Date   

Re: [Amel Yacht Owners] Mainsail outhaul gearbox

eric freedman
 

Mike, the brass gear is probably worn in the gearbox. I know mine was. I think getting a new gearbos is not a bad idea, possibly Amel can order you a new top plate as a spare.

Fair Winds

Eric

Kimberlite Amel Super Maramu #376’

 

 

From: amelyachtowners@... [mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 6:31 PM
To: amelyachtowners@...
Subject: Re: [Amel Yacht Owners] Mainsail outhaul gearbox

 

 

Thanks Mike,

I think you will find it much cheaper and quite satisfactory to have a new top plate made by an engineering firm rather than buying a new gear box

Regards

Danny

 


From: "'Mike Ondra' mdondra@... [amelyachtowners]" <amelyachtowners@...>
To: amelyachtowners@...
Sent: Tuesday, 7 June 2016 9:00 AM
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox

 

 

Thanks Danny. As usual, there is more than 1 way to skin a cat. And it seems Amel owners find many ways.

Mike

ALETES SM#240

From: amelyachtowners@... [mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 3:40 PM
To: amelyachtowners@...
Subject: Re: [Amel Yacht Owners] Mainsail outhaul gearbox

Hi Mike, I had the same problem. Heat from a gas torch works well, you and I both should have started there. I was hauled out at the marina in Colon and as preventative maintenance decided to replace the bearings before the big pacific crossing. When the shaft wouldn't move I asked the yard for a man with a gas torch. I got a big man with a big gear puller and a big hammer.. Same result as you. Then they sent a man with a gas torch, came apart easily. I got a new top plate made at an engineering firm in Colon. When you are fixed and reassembling put lanacote on the shaft, works long term, much better than grease

Regards

Danny

SM 299 Ocean Pearl

_____

From: "'Mike Ondra' mdondra@... [amelyachtowners]" <amelyachtowners@...>
To: amelyachtowners@...
Sent: Monday, 6 June 2016 11:32 PM
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox

I know others have had difficulty extracting from the gearbox the shaft that drives the gypsy, an operation that often requires some significant force.. After neglecting to lubricate that shaft for a year or two (maybe more) I had the same problem. Tensioning a halyard to the top of the shaft and some aggressive upward pounding with a sledge hammer succeeded in breaking the top plate of the gearbox. While this facilitated partial disassembly of the gearbox in place, we are left with the core of the gearbox and the gear still in place and frozen to the shaft which remains through the boom.

Proposed next steps:

1) Remove the large gear from the core. It was not obvious to me how that gear is splined to the core. Can that gear be extracted downward with a gear puller?

2) After removing the gear, my thought is to expand the core by heat which hopefully will then allow the shaft to be extracted.

Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.

Suggestion to others, remove and grease the mainsail outhaul shaft at least once a year.

Mike Ondra

ALETES SM#240

Rock Hall, MD

[Non-text portions of this message have been removed]

 


Re: [Amel Yacht Owners] Mainsail outhaul gearbox

eric freedman
 

I have been using the marine grade anti seize twice a year . (Link Below)

The shaft slips out easily.

I also took about a two thousands of an inch off of the width of the key.

http://www.mcmaster.com/#antiseize-lubricants/=12qpw4z

Fair Winds

Eric

Kimberlite Amel Super Maramu #376

 

From: amelyachtowners@... [mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 3:40 PM
To: amelyachtowners@...
Subject: Re: [Amel Yacht Owners] Mainsail outhaul gearbox

 

 

Hi Mike, I had the same problem. Heat from a gas torch works well, you and I both should have started there. I was hauled out at the marina in Colon and as preventative maintenance decided to replace the bearings before the big pacific crossing. When the shaft wouldn't move I asked the yard for a man with a gas torch. I got a big man with a big gear puller and a big hammer. Same result as you. Then they sent a man with a gas torch, came apart easily.  I got a new top plate made at an engineering firm in Colon. When you are fixed and reassembling put lanacote on the shaft, works long term, much better than grease

Regards

Danny

SM 299 Ocean Pearl

 


From: "'Mike Ondra' mdondra@... [amelyachtowners]" <amelyachtowners@...>
To: amelyachtowners@...
Sent: Monday, 6 June 2016 11:32 PM
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox

 

 

I know others have had difficulty extracting from the gearbox the shaft that drives the gypsy, an operation that often requires some significant force. After neglecting to lubricate that shaft for a year or two (maybe more) I had the same problem. Tensioning a halyard to the top of the shaft and some aggressive upward pounding with a sledge hammer succeeded in breaking the top plate of the gearbox. While this facilitated partial disassembly of the gearbox in place, we are left with the core of the gearbox and the gear still in place and frozen to the shaft which remains through the boom.

