRANGEMENT WIN DISE INCO POR RACINE WI 53403 USA 1020254 SHEET 2 OF 2 ASSEMBLY NOTES 1 THESE NOTES APPLY TO PISTON SUBASSEMBLY 1020257 TUBE SUBASSEMBLY 1020256 AND THE REMAINING PARTS SUBASSEMBLIES ARE ASSEMBLED IN ACCORDANCE WITH THEIR RESPECTIVE DRAWINGS 2 APPLY A THIN COAT OF LUBRICANT BETWEEN MATING SURFACES OF BALL BRACKET NUT LUBRICANT TYPE MUST BE A MARINE GRADE LITHIUM GREASE WITH PROPERTIES FOR SALT WATER ENVIRONMENT SUCH AS RED LITHIUM G
66. REASE MARKETED BY THE ZEP CORP ATLANTA GA USA UNLESS OTHERWISE STATED DO NOT LUBRICATE COMPONENT THREADS INSTALL THREADED PARTS WITH LOCTITE AS SPECIFIED IN THESE NOTES CLEAN THREADS PRIOR TO APPLYING LOCTITE 3 INSTALL LIGHTLY OILED SEAL WEAR RING AND SCRAPER IN ROD CAP LIGHTLY OIL ROD AND INSERT ROD THROUGH END CAP KEEP GREASE AWAY FROM THREADS PLACE BRACKET OVER THREADED END ENSURE AND ROD THREADS CLEAN THEN THREAD BALL ONTO ROD TORQUE TO SPECIFIED VALUE INSERT SET SCREWS MA1133D INTO BALL TORQUE AS SPECIFIED 4 ALIGN SLOT IN BALL WITH HOLE IN BRACKET INSTALL PIN 1020218 AND TORQUE SCREWS 960 TO SPECIFIED VALUE LUBRICATE NUT 1020216 AND BRACKET THREADS AND SCREW NUT INTO BRACKET UNTIL HAND TIGHT TORQUE TO SPECIFIED VALUE BACK THE NUT IF NECESSARY UNTIL PIN 1020219 CAN BE FULLY INSERTED TORQUE SCREWS MA960R TO SPECIFIED VALUE 5 ASSEMBLE THE PLUG SLEEVE ROD 1020211 AND CAP 1020209 TOGETHER AS A UNIT TORQUE AS SPECIFIED INSTALL 4 LIGHTLY OILED O RINGS INSERT THE ASSEMBLY FULLY INTO THE TUBE LIGHTLY OIL INTERNAL YOKE THREADS AND O RINC THREAD TUBE WITH STOP ASSEMBLY INTO YOKE HAND TIGHT ALIGN SET SCREW HOLES IN YOKE WITH DIMPLES IN TUBE INSTALL SET SCREWS MA1133C TORQUE AS SPECIFIED BRACKET 1020215 PIN 1020219 NUT 1020216 SEAL MA1129C SLEEVE 11318 SCRAPER 11328 643 6 THE PISTON SHOULD ALREADY BE INSTALLED ON THE ROD
67. Replace Hydraulic pump failure Steering helm malfunction Repair or replace Repair or replace Excessive drive noise or Misaligned inboard Align See Driveline vibration driveline Section Propeller damage Low drive oil level Repair or replace Check for leak Repair or Failed bearing or U joint service the system Air in trim cylinders Remove drive and repair Bleed hydraulic system Water in drive oil The oil Leak in thrust ball socket Tighten looks milky and brown seal Remove and replace the Leak in thrust tube rear oil seal seal Loose oil fill or drain plug Tighten or remove and replace the drain plug Arneson Surface Drive Service Manual 1020619 73 Installation Twin Disc Incorporated Periodic Visual Inspection 74 Check the propeller for any signs of damage daily Repair or replace as necessary Check the Cathodic Protection frequently on new vessels once a week for a month and at least every six months thereafter Replace zinc anodes when eroded to one half of full size Check all bonding wires and fittings Replace if required Inspect the oil lines for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required Check the condition of the Paint and Coating frequently on new vessels once a week for a month and at least every six months
68. SC INCORPORATED RACINE 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT 749 SHEET 1 PARTS DRAWING SHEET 2 ASSEMBLY NOTES SHEET 3 INSTALLATION INTERFACE SHEET 4 INBOARD STEERING CYLINDER ARRANGEMENT Q Cj aw 1018683 REF B O M 1020120 MATERIAL WEIGHT we UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm p 0 01 VAM UW WISG kg nem MACHINED DIMENSIONS SCALE UU RUP DIR AUT C D XX 0 25 1 00 PRAGNE 53403 USA HEAT TREAT FIRST USE 0 13 ASSY ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANGING ASD 15 ue 1020119 DRIVE ER ME SURFACE TREATMENT gt 79 975 74 540 00 6 304 06 STEERING CYLINDER 1020254 VIEW TRIM CYLINDER 1020205 866 14 SIDE VIEW RANGE OF PLATES IS AVAILABLE TO ACCOMMODATE VARIATION IN STEERING CYLINDER BRACKET POSITIONS SEE OPTIONAL RANGE FOR STEERING OVER MAX CYLINDER LOCATION NOTES 1 THIS DRAWING IS TO BE USED AS A GUIDE ONLY PLEASE REFER TO THE TWIN DISC INSTALLATION MANUAL FOR INSTALLING THE DRIVE AND CYLINDERS 2 TRANSOM ANGLE FOR ASD UNITS TO BE 6 DEGREES TO VERTICAL PLUS OR MINUS 1 DEGREE AS SHOWN IN THE SIDE VIEW A MOUNTING WEDGE IS REQUIRED FOR TRANSOM ANGLES OTHER THAN 6 DEGREES 3 BACKING PLATES OF SAME APPROXIMATE DIMENSIONS AS SHOWN FOR EQUIPMENT FOOTPRINT ARE SU
69. Spots and Streaks Large Gaps in Pattern Mostly Large Spots 8096 on Top Not Enough Total Contact Area Figure 34 Dye Contact Pattern Samples Arneson Surface Drive Service Manual 1020619 69 Installation Twin Disc Incorporated Corrosion Protection 70 As with any marine outdrive a cathodic corrosion protection system should be installed Follow American Boat and Yacht Council ABYC recommendations found in Project E2 electrically isolated components have been supplied with tapped holes to facilitate installation of a bonding system Twin Disc Incorporated recommends the usage of the proper Electrolysis Kit for ASD 15 15 for cathodic protection Reference instructions available from Twin Disc Incorporated for system installation and details The ASD 15 15 is coated with a quality marine primer during assembly An additional top coating of finish epoxy is required to adequately protect the surface drive from galvanic corrosion chemical attack or mechanical erosion The finish epoxy will be most effective if it is rated as a barrier coating indicating that it is impervious to electrical penetration A final coating of anti fouling bottom paint is recommended to protect the drive from marine growth The cylinders should be similarly coated with a paint system that is qualified for stainless steel Care must be observed to keep all coatings away from piston rods Bottom paint may be applied as the final step
70. TWIN DISC INCORPORATED Service Arneson Surface Drive Model ASD 15A1S Document Number 1020619 Twin Disc Incorporated makes no warranty or guaranty of any kind expressed implied or otherwise with regard to the information contained within this manual Twin Disc Incorporated has developed this manual through research and testing of the information contained therein Twin Disc Incorporated assumes no responsibility for any errors that may appear in this manual and shall not be liable under any circumstances for incidental consequential or punitive damages in connection with or arising out of the use of this manual The information contained within this manual is subject to change without notice Document Number 1020619 July 2002 Arneson Surface Drive Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL SURFACE DRIVE UNITS Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer asto which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twelve 12 months of service whichever o
71. The lubricating oil is specified as API Service category CF or higher certified to meet Caterpillar Test TO 4 SAE 30 100 cst 100 or SAE 40 141 cst 100 F Power Steering and Trim Lubrication Specifications Hydraulic fluid such as Dexron automatic transmission fluid should be used for the power steering and power trim hydraulic systems Arneson Surface Drive Service Manual 1020619 19 Description and Specifications Twin Disc Incorporated Specifications Maximum operating speed 2500 rpm Oil type and viscosity API Service category CF or higher certified to meet Caterpillar Test TO 4 SAE 30 100 cst 100 degrees or SAE 40 141 cst 100 degrees F Oil capacity 38 to 57 liters 10 to 15 gallons Approximate Dry weight of ASD 15 15 454 kg 1000 Ibs Approximate Dry weight of ASD 15A18 steering cylinder 67 kg 150 105 Approximate Dry weight of ASD 15 15 trim cylinder 138 kg 300 Ibs Approximate Dry weight of ASD 15A1S tie bar assembly 45 kg 100 Ibs 20 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Description and Specifications Torque Values for Fasteners Table 1 Torque Specifications for Fasteners used in ASD 15A1S DESCRIPTION 1124 o 17 1 1 11248 SCREW RETANERCOVER 60 00 900 WW 40 2 Z 17 020184 UT JAM LOCK PROP 860 1000 600 700 1052 SCREW U JOINT FIXATION 30 1052 5
72. The opening of the first seal installed should be down toward the housing and the opening of the second seal should be outward and away from the housing Install the retaining snap ring hos Figure 72 Place Input Up with Seals and Snap Ring left and center and Install Seals and Snap Ring right Arneson Surface Drive Service Manual 1020619 125 Assembly Twin Disc Incorporated Assembly of Thrust Tube and Ball Into Thrust Socket Note If the Thrust Socket was left attached to the transom of the vessel please see the section following this one for complete instructions and assembly procedures Assembly with the Socket Removed from the Transom 1 Support the socket assembly securely with the larger diameter end facing up Coat the U joint yoke splines with gear oil to assist in the installation of the yoke onto the propeller shaft 2 Place the forward retainer into the socket housing Make sure that the anti rotation pins are aligned with the notches in the socket housing and that the retainer is seated firmly against the shoulder in the socket Be sure to carefully inspect the retainer for damage prior to installing it Note The forward and aft edges of the forward retainer are manufactured with as sharp an edge as practical to assist in excluding dirt and debris from the spherical bearing surface Protect these edges from even the slightest dent or scratch Accidental damage to these edges must be smooth
73. ainer working it smoothly into place If bulk packing is used cut two pieces 1258 mm 49 53 in with the ends cut at a 45 degree angle The split line should be at either the 10 00 o clock or the 2 00 o clock position using the flat on the socket housing s external mounting flange as the 6 00 o clock position Place an o ring over the packing Arneson Surface Drive Service Manual 1020619 137 Assembly 138 Twin Disc Incorporated 3 Install the second packing on top of the o ring working it smoothly into place This split line should be at either the 2 00 o clock position or the 10 00 o clock position that was not used for the first packing above Shims will be added on top of the packing after the rear output end retainer is properly shimmed Figure 85 Install Packing left Followed by O ring center and Second Packing right 4 Support the thrust tube assembly in a horizontal position Place the rear retainer wear sleeve and approximately 5 08 mm 0 200 in of the 399 50 mm 15 73 in outer diameter by 366 mm 14 41 in inner diameter shims and the retainer cover in that order over the output end of the thrust tube assembly Shift all of the components to a position just forward of the large two holed boss on the thrust tube Apply a light coat of grease to the entire surface of the thrust ball 5 Coat the U joint yoke splines with gear oil to assist in the installation of the yoke onto the prop shaft Coat the ret
