Usage:
Hydraulic System
A good recommendation to follow is to install a new element in the oil filter housing before a hydraulic pressure test is to be made.
There is no adjustment for either the ahead or astern clutch. If a clutch does not engage or keep engaged when the control is in either the AHEAD (forward) or ASTERN (reverse) position, the hydraulic pump is damaged or the clutch discs are badly worn.
Operation Test
With the engine stopped, remove the plug from the tee in the control valve and install a 5M5317 Reducing Bushing in the tee. Install a 5S4648 Hose Assembly with an 8M2886 Pressure Gauge (0 - 600 psi) in the reducing bushing and tee.
OIL PRESSURE TEST
Start the engine and run it long enough to get the temperature of the oil, in the marine transmission, to approximately 150° (65°C). The correct oil pressure is 50 to 60 psi (345 to 415 kPa) with the control valve lever in the NEUTRAL position. The correct oil pressure reading is 300 psi (2050 kPa). With the control valve lever in the AHEAD (forward) or ASTERN (reverse) position.
If the pump is in good condition, and the pressure reading is too low, the pressure of the oil to engage a clutch can be increased.
Remove the cover from the bottom of the control valve. Bypass valve (3) and springs (2) can fall when the cover is removed. Add spacers (1), in bypass valve (3) under springs (2) to increase the pressure of the oil to engage a clutch. Remove spacers (1) if the pressure reading on the gauge was too high.
Put springs (2), bypass valve (3) with spacers (1) into the control valve and install the cover.
CROSS SECTION OF CONTROL VALVE
1. Spacers. 2. Springs. 3. Bypass valve.
Test the oil pressure again. When the pressure reading is correct stop the engine and remove the hose assembly and reducing bushing. Install the plug in the tee on the control valve.
Checking Pump Efficiency
It is best to make the efficiency tests of the pump on a test bench. The temperature of the oil in the test bench is 150°F (65°C).
For any pump test, the pump flow, measured in gpm (litre/min) at 100 psi (690 kPa), will be larger than the pump flow at 1000 psi (6900 kPa) at the same rpm.
The difference between the pump flow of two operating pressure is the flow loss.
Flow loss when expressed as a percent of flow loss is used as a measure of pump performance.
If the percent of flow loss is more than 10%, pump performance is not good enough.
*Numbers in examples are for illustration and are not values for any specific pump or pump condition. See the Specifications for pump flow of a new pump at 100 psi and 1000 psi.
Test On The Bench
Measure the pump flow at 100 psi (690 kPa) and at 1000 psi (6900 kPa). Use these values in Formula I.
If the test bench can not be run at 1000 psi at full pump rpm, run the pump shaft at 1000 rpm. Measure the pump flow at 100 psi (690 kPa) and at 1000 psi (6900 kPa). Use these values in the top part of Formula II. For the bottom part of the formula, run pump shaft at 2000 rpm. Measure the pump flow at 100 psi (690 kPa).
Come-Home Feature
If a clutch, in the marine transmission, can not be engaged and there is no way to get the vessel to port, the come-home feature is used. A clutch can be engaged by the force of four bolts (3) that can be put through gear (1) of the clutch. With the bolts tightened to the correct torque, the clutch is kept engaged until the bolts are removed.
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Use the come-home feature only when there is an emergency because there is not much lubrication for the bearings and gears when the pump is damaged. Run the engine at slow rpm. |
The engine must be warm before using the come-home feature (a warm engine is not as much load as a cold engine when it is started).
1. Stop the engine and remove the cover of the marine transmission.
2. Remove each plug (2) and install a bolt (3), 3/8-16, 2.00 in. (50.8 mm) in each of the plug holes. First tighten each bolt to a torque of 15 lb. ft. (20 N·m). Next tighten each bolt again until the torque is 32 ± 5 lb. ft. (43 ± 7 N·m).
TRANSMISSION WITH COVER REMOVED
1. Gear for clutch. 2. Plug.
INSTALLATION OF COME-HOME FEATURE
1. Gear (for the clutch). 2. Plug. 3. Four bolts; 3/8-16, 2.00 in. (50.8 mm).
3. Install the cover on the marine transmission. Be sure the level of the oil in the transmission is 5 to 6 in. (127 to 152 mm) above the full mark on the gauge.
4. Start the engine and run it at slow rpm.
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The starter motor now has more load (the marine transmission and the propeller are the added load) when it starts the engine and can soon get hot. If the engine does not start in just a few seconds, turn off the starter switch and let the starting motor get cool before using it again. Also remember the propeller moves the vessel as the engine is started. |
5. Stop the engine to stop the propeller.
6. With the engine stopped remove the cover from the marine transmission. Remove bolts (3) and install plugs (2) and then the transmission cover.
NOTE: If it was necessary to use the come-home feature for a long time, the recommendation is to make a thorough inspection of the bearings and clutch plates and discs. It may be necessary to install new parts because of not much lubrication can damage parts.
Alignment For Marine Transmission
ALIGNMENT SCHEMATIC
1. Input shaft flange (marine transmission). 2. Extension shaft. 3. Indicators. 4. Drive coupling. 5. Flywheel (engine). 6. Spacer. 7. Plate. 8. Boot. 9. Driven coupling. 10. .16 ± .01 in. (4.1 ± 0.3 mm) space dimension.
When either the marine transmission or the engine has been removed from the vessel, there must be an alignment made between the input shaft of the transmission and the flywheel of the engine when either of them are installed again.
The engine must be only on its installation screws when the alignment is made. The output shaft must be in correct alignment with the propeller shaft and the marine transmission must be installed (with all bolts and nuts tight) on the rails, in the vessel, for the engine and transmission.
The coupling group parts; drive coupling (4), boot (8), driven coupling (9) and plate (7) must be correctly installed in flywheel (5).
Use the installation screws to move the engine to install spacer (6) and to get .16 ± .01 in. (4.1 ± 0.3 mm) space dimension (10) between the back face of coupling (9) and the inside face of plate (7). It is necessary to remove spacer (6) to measure for .16 ± .01 in. (4.1 ± 0.3 mm) space dimension (10). Do not tighten the bolts in spacer (6).
Install indicators (3) on extension shaft (2). A 2N4661 Alignment Fixture Yoke with a 2N2462 Alignment Fixture Bar can be used to install the indicators on the extension shaft. Put the anvil of one indicator on the outside diameter and the anvil of the other indicator on the face of drive coupling (4).
Turn extension shaft (2), with indicators (3), and make an indicator reading at each 90° as the shaft is turned 360° (one turn). Use the installation screws to move the engine to get a "plus" indicator reading of .0055 to .0135 in. (0.140 to 0.343 mm) at the bottom (180°) and no more than .008 in. (0.2 mm) difference between the 90° indicator reading and the 270° indicator reading. The installation screws are also used to move the engine to get an indicator reading, at each 90° on the face, of no more than a total of .008 in. (0.2 mm).
When the indicator readings (both indicators) for each 90° of one rotation of the shaft are correct, tighten the bolts through extension shaft (2) and spacer (6). Install the permanent supports for the engine and tighten the bolts and nuts that hold the engine on the rail in the vessel.
Make another check for the alignment of the engine to the marine transmission after the installation is complete. If the check for the alignment is not correct the procedure for the alignment must be done again.
Vessel Either Pulled Or Pushed
Keep the propeller stopped when the vessel is either pulled or pushed with a stopped engine. The motion of the vessel can turn the propeller and there is no lubrication for the bearings, gears and clutch discs that turn with the propeller.