 

Proposed next steps:

 

1)      Remove the large gear from the core. It was not obvious to me how that gear is splined to the core. Can that gear be extracted downward with a gear puller?

2)      After removing the gear, my thought is to expand the core by heat which hopefully will then allow the shaft to be extracted.

 

Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.

 

Suggestion to others, remove and grease the mainsail outhaul shaft at least once a year.

 

Mike Ondra

ALETES SM#240

Rock Hall, MD

 


Re: [Amel Yacht Owners] Mainsail outhaul gearbox

Danny and Yvonne SIMMS
 

Thanks Mike,
I think you will find it much cheaper and quite satisfactory to have a new top plate made by an engineering firm rather than buying a new gear box
Regards
Danny



From: "'Mike Ondra' mdondra@... [amelyachtowners]"
To: amelyachtowners@...
Sent: Tuesday, 7 June 2016 9:00 AM
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox

 
Thanks Danny. As usual, there is more than 1 way to skin a cat. And it seems Amel owners find many ways.

Mike

ALETES SM#240

From: amelyachtowners@... [mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 3:40 PM
To: amelyachtowners@...
Subject: Re: [Amel Yacht Owners] Mainsail outhaul gearbox

Hi Mike, I had the same problem. Heat from a gas torch works well, you and I both should have started there. I was hauled out at the marina in Colon and as preventative maintenance decided to replace the bearings before the big pacific crossing. When the shaft wouldn't move I asked the yard for a man with a gas torch. I got a big man with a big gear puller and a big hammer.. Same result as you. Then they sent a man with a gas torch, came apart easily. I got a new top plate made at an engineering firm in Colon. When you are fixed and reassembling put lanacote on the shaft, works long term, much better than grease

Regards

Danny

SM 299 Ocean Pearl

_____

From: "'Mike Ondra' mdondra@... [amelyachtowners]"
To: amelyachtowners@...
Sent: Monday, 6 June 2016 11:32 PM
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox

I know others have had difficulty extracting from the gearbox the shaft that drives the gypsy, an operation that often requires some significant force.. After neglecting to lubricate that shaft for a year or two (maybe more) I had the same problem. Tensioning a halyard to the top of the shaft and some aggressive upward pounding with a sledge hammer succeeded in breaking the top plate of the gearbox. While this facilitated partial disassembly of the gearbox in place, we are left with the core of the gearbox and the gear still in place and frozen to the shaft which remains through the boom.

Proposed next steps:

1) Remove the large gear from the core. It was not obvious to me how that gear is splined to the core. Can that gear be extracted downward with a gear puller?

2) After removing the gear, my thought is to expand the core by heat which hopefully will then allow the shaft to be extracted.

Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.

Suggestion to others, remove and grease the mainsail outhaul shaft at least once a year.

Mike Ondra

ALETES SM#240

Rock Hall, MD






Re: [Amel Yacht Owners] Mainsail outhaul gearbox

Mike Ondra
 

Thanks Danny. As usual, there is more than 1 way to skin a cat. And it seems Amel owners find many ways.

Mike

ALETES SM#240



From: amelyachtowners@yahoogroups.com [mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 3:40 PM
To: amelyachtowners@yahoogroups.com
Subject: Re: [Amel Yacht Owners] Mainsail outhaul gearbox





Hi Mike, I had the same problem. Heat from a gas torch works well, you and I both should have started there. I was hauled out at the marina in Colon and as preventative maintenance decided to replace the bearings before the big pacific crossing. When the shaft wouldn't move I asked the yard for a man with a gas torch. I got a big man with a big gear puller and a big hammer. Same result as you. Then they sent a man with a gas torch, came apart easily. I got a new top plate made at an engineering firm in Colon. When you are fixed and reassembling put lanacote on the shaft, works long term, much better than grease