74. ainer with a light coat of grease 6 Remove four thrust socket to transom mounting bolts two from each side of the thrust socket Remove the bolts located nearest to the 3 o clock and 9 o clock positions 7 Fabricate jacking tool special tool 21570 shown in Special Tools This includes a left and right slide plate rear support plate and two one inch diameter threaded rods 8 Bolt the left and right side plate of the special tool to the socket flange and through the transom The four socket mounting bolts previously removed may have to be replaced with longer bolts for this operation Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 9 Suspend the thrust tube horizontally Keep the output end of the shaft clear for later installation of the jacking tool Using caution insert the thrust tube into the socket Make sure that the ball enters the socket evenly that the U joint engages smoothly and that the packings o ring and shims remain in place Figure 86 Carefully Guide Thrust Tube Assembly Into the Socket and U joint Do not attempt to pull the thrust tube into the thrust socket using the retainer ring as damage to the ball or retainer ring may result 10 Install the jacking tool s rear base plate and the threaded rods using two 2 1 in nuts to draw the thrust tube into the socket Apply even pressure to both sides of the rear base plate 11 Install the rea
75. ange companion flange onto the input shaft See Figure 18 Torque the flange retainer bolts to 100 N m 75 ft Ibs Figure 18 Torque Sequence for Socket to Hull 44 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation INPUT FLANGE REMOVAL 8 INSTALLATI INBOARD DRIVESHAFT INPUT SHAFT INPUT FLANGE COMPANION FLANGED Figure 19 Input Flange Removal and Installation Arneson Surface Drive Service Manual 1020619 45 Installation Twin Disc Incorporated Trim Cylinder Installation The trim cylinder provides the capability to position the drive at differing trim angles depending on operating conditions The following procedure sets the trim cylinder at mid travel See Figures 20 and 21 for assembly instructions for the cylinder ends 1 Connect the trim cylinder to the thrust tube using the supplied mounting hardware See Figure 20 2 Loosen the hose clamps on one end of the drive unit protective boot and rotate the thrust tube housing as required to locate the fin in the vertical plane 46 Arneson Surface Drive Service Manual 1020619 6190201 enuen Ajquassy sepuljA9 02 4 40 ASSEMBLY NOTES V UN 7 TORQUE VALUES es PONENT S CIFIED IN P N DESCRIPTION J RIOR TO APPLYING LOCTITE 2
76. ball out of the thrust tube watch for the shim pack located between the thrust ball shoulder and thrust bearings The shims may stick to the ball shoulder or the thrust bearing ifting Isolator gt Thrust Tube Figure 40 Raise the Ball from the Thrust Tube Remove O rings Shims and Isolator Place the ball aside and inspect for scratches dents or rough edges Smooth the ball surface with a fine emery cloth or similar material Do not create flat spots on the ball s outside surface Protect the ball surface from scratches and dents Arneson Surface Drive Service Manual 1020619 91 Disassembly 92 Twin Disc Incorporated Remove the isolator and o ring from the face of the thrust tube housing Check inside of the housing for the remaining shims located against the thrust bearings If the original bearings will be used in reassembly save the shims If the original bearings will not be used in the reassembly a new shim pack will be developed during reassembly Install a M12 x 1 75 eyebolt into the tapped hole on the forward end of the propeller shaft Attach a hoist to the threaded eye bolt and lift the propeller shaft from the thrust tube It may be necessary to tap the end of the shaft while lifting to remove the upper bearing cup Use care to avoid damage to the bearings and seal sleeve Support the shaft on wooden blocks CAUTION Do not strike end of the propeller shaft without a wood block ot
77. baseline Correct mounting of the unit may require a supplementary wedge When ordering the ASD 15 15 be sure to specify existing transom angle deadrise angle of hull and whether it s a single or twin installation Application inquiries can be correctly answered only if accompanied by an Application Data Sheet that is available from the dealer or the factory Inboard and outboard surfaces of the transom must be parallel to within 1 4 6 35 mm Transom outboard surface must be flat to within 1 16 1 59 mm Transom inboard surface must be flat to within 1 8 3 18 mm in way of the surface drive socket A CAUTION If the surface drive is installed with an incorrect mounting angle serious performance deficiencies could result Arneson Surface Drive Service Manual 1020619 35 Installation Twin Disc Incorporated 36 Mounting Hardware All mounting hardware used other than that supplied by Twin Disc Incorporated must be of stainless steel and must meet Twin Disc Incorporated standards Flat washers must be used under all nuts and bolt heads Thread lubricant must be used with all mounting hardware to prevent galling and or seizing All bolt holes through fiberglass material should be cleaned to prevent seizing by glass fiber residue All through hull fittings and bolts gaskets and mating flanges must be installed using recommended amounts of bedding compound suitable for underwater use Follow manufacture s instructions wit
78. by analysis Hydraulic and drive X system oil Check for leakage Hydraulic system X lock to lock Thrust Ball retaining ring X X bolts Torque to 60 N m 40 lbs Propeller Shaft Seal Whenever the vessel is hauled out remove the pipe plug Apply grease located at the aft end of the thrust tube and install the grease fitting M268 that is supplied with the drive Pump grease into the fitting until clean grease is seen emerging between the seal and the propeller shaft or from the gap in front of the propeller Use aquality marine rated grease such as Red Lithium Grease sold by the ZEP COMPANY Atlanta Georgia USA The plug and grease fitting thread size is 1 8 27 NPTF SAE 80 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Preventative Maintenance Propeller Torque Maintenance Note The propeller nut should be re torqued according to the following schedule Torque the propeller nut to 1220 N m 900 105 Torque the jam lock nut to 860 to 1000 N m 634 to 738 1 105 Approach the lower value then continue until a cotter pin slot in the nut aligns with the hole in the shaft Install the cotter pin 1 The propeller nut and lock nut must be checked for torque retention to the above values after initial use or within 10 hours of operation 2 The propeller nut torque MUST be checked in the following operational interval A The propeller nut torque must be checked
79. ccurs first This is the only warranty made by T win Disc Incorporated and isin lieu of any andall other warranties expressor implied includingthe warranties of merchantability or fitness for a particular purpose and no other warranties are implied or intendedto be given by T win Disc Incorporated W arranty istransferable from original owner of vessel in the event that title is legally transferred via sale of vessel or other legal proceedings W arranty period will be the duration of remaining term left from original date of issue and will in no way be extended for any reason The customer is not to rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated S application engineering Twin Disc Incorporated is not responsible for any specific application installation or performance standard Any analysis program by Twin Disc Incorporated based upon customer supplied information is done solely as an accommodation to the customer and is not to be interpreted or construed as an approval for specific application or installation or a guarantee of performance Twin Disc Incorporated cannot be held liable or responsible for incorrect information supplied or deviations from project specifications provided Among the condition which will affect performance and as to which no warranty or representation is made are the following vessel weight center of gravity rated horsepower and torque reduction ratio of gearbox or drive uni
80. corporated 8 Support the socket housing with the large opening facing up If necessary heat the outside of the socket small diameter end section with a butane or propane torch to assist in the installation of the forward bearing cup Do not allow the temperature of the housing to exceed 200 F 93 3 C Install the chilled bearing cup into the housing with the thin end up 9 Insert two guide screws M10 1 5 into two of the threaded holes that will be used to align the bearing sleeve and its shims Place approximately 1 3 mm 050 in thickness of bearing shims into the thrust socket This ensures that initially there will be end play on the bearing set ma Gjide hilled up Shims an Figure 69 Install Chilled Bearing Cup left and Insert Guide Pins and Starting Shim Pack right Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 10 Useabhoistto suspend the input shaft and U joint assembly above the Socket Lubricate the bearings with oil Lower the assembly into the thrust socket until seated in the forward tapered roller bearing cup Figure 70 Lubricate Bearing and Lower the Input Shaft Assembly Into Housing Arneson Surface Drive Service Manual 1020619 123 Assembly 124 Twin Disc Incorporated Install four M10 1 5 x 30 socket head capscrews to retain the bearing sleeve Torque to 55 N m 40 ft Ibs Turn the thrust socket over so that the input end
81. culated above and reinstall shims over packing Install the rear retainer wear sleeve shims and cover Install 24 M12 1 75 35 socket head capscrews and torque to 60 N m 40 lb ft Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly Assembly with Socket Attached to Transom Note Inspect the packings and the o ring for damage Replace the packing if there is any doubt as the packing and o ring prevent water ingression into the socket of the surface drive If replacement is not necessary proceed to step 4 If they are being replaced remove the old packing and o ring discard and clean and lubricate the socket and retainer Note The forward and aft edges of the forward retainer are manufactured with as sharp an edge as practical to assist in excluding dirt and debris from the spherical bearing surface Protect these edges from even the slightest dent or scratch Accidental damage to these edges must be smoothed by hand working with a machinist s scraping tool files and emery cloth Restore the spherical surface if itis locally deformed 1 Place the forward retainer into the socket housing Make sure that the anti rotation pins are aligned with the notches in the socket housing and that the retainer is seated firmly against the shoulder in the socket Figure 84 Notches In the Socket left and Anti rotation Pins In the Retainer right 2 Install the first packing on top of the ret
