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TWIN DISC

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2. 34 92 1 37 CARTRIDGE VALVE CONNECTIONS ARE NOT POLARITY SENSITIVE CONNECTOR MATES WITH METRIPACK MAIN PRESSURE CHECK
3. 230 1 VALVE 5 Gane OPEN gu does ie PUG PROPORTIONAL VALVE E ASSEMBLY BUM ASSEMBLY SENSOR PLUG PLUG si MANIFOLD VALVE 1020152 DAR No IDENTIFIER SEE NOTE CN RQUE TO 33 N m ORI NU ee 5 abe BA n RAE m ae m Rm EU 1020729A
4. HEAT E REQUIREME EXCHANGER H NTS REFER TO B3649 FOR HEAT EXCHANGER REQUIREMENTS MOUNTING 6 RECOMMENDED ACCEPTED 21 0 DRILL THRU ON PADS 4PLACES NOT RECOMMENDED 5 4 WATER JN WATER OUT 5 2m UN 12 55 0 WAN 1 11788 M im 9 Ff 5 Ul t 5 1 11788 e d EMM us RU al M PEN UR zig 2 2 gt WO BL d 22579 z Sa Ed z25 DEI o 1o x o LOL O CL Sg e E 9 add Heo VS NOT SUPPLIED BY TWIN DISC ERROR 2 e F 12 2057 300 0 266 0 n Su METRIC EI SCALE nom SIMILAR TO 0 1 0 20 3 0 WEIGHT wR TE PACER EtaRY FORMATION WA S 7009 DUISG NOT TO BE USED IN ANY MANNER res UBS IN SCALE INCORPORATED FOR OTHERS INSTALLATION DIMENSIONS DETRIMENTAL TO THE INTERESTS OF bo 1 4 Mp HEN 26 TWIN DISC INCORPORATED DRN SEE DRAWING 11840 SHEET 2 VPIS INCORPORA assy
5. 4 OPTIONAL AUXILIARY LUBE SYSTEM USER TO SUPPLY COMPONENTS AND INSTALL LUBE HOSES TO MEET REQUIREMENTS OF 5697 TWIN DISC OR CUSTOMER SUPPLIED PRIMARY amp SECONDARY E HEAT EXCHANGER AND CONNECTION SHAFT LUBE nodi _ REFER TD INSTALLATION DRAWING SE E TF PLUG TWIN DISC OR CUSTOMER 1 SUPPLIED HEAT EXCHANGER MARINE TRANSMISSION E E AND CONNECTION LINES i INSTALLATION DRAWING fo d g 10 REFER TO INSTALLATION AD STA OPE LINE gs INSTALLATION OF OPTIONAL 20 ok DRAWING CHECK TRANSMISSION HYDRAULIC TEMPERATURE INDICATING ea 9 B xu X Valve CIRCUIT SWITCH USING PIPE TEE WITH 4 FILTER 4 REDUCER BUSHING HOSE PIPE TEE No i L t i i i ke t J ELECTRIC MOTOR PUMP pump DRIVEN PUMP 5 10 gpm HOSE INSTALLATION OF OPTIONAL TEMPERATURE SCR SCR INDICATING SWITCH USING PIPE TEE WITH REDUCER BUSHINGS DRAIN PLUG REFER TO INSTALLATIO DRAWING HYDRAULIC DIAGRAM THIRD ANGLE GRAPHICAL J I C SYMBOLS EL PROJECTION SIMILAR TO MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm 11DECO3 110 D Ise kg Nm MACHINED DIMES SCALE INCORPORATED NOTICE THIS PRINT CONTAINS HEAT TREAT FIRST USE on 052 RACINE 53403 USA BE USED IN ANY WANNER i TOLER e PRAWN DETRI
6. P T O ASSEMBLY TO MARINE TRANSMISSION FACTORY AND FIELD INSTALLATION 9 1 FOR FACTORY INSTALLATION THE PARTS 4 A2916BE RING O 1 PM1996F SCREWS 4 7 STAND P T O ON ITS E OUTPUT END LOOKING DOWN INTO CLUTCH PACK 202347 COVER 1 MA1038A 2 ON MANIFOLD MUST BE OMITTED ALIGN TEETH OF DRIVING PLATES BY EYE AND CAREFULLY SLIDE P 11601 DRIVING PX11610 RING INTO P T O HOUSING SO THAT ENGAGES THE TEETH OF ALL DRIVING b dede FOR FIELD INSTALLATION THE ABOVE PARTS 4 MUST BE REMOVED PLATES ANDRO OMS AGRIS MES INSIDE OSA TE dS Rs SEE 8 APPLY AIR PRESSURE 89 6 KPA 13PSI MIN TO CLUTCH HOUSING PX 11611 AND MAINTAIN M1990E OUTLET JOC FILTER NOTE 2 CLEAN MATING SURFACE INPUT END OF 11611 0 HOUSING PRESSURE THIS LOCKS PLATES IN PROPER ALIGNMENT FOR ASSEMBLY SLIDE DRIVING INLET FROM HE 2 P pi __ 3 INSTALL 2 4049 DOWEL PINS INTO MANIFOLD AT MATING FACE NEAR REAR END RING OUT OF P LO HOUSING v OF PRIMARY SHAFT FW D SHAFT CHAMFERED END OF PINS SHOULD BOTTOM INLET FROM EXTERNAL H E IN HOUSING HOLES 9 ASSEMBLE M1904AQ PISTON RING INTO GROOVE OF DRIVING IF NOT ALREADY DONE NOT SUPPLIED 11 s 4 INSTALL B3642 P T O HOUSING GASKET OVER 2 PM 4049A DOWEL PINS AND ENSURE 10 ASSEMBLE DRIVING RING TO REAR END OF PRIMARY SHAR CW D SHAFT BY SLIDI
7. PRESSURE REGULATOR B Th a 27A x FERT ii s 5 af v i ES 50 NE i 1 1 UR Twin DISC 28 CUSTOMER SUPPLIED HEAT EXCHANGER LX AMD LUNMEZ Z NES ie 1557481 ATION ad EI 8 DRAWTNC 1 zt E Ed Ie E EN f gt 1 4 x terry i z as gt A INSTA LATION OF OPTIONSL TEMPERATURE x INDICATING 542124 USING PIFE EE i WITH REDUCER BUSHINGS MAIDAUB IRAIN PLUG x BD THREAD 3 REFER TO INSTALLATION A Se IRAWING Figure 12 Hydraulic Schematic JIC Symbols Marine Transmission Service Manual 1022127 45 Operation Twin Disc Incorporated Manual Direction Control Valve Operation The manual direction control valve is locked in the NEUTRAL center position during normal operation There are three possible positions of the manual direction control valve stem If conditions exist that the operator wishes to manually operate the transmission for any reason the operator can remove the locking pin from the direction control valve and push the stem into the valve for the engagement of clutch A or pull it out of the valve for the engagement of clutch B The manual direction control valve has an integral switch with contacts that are closed only when the manual direction control valve is in the NEUTRAL position This switch must be wired such that the engine cannot be started while clutch A o
8. P10837 SEE CHART 1003738 11828 11828 11903 M 1990 D BALL STEEL 11446 e 1016217 1064 1996 10667 M2051F PM 2057AJ PM 1357G 11154 2702 MA1038A 2009 1677 11680 11665 aA p MA1038F 11358 10930 2009 0 11452 11682 11452 M1927L ROLL PIN A2916KB Sere 11786 4330 1018234 2916 11453 11453 P 11453 B P 11453 C 9 205727 1996 MA1038A M2988J M2702E ETIN SEE NOTE 6 A2669DK 2057 A2916CR 10931 EBENE P 10936 PM 1357G XB2301J P 11681 82501 11356 2074 PM1399H 11354 13576 PM1349 AA MA1041E 1996 20572 2006 2406 B 2423 Eek M2051K 9 19966 12 _ a un 2423 5841 6 20572 B 2423 B PM 1996 R 202347 1016215 1996 SEE NOTE 3 MA1038A 11954 LEVEL MAX amp 1534 422 8 OIL LEVEL MIN ES SEED erecti PM1996 J 1190 1040 1190 A
9. 144 Install External Components 154 Assembly of GP Control Valve with Electronic Interface 162 Adjustment of Main 166 lcicirirenm 169 Prior Installation 169 Alignment also reference SAE J 1033 and J 617 170 ign fee 173 Electrical Controls Installation 179 Wiring ConnectionS mM 181 8 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Table of Contents Special TOO S En 185 List of Special TOONS c M 185 Recommended Pump Set and Fluids 186 Release Spring Compressor 188 Special Bearing eee tseeti titii ati nort nian Ro Heo sa kese Enea das ea si asREA 189 Front Outer Bearing Race Installation Tool 190 Inner Bearing Race Installation Tool 191 Rear Outer Bearing Installation Tool 192 Seal Installation TOON 193 End Play 194 Output Gear Advance
10. 65 Prior to gc m rc 67 Remove External Parts ioco Eia Eoo sanc eHE e Ene 68 Remove Internal Parle hee epo ee aa FRU xxxn e HEEt eSne o FERE ER ee 77 Remove Output Gear and Shaft 88 Primary Clutch Shaft Disassembly 95 Secondary Clutch Shaft Disassembly 100 Disassembly of GP Control Valve with Electronic Interface 105 DISS SCION 106 Cleaning and Inspection 113 H nuorIem 113 MVS OC GUNN M 115 PS SCY s 119 tC gr ee 119 Prior to Assembly Output End Bearings 121 Primary Shaft Assembly esos 122 Secondary Shaft Assembly 127 Main Housing Assembly 132 Output Gear and Output Shaft Assembly 133 Bearing Preload Measurement and Shimming 141 aiz iddi pgs
11. M10X1 THREAD ISO 6149 63 67 2 51 65 79 2 59 IN FROM HEAT EXCHANGER M33x2 TH D 150 6149 REMOVE ALUMINUM THREAD PROTECTOR BEFORE OPERATING UNIT QIL OUT TO HEAT EXCHANGER o 1 11 1 2 NPTF TH D DRYSEAL REMOVE ALUMINUM THREAD PROTECTOR BEFORE OPERATING UNIT 62 65 2 47 ammo 82 65 3 25 SECONDARY CLUTCH ACTUATING PRESSURE M12x1 5 ISO 6149 MECHANICAL BACK UP VALVE N MECHANICAL PULL PUSH EFFORT REQUIRED 111 156 25 3516 FROM NEUTRAL POSITION 36 53N 8 12Lb FROM SHIFTED POSITION 302 8 HEAT EXCHANGER H E REQUIREMENTS REFER TO B3649H FOR HEAT EXCHANGER DATA 373 8 PRIMARY SOLENOID ENGAGED CLUTCH ON PRIMARY SHAFT SECONDARY SOLENOID ENGAGED CLUTCH ON SECONDARY SHAFT PAD CAN OIL DRAN amp OIL IN FROM HEAT EXCHANGER 204 00 EYEBOLT OIL FILLER HOLE Go Penney G CLUTCH ACTUATING PRESSURE 12 1 5 50 6149 PRIMARY acr 0 REMOVE OIL GAGE CAN BE BENT IF NECESSARY py Ap PRESSURE M14x1 5 ISO 6149 1 19 460 82 __ FILTER DRAIN 21 5 476 88 INLET 25 4 29 9
12. 5 Slide the pinion assembly from the shaft DCP_1046 Figure 76 Pinion Assembly Removal Marine Transmission Service Manual 1022127 101 Disassembly Twin Disc Incorporated 6 Remove the rear two thrust washers and needle bearing Note Record location of the rear two thrust washers and needle bearing for proper assembly The first washer removed pilots in the bore of the pinion and the second pilots on the shaft This thrust washer also has a counterbore to fit over the snap ring DCP 1048 063F Figure 77 Rear Two Thrust Washers and Needle Bearing Removal 7 Remove the internal snap ring and clutch back plate from the clutch housing MG_051 Figure 78 Internal Snap Ring and Clutch Back Plate Removal 102 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 8 Remove the 9 steel plates and 10 clutch friction plates from the clutch housing MG_052 Figure 79 Steel Plate and Clutch Friction Plate Removal 9 Position the secondary shaft and clutch housing under a hydraulic press a Place Special Tool T 18502 on the spring retainer b Compress the release spring enough to expose the snap ring Remove the snap ring MG 053 Figure 80 Compressing Release Spring and Snap Ring Removal Marine Transmission Service Manual 1022127 103 Disassembly Twin Disc Incorporated d Carefully remove tension on the release spring e Remove the spring retainer and re
13. tanta ban iia nana 195 1020117 S Valve Test Body 196 B2408AL S Valve Test Procedure 197 Engineering Drawings 199 List of Engineering Drawings 199 Marine Transmission Service Manual 1022127 9 Table of Contents Twin Disc Incorporated NOTES 10 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc MGX 5135SC marine transmission 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 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 unacceptable maintenance working practices Marine Transmission Service Manual 102212
14. 1 Remove the two flat head screws that retain the manifold bushing 2 Use a bearing driver to remove the manifold bushing from the manifold 5135 0253 5135 0256 Figure 40 Primary Clutch Shaft Manifold Bushing Removal 3 Remove the O ring from the manifold 5135_0257 Figure 41 Primary Clutch Shaft Manifold Bushing O ring Removal Marine Transmission Service Manual 1022127 79 Disassembly Twin Disc Incorporated Bearing Shims and Spacer T Remove the primary clutch shaft shims and spacer Tag the components with identifying information 308 5135 Figure 42 Primary Clutch Shaft Bearing Shims and Spacer Removal 2 Remove the secondary clutch shaft shims and spacer Tag the components with identifying information 309 5135 Figure 43 Secondary Clutch Shaft Bearing Shims and Spacer Removal 80 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Rear Bearing Carrier T The rear bearing carrier is equipped with two pusher screw locations to assist in the removal of the bearing carrier Thread two M12 mm fully threaded capscrews lubricated into the pusher screw locations to push the bearing carrier away from the main housing A IMPORTANT Always lubricate the pusher screw threads before use Always tighten the pusher screws evenly 313 5135 314 5135 Figure 44 Rear Bearing Carrier Removal 2 Discard the bearing carrier gasket Note Remove the bearing cups from the
15. 2888 AW OPTIONAL EXTRA SUPPLIED ONLY WHEN SO SPECIFIED 11654 1 17102 SUCTION SCREEN 11647 SAEgO 1055 1 8 MA1048E 8 SHEE CROSS SECTION WITH PARTS NUMBERS MAN SELECTOR SHEET INSTALLATION DRAWING A2916JT SHEET 9926 OUTPUT SPEED SENSOR TET INSTALLATION DRAWING VL mE APPLY ANAEROBIC SEALANT MEETING MA08 LOCTITE 242 SHEET MOUNTING PADS 908 LOCTITE 242 5 250566 621508 TO SPEED SENSOR THREADS ASSEMBLE SENSOR UNTIL 4 CONTACTING TIP OF GEAR TOOTH AND THE BACK OUT SENSOR SHEET views TWO FULL TURN USE JAM NUT TO SECURE SENSOR POSITION 5 11676 11676 95 SHEET FLEXIBLE COUPLING E E 2 35S 12182 DIAGRAM E i i 1 i HE i 1 E 1020552 5244 2 MASS ELASTIC SYSTEM dE d 3 3649 n HEAT EXCHANGER REQUIREMENTS ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER S570BN CUSTOMER NOTES Oasu 1 THRU 7 ARE S570BN a ar a A SECTION D D MAX INPUT SPEED 2500 R P M L OIL CAPACITY 15 1 L 4 00 GALS LESS 0955 NOTE 8 CONTROL VALVE BOLTS ONLY ARE TO HOSES HEAT EXCHANGER CONSULT SALES DEPT APPLICATION 22 NOT SERVICEABLE SEPARATELY 50 48 BO WELL Gleb TO PJ RUIRLON
16. 3254H 1 al Le PAM els 50 50 3 75 14 ASSEMBLE CLUTCH ENGAGING PRESSURE FITTINGS SS EHESITSSH PM 32548 4 5 29 zm FROM THE BODY VALVE PX 11610 TO THE ae 1205 1BH oll PX 11602 1 NE 2 101 54 she CONTROL VALVE AND HEAT EXCHANGER x MA 1038A 1 11602 1 E oj M1945BV 1 11615 M1945AJ 12 oly Slot PM2261 D 1 pro M2078M 1 gt Hs 494 M2031 D 1 E PM 11139 SECTION B B 2 tS SIS gira a a OUTLET VALVE MAS83 1 o SOUTER a dr M HYDRAULIC P T O ett X PMZ261 D i SHAFT DRIVE 83628 gt E t 11615 H MA996 S 410 Ig 2 A PM 2057Z 4 d ES PRIMARY 590 0 KA2701BH 12 f A2701BH 1 23 23 27 1 E ECL zasa 82506 2 S PM 11261A Ojo LE e AX S i D ris KEER 1357 4 108648 CONTROL VALVE D E Y 28050 D 2012 1 NV 422 2 ES o i if LL NN V PM4330U 2 e O WATE _ WATER 3 NS Jj HYDRAULIC DIAGRAM WITH TWINSA ELECTRIC VALVE 2 j j j HYDRAULIC P T O PUMP DRIVE lt a Ox O SPECIFICATIONS Ls tw J 5 LOG mei HORSEPOWER RATING 162HP AT 1800 R P M 7 BE E H MAX P T O WORKING TORQUE 641Nm 473 LB FT Dx ES 42 INLET TO FILTERC 1 LH B BOSE
17. Marine Transmission Components MGX 5135SC Document Number 1022127 NOTICE 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 1022127 July 2005 Marine Transmission Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY MARINE PLEASURE CRAFT TRANSMISSION A 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 as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of thirty six 36 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twenty four 24 months of service whichever occurs first This is the only warranty made by Twin Disc Incorpora
18. 42223 A 102100041 101 NONE 1038 NONE 020520 350 H xil ZUM 3 10210004A 10 NONE 1038 NONE 1018528 250 ALP ells i __ ET Pe pd C 1021000 NONE 420515 MA1038E NONE 018528 250 PROPORTIONAL VALVE 4 D E E TM h 10210004 NONE 20515 1038 NONE 020520 350 Xr EN DU MET L AUR E E M194 Sims ASRS r 4 6 1020729 42516 1020542 NONE 20515 1038 19455 1018528 250 j 1020789F 42974 F 1021000 NONE 20515 11185 2500 y n pes amp vn ses LUBE me TLES ERE Hi A N PE VEN EE D LL SUMP 5 SEE NOTE Li LUBE e PLUG SEE CHART LL PORT SCREW 961 6 Lol LJ PRESSURE REGULATOR mt VS AE 7 PLUG MA1038B 2 HYDRAULIC DIAGRAM GRAPHIC SYMBOLS CLUTCH PRESSURE PORT VUL een xd PLUG MI038B 12 1 5 THD CONFORMS MAIN PRESSURE PORT TH ISO 6149 12 15 THD CONFORMS PLATE 1018175 TU ISU 6149 N RING A2916JT D SCREW MAMOOB A PROPORTIONAL VALVE SEE CHART 2 4 A espe d N 4 PLACES a X Or A SEE NOTE x VALVE SEE CHAR I 1 ma 1 i lt TORQUE TO 36 N m gt 1 7 SEE NOTE B gt lt D c e ru OQO f VALVE ASS Y 1081873 4 y 7 VALVE 10206705
19. DCP 1020 Figure 122 Bearing Spacers and Shim Pack Installation 146 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Install the 5 valve into the primary clutch shaft a a Calibrate the 5 valve following the procedure shown in Special Tools Section Lubricate and install the external O ring Install the S valve into the bore in the output end of the clutch shaft Install the spacer Note that the primary shaft spacer is shorter than the secondary clutch shaft spacer Apply Loctite 242 to the threads of the plug Torque the plug to 12 Nem 9 Ib ft Install the S valve into the secondary clutch shaft Calibrate the S valve following the procedures shown in Special Tools Section Lubricate and install the external O ring Install the S valve into the bore in the output end of the clutch shaft Install spacer Note that the secondary shaft spacer is longer than the primary shaft spacer Install the pump drive adapter and torque the two M8 1 25 x 20 socket head capscrews to33 Nem 23 5 Ib ft Marine Transmission Service Manual 1022127 147 Assembly Twin Disc Incorporated 11 Install the piston rings in the grooves at the end of the primary and secondary clutch shafts DCP 1019 Figure 123 Piston Ring Installation Manifold 1 If removed install a new primary clutch shaft bushing in the manifold a Install a new O ring into the g
20. Disconnect the swivel end of the hose first 5135 0001 Figure 20 Disconnecting Heat Exchanger Hoses 68 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 2 Remove the four screws securing the heat exchanger Remove the heat exchanger from the bracket 5135 0002 Figure 21 Heat Exchanger Removal Control Valve Note To aid in assembly be sure to mark all wire connectors prior to removing the control valve GP Control Valve with Electronic Interface Disconnect the wiring Loosen the four capscrews Remove the electronic module 278 5135 Figure 22 GP Control Valve with Electronic Interface Removal Marine Transmission Service Manual 1022127 69 Disassembly Twin Disc Incorporated Top Valve T Remove the six capscrews that retain the top valve 2 Remove the top valve and gasket Discard the gasket 5135 0279 Figure 23 Top Valve Removal Bottom Valve 1 Remove the four capscrews retaining the bottom valve 2 Remove the bottom valve and gasket Discard the gasket 5135 0282 5135 0284 Figure 24 Bottom Valve Removal 70 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Dipstick Tube 1 Remove the dipstick 2 Remove the dipstick tube retaining nut 3 Remove the dipstick tube from the front housing 286 5135 287 5135 Figure 25 Dipstick Removal Top Cover 1 Remove the eleven M12 x 30 capscrews and one 8 x