Regards

Danny

SM 299 Ocean Pearl



_____

From: "'Mike Ondra' mdondra@verizon.net [amelyachtowners]" <amelyachtowners@yahoogroups.com>
To: amelyachtowners@yahoogroups.com
Sent: Monday, 6 June 2016 11:32 PM
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox





I know others have had difficulty extracting from the gearbox the shaft that drives the gypsy, an operation that often requires some significant force. After neglecting to lubricate that shaft for a year or two (maybe more) I had the same problem. Tensioning a halyard to the top of the shaft and some aggressive upward pounding with a sledge hammer succeeded in breaking the top plate of the gearbox. While this facilitated partial disassembly of the gearbox in place, we are left with the core of the gearbox and the gear still in place and frozen to the shaft which remains through the boom.



Proposed next steps:



1) Remove the large gear from the core. It was not obvious to me how that gear is splined to the core. Can that gear be extracted downward with a gear puller?

2) After removing the gear, my thought is to expand the core by heat which hopefully will then allow the shaft to be extracted.



Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.



Suggestion to others, remove and grease the mainsail outhaul shaft at least once a year.



Mike Ondra

ALETES SM#240

Rock Hall, MD







[Non-text portions of this message have been removed]


Re: [Amel Yacht Owners] Mainsail outhaul gearbox

Danny and Yvonne SIMMS
 

Hi Mike, I had the same problem. Heat from a gas torch works well, you and I both should have started there. I was hauled out at the marina in Colon and as preventative maintenance decided to replace the bearings before the big pacific crossing. When the shaft wouldn't move I asked the yard for a man with a gas torch. I got a big man with a big gear puller and a big hammer. Same result as you. Then they sent a man with a gas torch, came apart easily.  I got a new top plate made at an engineering firm in Colon. When you are fixed and reassembling put lanacote on the shaft, works long term, much better than grease
Regards
Danny
SM 299 Ocean Pearl



From: "'Mike Ondra' mdondra@... [amelyachtowners]"
To: amelyachtowners@...
Sent: Monday, 6 June 2016 11:32 PM
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox

 
I know others have had difficulty extracting from the gearbox the shaft that drives the gypsy, an operation that often requires some significant force. After neglecting to lubricate that shaft for a year or two (maybe more) I had the same problem. Tensioning a halyard to the top of the shaft and some aggressive upward pounding with a sledge hammer succeeded in breaking the top plate of the gearbox. While this facilitated partial disassembly of the gearbox in place, we are left with the core of the gearbox and the gear still in place and frozen to the shaft which remains through the boom.
 
Proposed next steps:
 
1)      Remove the large gear from the core. It was not obvious to me how that gear is splined to the core. Can that gear be extracted downward with a gear puller?
2)      After removing the gear, my thought is to expand the core by heat which hopefully will then allow the shaft to be extracted.
 
Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.
 
Suggestion to others, remove and grease the mainsail outhaul shaft at least once a year.
 
Mike Ondra
ALETES SM#240
Rock Hall, MD



Re: [Amel Yacht Owners] Mainsail outhaul gearbox

Mike Ondra
 

I agree on the value of a grease fitting and relief hole for the gearbox.
This gearbox is a bear to remove and open up to re-grease. I do want to
remind others, however, that this grease does not get to the rusty shaft
problem at all and periodic lubrication of the shaft is still required.

Mike Ondra

ALETES SM#240

Rock Hall, MD



From: amelyachtowners@yahoogroups.com
[mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 1:22 PM
To: amelyachtowners@yahoogroups.com
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox





Mike,

it is the same drawing. I believe it is one I might have sent to Bill to
post.

Looks like you will need a new gearbox (ouch) from Amel.



I was fortunate to get the last two disassemble gearboxes in the USA from
Emmerson Electric.



Before you mount the new gearbox, I would suggest you drill and tap a 5 mm
hole on the port and starboard side of the gearbox. The autoprop grease
adapter will fit in these holes. Drill one high and the other low. I fill
through the lower drill hole and wait till clean grease comes out of the
upper drill hole. I then install a short nylon bolt. They come in bags of
50.

I have done this on both gearboxes, and the genoa furler.

Fair Winds

Eric

Kimberlite Amel Super Maramu #376





From: amelyachtowners@yahoogroups.com
[mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 1:14 PM
To: amelyachtowners@yahoogroups.com
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox





Eric,

Thank you for the offer. Email is mdondra at Verizon dot net.

