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CAPITOL HY- 6900 Service Manual

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HY- 6900
HY-7700
SERVICE MANUAL
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Summary of Contents for CAPITOL HY- 6900

  • Page 1 HY- 6900 HY-7700 SERVICE MANUAL...
  • Page 2 NOTE THIS SERVICE MANUAL IS GUARANTEED EFFECTIVE FOR SERIAL NO. ONLY. CAUTION DO NOT OPERATE IN REVERSE MODE TO MOVE VESSEL FORWARD DO NOT OPERATE CONTINUOUSLY IN REVERSE MODE FOR MORE THAN 30 MINUTES AT 75% OF AVAILABLE HORSEPOWER. DO NOT OPERATE UNIT OVER 180º F (82ºC) DO NOT OPERATE UNIT WITH HIGH OR LOW OIL PRESSURE DO NOT ‘WINDMILL’...

  • Page 3: Table Of Contents

    Table of contents Section 1. Introduction page description Optional Equipment Section 2. Principles of Operation Output rotation Reduction Ratio Power Flow Clutch Hydraulic System Section 3. Installation and Operation Uncrating and Handling Installation Preparation Installation of Transmission Alignment of Output Coupling Water piping Start-up Procedure Operating Practices...
  • Page 4 Table of Contents (Continued) Transmission Housing and Related Parts Adapter Group Pinion Shaft and Related Parts Idler Gear and Related Parts 8.10 Output Gear, Cover and Related Parts 8.11 Reduction Gear Selection Chart 8.12 Oil Filter 8.13 Propeller Coupling Kits 8.14 Oil Coolers 8.15...

  • Page 7: Section 1. Introduction Page

    HOSE AND FITTING PACKAGE details may be obtained from the Kits that include the necessary hose and engineering department of Capitol Gears, fittings are available for use with capitol Inc., St. Paul, Minnesota, U.S.A. oil coolers. 1.1 DESCRIPTION PROP COUPLING KIT...

  • Page 8: Section 2. Principles Of Operation

    SECTION 2. PRINCIPLES OF OPERATION 2.1 OUTPUT ROTATION 2.2 REDUCTION RATIO The capitol marine gear in forward mode The reduction ratio is the number of teeth in provides output rotation in the opposite the reduction gear compared to the number direction as engine rotation.

  • Page 9: Clutch

    2.3 POWER FLOW (CONT’D.) REVERSE When reverse is chosen the clutch is held stationary to the housing. Engine power is transferred through the clutch bevel gears and the pinion is driven in anti-engine rotation at engine speed. This causes reduction gear and output flange to rotate in engine direction (reverse).

  • Page 10: Hydraulic System

    In neutral the ports to both the forward and 2.5 HYDRAULIC SYSTEM reverse sides of the clutch cylinder are opened and the balanced pressure that is drawn from the sump through a suction results keeps the clutch cylinder centered hose and then sent under pressure to a filter between the forward and reverse clutch and an oil cooler and the to the selector discs.

  • Page 11: Section 3. Installation And Operation

    Report immediately Keep all mating surfaces clean. Use any shortage or damage to your local distributor, cleaning solvent or diesel fuel. transfer agent or Capitol Gears. 3.2 INSTALLATION PREPARATION Remove the clutch assembly from SPECIAL TOOLS REQUIRED...
  • Page 12 9. Dial oil dam pilot O.D. as shown in figure 11. Dial indicate stub shaft on chamfer as 4. record reading. Total indicator reading shown in figure 6. Record reading. Total must not exceed .007 inch. indicator reading must not exceed .007 inch. The sum of readings in steps 4, 5 and 6 must not exceed .007 inch.

  • Page 13: Installation Of Transmission

    Replace oil pump drive shaft, gasket and oil pump. Secure pump with capscrews and lockwashers. 3.3 INSTALLATION OF TRANSMISSION Replace oil pump drive shaft, gasket and oil pump. Secure pump with cap Apply a small amount of grease to oil screws and lock washers.