21. LET PLUG SEE CHART is ORIFICE 1021751 _ 7 2 0 O RING POR CHAR TORQUE 27 N m gt DIL INLET V 2 ei SEE NOTE D GASKET 1020531 7 OC STAMP VALVE ASSEMBLY cius IDENTIFIER HERE E NOTE E VALVE BODY 1020518 NOTES 2 PROPORTIONAL CONTROL VALVE OPERATION D PRESSURE REGULATOR INITIAL ADJUSTMENT PROCEDURE F APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS AROUND 1 WARNING DO NOT CONNECT VALVE COIL DIRECTLY 1 WITH NO DIL FLOW TO VALVE TURN ADJUSTMENT CORE PLUG JUST BEFORE FINAL ASSEMBLY REFER TO S774 FOR BATTTERY POWER SUPPLY VOLATAGE STEM OF THE 10206704 VALVE COUNTER CLOCKWISE FURTHER INFORMATION ETE 3E APE Vaan ales 2 OPERATION TO BE PERFORMED WITH ONLY TWIN DISC UNTIL REACHING POSITIVE STOP BSULETE REPLACED 10 1658 CONTROL SYSTEMS OR MODULES 0008 WITH A MINIMUM OF 1 gpm ALLOW DIL TO FLUSH FOR PRODUCTION AND SERVICE Q PRESSURE RGEULATOR B MANUAL DIRECTIONAL CONTROL VALVE OPERATION 3 AFTER FLUSHING TURN ADJUSTMENT STEM OF THE LW N DIRECTIONAL CONTROL VALVE IN 10206704 VALVE CLOCKWISE UNTIL REACHING REQURIED ON PUSH TO ENGAGE PORT PRESSURE SPCIFIED IN MARINE TRANSMISSION PRODUCTION in R fi gt 2 DIRECTIONAL CONTROL VALVE IN TEST SPECIFICATION NIL ON PULL TO ENGAGE PORT 4 LOCK ADJUSTMENT STEM IN PLACE USING JAM NUT ZR um p ESA THIRD ANGLE A AND D ka PROJECTION MANU ROL VALV
22. ROM PUMP B PRESSURE REGULATOR S MANUAL DIRECTIONAL 4 CONTROL VALVE TN 10 a BN m PRIMARY amp SECONDARY SENSOR PORT M14 X 1 SHAFT LUBE Figure 5 Hydraulic Schematic GP control valve Assy 1021658 Marine Transmission Service Manual 1022127 39 Operation Twin Disc Incorporated Proportional Valves M12x 1 50 Manual Override A o ring plug Valve Top Valve Body Figure 6 Top Hydraulic Valve Body Assembly gt Ms e gt Main Valve Body Temperature Sensor gt 12 Pilot Relief Valve Main Regulator Spool Figure 7 Main Regulator Hydraulic Valve Assembly 1020729 Figure 8 Main Regulator Assembly 1021658 40 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation GP Control Valve Electronic Control Interface Profile or E Troll Module Note Some installations will consist of the hydraulic portion of this valve and the Electronic Control Interface will be replaced by an appropriate electronic control system The electronic portion of the GP Control Valve fastens to the hydraulic portion of the GP Control Valve and is located on the top surface If the ambient temperature of this mounting location exceeds 180 F the Electronic Control Interface must be relocated to a cooler area Contact Twin Disc for proper harne
23. SAE C to SAE B Mounting Brackets Steel fabricated mounting brackets for rigid mounting are available Torsional Input Coupling Several models of torsional input couplings are available including Silicon Vulkan VKE and Centa CF R Heat Exchanger A heat exchanger is available shipped loose or mounted Companion Flange Assembly The companion flange assembly consists of the companion flange and mounting hardware Trolling Valve electronic E troll module is available Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Table 5 Bearing Preload Specifications Transmission Primary and Secondary Shaft Tapered Roller Bearing Preload 0 00 mm 0 000 in 0 05 mm 0 002 in Transmission Ouptut Shaft Bearing Preload 0 13 mm 0 005 in 0 18 mm 0 007 Note A negative endplay indicates a pre load condition Table 6 Maximum Allowable Total Indicator Runout Maximum Allowable Total Indicator Reading Face of SAE 0 cover adapter from input spline 0 30 mm 0 012 in Table 7 Ouput Gear Advance 3 81 mm 0 150 in aa 5 33 mm 0 210 in Table 8 Transfer Gear Advance Primary 5 33 mm 0 210 in 6 86 mm 0 270 Marine Transmission Service Manual 1022127 29 Description and Specifications Twin Disc Incorporated Table 9 Clutch Pack Clearance Clutch Pack Endplay 2 30 mm 0 019 in 3 2
24. 20 capscrew with washers retaining the top cover 2 Gently tap the top cover to break the gasket loose from the main housing 3 Remove the top cover and gasket from the transmission housing Discard the gasket 289 5135 5135 0624 Figure 26 Cover Removal Marine Transmission Service Manual 1022127 71 Disassembly Twin Disc Incorporated PTO Cover 1 Remove the four M12 x 30 mm PTO cover capscrews 2 Gently tap the PTO cover if necessary to break the cover loose from the main housing d Remove the PTO cover and O ring DCP 1001 1004 Figure 27 PTO Cover Removal Input Coupling 1 Remove shipping wire if equipped retaining the input coupling to the input housing 2 Remove input coupling from input shaft 5135 0141 5135 0142 Figure 28 Input Coupling Removal 72 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Hydraulic Pump T Remove the hydraulic pump from the main housing 5135 402 Figure 29 Hydraulic Pump Removal A CAUTION The hydraulic pump can be installed two ways therefore before removing the pump place indexing marks on the pump and the manifold to ensure correct installation Do not remove the pump pipe plug Do not disassemble pumps They are not serviceable 2 Remove the four capscrews securing the hydraulic pump to manifold assembly and remove the pump and gasket Marine Transmission Service Manual 1022127 73 Disas
25. 36 11661 46 1 2821 PX 11801A 2 STREET uina Pom PRIMARY PINION 1 REQ S GEAR OUTPUT 1 REQ S 11771 1 px 12107 P 12107 1 7 2073 0 39 PISTON 1 penal Es 2 n ae m 1 oon SECONDARY PINION 1 REQ S 12109 45 1 10 1 WASHER ___ FS 25 8 WA B Px 12108 P 12108 _ _ M 2073 DR 39 L rouen e 4 PRIMARY PINION 1 REQ S GEAR OUTPUT 1 REQ S PI PX 11662 11662 7 M 2073 DR 41 30480 7 L SECONDARY PINION 1 REQ S P 11663 41 1 00 1 PX 11664 P 11664 M 2073 DR 41 XB6239A c RH ENGINE IC INPUT SPEED SENSOR cem APPLY ANAEROBIC SEALANT MEETING MA9O8 LOCTITE 242 M1904AQ Steal qe TO SPEED SENSOR THREADS ASSEMBLE SENSOR UNTIL CONTACTING TIP OF GEAR TOOTH AND THE BACK OUT SENSOR ala 1001218 ONE FULL TURN USE JAM NUT TO SECURE SENSOR POSITION 5 M2020AD 0 alo a z 1003790 5 RI olvlol le s slo zlela zelo Ss lane T n 98518 r gEeSRSSS je2955rs99 S FILTER BY PASS 28 2 8193 ROTATION ONLY e a bea 201513 1 EE E REESE we 3820585 L5 ES T 2027 1 OO m w2081 J 1 TWIN DISC S A pressure SECTION C C e 1190 1349 1 4 ue PM5967B PX11570 1021658 A MA 1052 U SET SPRING LENGTH TO 30 2mm 1 19 IN
26. APPLY ANAEROBIC SEALANF MEETING 842228 REQUIREMENTS ue 1021563 AROUND CORE PLUG JUST BEFORE FINAL ASSEMBLY REFER 5774 FOR FURTHER INFGRMATION 1221 682 G MODIFICATKZN KI TO GPGRADE EXISTING E020729 710223595 5 x A S l 7245 F PLUG SEE CHART SERIES VALVE ASSEMBLES 1522458 SERIES VALVE ASSEMBLY CPHCNA INLET PORT m t SC OSA 1 T M27x2 6 THD CONFORMS SCREW MASSDH 54 TO ISO 5149 COVER 1621661 SPOOL 1021552 SC RIA A 1 SCREW MAS DA 4 75 2 Lae pou VALVE 1020942 MP A WASEER A2782AV 1021559 2 nd c es 5 1002144 SPRINGIS 5 ps SEE NOTE D SEE CHART STAMP VALVE ASSEMBLY d IDENTIFIER HERE NUT 1002145 RING AZ 16L PISTON 10209394 E P VALVE PRESSURE o S aj M 30M vay ZE R PROpORTONAL MODIRGATCON PART NO IDINTFIE2 2 VALVE SENSOR PLUG LES VALVE MERSSRA A AD ZO 10010008 20515 12000520 2 10216558 3 Bt fe 102008 MONE 20515 MAIOSSE NONE 10 8528 MER 1021558 43122 BEEF SIE 19204 20515 MAISI xoz E2052 232 5 Ln ee m PORT 10216580 2
27. ARROW ANE PUMP POSTION TOR Rats LIMITING CONDITIONS 39 45 LB FT OR WELL OILED TO ENGINE 15 SHOWN FOR L H ENGINES ROTATION OIL TEMPERATURE INDICATING SWITCH 83424 a maur 6939 12280803 REMOVE BEFORE OPERATING 2 PLACES 45 0 49 0 m 32 36 LB FT PLATE ARROW POINTING TO RIGHT AND SCREWS FOR INSTALLATION LOCATION SEE HYDRAULIC CNCEIP AEOMINUNE LOGS MUST BE ADDED TO INDICATE OPPOSITE DIRECTION DIAGRAM AND SHEET 2 SRT WRA WEG we UNLESS OTHERWISE SFEOFES JINE TINDE AND PUMP TO BE RELOCATED PER INSTRUCTIONS A er 10APRO2 F 6865 30APRO3 P 7292 270CTO4 SHOWNTON SHEET 2 OIL PRESSURE GAGE 817030 kg Nm ac ENSO E 6849 10 N 7261 205 04 OPTIONAL FOR SAE 1 THESE STANDARDS APPLY FOR INSTALLATION LOCATION SEE HYDRAULIC ur Xx 2023 1 2 D 6760 28 0 02 M 7245 095 0 4 hal Sea aa ee c OPTIONAL EQUIPMENT DIAGRAM AND SHEET 2 ous MCN xx 3013 DRAW C 6728 24602 L 7154 23APRO4 OPTIONAL FOR S A E 0 574 FASTENER TORQUE REQUIREMENTS COMPANION FLANGE ASS Y PX 11654 cra w ALL ANGULAR TOLERANCES t sP 5692 THRUST BEARING SHIMMING LME P T O PX 11824 TWIN DISC INCORPORATED SEP AS SE TEES me I ere 9 OPTIONAL FOR SPEED SENSORS 5765 TAPERED JOINT ASSEMBLY HYDR CLUTCHED P LO SHAFT DRIVE 11615 0 Wi Ee Dern 199 11840 a 5774 ANAEROBIC SEALANT APPLICATION HYD
28. Electronic Interface Module to the Hydraulic portion of the valve assembly If the Electronic Interface is not being replaced it can be set aside without disconnecting the remaining wires from the installation Figure 84 Electronic Profile Module typical 2 Remove the six M10 1 50 x 70 capscrews that retain the top valve body assembly to the transmission and remove the top valve body assembly with gasket if not previously removed 106 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Proportional Valves Manual Override Valve Figure 85 Top Hydraulic Valve Body Assembly 2 Remove the four capscrews that retain the main regulator valve assembly to the transmission housing or ditch plate and remove the valve assembly and gasket 9 e Valve Body 4 4 Temperature Sensor 3 Pilot Relief Valve Main Regulator Spool Figure 86 Main Regulator Hydraulic Valve Assembly 1020729 Figure 87 Main Regulator Hydraulic Valve Assembly 1021658 Marine Transmission Service Manual 1022127 107 Disassembly Twin Disc Incorporated 4 Remove the manual direction control valve with switch or the plug assembly from the top valve body Override Valve with Neutral Switch Locking Pin Plug if applicable Figure 88 Manual Direction Control Valve or Plug 108 Marine Transmission Service Manual 1022127 Twin Disc Incorpora
29. FLYWHEEL OUTLINE MUST CONFORM TO_SAE J620 33 4 NO 355 14 T 6 0 N e x Bl 85 8 d 8 amp S xl else x E 5 8 255558 PRIMARY CLUTCH CLEARANCE TO REMOVE OIL PUMP SHAFT 46443 LUBE Ps AG AUXILIARY LUBE SUPPLY INLET CENTER OF GRAVITY 184 00 2 5 s 6500 G 482 72 56 CLEARANCE TO R MOVE SUCTION NO 457 18 FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 17 0 670 DRILL THRU 6 HOLES EQUALLY SPACED USE 8 PROPERTY CLASS QUALITY PER 150 898 7 GRADE 5 QUALITY CAPSCREWS 15 7 13 5 PER SAE J429 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES FOR INSTALLATION DIMENSIONS SEE MARINE TRANSMISSION INSTALLATION DRAWING THESE TWO FLANGES DO NOT REQUIRE FITTED CAPSCREWS THE CAPSCREWS SHOWN DO PROVIDE ADEQUATE TORQUE CAPACITY WHEN 178 0 TORQUED AS RECEIVED TO G14 706Nm 453 521Lb ft 51 0 18 0 5 08 E 200 00 390 0 OPTIONAL EXTRA SUPPLIED ONLY WHEN 50 SPECIFIED 14 0 551 DRILL THRU 60 0 16 HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY ISO 8
30. FOR AHEAD PROPULSION SECONDARY S CLUTCH ACTUATING S PRESSURE 14 1 5 50 6149 5 OUTPUT e SHAFT S O 23 8 g LUBE P S l 14 1 5 TH D ISO 6149 10 1 5 THREAD 7 6 30 DEEP SUCTION SCREEN WHEN MOUNTING ENGINE TRANSMISSION IN BOAT ALL THE MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW THE PX 11840 CONFIGURATION MOUNTING IS NOT SUITABLE FOR REMOTE RECOMMENDED ACCEPTED UM NOT RECOMMENDED 45 45 LH PROPELLER ROTATION RH ENGINE DRIVING THRU SECONDARY CLUTCH FOR AHEAD PROPULSION 920 2 THRU 8 HOLES AS SHOWN 265 0 305 0 202 32 281 74 302 0 305 0 ALL POINTS AVAILABLE FOR TESTING ARE CODED QO OIL DRAIN PLUG M33x2 TH D IS0 6149 ourPur SPEED Pick up 12 MAX INPUT SPEED 2500 R P M CONSULT SALES DEPT APPLICATION ENGINEERS FOR OTHER LIMITING CONDITIONS lt gt _ THIRD ANGLE PROJECTION SIMILAR TWIN DISC NOTICE THIS
31. Incorporated Description and Specifications Table 14 Tapered Pipe Plugs with thread lubricant Torque Values for Lubricated Pipe Plugs Recommended Torque Nem NPTF Size Installed in Cast Iron or Steel Installed in Aluminum 1 16 28 1 16 27 11 5 1 3 8 5 1 0 7 5 0 9 5 5 0 7 1 8 28 1 8 27 14 2 1 8 10 5 1 3 8 8 1 1 6 5 0 8 1 4 19 1 4 18 34 4 25 3 22 3 16 2 Ls rese eme Note The lubricant is to be John Crane insoluble plastic lead seal No 2 or equivalent or Loctite No 92 or equivalent and plugs are to be capable of removal with out damage Overtightening may cause initial leakage plus potential removal damage An option of a maximum of two full turns after finger tightening the plug may be used if required and if removal conditions are met Marine Transmission Service Manual 1022127 33 Description and Specifications Twin Disc Incorporated Table 15 Tubing Nuts Torque Values for Tubing Nuts Recommended Torque Ibeft Nominal Tube Size Table 16 Banjo Fittings amp Sealing Plugs with Copper Washers Torque Values for Banjo Fittings amp Sealing Plugs with Copper Washers Recommended Torque Thread Size Nem Ibeft 14 1 5 16 1 5 24 1 5 Clutch Plate Wear Limits Clutch steel plates Minimum thickness 2 34 mm 0 092 in Clutch friction plates Minimum thickness 3 07 mm 0 121 in 34 Marine
32. Lubrication oil flows through the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings Main pressure is supplied to the inlet of each proportional valve and to the inlet of the manual direction control valve In Neutral the inlet port of both clutches is connected to the sump Since the area behind the clutch pistons is open to sump the clutches are disengaged When one of the clutches is commanded to engage the proportional valve directs main pressure to a passage in the clutch shaft The oil is directed toa small area chamber behind the clutch apply piston and also against the sequence 5 valve that is located in the clutch shaft The pressure on the small area of the clutch apply piston quickly moves the piston to engage the clutch at a low capacity level The pressure rises until the S valve opens allowing the high pressure oil to be supplied to the large area of the clutch apply piston providing a rapid increase in the clutch capacity The rate of rise is controlled electronically and prefills the engaging clutch at a predetermined level and then increases to full pressure following a predetermined timing sequence The initial prefill level is factory adjustable by means of an adjustment screw embedded in the bottom surface of the electronic interface Field adjustment of this feature should never be attempted without special equipment and knowledge of its use to prevent serious mechanica
33. MAX P T O OPERATING SPEED 2500 R P M j 25 RECOMMENDED MAX ENGINE SPEED WHE 201411 i H 1 ENGAGING CLUTCH 5x MATCH POINT SPEED y i P e 1e P T O SHAFT ROTATION SAME AS N SDN RE 152203A011e 1 ENGINE ROTATION 1 1 45 R oo 1 0 BE USED WITH OR LH PUMP SPLINE DATA 1 ki L 94H ROTATION ENGINES TI 2 22 0 PRIMARY CLUTCH DASS gt FEAT e A XNPRIMARY CLUTCH 1 P T O ACCEPTS S A E J744 SIZE PUMP SHAFT N 12 24 PITCH VU SEA H IL d 307 PRESS ANGLE H IN HYDRAULIC P T O SHAFT DRIVE N j 1 167 PITCH DIA J 24 0 2 SPECIFICATIONS 94 PM3533 AU 1 3 x ve Ip EE F 1 4 stubs HORSEPOWER RATING 162HP AT 1800 R P M 11806 2 Seo fe NS G MAX P T O WORKING TORQUE 641Nm 473 LB FT CINE sc S T 2 e AA QRS TTS e AX P T O OPERATING SPEED 2500 R P M DOWEL PIN 2 RECOMMENDED MAX ENGINE SPEED WHEN Pu iseev le 2 Sa A Gales ENGAGING CLUTCH 5x MATCH POINT SPEED H SHAFT ROTATION SAME AS B 1395717 Te ENGINE ROTATIO P 11611 1 H h SECONDARY CLUTCH lt P T O BE USED WITH R H in SHAFT Q p ROTATION ENGINES ONLY 11581 1 le BACKDRIVING OF P T O IS_NOT PERMITTED HYDRAULIC P T O 11581111 S A E J744 SIZE C MAX EXTERNAL
34. PRINT CONTAINS PROPRIETARY INFORMATION AND 15 NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF RACINE WI 53403 USA THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERMENT OR OTHERS BY CONTRACT INCORPORATED mnm 2 WEIGHT UNLESS OTHERWISE SPECIFIED DATE GEAR RATIOS 129 T DIMENSIONS ARE mm ismavo2 SPA UN DISe kg 2 MACHINED DIMENSIONS SCALE X 0 75 1 3 NCORPORATED FIRST USE XX 0 25 RACINE WI 53403 USA 0 13 aa ASSEMBLY ALL ANGULAR TOLERANCES 1 SP GEOMETRIC TOLERANCING 1 1 8 LO MODEL PER 5 Y14 5M 1982 CHECKED t SURFACE TREATEMENT NAME APPROVED 5135 5 ASSEMBLY DRAWING JCP nan UI FORMAT AI HEAT EXCHANGER H E REQUIREMENTS REFER TO B3649H FOR HEAT EXCHANGER DATA ELECTRIC CONTROL VALVE 3 2107 9 4 25 ENGAGING 1021658A SECONDARY CLUTCH 103 24 4 06 NEURAL POSITION 188 13 7 41 98 3 3 87 ENGAGING PRIMARY CLUTCH
35. REQUIREMENTS OIL LINES TRANSMISSION TO H E AND RETURN 1 MAX VELOCITY IN FITTINGS PIPE HOSE AND TUBES 7 6m sec 25FT SEC 2 BURST PRESSURE MIN 10 x PEAK OIL PRESSURE AT H E 3 HOSE SAE J517 100R1 MEETING USCG 46CFR 56 60 25 C 135 C 275 F TEMP RATING 4 PROTECT LINES FROM MECHANICAL DAMAGE ZINC ANODES PROTECT H E RAW WATER PASSAGES FROM CORROSION CHECK amp REPLACE THEM FREQUENTLY B3649H 24 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Specifications and Maintenance Frequent reference to this data and application of the information will result in better service from the transmission Oil Capacity 15 1 Liters 4 0 US Gal less hoses and heat exchanger The transmission should be warmed to operating temperature when oil is checked Oil Pump Capacity 14 1 GPM 1800 RPM Minimum Oil Pressure When Cruising Check your unit s identification plate MGX 5135SC has a minimum oil pressure at rated engine RPM located on the name plate of 1860 kPa 270 psi non trolling mode Maximum Input Speed 2500 RPM Dry Weight Approximately 300 Kg 661 Ibs Type of Oil and Oil Viscosity Note Multi viscosity oils i e 10W 20 etc should not be used in Twin Disc MarineTransmissions The recommended oil is mentioned on the lubricant nameplate located on the housing of your Marine Gear Marine Transmission Service