Also Walter already uploaded to Yahoo the Leroy Sumer technical data and
drawings. Perhaps yours are different?

Mike

ALETES SM#240

Rock Hall, MD

From: amelyachtowners@yahoogroups.com
[mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 12:57 PM
To: amelyachtowners@yahoogroups.com
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox

Mike,

Please send me your email and I will send you a drawing of the gearbox.

I removed the shaft by removing the boom, turning it upside down on the deck
supported by wood dunnage,

And then installing a long socket head cap screw-grade 10 and then driving
it out with a large sledge hammer. I use an anti-seize compound on it twice
a year now.

Fair Winds

Eric

Kimberlite Amel Super Maramu #376

From: amelyachtowners@yahoogroups.com
[mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 7:33 AM
To: amelyachtowners@yahoogroups.com
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox

I know others have had difficulty extracting from the gearbox the shaft that
drives the gypsy, an operation that often requires some significant force.
After neglecting to lubricate that shaft for a year or two (maybe more) I
had the same problem. Tensioning a halyard to the top of the shaft and some
aggressive upward pounding with a sledge hammer succeeded in breaking the
top plate of the gearbox. While this facilitated partial disassembly of the
gearbox in place, we are left with the core of the gearbox and the gear
still in place and frozen to the shaft which remains through the boom.

Proposed next steps:

1) Remove the large gear from the core. It was not obvious to me how
that gear is splined to the core. Can that gear be extracted downward with a
gear puller?

2) After removing the gear, my thought is to expand the core by heat
which hopefully will then allow the shaft to be extracted.

Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.

Suggestion to others, remove and grease the mainsail outhaul shaft at least
once a year.

Mike Ondra

ALETES SM#240

Rock Hall, MD


Re: [Amel Yacht Owners] C Drive Photos

eric freedman
 

Hi Craig,

Wow you did some job on that sail drive. Although it is different than the Super Maramu it is similar in many ways. Do you have more photos of the engine room side?

Fair Winds

Eric

Kimberlite Amel Super Maramu #376

 

From: amelyachtowners@... [mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 7:03 AM
To: amelyachtowners@...
Subject: RE: [Amel Yacht Owners] C Drive Photos

 

 

Hi Eric, 

Have sent the pics to your private email. 

 

Btw, as I did this project I noticed there's a drain hole in the bottom of the lower C drive, similar to the hole in the bottom of the rudder, as that section below the propeller is simply a hollow fairing. One more interesting Amel design detail.  So if you get water weeping from the C drive after you haul, this is why. Worth cleaning up any fouling in the gap between the keel shoe plate and the bottom of the C drive.

Cheers,

Craig


Re: [Amel Yacht Owners] Mainsail outhaul gearbox

eric freedman
 

Mike,

it is the same drawing. I believe it is one I might have sent to Bill to post.

Looks like you will need a new gearbox (ouch) from Amel.

 

I was fortunate to get the last two disassemble gearboxes in the USA from Emmerson Electric.

 

Before you mount the new gearbox, I would suggest you drill and tap a  5 mm hole on the port and starboard side of the gearbox. The autoprop grease adapter will fit in these holes. Drill one high and the other low. I fill through the lower drill hole and wait till clean grease comes out of the upper drill hole. I then install a short nylon bolt. They come in bags of 50.

I have done this on both gearboxes, and the genoa furler.

Fair Winds

Eric

Kimberlite Amel Super Maramu #376

 

 

From: amelyachtowners@... [mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 1:14 PM
To: amelyachtowners@...
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox

 

 

Eric,

Thank you for the offer. Email is mdondra at Verizon dot net.

Also Walter already uploaded to Yahoo the Leroy Sumer technical data and
drawings. Perhaps yours are different?

Mike

ALETES SM#240

Rock Hall, MD

From: amelyachtowners@...
[mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 12:57 PM
To: amelyachtowners@...
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox

Mike,

Please send me your email and I will send you a drawing of the gearbox.

I removed the shaft by removing the boom, turning it upside down on the deck
supported by wood dunnage,

And then installing a long socket head cap screw-grade 10 and then driving
it out with a large sledge hammer. I use an anti-seize compound on it twice
a year now.