82. e If the gap measured is 115 inches remove 120 inch in shims This creates a slightly tight fit between the rear retainer wear sleeve and the ball The rear retainer wear sleeve has now been shimmed properly to the ball The thrust ball clearance shim pack developed in these preceding steps must be installed into position in the thrust socket while adjusting the previously installed packing and o ring No further adjustment of the thrust ball clearance shims will be required Note The thrust ball is sealed to the thrust socket with the combination of two rope packings and an o ring that were installed previously To provide a tight seal the packing and o ring must be compressed by the rear retainer wear sleeve 1 25 mm 25 mm 0 050 010 in The amount of compression is adjusted with packing shims These packing shims measure 399 75 mm 15 74 in outer diameter by 384 75 mm 15 15 in inner diameter 132 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly IOUSING 2 ELA RETAINER Figure 79 Ball and Socket Parts Identification Arneson Surface Drive Service Manual 1020619 133 Assembly 134 Twin Disc Incorporated 15 Raise the cover and the shim pack and hang them on the thrust tube Remove the rear retainer wear sleeve
83. e or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents or by steam cleaning Parts must he dried and oiled immediately Bearings should not be exposed to moisture Examine all parts carefully for grit dirt and abrasives and reclean them if necessary Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent flush oil pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher screw locations Cleaning Bearings Do not remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease A CAUTION Never dry bearings with compressed air Do not spin non lubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Arneson Surface Drive Service Manual 1020619 103 Cleaning and Inspection Twin Disc Incorporated Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently itis important to keep bearings clean Do not remove grease from new bearings
84. e pattern and drill the 22mm 0 875 mounting holes in the transom Stainless steel 19mm 0 75 diameter bolts nuts and washers are required for this installation Install the bolts backing plate washers and nuts Torque nuts to 122 N m 90 ft lbs Use thread lubricating compound to prevent seizing Apply a generous layer of marine transom sealant under the bracket and in the fastener holes in the transom to prevent water leakage 1 STEERING PIVOT POINT E 5 85 1 7 9 f N N 3s p RANGI OR 51 NG CYLINDER Figure 24 Transom Layout Dual Drive Arneson Surface Drive Service Manual 1020619 51 Installation Twin Disc Incorporated Steering Cylinder Installation The following installation procedure positions the steering cylinders to allow maximum steering capability without damage to the drive The steering cylinders should reach both travel limits just prior to the ball thrust tube contacting the socket at all trim cylinder positions 1 On single drive installations the steering cylinder must be located to offset the effects of the propeller torque If propeller rotation is clockwise as viewed from the rear the cylinder must be located on the starboard side The cylinder must be on the port side for counterclockwise rotation On twin drive installations each of the steering cylinders may be located to the lef
85. e to angle down to the point where the ball thrust tube assembly makes contact against the thrust socket SUCKE BAI CLEARANCE CAUTION SUPPORT END DF PROPELLER SHAFT TO PREVENT SEVERE DAMAGE DRIVE CAUTION SEVERE DAMAGE TO DRIVE w FROM ALLOWING CONTACT AS SHOWN Figure 8 Protect Ball from Damage 30 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Removal from Vessel 3 Remove the cotter pin and jam nut Loosen the propeller nut until it is flush with the end of the shaft to prevent damage when the propeller moves from the tapered pilot Remove the propeller from the splined shaft using suitable pullers soft blocks and mallets as necessary allowing the propeller to stop against the spacer and propeller nut Remove the propeller nut spacer and propeller from the rear end of the propeller shaft Spacer Propeller Nut Figure 9 Propeller Retaining Parts left and Propeller Installed right 4 Drain the oil from the surface drive through the drain holes in the housings or from the lower oil reserve hose inside the boat 5 Disconnect the steering cylinder from the trim cylinder yoke pin Disconnect the tie bar from the tie bar pin Remove the trim cylinder yoke pin and the tie bar pin Trim Cylinders fi unn Tie Bar Steering Steering Cylinder Figure 10 Rear View of Dual Installation Showing Cylinders and Tie
86. ecial tool T 21567 to lift up on the prop shaft with a force of approximately 300 lbs Rotate the shaft several turns and zero the dial indicator Mark the angular location of the indicator stem on the housing Lower the prop shaft rotate several turns stopping on the mark and read the indicator The clearance must be 002 in to 005 in 0 51 mm to 0 127 mm Ifthe indicated reading is out of tolerance turn the thrust tube over so that the forward end of the tube is facing up Remove the thrust ball and add the required amount of shims to the top of the front bearing cup to reduce the bearing clearance into tolerance 10 Repeat Step 9 until the bearing clearance is in tolerance The correct bearing end play is extremely important to the proper operation of the surface drive Arneson Surface Drive Service Manual 1020619 115 Assembly 116 Twin Disc Incorporated 11 the proper bearing end play is verified turn the thrust tube with the thrust ball up and remove the thrust ball Grease the two o rings with water resistant lithium grease and install one in the groove located to the outside of the bolt holes on the face of the thrust tube housing and the other in the groove in the thrust ball Install the isolator onto the thrust tube The grease must hold the o ring in place during assembly Place the isolator on the thrust tube over the o ring 12 Clean the threaded holes with denatured alcohol to prepare for Loctite
87. ed and bolted to the vessel s transom The engine and marine transmission must be adjusted so that the output shaft centerline is parallel to the surface drive input shaft centerline and the offset angle is within the proper limits 1 Fabricate pointer plates that can be mounted to the same transmission output flange adapter that the driveline will connect to and to the surface drive input flange that the driveline will connect to Fabricate inner hollow tubes and outer hollow tubes and weld pointers indicator ends onto inner shafts Drill a hole in same length outer tube and then weld a nut to the tube This will be used as the retention device for the inner tube once the inner tube is slid into the outer tube Weld the tube assemblies to the plates making sure that the tube to plate runout is zero This will allow for adjustment of both shafts to identical lengths Make sure there is a tight fit between the outer tube and inner tube the closer the fit the more accurate the alignment will be Arneson Surface Drive Service Manual 1020619 59 Installation Twin Disc Incorporated Bolt one pointer onto the transmission output shaft flange Bolt the other pointer onto the surface drive input shaft flange These pointers are an extension of the shaft centerlines on which they are mounted If the installation requires that the transmission output shaft centerline is not parallel to the surface drive input shaft centerline adju
88. ed by hand working with a machinist s scraping tool files and emery cloth Restore the spherical surface if itis locally deformed Figure 73 Notches In the Socket left and Anti Rotation Pins In the Retainer right 126 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 3 Install the first packing on top of the retainer working it smoothly into place If bulk packing is used cut two pieces 1258 mm 49 53 in with the ends cut at a 45 degree angle The split line should be at either the 10 00 o clock or the 2 00 o clock position using the flat on the socket housing s external mounting flange as the 6 00 o clock position Place an o ring over the packing 4 Install the second packing on top of the o ring working it smoothly into place This split line should be at either the 2 00 o clock position or the 10 00 o clock position that was not used for the first packing above Shims will be added on top of the packing after the rear output end retainer is properly shimmed Figure 74 Install Packing left Followed by O ring center and Second Packing right Arneson Surface Drive Service Manual 1020619 127 Assembly Twin Disc Incorporated 5 Place the rear output end retainer wear sleeve and approximately 5 08 mm 0 200 in of the 399 50 mm 15 73 in outer diameter by 366 mm 14 41 in inner diameter shims over the thrust tube assembly Place the cover over the thrust tube Apply a l
89. eign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part Inspect threaded openings for damaged threads Chase all threads with a thread chaser of the correct size to remove old loctite material Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels This applies where a matched set of parts is not involved Inspect dowel pin holes for wear due to movement between mating parts If a dowel pin hole is worn re bore and sleeve the hole when possible Otherwise replace the parts This applies where a matched set of parts is not involved 05 Inspect bearings for roughness of rotation Replace the bearing if the rotation is rough Inspect bearings for corrosion and for indication of wear of balls or rollers Inspect for scored scratched cracked pitted or chipped races Replace the bearing if you find one of these defects Inspect bearing bores and shafts for grooved burred or galled conditions that would indicate the bearing has been turning in its housing or on its shaft If you cannot repair the damage with a crocus cloth replace the part Arneson Surface Drive Service Manual 1020619 105 Cleaning and Inspection Twin Disc Incorporated Bushings and Sleeves Inspect bushings and sleeves for size and out of roundness Inspect for scores burrs sharp edges and evidence of overheating Remove sco
90. er 191 1020203 page 2 of 2 Cylinder 192 1020290 Tie Bar Assembly 193 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc model ASD 15 15 Arneson Surface Drive Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wisconsin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and application of the material in this manual will result in consistent performance from the unit and help reduce downtime Arneson Surface Drive Service Manual 1020619 11 Introduction Twin Disc Incorporated Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Inc will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unaccepted maintenance working practices Important Safety Notice 12 Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents
91. ere is no damage or excessive wear Arneson Surface Drive Service Manual 1020619 97 Disassembly Twin Disc Incorporated 8 Turn the socket housing over so that the input end is facing up Remove the seal retaining ring from inside the small diameter end of the socket 9 Drive the seals out and discard Replace all seals and o rings Figure 46 Housing with Seals and Snap Ring Removed Both ends shown 10 Inspection Flush the thrust socket housing and components with clean solvent to remove all chips or debris Visually inspect all parts for damage or dirt Inspect all seal or bearing surfaces for wear or damage The forward retainer should be free from any rough edges or burrs Smooth any rough areas with 400 grit or finer emery cloth See Cleaning and Inspection Note The forward and aft edges of the forward retainer are manufactured with as sharp an edge as practical to assist in excluding dirt and debris from the spherical bearing surface Protect these edges from even the slightest dent or scratch Accidental damage to these edges must be smoothed by hand working with a machinist s scraping tool files and emery cloth Restore the spherical surface if itis locally deformed 98 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly U joint Input Shaft Disassembly 1 Once the input shaft with the universal joint is removed from the socket housing separate the u joint from the shaft Stand
92. ering Care must be taken not to damage the surface of the thrust ball trim and steering cylinder rods or exposed portion of the propeller shaft Nicks and scratches can cause premature seal failure and subsequent oil leaks Structural Strength of Mounting The vessel structure in the area of the transom and the transom itself bears the entire weight of the surface drive and the torque and thrust loads generated by the propeller s A solid mounting base and a properly designed transom structure is essential for the successful installation of surface drives If the transom and mounting base is not sufficiently strong it is possible to damage the surface drive or the vessel itself Twin Disc Incorporated will not be responsible for surface drives that have been improperly mounted or where mounting is deemed to be unsafe or structurally unsound Such mounting will void all Twin Disc Incorporated warranties Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Mounting Requirements The ASD 15 15 propeller requires clean water flow to operate at a proper efficiency The bottom of the vessel hull should be clean and clear of any obstructions such as water intakes speedometer sensors etc for an area at least eight inches 21 cm each side of the propeller tips and at least six feet 1 83 meters forward of the transom The optimum mounting angle for ASD 15 15 is six degrees to the vessel s
93. eshooting Chart The following chart is intended as a guide for determining the cause of problems that could be encountered and the corrective actions for those difficulties The surface drive is one part of a complete power package Problems in the input power system engine or the output power delivery components transmission and driveline can cause problems that may be erroneously interpreted as being surface drive related It is important that the entire power package and control systems be considered when problems are encountered The Troubleshooting Chart is shown on the following page Arneson Surface Drive Service Manual 1020619 83 Troubleshooting Twin Disc Incorporated Table 4 Troubleshooting Chart Probable Cause Propeller does not turn Transmission malfunction Repair or replace Broken transmission Repair or replace coupling Broken drive coupling Repair or replace Broken internal U joint Repair or replace Trim steering function Low oil Check for leak in the failure reserve system Pump belt broken Replace Leak in hydraulic line Replace Leak in cylinder Replace Trim control switch failure Replace Trimcontrol solenoid failure Replace Hydraulic pump failure Steering helm malfunction Repair or replace Excessive drive noise or Misaligned inboard vibration driveline Propeller damage Repair or replace Low drive oil level Check for leak Repair or service the system Failed bearing
94. eve It may be necessary to use an acetylene or butane torch to quickly heat the sleeve 6 Remove the forward bearing from the input shaft using a split type bearing puller The cutting method can be used here if desired 100 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly 7 Clean and Inspect Clean parts and inspect for damage Examine the seal sleeve for scratches on the seal surfaces and clean the area with a 400 grit or finer emery cloth Inspect the yoke splines for burrs and remove if present See Cleaning and Inspection A CAUTION Use extreme caution when removing rough edges or burrs from critical shaft surfaces Removing excess material will cause the loss of press on races bearings or seal surfaces If the U joint requires further disassembly Twin Disc recommends that the work be performed by qualified personnel familiar with U joint disassembly and assembly For service on universal joints Twin Disc recommends the following Driveline specialty shop Authorized Twin Disc Arneson repair facility Twin Disc Incorporated factory Arneson Surface Drive Service Manual 1020619 101 Disassembly Twin Disc Incorporated 102 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Cleaning and Inspection Cleaning Cleaning and Inspection Note Replace all oil seals gaskets O rings packing retaining snap rings etc as a part of any maintenanc
95. excess compression Add A tight retainer bolts to D excess compression The sum is equal to the thickness of packing shims that must be removed in order to compress the packing and o ring to the desired amount of 1 25 mm 25 mm 0 050 010 in Calculation Example B Loose retainer bolts 0 110 in 2 80 mm A Tight Retainer bolts 0 030 in 0 75 mm Actual Compression 0 080 in 2 03 mm C Actual Compression 0 080 in 2 03 mm 40 Specified Compression 0 050 in 0 010 in 1 25 mm 0 25 mm D Excessive Compression 0 030 in 0 010 in 0 75 mm 0 25 mm A Tight Retainer Bolts 0 030 in 0 75 mm 40 Excess Compression 0 030 in 0 010 in 0 75 mm 0 25 mm Thickness of packing shims to remove 0 060 in 0 010 in 1 50 mm 0 25 mm Figure 95 Example of Packing Shim Calculation 28 29 30 Remove the cover rear retainer wear sleeve shims and rear retainer wear sleeve Remove the packing shims Adjust the shim pack as calculated above and reinstall shims over packing Install the rear retainer wear sleeve shims and cover Install 24 M12 1 75 x 35 socket head capscrews and torque to 60 N m 40 lb ft Remove the jacking tool and install the four mounting bolts Torque the mounting bolts to 176 to 203 N m 130 to 150 ft lbs Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly Removal and Replacement of Thrust Packing and O Ring Note
96. ft is supported by two tapered roller bearings on the input end and by a spherical roller bearing on the output end The bearing clearance on the two tapered roller bearings is controlled by the use of a single shim pack between the thrust ball and the forward bearing cone Shafts Both of the shafts are heat treated stainless steel material U joint Assembly The U joint assembly is a constant velocity universal joint assembly that is spline connected to the input shaft and the propeller shaft Itis located and retained to the input shaft to prevent axial float The output spline is sized to slip freely on the propeller shaft allowing relative axial movement at the universal joint output end only 18 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Description and Specifications Drive Lubrication Features The lubrication system consists of an oil reservoir that is located in the boat a valve to allow removal and filling of the drive with an external pump and hoses clamps and push lock couplings The reservoir is mounted a minimum of 254 mm 10 in above the ASD 15 15 centerline and the internal drive cavity completely filled with appropriate oil The reservoir is filled to one third full to allow for expansion and agitation of the oil during operation Drive Oil Capacity The approximate capacity of the drive and reservoir is 38 to 57 liters 10 to 15 gallons Lubrication Specifications
97. h regard to surface cleaning and preparation Note Twin Disc Incorporated recommends that accepted standard installation and construction practices for marine components be followed throughout The American Boat and Yacht Council publication Safety Standards for Small Craft provides useful general guidelines This publication may be obtained from The American Boat and Yacht Council P O Box 806 Amityville New York 11701 USA Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Thrust Unit Installation In order to maximize drive efficiency the lower 5096 of the propeller should be immersed in the water when running at planing speeds Because the flow pattern from a planning hull tends to move upward several inches from transom to the output end of the drive a straight edge running aft from the hull bottom to the propeller will normally be even with or for the larger drives belowthe lower edge of the thrust tube at its aft end The thrust socket ball must be positioned out of the water under planing conditions which is the intent of these installation procedures All through transom holes must be drilled perpendicular to the transom outer surface to allow the mounting bolts washers to seat flush against the drive flange A CAUTION The drive unit must be supported as shown in Figure 11 at all times prior to trim cylinder final installation Do not allow the ball joint thrust tube to bottom agains
98. haft right Figure 55 Use Special Tool T 18050 777 to Seat the Sleeve Against the Bearing CAUTION Do not allow dust or debris to settle on bearings components Failure to keep components clean will result in damaged parts 7 Lubricate the bearings and this assembly aside Cover and protect the bearings and splines Do not allow dust or debris to settle on bearings or components Arneson Surface Drive Service Manual 1020619 111 Assembly Twin Disc Incorporated Thrust Tube Assembly 1 Stand the thrust tube housing in the vertical position with the large diameter end up and with at least 534 mm 21 in of clearance below the bottom of the end of the housing A roll over stand over a pit works very well if available See special tool T 21089 5D in Special Tools Figure 56 Thrust Tube Housing In Stand left and Heat Housing in Bearing Area right 2 Freeze the two bearing cups to a temperature of 20 F 29 C 112 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 3 Install the chilled rear bearing cup into the thrust tube Ensure that the bearing cup seats against the shoulder in the thrust tube 4 Thread a M12 x 1 75 swivel eyebolt into the tapped hole on the forward end of the propeller shaft Attach a hoist to the eyebolt Lubricate the bearings and the races on the propeller shaft with 10 wt or 30 wt oil Figure 57 Place Chilled Bearing Cup in Bore left