36. SERVICE W IMPORTANT REPLACED BY PX12180 A DATE 1900706 TEMPERATURE BRAKE PLATE IS PROBABLY WORN IMPORTANT E se os REPLACE IT AND SERVICE CLUTCH AS REQUIRED TO FOR INSTALLATIONS DRAWING WITH SCAT WATER Wer Lu UNLESS OTHERWISE SPECIFIED DW ELIMINATE TURNING IN NEUTRAL BEFORE FURTHER OPERATION HEAT EXCHANGER SEE 11380 5 2 DIMENSIONS ARE mm 1x0 TOVIN DISC ao a ooo 2 AND FOR OTHER DIMENSIONS SEE PX 11380 SHEET 2 iS MEHNED DIMENSIONS E INCORPORATED T54PROS UNMARKED PARTS COMMON TO BOTH DRIVE 0 5 NOTE _ __ OBE 1 2 FEDERER BOSE OON DENOTES PARTS FOR SHAFT DRIVE HYDRAULIC P T O ONLY PX 11615 ALL POINTS AVAILABLE FOR OPTION WITH HEAT EXCHANGER ON UNIT TE rut td issu wiPX 11380 AL B__ 6819__ 20FEBOS DENOTES PARTS FOR PUMP DRIVE HYDRAULIC P T O ONLY 11615 TESTING ARE CODED OPTION LESS HEAT EXCHANGER ON UNIT TWIN DISC INCORPORATED woo MGS13S A SC PE A DAR TUE PX 11615 A 6537 31JANO2 AOE 33403 SURFACE TENEMENT WE TO NULLIFY OR LIMIT RIGHTS 3 IPPROVED SYM cH NO DATE SYM CH DATE DERE U GOVERMENT POWER TAKE OFF ASSY n0 FORUTAT
37. THRUST LOAD ON P T O SHAFT E meet MOUNE ep N EITHER DIRECTION 5xSIDE LOAD CAPACITY L _PX 11615 A STUDS WITH NUTS EQUALLY WITH NO SIDE LOAD ON SHAFT SPACED ON 161 92 6 375 DIA oo 99 MAX P T O SIDE LOAD M 2051 T pe BASIC H C i THE FOLLOWING GENERAL FORMULA 2052 1 SIDE LOAD SHOULD BE USED FOR DETERMINING e 2988 1 6 CAPACITY GON THE APPLIED LOAD 11570N 280018 126 000xHP xF O T 2600LB 10680N On n 183 560 7 xF a EE 979oN 2400187 e ND 2200LB 8900N WHERE 8010N 2000LB 2 L ACTUAL APPLIED LOAD N OR LBS 703 0 800 8 51 N SPAFT SPEED RPM 16001 Two 1400LB 5340N F LOAD FACTOR 252 1 0 FOR CHAIN OR GEAR DRIVE 4500n 120018 1 5 FOR TIMING BELTS PTO OIL DRAIN TO MARINE 1000LB 3560N I FOR FLAT BELTS H RANSMISSION SUMP 2670N 8001 FOR RECIPROCATING COMPRESSORS SAE 0 60018 508 101 6 AND OTHER SEVERE SHOCK DRIVES JSS I 2 00 4 00 MULTIPLY ABOVE FACTORS BY 2 1 Es 254 07762 NL 1 00 3 00 DISTANCE X FROM REAR OBSOLETE ASSEMBLY INSTRUCTIONS FACE OF P T O HOUSING FOR PRODUCTION TEN SEE VIEW AT LEFT Ee R gt AND
38. The position can vary depending on the engine direction of rotation If necessary refer to the Engineering Drawings at the end of this manual 3 Torque the four M10 x 45 capscrews to 46 Nem 34 Ib ft 5135 402 Figure 138 Hydraulic Pump Installation Marine Transmission Service Manual 1022127 157 Assembly Twin Disc Incorporated Hydraulic Oil Filter Lubricate the O ring and install the hydraulic oil filter to the manifold 5135_405 Figure 139 Hydraulic Oil Filter Installation Dipstick Tube 1 Apply pipe thread compound to the threads and install the dipstick tube into the front housing 2 Tighten the dipstick tube to 23 Nem 17 lbeft d Install the dipstick 286 5135 Figure 140 Dipstick Tube Installation 158 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Top Cover 1 Position the top cover and gasket on the transmission housing 2 Install the eleven M12 x 30 capscrews and tighten to 80 Nem 59 Ib ft Install one M8 x 20 capscrew with washers and tighten to 23 Nem 17 lbeft 289 5135 5135 0624 Figure 141 Top Cover Installation Input Coupling 1 Place input coupling on input shaft 2 Use shipping wire to secure the flywheel 5135 0141 5135 0142 Figure 142 Input Coupling Installation Marine Transmission Service Manual 1022127 159 Assembly Twin Disc Incorporated Heat Exchanger If Equipped 1 Install the heat exchanger Tighten
39. Tools Ground Bearing Cups Prior to using these cups for measuring end play place the unit s cup onto the appropriate bearing cone and measure the total length of the bearing Place the special grind cup onto the same bearing cone and measure the total length of the bearing Note the difference in the two measurements for the end play calculation Repeat for each bearing cup that is used for setting end play Rear Primary Bearing Bearing height w original cup O Bearing height w ground cup G Difference D O G Rear Secondary Bearing Bearing height w original cup O Bearing height w ground cup G Difference D O G Rear Output Bearing Bearing height w original cup O Bearing height w ground cup G Difference D O G Marine Transmission Service Manual 1022127 121 Assembly Twin Disc Incorporated Primary Shaft Assembly jM If removed install a new rear taper bearing cone on the output end of the shaft a Heat the bearing cone to 120 C 250 F AWARNING Handle the bearing cone with care The bearing cone is HOT b Place the bearing cone on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing cone against the clutch housing as the bearing cools 2 Install the clutch piston into the clutch housing a Lubricate and install a new piston ring on the outside diameter of the clutch piston b Lubricate and install a new piston ring on the small area
40. after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the filter is clean and then change the oil and filter after 1000 hours of service or more often if conditions warrant Marine Transmission Service Manual 1022127 Twin Disc Incorporated Preventative Maintenance Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Use a 27 mm wrench to loosen the drain plug Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located in the manifold below the pump See Engineering Drawings for suction strainer location See discussion under oil change interval Type Oil Recommended See Description and Specifications Filling 1 2 Remove the filler breather in the top of the transmission Fill the transmission s sump with the proper weight and type oil See Description and Specifications for oil recommendations Start the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the o
41. diameter of the clutch piston and from the outer bore of the small area of the piston Remove the O ring from the inner diameter of the clutch piston MVC_772F Figure 73 Piston Ring and O Ring Removal Marine Transmission Service Manual 1022127 99 Disassembly Twin Disc Incorporated Secondary Clutch Shaft Disassembly 1 Remove the rear bearing cone Note Only remove the cone from the secondary clutch shaft if it needs to be replaced If removed a new bearing must be installed during assembly a Cut off the bearing cage and remove the rollers b Use a cheese cutter type puller to pull on the rear shoulder of the inner bearing race Heat the inner race to assist in its removal A CAUTION DO NOT overheat the inner race as it could result in annealing the clutch shaft Handle the inner race and shaft with care The inner race and shaft are HOT 2 Position the secondary clutch shaft with the input end facing up 2 Remove the snap ring DCP1043 Figure 74 Snap Ring Removal 100 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 4 Remove the front two thrust washers and needle bearing Note Record location of the front two thrust washers and needle bearing for proper assembly The first washer to be removed pilots on the shaft and the second one pilots in the pinion bore _1045 Figure 75 Front Two Thrust Washers and Needle Bearing Removal
42. during rotation additional alignment is necessary or the marine transmission and shaft couplings should be checked for proper face runout Runout must not exceed 0 10 mm 0 004 in Excessive face runout on the marine transmission output flange can usually be corrected by repositioning the coupling on its spline or taper Excessive shaft coupling runout is usually due to inaccuracy of the taper fit or key to keyway interference The optimum relative mating location will be where the measured runout dimensions of the transmission flange and the shaft coupling flange compliment each other to result in the least relative out of true parallel measurement Figure 160 Checking Output Flange Face Runout Marine Transmission Service Manual 1022127 177 Installation 178 Twin Disc Incorporated Figure 161 Checking Output Flange Pilot Eccentricity Some boats are not structurally rigid and some carry their load in such a way that they will hog or go out of normal shape with every loading and unloading Where this condition exists it important to apply common sense alignment techniques to minimize the potential damage to any of the components During the process of securing final alignment it may be necessary to shift the engine many times When the final alignment is accomplished mark and drill the holes for the lag studs or locating dowel pins Then with final alignment secured make up the necessary poured steel or hardwood shim
43. installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated 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 C 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 the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment Only a Twin 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 subsequen
44. length of the shaft from the last support bearing to the gearbox is excessive or a flexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Engine and Marine Transmission Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boat to change its form with various loads and with age Engine and shaft alignment can also change on a boat due to varying loads and the boat s age The following steps may be taken to secure proper marine transmission alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure Install the mounting brackets on the side mounting pads of the marine gear Install the driving ring on the engine flywheel Bolt an indicator to the engine block and set the indicator stem on the engine flywheel housing Marine Transmission Service Manual 1022127 173 Installation Twin Disc Incorporated INDICATOR INDICATOR STEM MARINE GEAR ENGINE FLYWHEEL HOUSING LE BEDRAIL _ ee mr ee Figure 157 Marine Gear Alignment Set the indicator gauge at zero 0 Lift the marine gear with a hoist or othe
45. operation All gears are in constant mesh The primary and secondary transfer gears and the output gear are mounted on keyless tapers Marine Transmission Service Manual 1022127 21 Description and Specifications Twin Disc Incorporated Flexible Torsional Input Coupling The purpose of the torsional coupling is to transmit power from the engine to the marine transmission through a rubber or silicone element that will Dampen torsional vibrations Change the natural frequencies of a system to move critical frequencies out of the operating speed range m Accommodate a certain amount of misalignment m Absorb shock and reduce noise Minimize gear rattle Several couplings are available from Twin Disc and are selected based on the customer supplied engine information Final coupling selection must be confirmed by the packager based on the torque rpm ratings and the results of the system torsional vibration analysis TVA and on engine rotation Care must be taken when servicing that replacement couplings are matched to this criteria 22 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing coolant from the engine through the heat exchanger The heat exchanger is mounted on a special bracket bolted on the live PTO face The
46. or equivalent credit In this context labor is defined as the flat rate labor hours established by Twin Disc Incorporated in the published Twin Disc Flat Rate Schedule required to remove disassemble inspect repair reassemble reinstall and test the Twin Disc Incorporated product only Authorized reasonable travel and living expenses will be considered for payment in all model except MG340 and MG360 Under no circumstances including a failure of the exclusive remedy 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 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 repair 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
47. pump into the lubrication circuit Refer to the hydraulic system schematics for more details on the optional trailing pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Marine Transmission Service Manual 1022127 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services 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 14 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 using 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 o
48. recessed bore over the snap ring needle bearing and thrust washer pilots in bore of pinion DCP_1048 Figure 97 Installing Front Thrust Needle Bearing and Thrust Washers 9 Lubricate the area of the clutch shaft that will contact the pinion assembly Install the pinion assembly Gently rotate the pinion as it is lowered into the clutch plates until the splines are fully engaged in all the clutch plates DCP_1046 Figure 98 Pinion Assembly Installation Marine Transmission Service Manual 1022127 125 Assembly Twin Disc Incorporated 10 Install the thrust washer into the pinion bore 11 Install the front needle bearing Note The snap ring retainer serves as the thrust washer on the primary shaft DCP 1045 Figure 99 Front Thrust Washers and Needle Bearing Installation 12 Installthe snap ring to retain the front needle bearing thrust washer and pinion DCP 1043 Figure 100 Snap Ring Installation 126 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Secondary Shaft Assembly 1 If removed install a new rear taper bearing cone on the output end of the shaft a Heat the bearing cone to 120 C 250 F Handle the bearing cone with care The bearing cone is HOT b Place the bearing cone on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing cone against the clutch housing as the bearing cools 2 Insta
49. sanding or grinding This will cause loss of fit of bearings or races Inspect 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 foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part Inspect ground tapers for scratches galling or scoring damage If any of these are present replace the part Q Inspect ground tapers for burrs or nicks If you cannot remove the defect with a soft stone replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels 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 Marine Transmission Service Manual 1022127 115 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Be
50. sealing surface of the clutch piston Lubricate and install new O ring the inside diameter of the clutch piston d Install the clutch piston into the clutch housing Note Ifthe clutch piston is difficult to install by hand remove the clutch piston and inspect the piston rings MVC_772F Figure 93 Piston Rings and O Ring Installation 122 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 3 Position the primary clutch shaft under a hydraulic press a Slide the release spring over the shaft b Place the spring retainer on the release spring Use Special Tool T 18502 to compress the release spring far enough to expose the snap ring groove in the shaft d Install the snap ring 054 MG 053 Figure 94 Release Spring Spring Retainer and Snap Ring Installation 4 Install the clutch plates as follows Install a friction faced plate and alternate with steel and friction plates until the 9 steel and 10 friction plates are installed finishing with a friction plate MG 052 2001 Figure 95 Clutch Plates Installation Marine Transmission Service Manual 1022127 123 Assembly Twin Disc Incorporated 5 Install the clutch back plate 5 Press the back plate firmly into the clutch housing to ensure the splines of the clutch are aligned 6 Place the internal snap 6 ring next to the clutch back plate AAR6557 069 6557 1012 Figure 96 Clutch Back Pl
51. versions of Electronic Profile or E Troll Module Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System Marine Transmission Service Manual 1022127 41 Operation Twin Disc Incorporated Figure 9 Electronic Profile Module MGX non troll Solenoid A on Red LED Power OK Green LED Solenoid B on Red LED Figure 10 Electronic E Troll Module MGX E Troll 42 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation Hydraulic System with GP Control Valve The oil pump draws oil through the strainer from the oil sump and discharges it through the heat exchanger to the oil filter Filtered oil enters the control valve through the inlet port The incoming oil Assembly 1020729 is supplied to the main pressure regulating relief pilot cartridge and the main regulating valve cartridge satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit The incoming oil Assembly 1021658 is supplied to the main pressure regulating valve and is supplied in parallel paths through a ball check valve and an orifice with filter to quickly regulate and dampen pressure oscillations satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil
52. with Adjustment Spool Spring Cap Figure 92 Remove Main Pressure Regulator Valve Components Marine Transmission Service Manual 1022127 111 Disassembly Twin Disc Incorporated NOTES 112 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Cleaning and Inspection Cleaning and Inspection Cleaning Note Replace all oil seals gaskets O rings piston rings seal rings snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents by steam cleaning Parts must be dried and oiled immediately to prevent corrosion Examine all parts carefully for grit dirt abrasives and reclean them if necessary Clean all oil passages by working piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent to 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 Marine Transmission Service Manual 1022127 113 Cleaning and Inspection Twin Disc Incorporated 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 p