Fair Winds

Eric

Kimberlite Amel Super Maramu #376

From: amelyachtowners@...
[mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 7:33 AM
To: amelyachtowners@...
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox

I know others have had difficulty extracting from the gearbox the shaft that
drives the gypsy, an operation that often requires some significant force.
After neglecting to lubricate that shaft for a year or two (maybe more) I
had the same problem. Tensioning a halyard to the top of the shaft and some
aggressive upward pounding with a sledge hammer succeeded in breaking the
top plate of the gearbox. While this facilitated partial disassembly of the
gearbox in place, we are left with the core of the gearbox and the gear
still in place and frozen to the shaft which remains through the boom.

Proposed next steps:

1) Remove the large gear from the core. It was not obvious to me how
that gear is splined to the core. Can that gear be extracted downward with a
gear puller?

2) After removing the gear, my thought is to expand the core by heat
which hopefully will then allow the shaft to be extracted.

Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.

Suggestion to others, remove and grease the mainsail outhaul shaft at least
once a year.

Mike Ondra

ALETES SM#240

Rock Hall, MD


Re: [Amel Yacht Owners] Mainsail outhaul gearbox

Mike Ondra
 

Eric,

Thank you for the offer. Email is mdondra at Verizon dot net.

Also Walter already uploaded to Yahoo the Leroy Sumer technical data and
drawings. Perhaps yours are different?

Mike

ALETES SM#240

Rock Hall, MD



From: amelyachtowners@yahoogroups.com
[mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 12:57 PM
To: amelyachtowners@yahoogroups.com
Subject: RE: [Amel Yacht Owners] Mainsail outhaul gearbox





Mike,

Please send me your email and I will send you a drawing of the gearbox.

I removed the shaft by removing the boom, turning it upside down on the deck
supported by wood dunnage,

And then installing a long socket head cap screw-grade 10 and then driving
it out with a large sledge hammer. I use an anti-seize compound on it twice
a year now.

Fair Winds

Eric

Kimberlite Amel Super Maramu #376





From: amelyachtowners@yahoogroups.com
[mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 7:33 AM
To: amelyachtowners@yahoogroups.com
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox





I know others have had difficulty extracting from the gearbox the shaft that
drives the gypsy, an operation that often requires some significant force.
After neglecting to lubricate that shaft for a year or two (maybe more) I
had the same problem. Tensioning a halyard to the top of the shaft and some
aggressive upward pounding with a sledge hammer succeeded in breaking the
top plate of the gearbox. While this facilitated partial disassembly of the
gearbox in place, we are left with the core of the gearbox and the gear
still in place and frozen to the shaft which remains through the boom.



Proposed next steps:



1) Remove the large gear from the core. It was not obvious to me how
that gear is splined to the core. Can that gear be extracted downward with a
gear puller?

2) After removing the gear, my thought is to expand the core by heat
which hopefully will then allow the shaft to be extracted.



Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.



Suggestion to others, remove and grease the mainsail outhaul shaft at least
once a year.



Mike Ondra

ALETES SM#240

Rock Hall, MD


Re: [Amel Yacht Owners] Mainsail outhaul gearbox

eric freedman
 

Mike,

Please send me your email and I will send you a drawing of the gearbox.

I removed the shaft by removing the boom, turning it upside down on the deck supported by wood dunnage,

And then installing a long socket head cap screw-grade 10 and then driving it out with a large sledge hammer. I use an anti-seize compound on it twice a year now.

Fair Winds

Eric

Kimberlite Amel Super Maramu #376

 

 

From: amelyachtowners@... [mailto:amelyachtowners@...]
Sent: Monday, June 06, 2016 7:33 AM
To: amelyachtowners@...
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox

 

 

I know others have had difficulty extracting from the gearbox the shaft that drives the gypsy, an operation that often requires some significant force. After neglecting to lubricate that shaft for a year or two (maybe more) I had the same problem. Tensioning a halyard to the top of the shaft and some aggressive upward pounding with a sledge hammer succeeded in breaking the top plate of the gearbox. While this facilitated partial disassembly of the gearbox in place, we are left with the core of the gearbox and the gear still in place and frozen to the shaft which remains through the boom.

 

Proposed next steps:

 

1)      Remove the large gear from the core. It was not obvious to me how that gear is splined to the core. Can that gear be extracted downward with a gear puller?

2)      After removing the gear, my thought is to expand the core by heat which hopefully will then allow the shaft to be extracted.