99. he steering cylinder bracket against the transom and mark the location Do not re adjust the trim cylinder Mark the bracket outline on the transom Pivot the drive horizontally in the other direction extend the cylinder completely and repeat the procedure Do not adjust the trim cylinder Let it swing with the thrust tube Mark the steering cylinder bracket outline on the transom Position the mounting bracket at the center of these two marks Transfer the bracket hole pattern and drill the 22mm 0 875 mounting holes in the transom Stainless steel 19mm 0 75 diameter bolts nuts and washers are required for this installation Torque nuts to 122 N m 90 ft lbs Use thread lubricating compound to prevent seizing Apply generous layer of marine sealant under the bracket and within the fastener holes in the transom to prevent water leakage Arneson Surface Drive Service Manual 1020619 53 vs 1 792 4 61902014 enuen enS 1 APPLY THIN COAT OF LUBRICANT BETWEEN MATING SURFACES OF BALL BRACKET NUT PIVOT PIN CLEVIS AND CLEVIS PIN CLE UBRICANT TYPE MUST BE A MARINE GRADE LITHIUM G PROPERTIES FOR SALT WATER ENVIRONMENT SUCH 4 ALIGN SLOT IN BALL ATLANTA 1020218 AND TORQ 5 UBRICATE NUT THREADS 1 H HOLE IN BRACKET INSTALL PIN NS TO SPECIFIED VALUE 2 AND SCR NUT INTO BY THE ZEP CO TED DO NOT LU SS OTHERWIS
100. he cutaway area on the thrust socket flange should be aligned parallel with the hull deadrise The 1 inch clearance must be with the main drive boot in place N HU BUT TUM JUA Figure 16 Measure for Clearance F Remove the drive unit and drill 13 26 5 mm 1 16 in diameter holes and 2 38 mm 1 5 in lubrication holes using Template 1020306 Holes should be drilled perpendicular to the transom 42 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation G Mount the basic drive unit trim and steering cylinders not installed using the backing plate and 1 diameter stainless steel bolts nuts and washers as shown in Figure 17 Uniformly torque the nuts to 320 N m 235 lbs using the tightening sequence on Figure 18 Note The backing plate must be oriented with the spot faced holes outward and with the stamped top upward Use thread lubricant to prevent seizing Spot faced holes are only on backing plates for drives with wedges DRIVE INSTALLATION 13 QTY ry R s TA AFER 13 QTY 3mm C178 THICK DELRIN NU 15 1 16 CK DELRIN 13 QTY SOCKET LOCKNUT 27 4 BACKING PLATE ae RANSOM QNA Figure 17 Drive Installation Arneson Surface Drive Service Manual 1020619 43 Installation Twin Disc Incorporated H Install the input fl
101. her suitable protection against the shaft Failure to protect the shaft can cause damage Figure 41 Install Eyebolt Into Shaft Raise Shaft Assembly Out of Thrust Tube Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly 10 Remove the front inner bearing cup from the thrust tube Use caution if using heat on the housing This could damage the painted finish Mark the angular location of the bearing sleeve in the thrust tube If the bearing sleeve is removed from the thrust tube it must be reinstalled in the same angular location in the thrust tube Insert a long rod or drift into the rear of the thrust tube Tap the rod evenly around the cup with a mallet until the cup is free Discard the bearing cup 11 Flush the thrust tube using clean solvent to remove any dirt or other materials trapped inside All components such as shafts retainer rings etc should also be cleaned prior to reassembly See Cleaning and Inspection Arneson Surface Drive Service Manual 1020619 93 Disassembly Twin Disc Incorporated Prop Shaft Disassembly 1 On the forward end of the prop shaft remove the lock nut that holds the inner and outer taper bearings in place The lock nut is retained by a lock washer with a fold over tab The tab must be bent away from the lock nut Turn the lock nut counterclockwise for removal Use a hammer and punch or a spanner wrench to loosen the lock nut Figure 42 Bend Lock Tab Up
102. ie bar is per Figure 18 using the mounting hardware provided Adjust the length of the tie bar as required to make the drive thrust housings parallel Torque tie bar jam nuts as shown on Figure 28 Comply with all requirements and torque values shown in Figure 28 10 Slipthethrustball boot back over the socket and tighten the boot clamps Verify that the boot is not twisted 56 Arneson Surface Drive Service Manual 1020619 6190201 eoi ajos e eung 29 quiessy 82 4 OF ZEP RED 3 CENTER TU PROPER HIN COAT OF AND T LOCKING MARKED GRADE LITHIUM PAR WATER ENVIRONMEN NUT UBRICATE COMPONENT THREADS Nure A SCREW DA US NUT C MBLY TO EQUALIZE LENGTH OF EXPOSED COMPUND 242 BLUE TH GREEN OR EQUAL OF PIN PIVOT PIN m 2 0 5222 22 SCREW A OPPOSITE SIDE OF PIN WASHER 96101 UIML Installation Twin Disc Incorporated Driveline Installation 58 The driveline between the transmission output shaft and the surface drive input shaft must be properly aligned for maximum life and minimum vibration 1 The t
103. ight coat of grease on the entire surface of the thrust ball 6 Place a swivel eyebolt and special tool T 21567 onto the output end of the propeller shaft Lift the thrust tube assembly and position above the thrust socket Make sure the u joint spline is vertical Ease the thrust tube into the socket making sure that the propeller shaft spline enters the spline of the u joint While lowering align the flat on the socket with the flat bolting surface of the thrust tube 7 Install the rear output end retainer wear sleeve into the socket FLAT lt H FLAT Figure 75 Insert Prop Shaft Into U joint left and center and Align Flat for fin with Flat On Housing right 128 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 8 Place the shims on the top of the rear output end retainer wear sleeve The rear retainer wear sleeve will be deliberately over shimmed 9 Install the cover onto the socket assembly There will be a gap between the socket housing and the cover 10 Install every third M12 1 75 x 35 socket head capscrew retaining the cover to the socket M Figure 76 Place Shims On Retainer Install Cover and Tighten Screws Evenly Arneson Surface Drive Service Manual 1020619 129 Assembly Twin Disc Incorporated 11 Evenly tighten the capscrews while using a feeler gauge to obtain zero gap between the thrust ball and the rear retainer wear sleeve
104. instructions and requirements as defined in this manual Twin Disc Incorporated will not be responsible for surface drives that have been improperly installed or where such installations shall be deemed to be unsafe or structurally unsound Such improper installation shall immediately void all Twin Disc Incorporated warranties Rated Capacity The ASD 15 15 is designed for a maximum intermittent torque loading of 11 500 foot pounds applied at the input shaft flange Please verify that output of the power unit to be used does not exceed this torque rating Consult Twin Disc Incorporated for applications exceeding this capacity or if the installation is intended for commercial or heavy duty use Reduction Ratio and Propeller Gearbox reduction ratio and propeller pitch diameter selection are based on hull design normal operating weight and rated engine performance Twin Disc Incorporated is prepared to provide preliminary recommendations but actual propeller requirements may change in service Arneson Surface Drive Service Manual 1020619 33 Installation Twin Disc Incorporated 34 Packing List Consult packing list and verify that all listed items have been received and are undamaged Note All internal components of the surface drive must be protected from the damaging effects of dirt grit and dust prior to installation Take care to insure these components are kept clean by the use of plastic or other clean cov
105. is within the allowable limits to ease in the adjustments TRANSMISSION OUTPUT SHAFT CENTERLINE WILL BE PARALLEL TO ASD15 INPUT SHAFT CENTERLINE FABRICATED POINTERS TO BE USED IN PLACE OF DRIVE SHAFT TO COMPLETE ALIGNMENT OF TRANSMISSION OUTPUT SHAFT CENTERLINE TO ASD15 INPUT SHAFT CENTERLINE ADUSTABLE SHAFTS ON BOTH SIDES LENGTHS MUST BE SET EQUAL ADJUSTMENT LOCKING BOLTS N gt ALD H J d lt 5 amp m gt 2 gt E ec 22 9 2 od 2 1 a Og Qo 2 ia 86 lt 2 RUNOUT IN THIS AREA IS NO GREATER THAN 1 59 0625 BOTH SIDES PRIOR TO ALIGNMENT ROTATE BOTH SHAFTS TO VERIFY WITHIN SPECIFICATION Figure 30 Remote or Island Mounted Alignment Tool Shafts Parallel Arneson Surface Drive Service Manual 1020619 61 c9 6190 01 enuen enS 4044 pue jo 941614 nonono D TRANSMISSION UTPUT SHAFT INE 3 03 ARNESUN INPUT SHAFT A CENTERLINE ne H au o P CORRECT ALIGNMENT USING PARALLEL PLANES BETWEEN TRANSMISSION OUTPUT SHAI AND ARNESUN INPUT SHAFT VARIABLE LENGTH UNIVERSAI SHAFT MUST BE USED _f 4 CORRECT ALIGNMENT WEEN TRANSMISSION DUTPUT SHAFT AND ARNE INPUT SHAFT THE TRANSMISS
106. l of Thrust Tube While Thrust Socket Remains Mounted to Transom Always disconnect the battery cables and remove the key from the ignition before beginning this procedure A CAUTION Support the thrust tube with a block and tackle forklift or other system capable of carrying the weight of the thrust tube Do not allow the thrust tube to angle down to the point where the ball thrust tube assembly makes contact against the thrust socket Severe damage to the ball and the socket could result 24 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Removal from Vessel 1 Disconnect the battery cables and remove the key from the ignition 2 Support the drive with a block and tackle forklift or other system capable of carrying the weight of the entire drive Do not allow the thrust tube to angle down to the point where the ball thrust tube assembly makes contact against the thrust socket CLEARANCE CAUTION SUPPORT END OF PROPELLER SHAFT TO PREVENT SEVERE DAMAGE DRIVE SEVERE DAMAGE DRIVE FROM ALLOWING CONTACT AS SHOWN Figure 2 Protect Ball from Damage Arneson Surface Drive Service Manual 1020619 25 Removal from Vessel Twin Disc Incorporated Remove the cotter pin and jam nut Loosen the propeller nut until it is flush with the end of the shaft to prevent damage when the propeller moves from the tapered pilot Remove the pro
107. ll the cotter pin Note The propeller nut should be re torqued following the following schedule 4 INSIALLATILN 74 2 PROPELLER THRUST TUBE a 2 2 SPACER BLUE THIS AREA FUR PROP FIT COTTER PIN v i q X 5 JAM LOCK NUT APPLY ANTI PROPELLER NUT SEIZE x THIS AREA ONLY N N N Figure 33 Propeller Installation 66 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation 3 The propeller nut and lock nut must be checked for torque retention to the above values after initial use or within 10 hours of operation 4 The propeller nut torque MUST be checked in the following operational interval A The propeller nut torque must be checked in accordance with step 2 after an additional 250 hours of operation If the torque is correct go to step B If the torque is incorrect re torque the nut and repeat step A The propeller nut torque must be checked in accordance with step 2 after an additional 500 hours of operation If the torque is correct go to step C If the torque is incorrect re torque the nut and repeat step B The propeller nut torque must be checked in accordance with step 2 after an additional 1000 hours of operation If the torque is correct go to step D If the torque is incorrect re torque the nut and repeat step C The propeller nut torque