  • Page 14: Alignment Of Output Coupling

    3.4 ALIGNMENT OF OUTPUT COUPLING Now align shaft coupling to reverse gear In marine application, final alignment of coupling. Lay a straight edge across the output flange and propeller shaft coupling edges at top and sides to line up couplings. must be accomplished when the vessel is Do not burr or mar mating surfaces.

  • Page 15: Water Piping

    3.5 WATER PIPING To assure proper cooling of the Capitol’s reverse gear units, connect the cooling system as indicated on one of the three diagrams shown. It is extremely important that the marine gear oil be cooled properly; the oil cooler must receive an ample supply...

  • Page 17: Start-Up Procedure

    Start engine and check all connections CAUTION for leaks. 1. A Capitol reverse gear should normally not be shifted unless engine is at idle speed. Oil pressure is adjusted at factory for 2. Reverse gear cannot be operated continuously...

  • Page 18: Section 4. Preventive Maintenance

    (38º-66ºC) at control valve. Unit will tolerate higher temperatures but clutch life may be shortened considerably. To insure a long service life of the Capitol 4.2 ROUTINE MAINTENANCE Marine gear and to prevent costly and unexpected failures it is very important that...

  • Page 19: Maintenance Schedule And Check Sheet

    Engineer____________________ Reverse gear serial no._________ 4.3 MAINTENANCE SCHEDULE AND CHECK SHEET Date Service Began___________ INTERVAL MAINTENANCE DESCRIPTION RECORD Normal Operation DAILY -Check oil level -Check oil pressure After first 100 hours -Change oil and flush sump Every 400 hours -Check zinc pencils -Change oil if contaminated -Remove and clean oil breather and suction tube...

  • Page 20: Section 5. Trouble Shooting

    SECTION 5. TROUBLE SHOOTING 5.1 TROUBLE/REMEDY CHART SYMPTOM PROBABLY CAUSE REMEDY A. Low oil pressure (at full 1. Faulty pressure gauge 1. Check gauge against one of known accuracy operating speed and temperature 2. Low oil level 2. Inspect gaskets, seals, hoses and fittings for leakage.
  • Page 21 D. Overheating 1. Insufficient Oil cooler Capacity 1. Install adequate oil cooler 2. Insufficient flow of cooling water 2. Increase water line sizes 3. Clutch slipping 3. Refer to symptom A 4. Water temperature too high at 4. Decrease water temperature to cooler cooler or relocate heat exchanger in cooling system.
  • Page 22 I. Clutch burned out 1. Low oil pressure 1. See symptom A 2. Clutch is shifted at other than 2. Install interlock shift controls engine speed 3. Transmission misaligned 3. Check installation and alignment as described in installation section 4. Excessive heat 4.

  • Page 23: Section 6. Repair Of External Subassemblies

    SECTION 6. REPAIR OF EXTERNAL SUBASSEMBLIES CAUTION: Avoid contact with rotating output coupling and always shut down engine when doing even minor inspection or repair. Avoid contact with metal surfaces as operating temperature may exceed 200º. 6.1 OIL PUMP A.PRESSURE RELIEF ASSEMBLY 3.
  • Page 24 1. Screw pressure relief screw into Inspect bushings in cover for wear (see wear limits p.23), out of round condition relief valve insert just enough to or burrs. If they are worn, damaged or start threads. loose, replace and ream to size (see p.23).
  • Page 25 10. Generously lubricate relief plunger with 3. Apply grease to bearing container and Vaseline or lubriplate and position cup locate new oil pump gasket on container. end last in bore of adapter. Check to make sure plunger slides freely. 4. Install oil pump (and filter) on bearing container.
  • Page 26 6.2 SELECTOR VALVE AND 3. Note position of cover). Remove cover, cover gasket, and rotor from RELATED PARTS block. A. REMOVAL 4. Remove safety relief adjustment screw, washers, spring and plunger. 1. Disconnect hoses and control NOTE: SPRING IS UNDER linkage from lever on selector valve.
  • Page 27 D. ASSEMBLY NOTE: On all fittings use Permatex ‘super 300’ sealant, graphite paste, or equivalent. CAUTION: Do not use No.1 Permatex or Teflon tape. 1. If necessary install new seal in cover. Press seal in until it bottoms in bore (rubber face out). Apply lubricant to seal.