53. with the energizing coil of the not in neutral relay Plug the appropriate connectors from the Profile Generator into the appropriate Proportional Valves Q Plug the appropriate connectors from the Profile Generator into the Engine Speed sensor and the Propeller speed sensor if equipped When the not in neutral circuit is not used insulate and secure the blue and black wires 182 Marine Transmission Service Manual 1022127 Twin Disc Incorporated SOLENOID B ON RED LED POWER OK GREEN LED SOLENOID A ON RED LED WIRING SCHEMATIC TROLL ENABLE SWITCH CLOSED TROLL MODE OPEN CRUISE MODE PINK CUSTOMER SUPPLIED RED ORANGE GREEN VIOLET GREEN TAN 5V TROLL SPEED POTENTIOMETER 1K OHM 0 0 TO 0 5 VOLT MINIMUM TROLL CUSTOMER SUPPLIED TROLL SPEED CURRENT INPUT 4 20MA SEE NOTE 1 TAN RED A BROWN c GREEN BLACK DH BLACK 2 RED SEE MODULE POWER CONNECTION CHART 4 75 TO 5 0 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 ENGINE SPEED SENSOR 1 PROPELLER SPEED SENSOR lt SOLENOID A MP aaa RED BLUE BLACK WHITE N BLACK YELLOW SOLENOID B SWITCH CUSTOMER SUPPLIED lt A B SOLENOID B MP 200 mA MAXIMUM SEE MODULE POWER SOLENOID A SWITCH CUSTOMER SUPPL
54. 0 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Output Shaft he Use a hoist and lift the output shaft from the main housing 5135 out shaft Figure 58 Output Shaft Removal 2 Remove the output gear through the top cover opening of the main housing Set the output gear aside 5135_415 Figure 59 Output Gear Removal 3 Remove the front output bearing cone from the cup 4 Remove the rear bearing from the shaft by pressing if it has not already been removed Marine Transmission Service Manual 1022127 91 Disassembly Twin Disc Incorporated Input Shaft Seal T Remove the snap ring from the front housing 51 35 0267 5135 0268 Figure 60 Input Seal Snap Ring Removal 2 Thread two eyebolts into the seal retaining ring 3 Using two pry bars carefully pry the seal retaining ring from the front housing cr 5135 0270 5135 0275 Figure 61 Input Seal Retaining Ring Removal 92 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 4 Remove the O ring 5135_0277 Figure 62 O ring Removal 5 Turn the front housing over and remove the input shaft seal 5135_0012 Figure 63 Input Shaft Seal Removal Marine Transmission Service Manual 1022127 93 Disassembly Twin Disc Incorporated Front Housing Bearing Cups If the front housing bearing cups require replacement weld a bead midway around the circumference of the bearing cu
55. 0 mm 0 126 in 2 30 mm 0 019 in 71 3 20 mm 0 126 in Table 10 Sequence Valve Adjustment Sequence Valve Adjustment 30 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Torque Values for Fasteners Note Lubricate all threads and bearing face with light oil film prior to assembly Note Use grade 5 and Property Class 8 8 specs when threading into aluminum Table 11 Metric Coarse Thread Capscrews Bolts and Nuts poss Property Class 8 8 Property C Property C lass 10 9 lass 12 9 o9 om 9 oye 16 18 21 25 23 26 31 35 25 29 34 40 32 36 43 49 44 51 60 68 51 59 70 80 Table 12 Metric Stainless Steel Capscrews Bolts and Nuts Note The use of nickel anti seize compound is required to prevent corrosion due to galvanic action Apply nickel anti seize compound to the threads of these stainless steel fasteners before torquing to specification See Standard Sheet S574B for a more complete listing of stainless steel fastener torque values Metric Coarse Thread Stainless Steel Capscrews Bolts and Nuts Marine Transmission Service Manual 1022127 31 16 Description and Specifications Twin Disc Incorporated Table 13 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal Thread ett Thread 59 ho Diameter PO aus Diameter ONES 32 Marine Transmission Service Manual 1022127 Twin Disc
56. 100 D 115 D 125 Marine Transmission Service Manual 1022127 191 Special Tools Twin Disc Incorporated Rear Outer Bearing Installation Tool 2 00x45 2 places Outer Bearing Installation Tools for MG 5135A 100 125 129 149 710 110 D 80 D 125 192 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Seal Installation Tool Special Tools gt OA OB C Seal Installation Tools for MG 5135 A A 70 A 70 82 100 108 120 Marine Transmission Service Manual 1022127 2 00 12 00 193 Special Tools Twin Disc Incorporated End Play Bracket 5 2718 E NYHL OH OZ 1 e M 194 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Special Tools Output Gear Advance Tool ol LO Al 2 PLACES Bolt Weld 1 4 BSP pipe nipple or plug Marine Transmission Service Manual 1022127 195 Twin Disc Incorporated cial Tools Spe S Valve Test Body 1020117 1531 3AWA 39 18 2 2008 Se 9 201 ARS 9 p SE EN 1022127 196 Twin Disc Incorporated Special Tools B2408AL S Valve Test Procedure i Riess nt mmn ry 6 Add or remove the ans 5 psi
57. 150 SERIES M12x1 5 TH D ISO 6149 609 0 MECHANICAL 506 54 BACK VALVE 563 36 MECHANICAL PULL PUSH EFFORT REQUIRED 2 111 1568 25 351 FROM NEUTRAL POSITION m 36 53N 8 12Lb FROM SHIFTED POSITION 48272 z 4 7 i s 5 g 7 3 E 8 46567 62 65 2 47 4852 ON THIS SIDE 2 47 SECONDARY 82 65 525 366 6 CLUTCH ACTUATING PRESSURE M12x1 5 ISO 6149 ON OPPOSITE SIDE sor 11 9 15 32 DRILL THRU PRIMARY 12 HOLES EQUALLY SPACED EYEBOLT CLUTCH ACTUATING 285 30 302 8 373 8 USE 8 8 PROPERTY CLASS QUALITY PRESSURE M12x1 5 ISO 6149 i RO EY 045 OTHER SIDE OL DRAN amp OIL IN FROM HEAT EXCHANGER GRADE 5 QUALITY CAPSCREWS PER SAE J429 AND TORQUE TO 265 61 OIL FILLER HOLE 204 00 236 65 5574 OR SERVICE MANUAL VALUES EYEBOLT DISTANCE REQUIRED TO 199 0 204 0 REMOVE GAGE eeo De RUM EYEBOLT NECESSARY USE 8 8 PROPERTY CLASS QUALITY 21930 203 0 ME E OTHER SUE GRADE 5 QUALITY CAPSCREWS PER SAE J429 AND TORQUE TO 153 30 EYEBOLT SN 574 OR SERVICE MANUAL VALUES THIS SIDE USE HARDENED FLAT STEEL U i ENGAGED CLUTCH ON p PRIMARY SHAFT gt I 25 4 150 LUBE P S SECONDARY SOLENOID 29 9 14 1 5 TH D ISO 6149 ENGAGED CLUTCH ON Dies SECONDARY ST EE 354 NO 355 14 D ol iie eri GR sie THREAD 11717211685 PRESSURE M14x1 5 IS
58. 43195 e SAE H 10210065 10151225 NONE MABE NONE tOOS20 uc 1921000 1018 22 NONE NOW 10185258 E on 8 10216585 43197 H291000A 10151224 NONE 1020520 Loe 1228585 43198 3 1020522 NONE 1 20515 MAIOSBE 1218528 Kiss 102 556H H i 43194 1 102100084 2 202555 MATIESA NONE 1658528 x 20588172 4320 ES 1020542 M20515 MATIDSSG NONE _ 1018228 K1418 1 BOTTOM VIEW 50 55 TWIN DISC HAS 74 METRIC p Quem me 152 amp z ECN 2581 T 28 04 p E m ET 1021 658 12537 8 2 4 gt LIRE VALVE ASSY r e Se Ss Se cM n St 038 see ime ee se eme ES A1 c E F E n B A 1022127 07 05 POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
59. 5 amps DO NOT connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System The customer supplied selector switches for each of the transmission clutches and for troll if equipped must be connected directly to the wires of the Profile or E Troll Module and connected to the power source as shown in the table that follows No other electrical loads should be connected to this circuit Make the following Connections The following power connection chart lists the possible configurations for connecting Electronic Profile or E Troll Module to the power source for the three possible wiring options Option 1 connections are used when the Profile or E Troll Module is connected to non electronic lever heads Option 2 connections are used when the Profile or E Troll Module is connected to electronic gear controllers Option 3 connections are used when the Profile or E Troll Module is connected to electronic control solenoid driver outputs The electronic control s Solenoid A and B returns or negative signals should be connected together and connected to the E Troll module return if equipped Electronic control solenoid drivers must have their solenoid return internally connected directly to ground If not the Profile or E Troll Module must be interfaced to the electronic control with relays Marine Transmission Service Manual 1022127 181 Installation Twin Disc Incorporated Table 20 Mo
60. 7 11 Introduction 12 Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents 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 Selecting NEUTRAL disengages transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a shaft brake or other shaft locking device must be used To prevent accidental starting of the engine when performing routine transmission 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 thre
61. 9 Es IE Ss 7 5 LH PROPELLER ROTATION AL RH ENGINE FLYWHEEL OUTLINE MUST OPTIONAL EXTRA SUPPLIED DRIVING THRU CON DRM SAE 1520 ONLY WHEN SO SPECIFIED SECONDARY CLUTCH a LE as 7 6 1 30 DEEP SUCTION SCREEN 9190 50 E Hn N mE REF H C 45 Th 45 17 0 670 DRILL THRU J 6 HOLES EQUALLY SPACED EN 155 USE 8 8 PROPERTY CLASS QUALITY GRADE S QUALITY CAPSCREWS 15 7 12 CLEARANCE 920 2 THRU EER SOE AND TORQUE 0 140 551 DRILL THRU M20x2 5 TH D 32 5 1 28 DEEP c 5574 OR SERVICE MANUAL VALUES 60 0 16 HOLES EQUALLY SPACED EACH SIGE USE eee d 26 00 110 0 8 HOLES AS SHOWN USE 8 8 PROPERTY CLASS QUALITY ALL 12 HOLES FOR MOUNTING UNIT 150 GRADE MER aD USE 8 8 PROPERTY CLASS QUALITY 110 0 265 0 CAPSCREWS PER ISO 898 1 ARGUS NU 2 POLI GUA Em FOR INSTALLATION DIMENSIONS SEE MARINE BAE 429 AND TORQUE TO RAN MISSION SIN STAREAT DN DRANG 574 OR SERVICE MANUAL VALUES 202 32 sa 425 57 281 74 5 THESE TWO FLANGES DO NOT 89 6149 REQUIRE FITTED CAPSCREWS THE 302 0 CAPSCREWS SHOWN DO PROVIDE 502 28 ADEQUATE TORQUE CAPACITY WHEN 178 0 305 0 TORQUED AS RECEIVED p s n 614 706Nm 453 521Lb ft 51 0 NOTE 534 94 18 0 WHEN MOUNTING ENGINE TRANSMISSION IN BOAT ALL THE MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW COMPAN
62. 98 1 102 8 GRADE_5 QUALITY CAPSCREWS 4 ER SAE 4429 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES M20x2 5 TH D 32 5 1 28 DEEP 12 HOLES 6 EACH SIDE USE ALL 12 HOLES FOR MOUNTING UNIT USE 8 8 PROPERTY CLASS QUALITY 15 0 CLEARANCE TO REMOVE DRAIN PLUG CAPSCREWS PER ISO 898 1 GRADE 5 QUALITY CAPSCREWS PER SAE J429 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES 534 94 COMPANION FLANGE 9228 60 4152 40 152 45 i N BORE 9139 70 SUITABLE FOR MAX BORE OF 76 2 WITH 19 05 SQUARE KEY CENTER OF GRAVITY Y 2 DISTANCE REQUIRED GAGE_IS FLEXIBLE AND INTPUT SPEED PICK UP 0 14 1 5 TH D ISQ 6149 E 8 OIL FILLER HOLE LUBE P S I M10x1 0TH D IS0 6149 AUXILIARY LUBE SUPPLY INLET BREATHER REFER HYDRAULIC DIAGRAM OE A cH Wm LILIT 5 E 2 n 8 s 3 8 443 3 3 2 7 2 18 Q 8 2 g 3 3 E ha 8 5 lo S E 7188 SECONDARY S CLUTCH SHAFT Q d RH PROPELLER ROTATION 8 P ETE IN ol lm 0 4 RH ENGINE 5 m DRIVING THRU amp 5 PRIMARY CLUTCH 3 172 29
63. E MODE SWITCH ke 1 LY CLOSED WHEN MANUAL E REFER TO MARINE TRANSMISSION ASSEMBLY DRAWING OR SIMILAR TO VALVE IS IN THE CENTERED BILL OF MATERIAL FOR VALVE MOUNTING GASKET AND SCREWS REVISED AND REDRAWN SUPERSEDES 1020729 DATED 8 9 02 HEN LEVER IS ACTUATED FROM 1020525 MAX M 2 ECN12561 E B6 11 18 03 NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT wr UNLESS OTHERWISE SPECIFIED DATE Iv DMIR REFER L aa RUPRIETARY INFORMATION AND IS DIMENSIONS ARE 8 9 02 AU 2 L BS 12457 B6 T BE USED IN ANY MANNER ke wn NED PINS SCALE 1 Du o K E2 12413 D FERT aREAT FIRST USE RACINE WI 53403 USA SN T WIN SE CORPORA DT 50 231 RACINE WI 53403 T ui MGX 51144 AEYERS 1020 29 2 gt THIS NOTICE IS NOT INTEND T gt 6 n TO NULLIFY OR LIMIT RIGHTS SURRAGE lt I SEATHENT ALC SERIES SERVICEABLE SEPARATELY 4 GRANTED TO THE U S GOVERNMENT VAL VE S S Y APPD x NOT lt C R Y Rev SHEET Zune Rev SHEET ZENE 7 OTHERS BY CONTRACT GAM SHEET 1 oF l1 Rev M F E D C B NOTES RING A291 555 2 1018175 A PROPORTIONAL CONTROL OPERATION SCREW MASSEX 46 TL WARNING DO NOT CONNECT VALVE COIL DIRECELY PLUG amp 1A103883 MAIN PRESSURE CHECK d uii D Doc FO BATTERY 2OWEz Y
64. IED CONNECTION CHART TRANSMISSION MANUAL OVERRIDE SWITCHES Installation NORMALLY CLOSED NOT IN NEUTRAL RELAY CLOSED IN NEUTRAL CUSTOMER SUPPLIED SOLENOID RETURN Figure 162 E Troll Wiring Diagram WIRING SCHEMATIC SOLENOID RETURN TRANSMISSION MANUAL Fx OVERRIDE SWITCHES 4 TO START CIRCUIT 87A SOLENODAON m RED LED BLACK WHITE 200 mA MAXIMUM WHITE SOLENOID B ON BLACK NORMALLY CLOSED RED LED SLAGR SOLENOID A NOT IN NEUTRAL RELAY lt B CLOSED IN NEUTRAL MP CUSTOMER SUPPLIED RED lt y SOLENOID RED Be POWER OK GREEN LED BLACK oo PN RED SEE MODULE SOLENOID SWITCH POWER CONNECTION CUSTOMER SUPPLIED HART o_o SOLENOID A SWITCH CUSTOMER SUPPLIED Figure 163 Profile Module Wiring Diagram Marine Transmission Service Manual 1022127 183 Installation Twin Disc Incorporated Final Checks Be sure the transmission is filled with oil before starting See Description and Specifications and Preventative Maintenance for proper oil and filling procedure 184 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Special Tools Special Tools List of 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 continued on the fo
65. ION FLANGE THE 11840 CONFIGURATION IS NOT SUITABLE FOR REMOTE MOUNTING CENTER GRAVITY RECOMMENDED ACCEPTED i e METRIC w a MAX INPUT SPEED 2500 R P M AN NOTE CONSULT SALES DEPT APPLICATION THIRD ANGLE 9 ALL POINTS AVAILABLE FOR TESTING ARE CODED ENGINEERS FOR OTHER PROJECTION amp 85 8 LIMITING CONDITIONS amp 39 S s SIMILAR TO WEIGHT wR UNLESS OTHERWISE SPECIFIED DATE NDED 100 1 1 28 1 1 48 1 GEAR 198 9 388 d zoon DIMENSIONS ARE mm 15 2 SIUS UL kg Nm MACHINED DIMENSIONS SCALE x 0 75 1 5 INCORPORATED NOTICE THIS PRINT CONTANS HEAT TREAT FIRST USE xA 3002 2036 PROT USED IN ANT MANNER ALL ANGULAR TOLERANCES amp r DRAWN ASSEMBLY i DETRIMENTAL TO THE INTERESTS OF GEOMETRIC TOL ERANEING SP p x 1 1 8 SUITABLE FOR MAX BORE TWIN DISC INCORPORATED MODEL N PER ANSI Y14 5M_1982 CHECKED T OF 76 2 WITH 19 05 SQUARE KEY RACINE 53403 USA SURFACE TREATEMENT OUS perron GRANTED TO THE US GOVERMENT MGX 5135 SC ASSEMBLY DRAWING JCP sHeer 5 REVISION Q FORMAT A1 NOTE WHEN MOUNTING ENGINE TRANSMISSION BOAT ALL THE MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE TRANSMISSION SIDE MOUNTING PADS FAILURE DO SO MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW THE PX 11840 CONFIGURATION IS NOT SUITABLE FOR REMOTE
66. Ls Remove the capscrews still retaining the manifold 2 The manifold is equipped with two pusher screw locations to assist in the removal of the manifold Thread two M12 mm fully threaded capscrews lubricated into the pusher screw locations to push the manifold away from the bearing carrier A IMPORTANT Always lubricate the pusher screw threads before use Always tighten the pusher screws evenly 5135_0626 Figure 37 Manifold Removal 3 Lift the manifold and gasket taking care not to damage the piston rings on the end of the clutch shafts Discard the gasket Marine Transmission Service Manual 1022127 77 Disassembly Twin Disc Incorporated 4 Remove the oil lubrication tube 5135_0627 Figure 38 Oil Lubrication Tube Removal Secondary Clutch Shaft Manifold Bushing Note Only remove the manifold bushing from the manifold if it needs to be replaced If removed a new manifold bushing must be installed during assembly js Remove the two flat head screws that retain the manifold bushing 2 Use a pry bar on the bushing to remove it from the manifold 5135 0243 5135 0247 Figure 39 Secondary Clutch Shaft Manifold Bushing Removal 78 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Primary Clutch Shaft Manifold Bushing Note Only remove the manifold bushing from the manifold if it needs to be replaced If removed a new manifold bushing must be installed during assembly
67. MENTAL TO THE INTERESTS OF ASSEMBLY i EU TEE 1 SP TWIN DISC INCORPORATED MODEL GX SERIES PER ANSI Y14 5M 1982 CHECKED RACINE WI 93403 USA SURFACE TREATEMENT NAME YR ERIRE E ture sun GRANTED 10 THE US MGX HYDRAULIC DIAGRAM IEE a SN TT REG
68. Manual 1022127 25 26 Description and Specifications Twin Disc Incorporated Table 2 Marine Transmission Lubricant MARINE TRANSMISSION LUBRICANT OIL SERVICE CLASS USE S A E API SERVICE CLASS CD ENGINE OIL CERTIFIED BY VENDOR TO PASS TO 2 OIL TEST ALSO APPROVED ARE S A E API SERVICE CLASS CC ENGINE OIL MIL L 2104B AND TRANSMISSION FLUID TYPE C 3 VISCOSITY BASE SELECTION ON SUMP OIL TEMP CONDITIONS TABULATED BELOW START UP STEADY OPERATION VISCOSITY 32 F MIN 150 150 F 0 C MIN 65 85 C S A E NO 30 32 F MIN 175 210 F 0 C MIN 80 99 C S A E NO 40 STEADY OPERATION BELOW 150 F 65 C OR ABOVE 210 F 99 C IS NOT RECOMMENDED TWIN DISC INCORPORATED RACINE WI 65403 U S A B2411D B2411D Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Oil Pressures The following tables give oil pressures at different speeds and ranges Check your unit s identification plate for the Minimum Oil Pressure When Cruising Use this value to determine which table applies to your unit See MGX 5135SC rear view for location of oil pressure checkpoints Table 3 2414 kPa 350 psi Transmission Oil Pressure Specifications Limits for Marine Transmission Equipped with 2414 kPa 350 psi Proportional Valves Input Shift Main Pressure at Primary Secondary Speed Position Valve Inlet Clutch Min Clutch Min _ BEEE TE sw Seconda eer aware s rae m
69. NG 2 e Be sn el pua TAT THIS GASKET IS FLAT AGAINST THE MANIFOLD FACE BORE AND AGAINST PRIMARY SHAR EW D SHARD ASTEN USING 2 PM 1180G 1020152 1 5533 011 5519 ese eo 5 INSTALL 2 A2711AU DOWEL PINS PROVIDED INTO REAR END OF PRIMARY SHAFT SCREWS PROVIDED AND TORQUE SETA SR FA SERVICE MANUAL VALUES OUTRE BOTT OMINA SLIDE P T O ASSEMBLY STILL AIR PRESSURIZED CAREFULLY FORWARD OVER N ATOSS D 2 TET HOLE IS TAPPED FOR MIOX1 0 80 E1490 RING FITTING TO DELIVER AND BRING RINE E MN Fes P T O ASS Y MAY NEED TO BE ROTATED SLIGHTLY IN EITHER DIRECTION TO A Fic it BOLD 89 MINIMUM TO SE LUI CTILDURING ASSEMBLY ENGAGE THE PLATE TEETH IF P T O DOES NOT LINE UP WITH DOWEL PINS ENGINE zoe PRIMARY K Ad j UST BE HAND TURNED UNTIL P T O DOES LINE UP DO NOT RELEASE AIR PRESSURE SHAFT Al O CLUTCH PACK SECURE P T O WITH 4 MA996 S CAP SCREWS OR THE 4 1369 x STUDS AND 4 1399 NUTS PROVIDED AND TORQUE PER 5574 OR TO Y lF SERVICE MANUAL VALUES 10 5 12 AIR PRESSURE MAY NOW BE RELEASED DISCONNECT AIR LINE AND FITTINGS FROM CLUTCH HOUSING PX 11611 CARER Ie 3 ASSEMBLE BODY ASS Y 11610 ON CLUTCH HOUSING SECURE WITH a 5 53254 CAPSCREWS amp TORQUE PER 5 574 OR SERVICE MANUAL VALUES A LE 2033 T 110 12 7 12 7 95 2 KEY PM