108. nd an o ring that were installed previously To provide a tight seal the packing and o ring must be compressed by the rear retainer wear sleeve 1 25 mm 25 mm 0 050 010 in The amount of compression is adjusted with packing shims These packing shims measure 399 75 mm 15 74 in outer diameter by 384 75 mm 15 15 in inner diameter Arneson Surface Drive Service Manual 1020619 143 Assembly Twin Disc Incorporated i _ 227 Z 2 RETAINER TA PACKING Figure 91 Ball and Socket Parts Identification 144 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 19 Raise the cover and the shim pack and hang them on the thrust tube Remove the rear retainer wear sleeve and support it on the thrust tube Figure 92 Remove the Retainer or Wear Sleeve left and Install Packing Shim Pack right 20 Install a shim pack of the packing shims measuring approximately 3 8 mm 0 150 in in thickness These are placed on top of the packing material The packing will be deliberately over shimmed 21 Install the rear retainer wear sleeve followed by the shim pack and cover Install every third M12 1 75 x 35 socket head capscrew retaining the cover to the socket Evenly torque the screws to 34 N m 25 Ib ft Arneson Surface
109. of 2 172 Assembly Stand Adapter T 21089 5B 2 of 2 173 Assembly Stand Adapter T 21089 5C 1 of 2 174 Assembly Stand Adapter T 21089 5C 2 of 2 175 Stand Setup ASD 15A1S T 21089 5D 1 of 2 176 Stand Setup ASD 15A1S T 21089 5D 201 2 177 Shaft Indicator Holder 7 21549 28 178 Limng Fixture F 21507 innsinn 179 Jacking Tool T 21570 1 2 180 Jacking Tool T 21570 2 181 Engineering Drawings 183 List of Engineering Drawings 183 1020119 page 1 of 4 ASD 15A1S Drive Assembly Parts 185 1020119 page 2 of 4 ASD 15 15 Drive Assembly Notes 186 1020119 page 3 of 4 ASD 15 15 Drive Installation H ttt T t 187 1020119 page 4 of 4 ASD 15 15 Drive Inboard Steering Cylinder 188 1020234 1 of 2 Steering Cylinder 189 1020234 page 2 of 2 Steering Cylinder 190 1020203 1 of 2 Trim Cylind
110. om See the following illustrations for proper lifting procedures UN gt _ SUPPORT UNDER BALL UNDER PROPELLER SHAI TRANSOM Figure 99 Support Unit for Installation Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly SOCKET BAI CLEARANCE CAUTION SUPPORT END OF PROPELLER SHAFT PREVENT SEVERE DAMAGE DRIV SEVERE DAMAGE TO DRIVE RESULT 5 FRDM ALLDWING AS SHDWN Figure 100 Protect the Ball from Damage 2 Apply marine sealant brand 5200 marine sealant or equivalent is recommended to the transom area where the surface drive is to be installed 3 Using a suitable lifting device lift the surface drive up against the transom and if necessary place a Delrin plastic isolation pad between the socket and the transom 4 Align the mounting bolt holes 5 Coat each bolt with marine transom sealant 3M brand 5200 marine sealant or equivalent is recommended to prevent leakage 6 Install the mounting bolts with Delrin plastic bushings through the transom Arneson Surface Drive Service Manual 1020619 153 Assembly Twin Disc Incorporated 7 Place a Delrin plastic isolation pad inside the vessel between the backing plate and transom 8 Secure the backing plate with the capscrews washers and nuts 9 Install the nuts and washers inside the transom and torque to 319 N m 235 ft
111. ould be made at the same time that the engine is overhauled Periodic Visual Inspection Check the propeller for signs of damage daily Repair or replace necessary Check the Cathodic Protection System at least every six months Replace zinc anodes when 5096 consumed or if excessive corrosion is seen Check all bonding wires and fittings Replace if required Inspect the oil lines for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required Check the condition of the Paint and Coating every six months Clean any blemishes or corrosion and coat with antifouling paint A CAUTION Do not apply paint or other coatings to sacrificial anodes Arneson Surface Drive Service Manual 1020619 79 Preventative Maintenance Twin Disc Incorporated Table 3 Maintenance Checklist Location and Action Beginning After first First 500 hours of each day of 200 hours of operation but not operation operation to exceed a 12 month period Hydraulic reservoir fluid level Check visually Hydraulic oil filter X Replacement Propeller Check for X damage Propeller nut Torque See Propeller Torque Schedule on next page check Socket trim cylinder steering cylinder Check transom fasteners Hydraulic system X X X Perform manual and emergency operation Drive oil change As indicated
112. peller from the splined shaft using suitable pullers soft blocks and mallets as necessary allowing the propeller to stop against the spacer and propeller nut Remove the propeller nut spacer and propeller from the rear end of the propeller shaft Spacer Propeller Nut Figure 3 Propeller Retaining Parts left and Propeller Installed right Drain the oil from the unit through the drain holes in the housings or from the lower oil reservoir hose inside the boat Disconnect the steering cylinder from the trim cylinder yoke pin Disconnect the tie bar from the tie bar pin Remove the trim cylinder yoke pin and the tie bar pin P Trim cylinders Steering Tie Bar Steering Cylinder Figure 4 Rear View of Dual Installation Showing Cylinders and Tie Bar 26 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Removal from Vessel 6 Remove the circle clamps on the boot and push the boot back over the thrust tube Consider placing a container under the thrust socket to catch the normal oil spillage as the unit comes apart Figure 5 Remove clamps left and Slide Boot Back Over Thrust Tube right 7 Remove the retainer wear sleeve cover bolts 8 Remove the retainer wear sleeve cover shims and rear ball retainer Figure 6 Remove Retainer Cover Shims and Retainer Arneson Surface Drive Service Manual 1020619 27 Removal from Vessel Twin Disc
113. r 20 ch D NUL GRANTED TO THE US OR OTHERS BY CONTRACT ALL ANGULAR TOLERANCES 1 ame PER ANSI YIASM 1982 1 2 0 2 9 SURFACE TREATMENT NAME S F R I F 5 APPD Engineering Drawings Twin Disc Incorporated Notes 194 Arneson Surface Drive Service Manual 1020619 1020619 07 02 TWIN DIS C POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
114. r The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc ncorporated The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated Twin Disc Incorporated does not warranty any products used for race or competition type circumstances Racing applications are clearly not covered by any warranty policy or terms As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation
115. r retainer wear sleeve into the socket Figure 87 Insert Prop Shaft Into U joint Align Flat for fin with Flat On Housing Arneson Surface Drive Service Manual 1020619 139 Assembly Twin Disc Incorporated 12 Placethe shims on the top of the rear retainer wear sleeve The rear retainer wear sleeve will be deliberately over shimmed 13 Install the cover onto the socket assembly There will be a gap between the socket housing and the cover 14 Install every third M12 1 75 x 35 socket head capscrew retaining the cover to the socket Figure 88 Place Shims Retainer Install Cover Tighten Screws Evenly 140 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 15 Evenlytighten the capscrews while using a feeler gauge to obtain zero gap between the thrust ball and the rear retainer wear sleeve zero clearance is achieved the thrust tube should be tilted left right forward and back a resistance to movement will be felt to fully seat the ball The thrust tube assembly should remain attached to the overhead hoist during this procedure as a safety measure Do not allow the thrust ball to pivot against the edge of the installed retainer cover If the thrust tube drops against the socket damage may occur 16 Move the thrust tube back to the horizontal position and recheck for clearance between the thrust ball and rear retainer wear sleeve Add or remove
116. ransmission output shaft centerline must be parallel to the surface drive input shaft centerline or if offset the angle between the transmission output shaft centerline and the driveline must equal the angle between the driveline and the surface drive input shaft centerline The angular offset between the transmission output shaft centerline and the driveline centerline must not exceed the recommendation of the driveline manufacturer The angular offset between the transmission output shaft centerline and the driveline centerline must be within one half degree of the angular offset between the driveline centerline and the surface drive input shaft centerline Both ends of a two piece driveline must be in phase with each other The correct orientation of the yoke arms on each end of the driveline is for them to be parallel to each other Most drivelines contain a slip spline between the two ends and the male and female sides of the slip spline may be capable of assembly at random angular positions It is very important to maintain the two yoke ends parallel when reassembling the driveline after service Examples of proper and improper alignment are shown in Figure 31 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation A method of alignment is listed here to aid in proper alignment or checking an existing installation for proper alignment The surface drive input shaft centerline will be fixed as it is locat
117. red surface The more evenly the dye is applied the more accurate will be the reading Allow the dye to dry completely before proceeding 4 Slide the propeller onto the shaft until the male and female tapers touch Install the propeller nut and torque the nut to 200 N m 150 ft lbs Verify that the propeller is securely seated on the shaft taper 5 Remove the propeller nut and slide the propeller away from the shaft being careful not to disturb the layout dye on the shaft and on the propeller hub internal female taper 6 Evaluate the contact pattern on both tapers See Figure 34 for guidance on acceptable contact patterns The surfaces should match approximately 8096 of the total tapered area Note It is important that the contact should be biased toward the larger diameter end of both tapers If contact is predominant at the small end the shaft may be over stressed locally and may fail Contact Twin Disc if the taper contact pattern is not in accordance with Figure 34 8 Once the contact is confirmed to be acceptable clean the dye from the tapers with the above solvent and re install the propeller as outlined in the previous section 68 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Acceptable Unacceptable 2 5 5 gt cote ene eve rae 9 45 4 1349 2 2 2 b v3 EU Small Spots Large