 

Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.

 

Suggestion to others, remove and grease the mainsail outhaul shaft at least once a year.

 

Mike Ondra

ALETES SM#240

Rock Hall, MD


Re: [Amel Yacht Owners] Mainsail outhaul gearbox

ianjenkins1946 <ianjudyjenkins@hotmail.com>
 

Hi Mike,      If you think you will need a new gearbox and shaft, the simplest solution is the one adopted by Amel in Guadeloupe for us when we were in the same position---take a saw and cut through the shaft where it exits the gearbox. If you take a fret saw , detach the blade, thread it through the gap and reattach it to use it.


Ian and Judy, Pen Azen, SM 302, Greece


From: amelyachtowners@... on behalf of 'Mike Ondra' mdondra@... [amelyachtowners]
Sent: 06 June 2016 11:32:55
To: amelyachtowners@...
Subject: [Amel Yacht Owners] Mainsail outhaul gearbox
 

I know others have had difficulty extracting from the gearbox the shaft that drives the gypsy, an operation that often requires some significant force. After neglecting to lubricate that shaft for a year or two (maybe more) I had the same problem. Tensioning a halyard to the top of the shaft and some aggressive upward pounding with a sledge hammer succeeded in breaking the top plate of the gearbox. While this facilitated partial disassembly of the gearbox in place, we are left with the core of the gearbox and the gear still in place and frozen to the shaft which remains through the boom.

 

Proposed next steps:

 

1)      Remove the large gear from the core. It was not obvious to me how that gear is splined to the core. Can that gear be extracted downward with a gear puller?

2)      After removing the gear, my thought is to expand the core by heat which hopefully will then allow the shaft to be extracted.

 

Thoughts and suggestions? This is the Leroy Somer MVA M33C gearbox.

 

Suggestion to others, remove and grease the mainsail outhaul shaft at least once a year.

 

Mike Ondra

ALETES SM#240

Rock Hall, MD


New file uploaded to amelyachtowners

amelyachtowners@...
 

Hello,


This email message is a notification to let you know that
a file has been uploaded to the Files area of the amelyachtowners
group.


File : /Leroy Somer MVA Gearbox/Leroy Somer Minibloc MVA.PDF
Uploaded by : super_maramu_436 <amel-sm2k@gmx.de>
Description :


You can access this file at the URL:
https://groups.yahoo.com/neo/groups/amelyachtowners/files/Leroy%20Somer%20MVA%20Gearbox/Leroy%20Somer%20Minibloc%20MVA.PDF


To learn more about file sharing for your group, please visit:
https://help.yahoo.com/kb/index?page=content&y=PROD_GRPS&locale=en_US&id=SLN15398


Regards,


super_maramu_436 <amel-sm2k@gmx.de>


Re: Mainsail outhaul gearbox

Walter
 

Hi Mike,
I got it out by disassembling the boom, taking it from the boat and solid punching,
but
you need to put the support in the right place, otherwise you might brake something you don´t want to brake.
If you turn the boom upside down, the support of the boom should be at the hollow output shaft, the one to which the stainless shaft is connected (with a little key). Slide two solid metal bars side by side under the hollow shaft and support them, so there is no load on the boom or the gear box housing when punching.

I´ll put the exploded view of the gearbox in the files section under Leroy Somer Gearbox.

If you work with an shaft extractor it´s the same thing: you need to put the support/metal bar of the extractor to the hollow shaft.

Good luck!

Walter (Noa, SM2K 436)

 


Re: [Amel Yacht Owners] Re: Mainsail outhaul gearbox

Alexandre Uster von Baar
 

Hello Mike,

Here is how I removed the shaft on my vessel.
http://nikimat.com/outhaul_motor_rebuild.html

Thanks for the advice on lobbying the shaft Gary!
If you are still in Puerto Rico, would love to meet you!
I am at the San Juan Nautico Club, but I could rent a car and meet you at Fajardo!