70. O 6149 6 0 I s i OIL IN FROM HEAT EXCHANGER aj WATER OUT b 7 THREAD 1 1 2 11GAS BREATHER 5 LUBE 5 1 6 M10x1 0TH D IS0 6149 3 AUXILIARY LUBE SUPPLY INLET OIL FILLER HOLE REFER TO HYDRAULIC DIAGRAM 9 Mum 5 o e 9 3 8 D 3 IIT 9 S53 8 CD i 8 8 1 370 70 BREATHER A oL our HEAT excrancer Hy ma 5 f THREAD ISO 61 49 5 o a 18 8 _ e S a 9 460 62 FILTER DRAIN 8a 476 88 INLET zi 2 o gt CLEARANCE TO FILTER sl 9 REMOVE OIL PUMP DRAIN 2 aA 4 PRIMARY CLUTCH 8 SHAFT NO 464 43 LUBE P s G lt AUXILIARY LUBE E Le SUPPLY INLET 4 25 CENTER s glo EE OF GRAVITY W 2 CENTER EPI seconpary 7 OF GRAVITY CLUTCH N 47 62 LY SHAFT Q D gn 8 gt 8 i 130 00 7 d amp 8 dL eee Ee e RH PROPELLER ROTATION 8 2PL S E 8 8 463 67 8 R Co 3 PRIMARY CLUTCH y 65 00 3 X FOR AHEAD PROPULSION 2PL S G 48272 NS CLEARANCE SECONDARY 9 nla ajs REMOVE SUCTION S CLUTCH ACTUATING 22 Sle Ze ajn s f SCREEN 2 PRESSURE 14 1 5 50 6149 3 5 5 s 8553 8 H 5 D g OUTPUT SHAFT 8 j T OUTPUT m d SHAFT 8 2 8 S D al 8 ae 22 5 LUBE P S l 5 7 4 14 1 5 THD ISO 614
71. Py_11840 SRM OTHERS BY CONTRACT S MOAS T9990 MARINE TRANSMISSION TP uec SHEET REV 9 G B A PRIMARY SHAFT FRONT amp REAR BEARING PINION amp CLUTCH LUBE SHOWN ENGAGED SECONDARY SHAFT FRONT amp REAR BEARING PINION amp CLUTCH LUBE SHOWN DISENGAGED SYM CH N DATE SYM CH DATE LINES REDUCER BUSHIN STRAINER J MGX 5 HYDRAULIC DIAGRAM PICTORIAL FOR PRE SET PRESSURE SEE S 570 SER FOR PRE SET PRESSURE SEE 5 570 SER Bm n EN n SEQUENG SEQUENQ VALVE T VALVE T SHAFT SHAFT PRIMARY SECONDARY CLUTCH CLUTCH 1 FEMA VALVE 2 e i gt rior i i FEMA VALVE 2 CCW LEAR MATIX EA L pir fly Pies CW Lig SUMP oe PRESSURE REGULATOR
72. R CLUTCHED PUMP DRIVE 11615 pose Bnr GX 5135 SC MARINE ASS Y mo 11 9 15 32 DRILL THRU 12 HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY PER 150 898 1 GRADE 5 QUALITY CAPSCREWS PER SAE J429 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES 14 0 551 DRILL THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY PER 150 898 1 GRADE 5 QUALITY CAPSCREWS PER SAE J429 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES CARTRIDGE VALVE CONNECTIONS ARE NOT POLARITY SENSITIVE CONNECTOR MATES WITH METRIPACK 150 SERIES ELECTRIC CONTROL VALVE 10216584 188 13 7 41 98 3 3 87 ENGAGING 107 9 4 25 ENGAGING SECONDARY CLUTCH 103 24 4 06 NEURAL POSITION 34 92 1 37 MAIN PRESSURE CHECK M12x1 5 TH D ISO 6149 PRIMARY CLUTCH 606 54 285 30 265 61 OIL FILLER HOLE 219 30 EYEBOLT OTHER SIDE 153 30 EYEBOLT THIS SIDE USE HARDENED FLAT STEEL WASHERS 61 MIN UNDER SCREW HEADS 13 0 BREATHER
73. TAINED AS SPECIFIED IN THE SERVICE MANUAL OIL CAPACITY gal L AVAILABLE ON REQUEST REFER TO MARINE TRANSMISSION LUBRICANT 5 PLATE SHIPPED WITH UNIT BILL OF MATERIAL NO MUST GIVEN 3 WHEN ORDERING PARTS E U S PATENT NO 6 443 286 9 TWIN DISC INCORPORATED RACINE WI 53403 MADE BELGIUM EUR PATENT NO O P11954 Figure 1 Example of MGX 5135SC Nameplate 18 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Power Ratings Changing The MGX 5135SC transmission can be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation direction when viewing rear of engine Always reference the Bill of Materials BOM or Specification number when ordering service parts Rotation When shipped form the factory each unit is designated for use with a particular engine rotation Within their rated capacities these units may be operated continuously in either forward or reverse The unit can be adapted to either left or right hand engine rotation To adapt to opposite engine rotation remove the heat exchanger hose from the rear end of the pump Remove the pump turn it 180 and reinstall it Remove the plug from the rear of the pump and install where the heat exchanger hose was Install the heat exchanger hose where the plug was When changing from RH rotation
74. Torque Values for Fasteners susssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnana 31 Clutch Plate Wear Limits iei en cni n bavan dum FERREA RR deoa EE IRE 34 6 oT 12112 ne ee nr E 35 CIE 1 ERN RR tm 35 General Overview of GP Control Valve with Electronic Interface36 Hydraulic System with GP Control Valve 43 Power Take off aas Rae nua 47 Power FIOW ouais NE uREEI Mea ces INE NUR ANM INN 48 Preventative Maintenance 53 In boat Maintenance and Repair 53 General unn uan umana naa 54 Periodic Visual Inspection nep 56 Marine Transmission Service Manual 1022127 7 Table of Contents Twin Disc Incorporated 59 Troubleshooting of Electric Control Valve 59 Press re Test 60 Troubleshooting of GP Control Valve with Electronic Interface 61 Disassembly c 65 Prepare Transmission for Disassembly
75. Transmission Service Manual 1022127 Twin Disc Incorporated Operation Operation General The GP Control Valve with its Electronic Interface is used to obtain neutral and primary clutch engagement and secondary clutch engagement in this transmission When these positions are selected the control valve directs high pressure oil through internal passages to instantaneously and smoothly engage the clutches The pressure rate of rise controlled by the Profile Generator provides a rapid smooth clutch engagement Marine Transmission Service Manual 1022127 35 Operation Twin Disc Incorporated General Overview of GP Control Valve with Electronic Interface The General Purpose GP control valve is a hydraulic valve assembly for use with Twin Disc Marine Transmissions that may include an integral electronic interface control module The valve assembly contains current controlled proportional cartridges 36 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation GP Control Valve Hydraulic Portion The hydraulic portion of the GP Control Valve is made up of two blocks a lower main regulator valve body and an upper valve body The upper valve body contains two electrically actuated proportional valves and a manual direction control cartridge valve The lower valve body contains the hydraulic pressure regulating valve and a temperature sensor if the application requires it There are two different versions of t
76. VOLTAGE MIZ 5 THD CONFORMS PORT lt gt 22 SCREW MATTOOB 2 OPERATION PERFORMED WITH ONLY TWIN DISC 632 ae c os CONTROL SYSTEMS CR MODULES 5 2 5 e X PROPORTION AL VALVE MANUAL DIRECTIONAL CONTROL VALVE OPERATION QUA i TER gt SEE CHART 2 1 WTH MANUAE DIRECTIONAL CONTROL VALVE N 1026519 177 ON DX oce i SEE CENTERED POSITION FUSH TO ENGAGE PORT A ae ot cn Ta 2 WITH MANUAL DIRECTIONAL CONFRCL VALVE IN S RS CENTERED PULL TO ENGAGE PE UD MEE ME C MANUAL DIRECTIONAL CONTRO VALVE MODE SWITCH i IS NORMALLY CLOSED WHEN MANUA DIRECTION CONTROL VAEVE IS IN TEE CENTERED POSITION OPEN WHEN LEVER 5 ACTUATED FROM CENTERED POSITION 2 CURRENT 20 AMPS VALVE SEE CHART TO 35 102100CA SHOWN a 3 FOR WIRING SCHEMATIC REFER CO CONTROL MODULE SEE NOTE C t DRAWING p PLUG MA1S38B 2 D PRESSURE REGULATOR ADJUSTMENT CLUTCH PRESSURE PORT 1 REMOVE 1007144 CAP AND LOCSEN 1092145 NUT MI2xLSTHO CONSGRMS 2 CLOCKWISE ROTATION OF 19209394 PISTON INCR ASES TD 6149 PRESSURE COUNTER CLOCKWISE DECREASES PRESSURE GASKET 1020531 3 LOCK PISTON iN PLACE USING FAM NUT AND REPLACE Me E REFER TO MARINE TRANSMISSION ASSEMBLY DRAWING OR SEE NOTE BR P1072 CF MATERIAL FOR VALYE MOUNTING AND SCREPAS i 5 t
77. ace for assembly by using a Scotchbrite pad to remove any burrs b Clean the shaft tapered surface and the gear bore with an appropriate solvent Dry the shaft and clear all oil passages in the shaft with compressed air A CAUTION If the gear or shaft is damaged and cannot be repaired without material removal replace the part A CAUTION The tapered surface of the shaft and matching tapered gear bore must be completely free of grease oil dirt and solvent residue Failure to properly clean mating parts could prevent proper advance of the gear on the shaft and adversely affect torque carrying capacity of the assembled joint 2 Place the output shaft into the output gear and seat with a force of 445 890 N 100 200 Ibf 3 Measure from the end of the shaft to the shoulder of the shaft Measure three locations around the shaft The three readings should be identical Record this distance as Dimension A Marine Transmission Service Manual 1022127 133 Assembly Twin Disc Incorporated 4 Measure from the end of the shaft to the face of the output gear Measure three locations around the shaft The three readings should be identical Record this distance and Dimension B 5135_0050A Figure 108 Measuring Output Gear and Shaft Advancement 5 Subtract Dimension B from Dimension A to determine advancement The advancement should be 3 81 mm 0 150 in to 5 33 mm 0 210 in for all ratios 6 Remove the output gear
78. ad engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Transmission Service Manual 1022127 Twin Disc Incorporated Introduction Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Owner s Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment Under the conditiions described below the prop shaft must be locked in place to prevent backdriving Failure to do this can damage the marine transmission due to lack of component lubrication Backdriving also called windmilling occurs when an engine is shut down and the propeller shaft is being driven by the flow of water across the propeller which in turn rotates the components in the marine transmission During backdriving conditions the transmission does not receive proper lubrication Conditions where backdriving may occur Vessel is being towed One or more engines a multiple transmission vessel shut down while under way Sailboat under sail with auxiliary engine shut down Vessel tied or docked a heavy current Any of the following solutions are applicable if any of the above conditions are present Lock the propeller shaft to prevent rotation Add an optional trailing oil
79. all the Electronic Profile or E Troll Module on the top Valve Body and torque the four M6 1 0 capscrews to 9 5 Nem 7 Ib ft Figure 150 Place Profile or E Troll Module onto Valve and Tighten Capscrews 6 Connect the electrical wires to the proportional valves and connect any other wires that were removed during disassembly Marine Transmission Service Manual 1022127 165 Assembly Twin Disc Incorporated Adjustment of Main Pressure Valve Assembly 1020729 It is recommended that following the servicing of the GP Valve Assembly off of the transmission that a procedure be followed to ensure the flushing of oil through the valve assembly followed by adjustment of the main pressure 1 2 Install a main pressure gauge into the port on top of the Top Valve body Remove protective cover cap located at the end of the cartridge This will expose a 1 4 hex head adjustment stem Loosen the jam nut on the stem Adjusting Screw Figure 151 Pilot Relief Valve Assembly 3 166 Turn this adjustment stem counterclockwise until it reaches a positive stop This allows the engine transmission to be started and flush any debris past the relief valve Note This must be done with the transmission in Neutral Start engine with controls in neutral Main pressure should be approximately 100 psi or less Allow the fluid to flush the valve for approximately 1 minute Turn the 1 4 hex head adjustment stem clockwise to ach
80. aring cone Temporarily install the output seal carrier using four of the M12 capscrews Install capscrews and sealing washers to secure the gear pan Torque the M8 capscrews to 23 Nem 17 Ib ft Marine Transmission Service Manual 1022127 137 Assembly Twin Disc Incorporated Front Bearings Note Position the main housing with input end down Be sure the main housing is securely supported 1 Lubricate and install the primary clutch shaft front bearing 2 Lubricate and install the secondary clutch shaft front bearing 383_5135 Figure 113 Primary and Secondary Front Bearings Installation Install Secondary and Primary Clutch Shafts 1 Install an eyebolt into the end of the secondary clutch shaft Note When servicing a 1 1 ratio transmission it is necessary to remove or install both the primary and secondary clutch shaft assemblies at the same time 1_to_1_ spacer Figure 114 Primary and Secondary Clutch Shaft Installation 1 1 Ratio Transmissions 138 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 2 Lubricate the input end of the secondary shaft 3 Use a hoist to install the secondary clutch shaft in the main housing Be sure the snap ring retainer is on the shaft Use grease to hold itin place if necessary 4 Remove the eyebolt 5135_0628 Figure 115 Secondary Clutch Shaft Installation Install Primary Clutch Shaft ils Install an eyebolt into the output end of t
81. arings m 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 If you find one of these defects replace the bearing d 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 Bushings and Sleeves Inspect bushings for size and out of roundness Inspect for scores burrs sharp edges and evidence of overheating Remove scores with a crocus cloth If the bushing is out of round deeply scored or excessively worn replace it Thrust Washers and Spacers Inspect thrust washers for distortion scores burrs and wear Rework or replace any defective thrust washers or spacers 116 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Cleaning and Inspection Gears m Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the defect with a soft stone replace the gear Inspect gear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear Inspect thrust faces of gears for scores scratches and burrs If you cannot remove these defects with a soft stone replace the gear Splined Par
82. articularly dirty or filled with hardened grease A CAUTION Never dry bearings with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection 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 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 For previously sealed joints scrape surfaces to remove old gasket material or Loctite sealant Clean surfaces with 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 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Cleaning and Inspection Inspection Housings Cast Parts and Machined Surfaces Replace cast parts housings that are cracked Inspect bores for wear grooves scratches dirt Remove burrs scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by
83. ate 5 and Internal Snap Ring 6 7 Adjust the clutch pack clearance as follows a Install the plug in the center of the shaft where 5 valve would go b Install a hose clamp over the shaft next to the bearing to block the 8 mm 0 315 in sump passage in the shaft Place the shaft vertically with the backplate at the top of the clutch assembly d Apply a load of 100 200 N 23 45 Ibf to the backplate e Using a dial indicator zero the bottom position for the backplate Apply air pressure to the clutch apply hole located between the seal ring grooves at the shaft end f Observe the measurement of the clutch clearance on the dial indicator Clutch clearance must be between 2 30 3 20 mm 0 091 0 126 in If clutch clearance is out of specified range shim clutch using steel plates 2 34 2 38 mm 0 092 0 094 in thick friction plates 3 07 3 20 mm 0 121 0 126 in thick or cores from friction plates 1 54 1 57 mm 0 061 0 062 in thick 124 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly When shimming using friction or core plates the addition plate must be located between the backplate and last active friction plate When shimming using a steel plate the additional plate must be located between the last active friction and steel plates 0 Record the final clutch clearance 8 Install the front thrust bearing onto the input shaft in this order thrust washer pilots on shaft with
84. aw and refill with recommended oil See paragraph 1 Replace Proportional Valve Verify that green voltage supply light and red clutch energized lights are bright Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Disassembly The following procedure is for complete disassembly of the unit Prior to this procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility Note Photos are intended to illustrate the procedure and may not be consistent with previous disassembly steps Prepare Transmission for Disassembly Note During the service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the used components O rings gaskets and seals with the appropriate components for reference during the inspection and assembly process to make sure you don t forget the quantity size etc A CAUTION Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Pipe threads called out as PT British Standard Pipe Taper on drawings and in this text are different from NPT threads PT threads and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Most pusher screws used in the disassembly of this transmission are threaded through aluminum parts ALWAYS LUBRICATE the th