118. res with a crocus cloth If the bushing or sleeve is out of round deeply scored or excessively worn replace it If there is any question replace Splined Parts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses 106 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly Assembly Assembly Overview See Special Tools for detailed tool drawings References to special tool numbers are made when required See Engineering Drawings for the location and description of the referenced components Refer to Description and Specifications Troubleshooting and Preventative Maintenance for all lubrication specifications Arneson Surface Drive Service Manual 1020619 107 Assembly Twin Disc Incorporated Propeller Shaft Assembly Note Heat Shrink Assembly Methods When using heat shrink methods of assembly components should be installed by hand Occasionally when performing this procedure a race or bearing may become misaligned in a housing or on a shaft and will not slide properly into place Always have standby tools such as a drift and plastic mallet available to tap components into place Use light taps only when trying to realign a component 1 Heat the following parts to 250 F 121 C Two 2
119. rface Drive Service Manual 1020619 Twin Disc Incorporated Description and Specifications Description and Specifications General The ASD 15A1S 15 in line steerable propulsion system that supports and drives a surface piercing propeller at variable depth positions Nameplate The nameplate identifies the model bill of material BOM and the serial number of the unit These numbers are necessary to identify the correct parts for the surface drive See Figure 1 Figure 1 Nameplate for Arneson Surface Drive Arneson Surface Drive Service Manual 1020619 17 Description and Specifications Twin Disc Incorporated Construction Features Arrangement The ASD 15 1 is arranged as two major subassemblies the thrust socket assembly and the thrust tube assembly The thrust socket assembly is fixed to the vessel s transom and the thrust tube pivots on the socket Housings The ASD 15 15 is comprised of three housings the thrust tube the thrust ball and the thrust socket The thrust tube and thrust socket are of aluminum alloy material The thrust ball is stainless steel Bearings The input engine driven shaft is supported and located by two tapered roller bearings The bearing clearance for the input shaft is set by use of a single shim pack between the rear bearing sleeve and the socket housing The propeller sha
120. sembly 136 21 22 23 Twin Disc Incorporated Subtract A tight retainer bolts from B loose retainer bolts Record the difference as C actual compression C represents the actual compression that results from the packing and o ring being compressed with 150 in 3 81 mm thickness of packing shims Subtract the specified amount of compression 1 25 mm 25 mm 0 050 010 in from C the actual compression Record this new calculation as D excess compression Add A tight retainer bolts to D excess compression The sum is equal to the thickness of packing shims that must be removed in order to compress the packing and o ring to the desired amount of 1 25 mm 25 mm 0 050 010 in Calculation Example B Loose retainer bolts 0 110 in 2 80 mm A Tight Retainer bolts 0 030 in 0 75 mm Actual Compression 0 080 in 2 03 mm C Actual Compression 0 080 in 2 03 mm J Specified Compression 0 050 in 0 010 in 1 25 mm 0 25 mm D Excessive Compression 0 030 in 0 010 in 0 75 mm 0 25 mm Tight Retainer Bolts 0 030 in 0 75 mm D Excess Compression 0 030 in 0 010 in 0 75 mm 0 25 mm Thickness of packing shims to remove 0 060 in 0 010 in 1 50 mm 0 25 mm Figure 83 Example of Packing Shim Calculation 24 20 Remove the cover rear retainer wear sleeve shims and rear retainer wear sleeve Remove the packing shims Adjust the shim pack as cal
121. shims as necessary to obtain zero clearance between the thrust ball and the rear retainer wear sleeve Figure 89 Use Feeler Gauge and Obtain Zero Clearance Between Ball and Retainer Arneson Surface Drive Service Manual 1020619 141 Assembly Twin Disc Incorporated 17 Whenzeroclearance is obtained measure the gap between the socket housing and the cover The distance measured 15 equal to the thickness of the shims that must be removed from between the rear retainer and the cover to maintain the desired zero clearance between the ball and rear retainer wear sleeve Figure 90 Use Feeler Gauge to Obtain Average Gap Between Cover and Housing 142 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 18 Remove cover and remove the amount of shims equivalent to or the next size larger than the gap measured Example If the gap measured is 115 inches remove 120 inch in shims This creates a slightly tight fit between the rear retainer wear sleeve and the ball The rear retainer wear sleeve has now been shimmed properly to the ball The thrust ball clearance shim pack developed in these preceding steps must be installed into position in the thrust socket while adjusting the previously installed packing and o ring No further adjustment of the thrust ball clearance shims will be required Note The thrust ball is sealed to the thrust socket with the combination of two rope packings a
122. st both pointers to the same lengths so the pointed end indicator reference end of the inner shafts are in close proximity to each other Once this is completed use a dial indicator making sure that the run out on the pointers are no greater then 1 59mm 0625 inch It will be necessary to check runout on both shafts by turning them each 360 The engine and transmission package must be adjusted so that the pointer ends meet each other TRANSMISSION OUTPUT SHAFT CENTERLINE WILL NOT BE PARALLEL TO ASD15 INPUT SHAFT CENTERLINE FABRICATED POINTERS TO BE USED IN PLACE OF DRIVE SHAFT TO COMPLETE ALIGNMENT OF TRANSMISSION OUTPUT SHAFAT CENTERLINE TO ASD15 INPUT SHAFT CENTERLINE ADUSTABLE SHAFTS ON BOTH SIDES LENGTHS MUST BE SET EQUAL ADJUSTMENT LOCKING BOLTS BOTH MUST BE LESS THAN 1 59MM RUNOUT IN THIS AREA IS NO GREATER THAN 1 59MM 0625 INCH BOTH SIDES PRIOR TO ALIGNMENT ROTATE BOTH SHAFTS TO VERIFY WITHIN SPECIFICATION Figure 29 Remote or Island Mounted Alignment Tool Shafts not Parallel Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation 6 If the engine and transmission package can be adjusted so that the transmission output shaft centerline will be parallel to the surface drive input shaft centerline the engine and transmission package must be adjusted so that the two rods are parallel to each other The rods can be lengthened as long as the runout
123. stallation and Reinstallation and test for leaks 3 3 3 3 fi _ 1 pay a o 3 st gt August 9 2002 TDW P3008A Twin Disc Incorporated Table of Contents Table of Contents RR ETT 11 General Information 11 Safety and General Precautions 12 Preventative 13 Ordering Parts and Obtaining Services 14 Source of Service 15 Rebuilding ij 16 i inj t 16 Description and Specifications 17 Ulp TT rtm 17 Construction 18 Drive Lubrication Features 19 ec 9 RW 20 Torque Values for 21 Removal from Vessel
124. t or right side of their drive centerline as space permits Figure 25 Transom with Optional Inboard Steering 52 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Installation Position the drive in the neutral trim position and parallel to the vessel centerline See Figure 23 Attach the steering cylinder clevis to the trim yoke pin with the hardware supplied See Figure 26 Torque nutto 57 N m 40 ft Ibs Set the steering cylinder to the mid travel location and position the steering cylinder mounting bracket on the transom See Figure 24 The height and orientation of the mounting bracket should be such that the mounting bracket the clevis and the rod end are as close to centered as possible For hulls with moderate deadrise this height is usually dictated by clearance from the hull bottom Note If at all possible the mounting bracket holes should avoid stringers the hull bottom and any hull fittings that preclude the use of through bolts Mark the location orientation of the mounting bracket with a straight line approximately 12 long Slide the ball protective boot back from the thrust socket The trim cylinder should be supporting the weight of the thrust tube Remove the plastic gauge from the steering cylinder and compress the steering cylinder completely Push the drive in the direction of the steering cylinder allowing a 1 2 clearance between the thrust ball and socket Place t
125. t the thrust socket as shown in Figure 12 as this can cause damage to the ball and socket bearings The supporting mechanism must be capable of carrying the unit s weight approximately 1000 pounds Note When transom angle is other than 6 degrees to the vessel baseline and a wedge is to be used to mount the drive Template 1019886G should be applied to the wedge and not directly to the transom Arneson Surface Drive Service Manual 1020619 37 Twin Disc Incorporated Installation au N TR 5 Figure 11 Support Unit for Installation SUCKET BAI CLEARANCE X gt dih 3515 2 2 2227 4 22222 7 E 57 CAUTION END OF PROPELLER SHA SUPPORT TO PREVENT SEVERE DAMAGE TO DRIVE CAUTION SEVERE DAMAGE TO DRIVE ROM ALLOWING CUNTACT AS SHOWN WILL RESUL Figure 12 Protect Ball from Damage Arneson Surface Drive Service Manual 1020619 38 Twin Disc Incorporated Installation Locate a vertical line s on the transom through the intended drive centerline s as follows For twin drive installations it is recommended that drive centerlines be located in line with the engine centerlines For applications requiring offset drive mounting contact Twin Disc Incorporated for recommendations If at all possible drive mounting holes should avoid stringers and other h
126. ted Notes 182 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Engineering Drawings Engineering Drawings List of Engineering Drawings The following pages include the engineering drawings that are specific to this model The engineering drawings included are listed below Note Any part numbers listed in the following engineering drawings are for reference only Please refer to your bill of material for part numbers specific to your model 1020119 1 014 ASD 15 15 Drive Assembly Parts Drawing 1020119 2 of 4 ASD 15 15 Drive Assembly Notes 9 1020119 3 4 ASD 15 15 Drive Installation Interface 1020119 4 014 ASD 15 15 Drive Inboard Steering Cylinder Arrangement 1020234 1 012 Steering Cylinder 1020234 2 012 Steering Cylinder 1020203 1 of 2 Trim Cylinder 1020203 2 012 Trim Cylinder 1020290 Bar Assembly Arneson Surface Drive Service Manual 1020619 183 Engineering Drawings Twin Disc Incorporated 184 Arneson Surface Drive Service Manual 1020619 HOUSING GROUP 1020126 SOCKET 1020127 SLEEVE 1020128 SET SCREW 10376 INSERT MA1064E INSERT MA1064J 24 INSERT 1064 6 SHIPPING PLUG MA1040C O RING A2916JZ 2 PLUG M2051FT 3 RING M2078CC SCREW
127. tenance of the equipment and if observed minimum repairs aside from normal wear will result Arneson Surface Drive Service Manual 1020619 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services 14 All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you Note Do not order parts from the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number on the unit s nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating from any of the above stated changes will not be accepted for credit