  • Page 28: Section 7. Repair Of Internal Subassemblies

    7. Remove capscrews and CAPITOL GASKET AND SEAL KIT NO. lockwashers holding housing to oil 1-10169-0000 (HY-7700) 1-10168-0000 (HY-6900) 8. Insert screwdriver or similar object...
  • Page 29 7.2 TABLE: REPLACEMENT WEAR LIMITS NEW DIMENSIONS REPLACEMENT ITEM MINIMUM MAXIMUM WEAR LIMIT REDUCTION GEARS- Backlash .004 .008 .020 PINION SHAFT O.D At Forward Commutator 1.7450 1.7455 1.7440 O.D At rear Commutator 2.997 2.998 2.996 O.D At Forward Bearing 3.3380 3.3387 3.3360 O.D At Rear Bearing...

  • Page 31: Clutch

    7.3 CLUTCH Check all pinion bearings and A) DISASSEMBLY washers for distortion or rough operation. If one bearing needs NOTE: FOR REMOVAL replacement we recommend INSTRUCTIONS SEE PAGE 22. replacing all of them as a set. Remove socket head, capscrews, lock Clean all parts with a good grade washers, (and Allen nuts) securing both cleaning solvent or diesel fuel.
  • Page 32 10. Check both clutch flange ball carrier bore making sure holes are in bearings for wear, distortion, or line (See fig.22). rough operation. Again we recommend replacement of both Tap shaft about half way into bore so it bearings if either one shows wear. protrudes just slightly into recess.
  • Page 33 Replacement of return springs and C. Turn bevel gear carrier over (reverse side up) retainers (If necessary): Insert return and press remaining cylinder on, checking to see spring retainers into return springs and that cap screw holes in both cylinders are aligned secure in gear carrier using capscrews.
  • Page 34 7. Press ball bearing into forward clutch flange. Press bevel gear into ball bearing. 8. Likewise press the other ball bearing into reverse clutch flange (fig.26). Then press bevel gear into ball bearing. Check that ball bearings on both flanges are well seated. 9.

  • Page 35: Pinion Shaft: Removal And Reassembly

    7.4 PINION SHAFT- REMOVAL AND RE-ASSEMBLY Set transmission housing upright and support if necessary. 1. Disconnect hose from selector valve to oil pump and pump to sump. Disconnect idler hose, if present from pump. 2. Remove selector valve selector valve base plate and gaskets.
  • Page 36 B. CLEANING INSPECTION AND REPAIR 3. Inspect pinion teeth, threads and spline for damage. Inspect all bearing surfaces and 1. Inspect tapered roller bearings for rough commutator surfaces for grooved, burred or rotation. Corrosion, scoring, scratches, galled conditions. If damage cannot be burrs, cracks, pitted or chipped races and repaired with crocus cloth.

  • Page 37: Output Gear And Related Parts

    8. Remove oil pan 7.5 OUTPUT GEAR AND RELATED 9. Engine Rotation (E.R) Models only: PARTS Remove idler gear assembly from housing (or cover). Remove snap rings and bearings. Discard o-ring. A.REMOVAL AND DISASSEMBLY 10. Remove snap ring and remove 1.

  • Page 38: Housing Parts

    5. E.R. Models only: Inspect idler gear for nicks, burrs, damage or wear. Check bearings for rough rotation or wear. Discard if necessary. Make sure internal oil passage in shaft is clear. Flush idler hose. 6. Inspect output coupling at bearing mating surface for nicks or burrs.