85. bearing bore in the main housing Install the bearing cup into the main housing Be sure the bearing cup is bottomed in the bore as the bearing cup warms to the ambient temperature 2 If removed install a new output shaft bearing cup in the main housing a Deep freeze the bearing cup to 51 C 60 F for at least two hours before installing it Handle the bearing cup with care The bearing cup is extremely COLD b Lubricate the bearing bore in the main housing Install the bearing cup into the main housing Be sure the bearing cup is bottomed in the bore as the bearing cup warms to the ambient temperature 3 Install a new input shaft seal a Apply MA1015 sealer to the outside diameter of a new input shaft seal b Press the seal into the housing using Special Tool TD 300492 Lip of seal should face away from the main housing when installed and rear of seal should be flush with the rear of the front housing bore 132 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Output Gear and Output Shaft Assembly Note To ensure the correct assembly of the output shaft into the output gear the advancement of the shaft into the gear must be measured The advancement is the distance the shaft will be pressed into the gear after metal to metal contact is made after placing the shaft into the gear by hand 1 Clean and inspect the output gear tapered bore a Prepare the gear tapered bore surf
86. chrome leather PTFE etc SKF LHMF 300 and LHDF 900 are available in 5 liter 5 3 qt cans Designation LHMF 300 5 and LHDF 900 6 Figure 165 SKF LHMF 300 and LHDF 900 Note Order Through Your Local Authorized SKF Distributor Marine Transmission Service Manual 1022127 187 Twin Disc Incorporated Special Tools Release Spring Compressor 0 t Marine Transmission Service Manual 1022127 188 Twin Disc Incorporated Special Tools Special Bearing Races Special bearing cups can be made by grinding 0 05 mm off the outside diameter A of standard outer bearing cups For Primary shaft preload adjustment Grind outer diameter A of one bearing cup PM 11445 For Secondary shaft preload adjustment Grind outer diameter A of one bearing cup PM11446 For Ouput shaft preload adjustment Grind outer diameter A of one bearing cup PM11448 Marine Transmission Service Manual 1022127 189 Special Tools Twin Disc Incorporated Front Outer Bearing Race Installation Tool 1 50x45 Outer Bearing Installation Tools for MG 5135A 120 144 122 149 134 159 190 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Special Tools Inner Bearing Race Installation Tool 2 00x45 2 places Inner Bearing installation Tools for MG 5135A 1 64 86 75 80 95 80 100 C 110 D
87. d drain oil from transmission Figure 19 Drain Plug 1 2 If equipped disconnect the water supply hoses to the heat exchanger 3 Mark the output flange and companion flange so they will always be assembled identically 4 Disconnect the output and companion flanges 5 Disconnect linkage wiring and plumbing and remove any items that would interfere with the removal of the transmission It may be advisable to remove the input and output speed sensors if equipped to avoid damaging them during transport 6 Support the transmission with a hoist and remove the mounting capscrews 7 Support the rear of the engine with blocks if necessary 8 Remove the 12 capscrews that secure the transmission to the engine 9 Push the transmission away from the engine Remove the transmission Remove the input coupling from the engine flywheel and secure it to the transmission for transport Marine Transmission Service Manual 1022127 67 Disassembly Twin Disc Incorporated Remove External Parts Note Place the main housing in the upright position to remove the following parts Be sure the main housing is securely supported Input and Output Speed Sensors If Equipped 1 Disconnect the input speed sensor and output sensor connector 2 Loosen the jam nut securing each sensor 3 Remove the input speed sensor and the output speed sensor from the main housing Heat Exchanger If Equipped Ti Disconnect the heat exchanger hoses
88. ducting or conduit Keep cable or harness away from hot surfaces moving parts and oil locations Attach cable or harness to vessel making the connector the highest point of the wire If not possible install cable or harness with drip loop Protect cable or harness with grommet loom or flex guard at any rub point particularly when passing a sheet metal hole Locate cable or harness away from potential hazards For example a capscrew cutting through the jacket and shorting a conductor to the chassis welding drilling heat exhaust burrs sharp edges etc Prevent the cable from becoming a step or handrail Make sure connectors will mate properly Locate and use the connector orientation key Circular connectors must be hand tightened and lock wired if possible Cable or harness bend radius must not be less than eight times the cable diameter Avoid twisting or winding the cable along its axis during installation or removal Marine Transmission Service Manual 1022127 179 Installation 180 11 12 13 14 15 16 17 18 19 Twin Disc Incorporated Whenever mating connectors always inspect each for damage or defects For example bent pins pushed back sockets broken keys etc Boots must be secured to cable or harness with cable tie to prevent boot from sliding off connector Cable tie must be installed over cable or harness and butted up against boot where the cable or harness exi
89. dule Power Connection Chart Wire Wiring Option1 Wiring Option 2 Wiring Option 3 Troll Enable Connect to the SANA Connect to the same Switch Return Negative terminal of the ground paint used hy point as the control s the gear controller or equipped engine battery the engine control power ground signal Connect to the Positive terminal of the engine battery through the switch contacts used to energize solenoid B Connect to the output in the gear controller that is used to energize Solenoid B Connect to the control s solenoid B Positive driver output Solenoid B Switch Connect to the Connect to the control s Solenoid Return Negative terminal of the grano peine teed solenoid Negative engine batter te gear See output circuit 9 the engine control Connect to the Positive terminal of the engine Solenoid A battery through the switch contacts used to energize Solenoid A Connect to the output in the gear controller that is used to energize Solenoid A Connect to the control s Solenoid A positive driver output Q The customer supplied normally closed not in neutral relay must be located in a position to not be affected by vibration The coil must have a 200 maximum current draw The coil must be connected to the two not in neutral wires of the Profile Generator da The contacts of the manual direction control switch closed in neutral must be wired in series
90. e threads and contact surfaces Pipe threads called out as PT British Standard Pipe Taper on drawings and in this text are different from NPT threads PT threads and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Where grease is specified use a lithium based grease NLGI 2 Submerge all new clutch friction plates in clean transmission oil for a minimum of one hour prior to installation This transmission uses liquid sealer in many locations The approved sealant is Loctite 518 MA1015 applied per S774 a thin layer of sealant is all that is required with Loctite Primer N MA1012 Avoid getting sealant into the O ring counter bores Marine Transmission Service Manual 1022127 119 Assembly Twin Disc Incorporated This transmission uses thread lockers MA908 and MA1007 at specified capscrew locations Note In the discussion that follows the input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing from the rear toward the front A CAUTION Appropriate eye protection must be worn during transmission assembly To avoid personal injury proper safety equipment must be used during installation of any heated bushings bearings and other components 120 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Prior to Assembly Output End Bearings Note Special
91. e transmission s hydraulic circuit before the control valve inlet and pressure regulator Pressurized oil from the filter is directed to the PTO control valve with the overage oil flowing to the transmission s control valve Marine Transmission Service Manual 1022127 47 Operation Twin Disc Incorporated Power Flow 48 Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is splined to the forward end of the primary forward clutch shaft causing the primary shaft to rotate in engine direction during engine operation Power is transmitted to the secondary shaft by means of the transfer gear teeth on the outer diameter of the primary clutch housing These teeth are in constant mesh with gear teeth on the of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in anti engine direction Application of the secondary clutch locks the secondary pinion to the secondary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in engine direction Note The following power f
92. f Twin Disc All returned parts new or old resulting from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty Marine Transmission Service Manual 1022127 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 If necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com 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 Marine Transmission Service Manual 1022127 15 Introduction Twin Disc Incorporated NOTES 16 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Description and Specifications General The MGX 5135SC is a reverse and reduction transmission with the additiona
93. f equipped and shims 88 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 3 Remove the seal from the seal carrier DCP 1037 DCP 1038 DCP 1039 Figure 56 Output Shaft Seal Carrier Removal 4 Remove the rear output bearing cup by pulling the output shaft assembly up 5 Place straps on rear to prevent shaft from coming out 6 Raise the transmission with a hoist Install the oil injector into the output shaft Note that these are special 1 4 19 BSP threads Support the transmission on suitable blocks Marine Transmission Service Manual 1022127 89 Disassembly Twin Disc Incorporated Note Raise the output shaft and use wooden blocks on each side of the gear to prevent damage to the main housing when separating the output gear from the shaft Aluminum bar stock also aids in removal of the gear from the housing ETE 5135 block Figure 57 Separating Output Gear From Output Shaft 7 Inject with viscosity of 900 mm S 900cSt at room temperature into the output shaft until the output gear lifts from the output shaft taper Note The front output shaft bearing cone will be forced part way off the shaft when the gear comes off the taper but will probably require additional removal force to remove completely 8 Lift the unit and remove the SKF fitting 9 Remove the upper blocks and support the shaft on a block and press the gear and bearing off the shaft 9
94. f pipe plug or optional temperature sensor into the valve body and torque to 23 Nem 17 d Install the M27 x 2 0 O ring plug into the valve body and torque to 75 Nem 55 Ib ft Regulator Valve Body 3 8 npt plug or Temp Sensor o ring Main Regulator Spool Pilot Relief Valve Figure 145 Main Pressure Regulator Components Assembly 1020729 162 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly s Valve Assembly 1021658 Assemble the Main Regulator Valve body a Install the filter into the threaded hole of the valve body and torque to 7 5 Nem 5 5 Ib ft If removed install a new check valve assembly into the bore of the valve body and drive it with a drift until it is flush with the face of the body Install the 3 8 pipe plug or optional temperature sensor into the valve body and torque to 23 Nem 17 Ib ft b Install the gasket and cover without the adjustment screw to the valve body with four M8 x 20 capscrews and torque to 23 Nem 17 Ib ft Install the spool with washer and spring into the bore Install the gasket and cover with the adjustment screw using four M8 x 25 capscrews Evenly tighten the capscrews and torque to 23 Nem 17 16 d Install the cap onto the adjusting screw finger tight as the main pressure must be set at the time of installation or testing Temperature Sensor Port Filter 3 Check Valve Cover Co
95. for MGX5145 or 1448 34 kPa 210 5 psi for MGX5147A and a flow rete S fS Umm 8 go Record final pressure at Z with flow rate of 2 3 Limin 6 gpm at 4 Increase rate at 5 3 8 L min 1 0 gpm Pressure at Z to be within range charted in 1 2 Record final pressure at Z with flow rate of 3 6 Limin 1 0 gpm at 5 set at charted pressure given in section II 2 t Dn 2 5 Leakage at 5 Date Marine Transmission Service Manual 1022127 197 Special Tools Twin Disc Incorporated NOTES 198 Marine Transmission Service Manual 1022127 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 and continued on the following page 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 11840 MGX 5135SC Marine Transmission Sectional View sheet 1 of 6 11840 MGX 5135SC Marine Transmission General View sheet 2 of 6 11840 MGX 5135SC Marine Transmission General View sheet 3 of 6 T PX 11840 MGX 5135SC Marine Transmission General View sheet 4 of 6 Q P 12182 Hydraulic Diagram 11615 11615 1020729 1021658 Marine Transmission Operator
96. from the output shaft 134 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 7 Position the main housing with the output end down Be sure the main housing is securely supported Place two wooden blocks inside the main housing and slide the output gear into the housing on the blocks Be sure the large end of the tapered bore is down 8 Carefully lower the main housing with gear onto the output shaft resting the weight of the gear on the taper of the output shaft 100_1271 Figure 109 Output Gear on Output Shaft in Main Housing 9 Place output gear advance tool over the end of the output shaft and center it Temporarily retain the tool with a special retaining bolt 1 4 19 BSP threaded bolt and washer Note It will be necessary to fabricate this special bolt Figure 110 Output Gear Advance Tool Secured to Output Shaft Marine Transmission Service Manual 1022127 135 Assembly Twin Disc Incorporated 10 Place assembly into a press supporting the output shaft end on the press Block the main housing for stability wm m 100 1269 100 1266 Figure 111 Main Housing with Output Gear in Press 11 Remove the 1 4 19 BSP special retaining bolt 12 Use output gear advance tool to press the output gear onto the output shaft Use the force shown in the following chart Static PressForce 500 706 kN 51 0 72 0 metric tons 451 628 kN 31 7 45 8 metric ton
97. g the cause of problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Marine Transmission Service Manual 1022127 59 Troubleshooting Twin Disc Incorporated Pressure Test Kit The Digital Pressure Transducer Kit BOM 42168 provides two pressure transducers 0 to 500 psi with hydraulic quick couplings a power supply box for the transducers and cables needed to connect the transducers to the power supply box and the signals out of the power supply box to a customer supplied digital volt meter Contact the Twin Disc Service Department Racine Wisconsin for specific information concerning this test kit One principle of troubleshooting is to start with the simple and move to the more difficult Check the simple items first Run the simple test first Then move to the more difficult Qty 2 Figure 17 Test kit 42168 60 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Troubleshooting Troubleshooting of GP Control Valve with Electronic Interface General The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause pr
98. he lower valve assembly The hydraulic pressure regulating valve in earlier versions Assembly 1020729 consist of two cartridge assemblies a pilot relief cartridge assembly and a main spool cartridge assembly The hydraulic pressure regulating valve in later versions Assembly 1021658 is not a cartridge assembly but is comprised of a spring and spool with an adjustment cover The regulating valve body contains a ball check valve assembly in parallel with an orifice with a filter that provides rapid fill and damping for the rear cavity of the regulator valve A kit is available to upgrade the earlier version to the later version The manual direction control cartridge valve contains a switch that is closed when the valve is in the neutral position Separate identical proportional cartridges are used for the primary and secondary clutch actuation When the primary or secondary clutch is selected by the operator the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate of rise profile is controlled electronically by the GP Control Valve Electronic Interface Profile or E Troll Module to provide a rapid smooth oil pressure increase in the clutch hydraulic passages during engagement A CAUTION The proportional valve coils are low resistance devices that are current driven The use of an uncontrolled power source may supply too much current and damage the proportional valve Note Installati