128. the original customer s and subsequent purchaser s employees and property due to their acts omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment OnlyaTwin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit August 9 2002 TDW P3008 TWIN DISC INCORPORATED C FLAT RATE HOUR ALLOWANCE E Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated COMMERCIAL SURFACE DRIVE UNITS Description of Flat Rate Labor _ di E 2E 3 hours allowed for function to the right gt Removal and Rein
129. the smaller diameter of the bearings toward the spline ends of the shaft Be sure to seat the bearings against the shoulder of the shaft as they cool Install the input shaft seal wear sleeve on the input shaft against the bearing on the end that has three axial holes Do not install it on the end with the threaded radial holes in the spline Clean the threaded holes that are cross drilled in the output end spline with denatured alcohol to prepare for Loctite 242 blue or similar liquid thread locker 4 Install one of the chilled bearing cup into the bearing sleeve with the thick end of the cup toward the bottom flange end of the sleeve 1 Figure 67 Install Bearings and Seal Sleeve left and Install Cup Into Sleeve right 5 Stand the input shaft in the vertical position with the output universal joint end up This can be identified as the spline that has a cross drilled and threaded hole through the shaft Lubricate the bearing and place the sleeve with the bearing cup over the output end of the input shaft 6 Lower the U joint assembly over the spline aligning the cross drilled holes in the shaft and u joint yoke 120 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly Coat the two clean M10 1 5 x 40 socket head capscrews threads with Loctite 242 blue or similar liquid thread locker and insert the capscrew through the collar Install the capscrew and collar through the holes in the u
130. thereafter Clean any blemishes or corrosion and repair damaged coatings Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Operation General Operation The following information is intended for use by the vessel operator It will help the operator understand the operation of the ASD 15 15 and applies to the surface drive only The vessel s operator manual must be referred to for procedures applicable to other vessel functions and for the operation of the control system for this drive The ASD 15A18 provides positive steering and a means for adjusting the depth of the surface piercing propeller while under way Prior to Daily Use Verify that the surface drive has adequate lubrication and that the hydraulic steering reservoir and trim pump reservoir are properly filled The lube oil reservoir must not be filled more than 1 4 full when cold with the drive stopped The level will rise during operation due to temperature increase and rotation of internal parts Surface Drive Operation For optimum performance the surface drive should be trimmed so that the center of the propeller hub is at the waterline under operating conditions Under way adjustments may be required when the vessel trim changes due to fuel consumption loading etc The surface drive should not be trimmed up to such a degree that the engine is allowed to operate higher than the maximum speed recommended by the engine manufacturer A CAUT
131. ts propeller size and selection Final specifications are assumed to include all information submitted at the time of order Any changes or modifications to project must be communicated to Twin Disc Incorporated s in writing prior to completion of manufacturing and delivery Twin Disc Incorporated reserves the right to change or cancel order based upon any new information submitted if information is contrary to acceptable parameters of Twin Disc Incorporated s program replacement of any Twin Disc Incorporated part or product found by Twin Disc Incorporated to be defective and the labor to perform that work and to remove and reinstall or equivalent credit Inthis context labor is defined as the flat rate labor hours established by T win Disc Incorporated in the published T win Disc Flat Rate Schedule required to remove disassemble in repair reassemble reinstall and test the T win Disc Incorporated product only Authorized reasonable travel and living expenses will be considered for ent Under no circumstances including a failure of the exclusive rem shall Twin Disc Incorporated be liable for economic loss consequential incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repai
132. two outer grooves of the cover Note The center groove is a passage for grease Figure 64 Seal Orientation Press First Seal In Followed by the Spacer Figure 65 Install Second Seal Third Seal Snap Ring O rings and Coat with Grease 118 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Assembly 16 Install the seal cover assembly onto the rear of the thrust tube housing Note that the notches in the seal cover must align with the roll pins in the thrust tube Clean the threaded holes with denatured alcohol to prepare for Loctite 242 blue or similar liquid thread locker Coat the clean capscrew threads with Loctite 242 blue or similar liquid thread locker and install eight M6 1 0 x 16 socket head capscrews Torque the capscrews to 4 0 N m 3 ft Ibs Figure 66 Match Notches in Seal Cover with Roll Pins left and Install Seal Carrier right 17 Spinthe propeller shaft by hand to assure smooth operation The shaft should spin smoothly There should be sufficient drag caused by the three lip seals Arneson Surface Drive Service Manual 1020619 119 Assembly Twin Disc Incorporated Thrust Input Shaft and Socket Assembly 1 Heat the two 2 tapered roller bearings and the input shaft socket end seal wear sleeve to 250 F 121 C 2 Freeze the two 2 bearing cups to 20 F 29 C 3 Assemble the previously heated tapered roller bearing cones onto each end of the input shaft with
133. ull fittings that preclude the use of through bolts See Figure 13 Template 1019886G duplicates the cross section of the thrust socket and wedge if applicable and is used to locate the drive centerline for 1 inch socket clearance Note When transom angle is other than 6 degrees to the vessel baseline and a wedge is to be used to mount the drive Template 1019886G should be applied to the wedge and not directly to the transom Twin Disc Incorporated may advise distance to be larger Ae lE CENTERLIN HCA TIUN 2 SLINI ICAL DRIVE VERTICAL 12 LDCAI TRANSOM CENTELINI RUM TRANS TRANSOM Figure 13 Drive Centerline Location Arneson Surface Drive Service Manual 1020619 39 Installation Twin Disc Incorporated 3 Use Template 1019886G to locate and mark drive centerline s as shown in Figure 14 A For single drive installations position centerline of Template 1020306 on transom centerline Locate and match Points on transom Template 1020306 Mark centers for mount holes 13 and lubrication holes 2 B For twin drive installations locate and match Points C on transom and Template 1020306 Rotate template until cutaway area on the thrust socket flange is parallel to the hull deadrise as shown in Figure 14 Locate and mark centers for mount bolts 13 and lubrication holes 2 STERN VIEW SIDE VIEW
134. ust Input Shaft and Socket Assembly 120 Assembly of Thrust Tube and Ball Into Thrust Socket 126 Removal and Replacement of Thrust Packing and O Ring 149 Boot Install al OF vesci tibiae evi UNES EDU md ME 149 Fin Reattachment RTT 150 Attaching Thrust Unit to 152 Propeller Installation Routine Maintenance 156 Propeller Installation New Applications 158 Arneson Surface Drive Service Manual 1020619 9 Table of Contents Twin Disc Incorporated Speca TOO 161 161 Input Socket Shaft Wear Sleeve Driver 18050 774 163 Input Socket Shaft Bearing Cup Driver T 18050 775 164 Thrust Bearing Cup Driver T 18050 776 165 Propeller Shaft Seal Sleeve Driver T 18050 777 166 Propeller Shaft Seal Driver Assembly T 18050 780 Detail 1 167 Propeller Shaft Seal Driver Assembly T 18050 780 Detail 2 168 Input Socket Shaft Seal Driver 18050 781 169 Assembly Stand Adapter T 21089 5A 1 of 2 170 Assembly Stand Adapter T 21089 5A 2 of 2 171 Assembly Stand Adapter T 21089 5B 1
135. vessel is reached If at any point in steps A through the haulout interval of the vessel is reached or surpassed the torque check interval may be established to be the same as the haulout interval Record the final interval for reference Arneson Surface Drive Service Manual 1020619 157 Assembly Twin Disc Incorporated Propeller Installation New Applications First time installation of new propellers will require a check to verify proper mating of the tapered shoulder on the propeller with the tapered shoulder on the shaft Mismatched tapers may result in a damaged or broken propeller shaft and a lost propeller Follow the procedure below to check the propeller to shaft fit 1 Clean the taper on the forward end of the propeller hub and the tapered shoulder of the shaft with alcohol or other cleaner and wipe dry 2 Apply a layout dye to the shaft taper as follows Use machinist s layout dye such as Dykem Steel Layout Blue Dykem part number DX100 marketed by ITW Dymon Company 805 E Old 56 Highway Olathe KS 66061 USA 3 Apply the layout fluid to the shaft taper as thinly and evenly as possible over the entire tapered surface The more evenly the dye is applied the more accurate will be the reading Allow the dye to dry completely before proceeding 4 Slide the propeller onto the shaft until the male and female tapers touch Install the propeller nut and torque the nut to 200 N m 150 ft lbs Verify that the
136. vice Manual 1020619 95 Disassembly Twin Disc Incorporated Thrust Socket Disassembly 1 Preparation Before disassembly the thrust socket it must be removed from the transom and it must be separated from the thrust ball assembly 2 Place the socket on a bench with the large diameter end facing up Remove the packing shims o ring and packing from inside the socket housing 3 The forward retainer is a slip fit and should slide out of the socket with little effort Remove the forward retainer Figure 44 Remove Packing and O ring Remove Retainer 96 Arneson Surface Drive Service Manual 1020619 Twin Disc Incorporated Disassembly Remove the aft tapered bearing sleeve bolts that are located inside the socket Use a hoist to lift the input shaft assembly which consists of the U joint input shaft bearings and sleeve from the socket housing Place the input shaft assembly aside for disassembly later Bearing Sleeve Bearing Sleeve bolts Figure 45 Remove Bearing Sleeve Bolts Lift Input Shaft Assembly Out of Housing Remove the bearing sleeve shims from the socket housing Shims may sometimes stick to the bearing sleeve during its removal Remove the front bearing cup from inside the socket housing The bearing cup is a slip fit and should slide out of the housing with little effort If necessary tap lightly against the bearing lip to assist in removal Do not damage the bearing because it may be reused if th

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