  • Page 39: Reassembly And Installation Of Output Gear And

    b). To make sure holes in commutator 7.7 RE-ASSEMBLY AND flange match up with spring pins in housing, INSTALLATION OF OUTPUT GEAR three guide pins (3/16” dia.) Should be used. AND RELATED PARTS c). Apply lubricant to commutator and press 1.
  • Page 40 8. (HY-7700) Install bearing locknut on 11. Apply new cover gasket to housing. A forward end of output shaft and secure with small amount of grease may be used to screw. keep gasket in place. (HY-6900) Install bearing nut and 12.

  • Page 41: Installation Of Output Coupling

    7.8 INSTALLATION OF OUTPUT COUPLING 1. If new coupling is used, check clearance between key and keyway in output coupling by locating key and coupling temporarily on shaft. Clearance should be .010” to .015”. Otherwise file key as necessary. 2. Heat output coupling in hot oil or water at 180 Fahrenheit (or 82 Celsius) for at least ½...

  • Page 42: Post-Assembly Inspection

    2. E.R. Models only: Mount a thousandths 8. Connect suction hose. Use joint dial indicator on rear cover at pinion bore so compound on fittings. that tip is resting on the side of an idler gear tooth. Hold output gear stationary and gently twist idler back and forth.

  • Page 43: Additional Assembly

    b). MOUNTING FACE: Mount thousandths indicator as shown and rotate coupling. VARIATION MUST NOT EXCEED .003” MAXIMUM. 7.11 ADDITIONAL ASSEMBLY 1. Install inspection covers and gaskets 2. Check for gear backlash as follows: A.E.R. MODELS (without idler gear): Mount 2. Install oil breather and dipstick thousandths dial indicator on top of housing so that arm extends through top inspection 3.

  • Page 44: Adapter Parts

    7.12 ADAPTER PARTS 3. While oil dam is removed, inspect 1. Clean and inspect stub shaft, clutch flywheel adapter and drive flange for driving drum. Check splines for chips, deep distortion or rough mounting surfaces. grooves or wear. Replace parts as Repair or replace as necessary.

  • Page 45: Section 8. Part Information

    B. Contact Capitol Gears, Inc. If the above cannot supply the part(s) you need write: Do not send any equipment to the factory without authorization from the customer...

  • Page 46: Selector Valve

    8.3 SELECTOR VALVE ITEM DESCRIPTION PART NUMBER REF. ASSEMBLY, SELECTOR VALVE 1-09427-2000 BODY 1-01141-3500 PIPE PLUG, HEX SOCKET; ¼ N.P 1-11279-0300 PIPE PLUG, HEX SOCKET; 1/8 N.P 1-11279-0200 VALVE (ROTOR) 1-01144-1000 GASKET, VALVE COVER 1-01156-3700 COVER 1-01142-3400 CAPSCREW, SOCKET HEAD; ¼-20X ½ LG 1-09432-0800 LEVER 1-01143-4200...
  • Page 48 OIL PUMP ASSEMBLY NO. 1-07800-0100 ITEM DESCRIPTION PART NUMBER REF. ASSEMBLY, OIL PUMP 1-07800-0100 ADAPTER, OIL PUMP 1-07721-0900 PLUNGER, RELIEF VALVE 1-07725-0800 SPRING, PRSSURE REGULATING 1-07743-0800 WASHER; 11/4” O.D 1-12901-0000 INSERT, RELIEF VALVE 1-07724-0800 WASHER; 7/8” O.D 1-12902-0000 SCREW, PRESSURE RELIEF 1-06660-0800 NUT, DOME 1-06667-0800...