99. he primary clutch shaft 2 Lubricate the input end of the shaft 3 Use a hoist to install the primary clutch shaft in the main housing Be sure the snap ring retainer thrust washer is on the shaft Use grease to hold it if necessary 4 Remove the eyebolt 5135 0629 Figure 116 Primary Clutch Shaft Installation Marine Transmission Service Manual 1022127 139 Assembly Twin Disc Incorporated Rear Bearing Carrier 1 Place the Special Ground Bearing Cups into the bearing carrier 2 Assemble and install the lube relief valve to the rear bearing carrier Torque the two M8 1 25 x 16 capscrews with washers to 23 Nm 17 Ib ft 3 Using a new gasket place the rear bearing carrier on the main housing 4 Install the appropriate spacer in each bearing carrier bore DCP 1023 DCP_1022 Figure 117 Rear Bearing Carrier with Special Ground Bearing Cups 140 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Bearing Preload Measurement and Shimming Note Place the transmission on the front housing Be sure the transmission is securely supported General There are two means of measuring the shaft end play to determine the appropriate amount of shims necessary to obtain the required shaft bearing preload One method is to measure the shaft movement while using a dial indicator and the other method is to use a depth micrometer to calculate the clearance available for shims Both methods require the
100. ieve the main pressure setting A helpful practice is to turn the adjustment stem slightly beyond the desired setting approximately 5 psi and then adjust for the target pressure This aids in reducing variance in pressure setting due to torsional wind up of the spring Note If main pressure is to be set with cold oil adjust the main pressure approximately 5 to 10 psi higher than the desired value with hot oil Tighten the jam nut to a torque of 20 Nem 15 lbeft install the protective and torque it to 14 Nem 10 Ibeft Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Valve Assembly 1020729 1 Install a main pressure gauge into the port on top of the Top Valve body 2 Remove protective cover cap located at the end of the adjusting stem This will expose a slotted adjustment stem Loosen the jam nut on the stem Figure 152 Main Pressure Regulating Valve Assembly 1021658 3 Start engine with controls in neutral Note This must be done with the transmission in Neutral 4 Turn the slotted adjustment stem clockwise to achieve the main pressure setting See the specifications in Description and Specifications 5 Tighten the jam nut to a torque of 20 Nem 15 Ib ft install the protective cap and torque it to 14 Nem 10 Ibeft Marine Transmission Service Manual 1022127 167 Assembly Twin Disc Incorporated NOTES 168 Marine Transmission Service Manual 1022127 Twin Disc Incorpora
101. il level to FULL mark on the oil gauge Allow the oil temperature to cool to normal cold oil conditions perhaps overnight Check the oil level while cold at low idle engine speed while in neutral This is the proper oil level with cold oil Make note of the oil level in the cold conditions for future reference DO NOT overfill the tranmission The oil level should not be over the full mark at operating temperature A IMPORTANT Liquid sealant must cure for a minimum of 24 hours prior to contact with oil Marine Transmission Service Manual 1022127 55 Preventative Maintenance Twin Disc Incorporated Periodic Visual Inspection 56 General Check the mountings for tightness or damage such as cracks Tighten loose mountings and replace damaged parts Check pressure and temperature gauge where applicable Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required Q Inspect unit nameplates for looseness and corrosion Tighten mounting screws that are loose and replace nameplates that are corroded Q Inspect and oil the exposed stem of the Manual Direction Control Valve for corrosion protection Torsional Coupling DO NOT obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling The ambient temperature of the air around the coupling should be between 6 C 22 F and 80 C 176 F Assure baffles are installed properly
102. il to be lost overboard 3 High main oil pressure Pilot Relief Valve is out of Adjust Pilot Relief Valve adjustment Replace if necessary Main Regulating Valve orifice Replace main Regulating Valve missing cartridge 62 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Troubleshooting Table 18 Troubleshooting Chart GP Control Valve continued Symptom 4 High temperature 5 Excessive noise 6 No neutral 4 1 Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Worn or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Clutch plates warped Disengaged clutch has apply pressure Marine Transmission Service Manual 1022127 4 1 Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch If pressure is low replace Proportional Valve and service the transmission oil filter Overhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve Overhaul marine transmission Remove marine transmissio
103. l Quickshift feature The output shaft is parallel ot the input shaft The MGX 5135SC offers conical gearing for quieter operation and is available in the rollowing ratios 1 00 1 1 10 1 1 28 1 1 48 1 1 73 1 2 04 1 2 57 1 and 2 90 1 The MGX 5135SC transmission is controlled by hydraulics Both the primary and secondary clutches are operated by main pressure oil supply The bearings clutches and gears are lubricated and cooled with low pressure oil Drawing PX 11840 identifies the installation information for the MXG 5135SC marine transmission Marine Transmission Service Manual 1022127 17 Description and Specifications Twin Disc Incorporated 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 your transmission MODEL QUICK i 19 SHif addis c BOM NO MARINE TRANSMISSION SERIAL NO LUBRICATION EVERY 10 SERVICE HOURS OR DAILY CHECK OIL LEVEL RATIO WITH ENGINE RUNNING AND MARINE TRANSMISSION IN NEUTAAL EVERY 1000 SERVICE HOURS OR 6 MONTHS or MER WHICHEVER COMES FIRST DRAIN AND REFILL HOUSING WITH CLEAN OIL REMOVE AND REPLACE FILTER ELEMENT REMOVE CLEAN AND REPLACE SUCTION SCREEN MIN OIL PRESSURE psi IN REAR COVER AT RATED RPM IMPORTANT WARRANTY IS VOID UNLESS TRANSMISSION IS LUBRICATED AND MAIN
104. l damage to the marine transmission or vessel Clutch release occurs when the proportional valve is de energized and the oil from the small area of the clutch apply piston is allowed to flow to sump through the control valve and the oil from the large area of the clutch apply piston is allowed to flow to sump through a dump ball in the clutch housing and through the 5 valve through a passage in the shaft into the transmission sump The electronic interface portion of the control valve allows only one proportional valve to be energized at a time thus only one clutch can be engaged at a time Marine Transmission Service Manual 1022127 43 Operation Twin Disc Incorporated and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Note Installations with this valve include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 75 or better Gy Se eee Mud Figure 11 Hydraulic Schematic MGX 5135A 44 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation 1 TEE s Bos EE i 2 A ol War FEHA VALVE L A WAL YE DUO d sx i
105. lation 2 Install the filter bypass valve in the manifold Secure the filter bypass valve in position with the retaining ring 5135 0261 5135 0259 Figure 126 Filter Bypass Installation 150 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 4 Place the manifold gasket on the rear bearing carrier 5 Position the manifold on its gasket Align roll and shim pack with clearance cavity in manifold Torque the capscrews to 46 Nem 34 Ib ft DCP 1017 DCP1014 Figure 127 Manifold Installation Output Flange Note Prior to installation of the output flange install the v ring on the output flange with the thin wiper away from the flange face ile Heat the output flange to 120 C 250 F for 30 minutes Assemble the flange on the output shaft Take care not to damage the oil seal when engaging the flange A CAUTION Handle the output flange with care The output flange is HOT Marine Transmission Service Manual 1022127 151 Assembly Twin Disc Incorporated 2 The flange can also be installed by the aid of a special tool TD 300389 Bolt the special tool washer to the output flange and install a hydraulic ram Use the ram to push the flange onto the shaft Output flange 1 Figure 128 Output Flange Installation d Measure the gap from the shoulder of the output flange on which the retainer washer rests on to the end of the output shaft Output flange 4 Figure 129 Measu
106. lease spring MG 054 Figure 81 Spring Retainer and Release Spring Removal 10 Removethe clutch piston from the clutch housing a Blow compressed air into the hole between the piston ring grooves at the rear end of the shaft to remove the clutch piston b Remove the piston rings from the outside diameter of the clutch piston and from the outer bore of the small area of the piston B Remove the O ring from the inner diameter of the clutch piston MVC 772F Figure 82 Piston Ring and O Ring Removal 104 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Disassembly of GP Control Valve with Electronic Interface The GP Valve is made up of a non serviceable electronic interface and two valve bodies with plugs and cartridges O ring kits are available for servicing the plugs and cartridges however none of the cartridges are field serviceable beyond replacement of the o rings The later version Assembly 1021658 of the hydraulic pressure regulator valve is serviceable and contains an orifice filter plug and a ball check valve assembly that are replaceable e Figure 83 GP Valve Assembly Mounted on Marine Transmission Marine Transmission Service Manual 1022127 105 Disassembly Twin Disc Incorporated Disassembly ls Disconnect the connectors at the proportional valves the neutral switch and the temperature sensor if equipped and loosen the four M6 1 0 capscrews that retain the
107. ll the clutch piston into the clutch housing a Lubricate and install a new piston ring on the outside diameter of the clutch piston b Lubricate and install a new piston ring on the small area sealing surface of the clutch piston C Lubricate and install a new O ring in the inside diameter of the clutch piston d Install the clutch piston into the clutch housing Note If the clutch piston is difficult to install by hand remove the clutch piston and inspect the piston rings MVC 772F Figure 101 Piston Rings and Installation Marine Transmission Service Manual 1022127 127 Assembly Twin Disc Incorporated 3 Position the secondary clutch shaft under a hydraulic press a Slide the release spring over the shaft b Place the spring retainer on the release spring Use Special Tool T 18502 to compress the release spring far enough to expose the snap ring groove in the shaft d Install the snap ring rom MG 053 Figure 102 Release Spring Spring Retainer and Snap Ring Installation 4 Install the clutch plates as follows Install a friction faced plate and alternate with steel and friction plates until the 9 steel and 10 friction plates are installed finishing with a friction plate MG 052 DCP 2001 Figure 103 Clutch Plates Installation 128 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 5 Install the clutch back plate 5 Press the back plate firmly into the cl
108. llowing page D D D D D D DO D D D THAP 300 Air Driven Pump Set Release Spring Compressor Special Bearing Races Front Outer Bearing Race Installation Tool Inner Bearing Race Installation Tool Rear Outer Bearing Race Installation Tool Seal Installation Tool End Play Bracket Output Gear Advance Tool 1020117 S Valve Test Body B2408AL S Valve Test Procedure Marine Transmission Service Manual 1022127 185 Special Tools Twin Disc Incorporated Recommended Pump Set and Fluids Twin Disc recommends the following products for use in the assembly and removal of tapered shafts using the oil injection method THAP 300 Air Driven Pump Set This set consists of the air driven pump with accessories such as an adapter block pressure gauge high pressure pipe or pressure hose with quick connection couplings and connection nipples The set includes one of each air driven pump THAP 300 adapter block 226402 pressure gauge 1077589 and high pressure pipe 2m 6 5 ft 227957 Figure 164 THAP 300 Air driven Pump Set 186 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Special Tools Mounting Fluid LHMF 300 and Dismounting Fluid LHDF 900 SKF LHMF 300 and LHDF 900 are recommended when using SKF hydraulic equipment like hydraulic pumps HMV nuts oil injection equipment etc The fluids contain anticorrosives and are non aggressive to seal material like nitrile rubber Buna N Perbunan
109. low illustrations are shown merely as examples of power flow and may not pertain specifically to your unit Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Operation_mg5135sc_N1 Figure 14 Example of Power Flow in Neutral Marine Transmission Service Manual 1022127 49 Operation Twin Disc Incorporated Primary When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel plates are spline connected through the clutch hub assembly to the pinion Because the primary input pinion is in mesh with the output gear the output gear and shaft will rotate in anti engine direction The secondary input pinion will be backdriven engine direction when the unit is in the primary position Operation_mg5135sc_P1 Figure 15 Example of Power Flow with Primary Clutch Engaged 50 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation Secondary In secondary the same parts are turning that were turning in neutral When the secondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates together The secondary inpu
110. n Replace worn or damaged coupling Select proper torsional coupling Overhaul marine transmission Check alignment of engine transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine Remove clutch plates Overhaul unit Replace Proportional Valve Service transmission oil filter 63 Troubleshooting Twin Disc Incorporated Table 18 Troubleshooting Chart GP Control Valve continued 7 Harsh engagement 8 Low lube pressure Oil spilling out of breather 10 Low clutch apply pressure 64 7 1 7 2 7 3 Faulty Proportional Valve Faulty temperature sensor if equipped Profile Generator defective or out of adjustment Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Low Main Pressure Defective Proportional Valve Low voltage to Profile Generator 7 1 7 2 7 3 Replace Proportional Valve Replace Temperature Sensor Replace Profile Generator Adjust if proper equipment is available Replace pump Remove clean inspect and install the suction screen Inspect and correct cause of suction leaks Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Dr
111. n the last active friction and steel plates 0 Record the final clutch clearance 8 Install the front thrust bearing onto the input shaft in this order thrust washer with recessed bore over the snap ring needle bearing and thrust washer 5135_0286 Figure 105 Installing Front Thrust Needle Bearing and Thrust Washers 9 Lubricate the area of the clutch shaft that will contact the pinion assembly Install the pinion assembly Gently rotate the pinion as it is lowered into the clutch plates until the splines are fully engaged in all the clutch plates 5135_0283 Figure 106 Pinion Assembly Installation 130 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 10 Install the larger diameter thrust washer into the pinion bore 11 Install the front needle bearing and remaining rear thrust washer Note This thrust washer pilots on the shaft 5135 0281 Figure 107 Front Thrust Washers and Needle Bearing Installation 12 Install the snap ring to retain the front thrust washers and needle bearing and pinion Marine Transmission Service Manual 1022127 131 Assembly Twin Disc Incorporated Main Housing Assembly 1 If removed install new clutch shaft input end outer bearing cups in the main housing a Deep freeze the bearing cup to 51 C 60 F for at least two hours before installing it Handle the bearing cup with care The bearing cup is extremely COLD b Lubricate the
112. nately missing Marine Transmission Service Manual 1022127 61 Troubleshooting Twin Disc Incorporated Table 18 Troubleshooting Chart GP Control Valve with Electronic Interface 1 Low main oil pressure 1 1 Partially clogged oil strainer 1 1 Remove and clean oil strainer 1 2 Contamination on Pilot Relief 1 2 Disassemble the Pilot Relief Valve seat Valve and clean Service the tranmission oil filter Contamination on Main Valve Clean or replace Main Valve Cartridge Cartridge and service the transmission oil filter Broken piston rings on clutch Remove the collector and shafts inspect the piston rings Damaged or worn oil pump Replace damage or worn oil assembly pump assembly pump is not serviceable Engine idle speed too low Raise engine speed 2 No oil pressure or erratic Oil pump suction strainer Remove and clean strainer low pressure at control plugged valve tap Oil level low Check oil level and correct Air leak on suction side of Correct cause of air leak pump Pump drive on reverse clutch Disassemble and repair as shaft broken required Pilot Relief Valve or Main Remove disassemble clean Regulating Valve stuck in open and repair the Pilot Relief position Valve Remove clean or replace the Main Regulating Valve This valve cannot be disassembled Oil pump defective Replace oil pump Leaking heat exchanger has Replace heat exchanger caused o