Sincerely, Alexandre
SM2K #289 NIKIMAT
Club Nautico de San Juan, Puerto Rico




--------------------------------------------

On Mon, 6/6/16, amelliahona <no_reply@yahoogroups.com> wrote:

Subject: [Amel Yacht Owners] Re: Mainsail outhaul gearbox
To: amelyachtowners@yahoogroups.com
Date: Monday, June 6, 2016, 6:58 AM


 









Mike:
I feel
for you but I hope you don't make a bad situation worse.
 I pounded on my shaft with a bolt screwed in the bottom
until I thought I would damage the boom and then sought
help.  What is needed was a too that rather easily
"pushed" the shaft upwards.  It was a unique type
of "pusher" as opposed to a "puller".
 I seem to recall a photo of the device somewhere on the
forum.  Basically it is a bar of steel that inserts
transversely thru the opening in the gearbox mounting
bracket that is below the boom.  Shims are placed under it
to bear on the upper surface of the gearbox shaft (the
hollow shaft into which the solid shaft seats and drives
with a woodruff key) and then this is tied with bolts to a
bar parallel to the upper one that is below the gearbox
shaft.  A threaded bold is screwed thru threads in the
lower bar such that as the bolt is screwed in, it pushes up
on the shaft (with a protective piece of metal in place so
as not to damage the shaft end).  Counter pressure is
supplied by the upper bar of steel [basically a puller in
reverse].  A picture would be worth a thousand words here.
 
Please remember
that aluminum remembers every stress and will fatigue fail
if stressed to much from pounding etc.  That is the reason
it is so important to have the pressure on the shaft bear on
the gearbox receptacle shaft (steel) rather than on the
aluminum cover of the gearbox or worse yet on the boom and
its bracket.
WARNING
TO ALL AMEL OWNERS WITH THIESE GEARBOXES, REMOVE AND LUBE
THIS SHAFT YEARLY or suffer the consequences.
Find someone with the right
"pusher".  In my case after I spent hours
pounding, penetrating oiling etc. the mechanic I consulted
had the pusher in his shop and extracted the pin in 10
minutes. 
I wish you
the best, 
Gary S.
Silver Amel SM #335Fajardo, Puerto
Rico   Puerto Del Ray Marina









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Re: [Amel Yacht Owners] Re: Mainsail outhaul gearbox

Mike Ondra
 

Gary,

Thanks,

Do you recall how the gear was removed?

Mike



From: amelyachtowners@yahoogroups.com [mailto:amelyachtowners@yahoogroups.com] On Behalf Of amelliahona
Sent: Monday, June 06, 2016 8:09 AM
To: amelyachtowners@yahoogroups.com
Subject: [Amel Yacht Owners] Re: Mainsail outhaul gearbox





Mike:

Here is a link to the "Pusher" tool



https://groups.yahoo.com/neo/groups/amelyachtowners/search/photos?query=outhaul#zax/albums_428821681



Hope this helps. I have some photos of the disassembled outhaul gearbox in a folder in the photos section.



Gary Silver

s/v Liahona

SM #335











[Non-text portions of this message have been removed]


Re: [Amel Yacht Owners] Re: Mainsail outhaul gearbox

Mike Ondra
 

Thanks Gary and Bill. Amazingly fast response.



To answer Bill’s question, the gearbox is basically the box with top and bottom plates with lipseals that seal to the gearbox “core” (for lack of a more precise term). The drive shaft that passes up through the boom tends to bind on that “core” with rust. In pounding on the shaft the upper plate broke at all four corner screws. Its shot. Looking at a new gearbox.

With the top plate broken, the rest of the gearbox housing could easily be taken apart. I am left with the shaft through the boom, the top plate, the “core” (rusted to the shaft) and the brass gear on the “core”. I need to separate the shaft from the “core” to get is out of the boom and reuse the shaft with a new gearbox.



Gary’s “pusher” approach will likely be my next effort.

Note that the sledge hammer approach is NOT the way to do this. Annual removal and greasing cannot be over stated.



Mike Ondra

ALETES SM#240

Rock Hall, MD



From: amelyachtowners@yahoogroups.com [mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 8:01 AM
To: amelyachtowners@yahoogroups.com
Subject: [Amel Yacht Owners] Re: Mainsail outhaul gearbox









Hey Mike -



Sorry to hear about your troubles... I too have been a victim of this process and due to "lack of maintenance" (no offense of course). Just to be clear and so I can paint a better picture in my head. There are two "plates" or covers that also house a seal on the top and bottom of the transmission... Was it this piece which broke?



Does the transmission spin when the out haul motor is engaged? If not does it spin at all or is it completely seized in its place?