  • Page 49: Clutch

    1.5 CLUTCH Clutch no. 1-00100-6000...
  • Page 50 PART NO. 1-00100-6000 ITEM DESCRIPTION PART NUMBER REF. CLUTCH ASSEMBLY 1-00100-6000 CAPSCREW, SOCKET HD 3/8-16X3 ¼” 1-12247-0000 LOCKWASHER 3/8 STD 1-08755-0800 FLANGE, CLUTCH (FORWARD) 1-00212-4100 BALL BEARING 1-00211-2500 GEAR BEVEL 1-00215-2600 CLUTCH DISC, DRIVING 1-00230-4400 CLUTCH DISC, DRIVEN 1-00233-1200 NUT, SELF-LOCKING ¼-28NF 1-00226-3600 SHAFT, BEVEL PINION 1-00220-3600...
  • Page 52 1.6 TRANSMISSION HOUSING AND RELATED PARTS ITEM DESCRIPTION PART NUMBER CAPSCREW, HEX HD; 5/16-18X1” 1-08372-0800 LOCKWASHER, LIGHT; 5/16 1-09458-0800 BREATHER 1-05243-0800 COVER, BREATHER/ INSPECTION 1-09188-0800 GASKET, INSPECTION COVER 1-01225-1500 GAUGE, PRESSURE 1-09669-0900 CAPSCREW, HEX HD.; 5/16-18X2 ¼ 1-12452-0000 COVER, INSPECTION 1-01228-1500 SPRING PIN;...

  • Page 53: Adapter Group

    8.7 ADAPTER GROUP ITEM DESCRIPTION PART NUMBER CAPSCREW, HEX HD. DRILLING END 1-06972-0800 DRIVE FLANGE ASSEMBLY (SEE “HY” INSTALLATION DRAWING) FLYWHEEL ADAPTER (SEE “HY” INSTALLATION DRAWING) HEX.NUT HEAVY SLOTTED 1-06973-0800 COTTER PIN 1-12769-5400 BUSHING, DRIVE FLANGE 1-00326-2600 OIL DAM ADAPTER (SEE “HY” INSTALLATION DRAWING) COVER, AIR VENT 1-01118-2700 LOCKWASHER, 5/16 DIA...

  • Page 54: Pinion Shaft And Related Parts

    8.8 PINION SHAFT AND RELATED PARTS 8.9 IDLER GEAR AND RELATED PARTS...
  • Page 55 PINION SHAFT AND RELATED PARTS ITEM DESCRIPTION PART NUMBER SPRING PIN 1-12096-1000 BUSHING ASSEMBLY, REAR COMMUTATOR 1-00248-4200 SNAP RING 1-07732-0800 BEARING, ROLLER 1-07727-0800 PINION AND SHAFT ASSEMBLY (SEE CHART P.54) BEARING ASSEMBLY (5 PIECES) 1-12958-0000 RETAINER, BEARING (INCLUDES RING) 1-12959-2600 LOCKWASHER, BEARING 1-13235-0000 LOCKNUT, BEARING...

  • Page 57: Output Gear, Cover And Related Parts

    8.10 OUTPUT GEAR, COVER AND RELATED PARTS ITEM DESCRIPTION PART NUMBER SET SCREW, SOCKET : ¼-20 X 3/8” 1-11993-0000 LOCKNUT, BEARING (MODIFIED) 1-07706-1200 CUP, BEARING 1-07706-1200 CONE, BEARING 1-07706-1000 GEAR, OUTPUT (SEE CHART P.54) SPRING PIN 1-12096-1000 KEY. DRIVEN GEAR 1-07714-0800 SHAFT, DRIVEN GEAR 1-07715-0800...

  • Page 58: Reduction Gear Selection Chart

    8.11 REDUCTION GEAR SELECTION CHART HOW TO SELECT THE CORRECT PINION AND OUTPUT GEAR FOR YOUR TRANSMISSION: LOCATE THE NAMEPLATE (ON TOP OF HOUSING) AND DETERMINE THE TWO REDUCTION REATIO OPTION CODE NUMBERS (CIRCLED IN SAMPLE BELOW) AND THE RATIO. THE NUMBER OF TEETH MAY BE CHECKED ALSO. MATCH THIS INFORMATION WITH THE CHART BELOW TO DETERMINE THE CORRECT PART NUMBER (S).