From what I remember, there are two gears. A worm gear coming from the motor shaft, and a main gear attached to that stainless steel shaft that your Andersen shaft runs through. That stainless steel shaft also has 2 large race bearings and a few locking snap clamps.



Please provide a few more details and I will do my best to help you out. I know if I cannot you will have no problem getting responses/advice from some of the more experienced members on this site.



Cheers,



Bill Maffei

SM #195

It's all Good


Re: [Amel Yacht Owners] C Drive Photos

karkauai
 

Hi Craig, et al.
I think it's in the thread about my CDrive problems somewhere that this hole in the bottom of the "foot" was the result of the manufacturing process.  Olivier said to fill and seal it.
I don't know what it communicates with.

Kent
SM243
Kristy
Currently Bonaire 


On Jun 6, 2016, at 7:03 AM, sangaris@... [amelyachtowners] <amelyachtowners@...> wrote:

 

Hi Eric, 

Have sent the pics to your private email. 

Btw, as I did this project I noticed there's a drain hole in the bottom of the lower C drive, similar to the hole in the bottom of the rudder, as that section below the propeller is simply a hollow fairing. One more interesting Amel design detail.  So if you get water weeping from the C drive after you haul, this is why. Worth cleaning up any fouling in the gap between the keel shoe plate and the bottom of the C drive.
Cheers,
Craig


Re: Mainsail outhaul gearbox

amelliahona <no_reply@...>
 

Mike:
Here is a link to the "Pusher" tool 


Hope this helps.  I have some photos of the disassembled outhaul gearbox in a folder in the photos section.

Gary Silver
s/v Liahona
SM #335 

 




Re: Mainsail outhaul gearbox

william_maffei@...
 



Hey Mike -

Sorry to hear about your troubles... I too have been a victim of this process and due to "lack of maintenance" (no offense of course). Just to be clear and so I can paint a better picture in my head. There are two "plates" or covers that also house a seal on the top and bottom of the transmission... Was it this piece which broke? 

Does the transmission spin when the out haul motor is engaged? If not does it spin at all or is it completely seized in its place? 

From what I remember, there are two gears. A worm gear coming from the motor shaft, and a main gear attached to that stainless steel shaft that your Andersen shaft runs through. That stainless steel shaft also has 2 large race bearings and a few locking snap clamps. 

Please provide a few more details and I will do my best to help you out. I know if I cannot you will have no problem getting responses/advice from some of the more experienced members on this site. 

Cheers,

Bill Maffei 
SM #195
It's all Good


Re: Mainsail outhaul gearbox

amelliahona <no_reply@...>
 

Mike:

I feel for you but I hope you don't make a bad situation worse.  I pounded on my shaft with a bolt screwed in the bottom until I thought I would damage the boom and then sought help.  What is needed was a too that rather easily "pushed" the shaft upwards.  It was a unique type of "pusher" as opposed to a "puller".  I seem to recall a photo of the device somewhere on the forum.  Basically it is a bar of steel that inserts transversely thru the opening in the gearbox mounting bracket that is below the boom.  Shims are placed under it to bear on the upper surface of the gearbox shaft (the hollow shaft into which the solid shaft seats and drives with a woodruff key) and then this is tied with bolts to a bar parallel to the upper one that is below the gearbox shaft.  A threaded bold is screwed thru threads in the lower bar such that as the bolt is screwed in, it pushes up on the shaft (with a protective piece of metal in place so as not to damage the shaft end).  Counter pressure is supplied by the upper bar of steel [basically a puller in reverse].  A picture would be worth a thousand words here.  

Please remember that aluminum remembers every stress and will fatigue fail if stressed to much from pounding etc.  That is the reason it is so important to have the pressure on the shaft bear on the gearbox receptacle shaft (steel) rather than on the aluminum cover of the gearbox or worse yet on the boom and its bracket.

WARNING TO ALL AMEL OWNERS WITH THIESE GEARBOXES, REMOVE AND LUBE THIS SHAFT YEARLY or suffer the consequences.

Find someone with the right "pusher".  In my case after I spent hours pounding, penetrating oiling etc. the mechanic I consulted had the pusher in his shop and extracted the pin in 10 minutes. 

I wish you the best, 

Gary S. Silver 
Amel SM #335
Fajardo, Puerto Rico   Puerto Del Ray Marina