  • Page 59: Oil Filter

    8.12 OIL FILTER ITEM DESCRIPTION PART NUMBER REF. ASSEMBLY, OIL FILTER 1-13811-0000 HEAD 1-13811-0100 SEAL, HOUSING 1-13811-0500 1-13811-0300 ASSEMBLY, ELEMENT (INCLUDES ELEMENT SEAL) SPRING, ELEMENT 1-13811-0600 HOUSING 1-13811—0200 CAPSCREW, HEX HEAD 1-12339-0000 LOCKWASHER 1-09458-0800 PLUG, DRAIN 1-11251-0500...

  • Page 60: Propeller Coupling Kits

    8.13 PROPELLER COUPLING KITS ITEM DESCRIPTION PART NUMBER REF. PROPELLER COUPLING KIT 1-13577-1000 NUT, SELF-LOCKING ¾-10 NC 1-13095-0000 COUPLING, PROP SHAFT 1-13826-0000 CAPSCREW, HEX HEAD ¾-10 NCX3 ¼” 1-08793-0800...

  • Page 61: Oil Coolers

    1.14 OIL COOLERS ITEM DESCRIPITION PART NUMBER SEA WATER COOLER (17”X 5 1/8” DIA) 1-13769-0000 FRESH WATER COOLER ( 19 1/2” X 6 1/8” DIA) 1-13795-0000 SEA WATER COOLER (12 ¾”X 4 3/8” DIA) 1-07808-5000 ZINC PENCILS 1-12445-0400 NOTE: Hose and fitting kit no. 1-13888-0000 may be ordered with any of the above oil coolers.
  • Page 63 8.16 HY- 6900...
  • Page 64 TRANSMISSION HOUSING AND RELATED PARTS HY-6900 ITEM DESCRIPTION PART NUMBER CAPSCREW, HEX HD.; 5/16-18X 1” 1-08372-0800 LOCKWASHER, LIGHT; 5/16 1-09458-0800 BREATHER 1-05243-0800 COVER, BREATHER/ INSPECTION 1-09188-0800 GASKET, INSPECTION COVER 1-01225-1500 GAUGE, PRESSURE 1-09669-0900 CAPSCREW, HEX. HD ; 5/16- 18 X 21/4 1-12452-0000 COVER, INSPECTION 1-01228-1500...

  • Page 65: Pinion Shaft And Related Parts Hy-6900

    8.17 PINION SHAFT AND RELATED PARTS HY-6900...
  • Page 66 PINION SHAFT AND RELATED PARTS HY-6900 ITEM DESCRIPTION PART NUMBER SPRING PIN 1-12096-1000 BUSHING ASSEMBLY, REAR COMMUTATOR 1-00248-4200 SNAP RING 1-07732-0800 BEARING ROLLER 1-07727-0800 PINION AND SHAFT ASSEMBLY (SEE CHART P.54-2) BEARING ASSEMBLY ( 5 PIECES) 1-12958-0000 RETAINER, BEARING (INCLUDES RING) 1-12959-2600 LOCKWASHER, BEARING 1-13235-0000...
  • Page 67 HY-6900...
  • Page 68 OUTPUT GEAR, COVER AND RELATED PARTS HY-6900 ITEM DESCRIPTION PART NUMBER LOCKWASHER, BEARING 1-00335-1900 LOCKNUT, BEARING 1-00335-2100 CUP, BEARING 1-06725-0900 CONE, BEARING 1-06725-1000 GEAR, OUTPUT (SEE CHART P.54-2) SPRING PIN 1-12096-1200 KEY, DRIVEN GEAR 1-06734-0800 SHAFT, DRIVEN GEAR 1-12226-0000 KEY, OUTPUT FLANGE 1-22228-0000 OIL PAN 1-10121-0000...

  • Page 69: Reduction Gear Selection Chart Hy-6900

    8.19 REDUCTION GEAR SELECTION CHART HY-6900 HOW TO SELECT THE CORRECT PINION AND OUTPUT GEAR FOR YOUR TRANSMISSION: LOCATE THE NAMEPLATE (ON TOP OF HOUSING) AND DETERMINE THE TWO REDUCTION RATIO OPTION CODE NUMBERS ( CIRCLED IN SAMPLE BELOW) AND THE RATIO.

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Hy-7700

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