113. ng Installation Suction strainer 1 Place the suction strainer in the manifold Install an O ring on the clamp plate 2 Secure the suction strainer with the clamp plate and capscrew washer d Torque the M12 1 5 capscrew to 80 Nem 59 Ibeft 4 Torque the M12 x 90 capscrew to 80 Nem 59 Ib ft 5135 0161 5135 0159 Figure 135 Suction Strainer Installation Marine Transmission Service Manual 1022127 155 Assembly Twin Disc Incorporated Oil Bypass Cover 1 Apply MA1015 seal to the oil filter bypass cover 2 Install the oil filter bypass cover e Torque the four M10 x 45 capscrews to 46 Nem 34 Ib ft 4 Torque the M12 x 90 capscrew to 80 Nem 59 Ib ft 5135 0157 5135 0156 Figure 136 Oil Filter Bypass Cover Installation PTO Cover Note Some units may have heat exchanger bracket 1 Lubricate and install anew PTO cover O ring 2 Install the PTO cover or the heat exchanger bracket 156 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 9 Torque the four M12 30 capscrews to 80 Nem 59 Ib ft 5135_0155 Figure 137 PTO Cover Installation Hydraulic Pump 1 Verify that the pump drive tang engages correctly in the slot at the end of the secondary clutch shaft 2 Observe the index marks on the pump and the manifold made during disassembly Install the pump and gasket following the index marks Note Verify that the pump is installed in the correct position
114. oblems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Electronic Interface LED Indicators The electronic interface control modules have one green and two red led indicator lights The green power light is illuminated ony when the transmission is in gear The following table lists the reasons for the various conditions where lights are illuminated This should guide in troubleshooting problems See the wiring schematics in the Installation Section Troubleshooting Tables begin on the next page Table 17 LED Light Status Light Status Profile Generator E troll Module Non trolling Green light on Supply voltage 9 0 volts Supply voltage 9 0 volts Red light on Valve coil command on Valve coil command on One red light flashing All Units Open circuit in an Open circuit in an energized energized valve coil circuit valve coil circuit or valve coil leads shorted together or low MG Units Only Valve coil leads coil current shorted together or low coil current Both red light flash MG Units Power is applied to After entering troll from neutral simultaneously solenoid A and B switch inputs with both voltage and current at the same time troll speed signals present or power is applied to solenoids A Units Not applicable and B switch inputs at the same time Both red light flash Not applicable Either or both speed signals alter
115. oes 7 avo Wewar Tese2000 e7ozeo o 0 vesa7e Note Cooling temperature range Delvac 1110 oil at 29 35 C 85 95 F or Mobilkote 501 at 32 38 C 90 100 F Required Primary lube pressure secondary lube pressure within 21 kPa 3 psi Primary and secondary clutches must be within 21 kPa 3 psi of each other ALL SHIFTS MUST BE DONE AT OR BELOW 1800 RPM Table 4 Limits for Marine Transmission Equipped with Hydraulic Clutched PTO Limits for Marine Transmission Equipped with Hydraulic Clutched PTO PTO Control Valve PTO Control Valve Disengaged Engaged 1793 1931 260 280 Transmission Control Valve Control Valve Note Transmission control valve is the right valve and the PTO valve is the left valve when viewed the rear of the transmission Marine Transmission Service Manual 1022127 27 Description and Specifications Twin Disc Incorporated Optional Equipment 28 The following optional equipment is available for the MGX 5135SC marine transmission except where noted through the nearest authorized Twin Disc distributor Power Take off A live pump mount power take off is available in sizes SAE J 744 No 127 4 and SAE J 744 No 32 4 SAE 4 bolt A clutchable pump mount power take off is available in sizes SAE J 744 No 127 4 and SAE J744 No 32 4 A clutchable shaft drive power take off is available PTO adapter from SAE J 744 size 127 4 to 101 4
116. of the rear two thrust washers and needle bearing for proper assembly The first washer removed pilots in the bore of the pinion and the second pilots on the shaft This thrust washer also has a counterbore to fit over the snap ring DCP 1048 MVC 763F Figure 68 Rear Two Thrust Washers and Needle Bearing Removal 7 Remove the internal snap ring and back plate from the clutch housing 051 Figure 69 Internal Snap Ring and Back Plate Removal Marine Transmission Service Manual 1022127 97 Disassembly Twin Disc Incorporated 8 Remove the 9 steel plates and 10 friction plates from the clutch housing MG_052 Figure 70 Steel Plate and Friction Plate Removal 9 Position the primary shaft and clutch housing under a hydraulic press a Place Special Tool T 1802 on the spring retainer b Compress the release spring enough to expose the snap ring Remove the snap ring Figure 71 Compressing Release Spring and Snap Ring Removal 98 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly d Carefully remove tension on the release spring e Remove the spring retainer and release spring MG_054 Figure 72 Spring Retainer and Release Spring Removal 10 Remove the clutch piston from the clutch housing a Blow compressed air into the hole between the piston ring grooves at the rear end of the shaft to remove the clutch piston b Remove the piston rings from the outside
117. ons with this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 75 or better Besides the valve s requirement on filtration the filter must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1022127 37 Operation Twin Disc Incorporated PROPORTIONAL VALVE a MANIFOLD 4 CN 3 _ V e n PROPORTIONAL VALVE p n MANIFOLD N o a a SUMP D gt W 1 p 2 2 LUBE 02 L 1 1 Li PRESSURE REGULATUR YDRAULIC DIAGRAM lt GRAPHIC SYMBOLS Figure 4 Hydraulic Schematic GP control valve Assembly 1020729 38 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation SEQU VALVE SECONDARY CLUTC TO CLUTCH 4 34 TO CLUTCH 4 1 PROPORTIONAL VALVE a 2 5 1 Wc W Mee Y EE PROPORTIONAL VALVE ccce ag 2 1 1735 aj ott HIX COS p i A f i be ec A e a 1 SUMP e A
118. or the engine flywheel housing Recommended Accepted Figure 158 Transmission Mounting Configurations When mounting the engine and transmission in the boat all of the mounting pads on both the engine and the transmission must be used Failure to do so may result in damage to the transmission Marine Transmission Service Manual 1022127 175 Installation 176 Twin Disc Incorporated Itis important to align the engine and transmission only when the boat is afloat and NOT in dry dock During this alignment period it is also advisable to fill the fuel tanks and load the boat in the typical manner that it is to be used Some boats are built with flexibility and may change shape as the loading varies When a heavy boat is dry docked it naturally undergoes some bending Therefore it is always good practice to unbolt the marine transmission coupling to prevent bending of the shaft With the engine and transmission in position on the engine bed arrangements must be made to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine can be raised by screwing down or lowered by backing off on the jacking screws to obtain the desired adjustment Steel plates must be inserted under the jacking screws so that the bolts will not damage the engine bed Lifting can al
119. ove 4 Install the output shaft seal carrier to the main housing a Place the previously selected shims and seal carrier on the main housing DCP 1039 DCP1038 Figure 119 Output Shaft Seal Carrier Installation 144 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly b Install the output speed sensor pickup bracket if equipped DCP_1037 Figure 120 Output Speed Sensor Pickup Bracket Installation Secure the seal carrier Torque the M12 1 25 capscrews to 80 Nem 59 Ibeft 5 Install new clutch shaft bearing cups in the rear bearing carrier a Deep freeze the bearing cup to 51 C 60 F for at least two hours before installing it A WARNING Handle the bearing cup with care The bearing cup is extremely COLD b Lubricate the bore of the rear bearing carrier Use a bearing installation tool to install the bearing cups into the rear bearing carrier 6 Assemble and install the lube relief valve to the rear bearing carrier Torque the two M8 1 25 x 16 capscrews with washers to 23 Nm 17 lb ft Marine Transmission Service Manual 1022127 145 Assembly Twin Disc Incorporated 7 Place the gasket and rear bearing carrier on the main housing Install and align the lube tube if it was removed from the bearing carrier DCP 1023 DCP 1022 Figure 121 Rear Bearing Carrier Installation 8 Install the bearing spacers and shim packs as determined by measurement
120. p with an electric welder This will cause the bearing cup to shrink allowing it to be removed weld_bearning_cup1 Figure 64 Example of Welded Bearing Cup 94 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Primary Clutch Shaft Disassembly 1 Remove the rear bearing cone Note Only remove the cone from the primary clutch shaft if it needs to be replaced If removed a new bearing must be installed during assembly a Cut off the bearing cage and remove the rollers b Use a cheese cutter type puller to pull on the rear shoulder of the inner bearing race Heat the inner race to assist in its removal A CAUTION DO NOT overheat the inner race as it could result in annealing the clutch shaft Handle the inner race and shaft with care The inner race and shaft is HOT 2 Position the primary clutch shaft with the input end facing up 2 Remove the snap ring DCP_1043 Figure 65 Snap Ring Removal Marine Transmission Service Manual 1022127 95 Disassembly Twin Disc Incorporated 4 Remove the front needle bearing and thrust washers DCP_1045 Figure 66 Front Two Thrust Washers and Needle Bearing Removal 5 Slide the pinion assembly from the shaft DCP_1046 Figure 67 Pinion Assembly Removal 96 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 6 Remove the rear two thrust washers and needle bearing Note Record location
121. pinions are supported on bushings and the end movement limited by thrust washers Bearing clearances for each clutch shaft are set by use of a single shim pack at the rear tapered roller bearing on each shaft Tapered roller bearings support the output shaft and have bearing clearance adjusted by use of shims Oil Pump Drive The oil pump is tang connected and driven by the secondary clutch shaft Marine Transmission Service Manual 1022127 Twin Disc Incorporated Description and Specifications Lubrication Features The MGX 5135SC transmission bearings and clutches on the primary and secondary shafts are lubricated through oil passages drilled in the shafts The output shaft bearing transfer gears primary and secondary pinions and their bearings are gravity and splash lubricated Suction Strainer The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and the oil pump in the hydraulic circuit The strainer can be replaced if necessary Oil Filter Assembly A spin on oil filter is a standard feature on MGX 5135SC transmissions filter is located between the heat exchanger outlet and the selector valve in the hydraulic circuit The replacement element should be replaced at 1000 hours or six month intervals whichever comes first The replacement filter part number is PM11652 Gears All gears are helical carburized hardened and ground for smooth quiet
122. porated General Maintenance 54 Overhaul Interval Acomplete overhaul and thorough inspection of the unit should be made at the same time as the scheduled engine overhaul Refer to Cleaning and Inspection for more detailed inspection instructions Oil System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil in it With the engine running at low idle and the transmission in Neutral check the oil again The oil level should be near the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval Maximum Note A suction screen is located in the suction line to the pump and the oil filter if equipped is located in the pump outlet line Both should be checked and cleaned at the stated intervals With a new transmission change the oil and filter element if equipped and clean the suction strainer screen within the first 50 hours of operation Change oil and filter element and clean the screen after each 1000 hours thereafter or more often if conditions warrant For a rebuilt transmission check the filter element and or screen after eight hours of operation If the filter and or screen is clean install a new filter element if equipped and then change the oil and filter element
123. r suitable means and place the unit in position against the engine flywheel housing Secure the flange of the marine gear main housing to the engine flywheel housing Use a feeler gauge between each mounting bracket and engine bed rail Add shims between the brackets and bed rails to equal the feeler gauge readings Carefully release the lifting force on the marine gear while observing the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading moves from zero lift the marine gear and insert additional shims Continue this procedure until the marine gear is completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of the engine flywheel housing secure the mounting brackets to the engine bed rails Before securing the mounting brackets to the engine bed rails the propeller shaft should be checked for alignment Note The transmission output flange and companion flange bolts must be torqued to the proper value as identified in Description and Specifications 174 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Engine and Marine Transmission Alignment A CAUTION Installation When mounting the engine and transmission in the boat all of the mounting pads on both the engine and transmission must be used Failure to do so may result in damage to the transmission
124. r clutch B is engaged A CAUTION Engagement of a clutch with the Manual Direction Control Valve should only be done with the engine at idle speed Locking Pin 4 Figure 13 Manual Direction Control Valve 46 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Operation Power Take off Optional There is a separate manual part number 1020075 which describes the operation installation troubleshooting and service of the optional Power Takeoffs PTO for this marine transmission Live Power Take off PX 11824 The live PTO drives accessories using engine horsepower Since the live PTO connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven whenever the engine is running Hydraulic Clutched Power Take off PX 11615 Series The PX 11615 model has a keyed PTO output shaft THe PX 11615A model has internal splines and accepts an SAE J744 size C pump The hydraulic clutched PTO also allows accessories to be driven using engine horsepower Since the PTO is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The PTO is engaged by rotating the lever of the PTO control valve The hydraulic clutched PTO operates with an engaged clutch pressure greater than that of the transmission s primary and secondary clutches For this reason the PTO control valve pressure increasing valve is in th
125. re Output Flange For Shims 152 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 4 Add shims that are 0 075 0 150 mm 0 003 0 005 in thinner than the gap Install the rectangular rubber washer and retainer washer Output flange 2 Figure 130 Output Flange Shim Installation 5 Install output flange clamp plate Apply Loctite 242 to the three M12 x 40 capscrews and torque to 80 Nem 59 Ib ft Output flange 3 Figure 131 Output Flange Clamp Plate Installation Marine Transmission Service Manual 1022127 153 Assembly Twin Disc Incorporated Install External Components Output Gear Pan Note Place the main housing in the upright position Be sure the main housing is securely supported 1 Place new seal washers on the four M8 output gear pan capscrews 1 2 Torque the capscrews to 23 Nem 18 Ibeft DCP_1031_4 Figure 132 Securing Output Gear Pan Front Output Cover 1 Lubricate a new O ring with grease 2 Install the O ring onto the cover e Press the cover 1 into bore of the main housing DCP 1031 1C Figure 133 Front Output Cover 1 Installation 154 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Input Housing 1 Position the input housing on the main housing 2 Secure the input housing wiht twelve M12 1 75 capscrews and washers Torque the capscrews to 80 Nem 59 Ib ft DCP_1030 DCP_1029 Figure 134 Input Housi
126. reads of the pusher screw before threading it into the mating part When installing pusher screws avoid rapid tightening with an impact wrench or similar device If an impact wrench is used with the pusher screws the threads may gall or seize in the aluminum part Tighten pusher screws in an even manner to avoid damaging components Marine Transmission Service Manual 1022127 65 Disassembly Twin Disc Incorporated Component Identification INPUT SHAFT ROTATION RH ENGINE PRIMARY CLUTCH LUBE PRESSURE CHECK CONTROL VALVE PRIMARY CLUTCH PRESSURE CHECK BREATHER OIL FILL PLUG LUBE PRESSURE o CHECK P E55 9701010 29 OIL PUMP GG INPUT SPEED SENSOR K OOOO 0009 i O A OIL LEVEL GAUGE SECONDARY O CLUTCH o a D LUBE PRESSURE OIL GAUGE TUBE ASSEMBLY 5 ad i o PTO COVER RH PROPELLER ROTATION RH ENGINE PRIMARY CLUTCH SECONDARY CLUTCH PRESSURE CHECK 8 1 25 D PUMP SUCTION STRAINER LH PROPELLER OUTPUT SPEED ROTATION RH ENGINE SENSOR OIL DRAIN PLUG SECONDARY CLUTCH MANIFOLD MG 311 Figure 18 GP Control Valve with Electronic Interface 66 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Prior to Removal Ts Remove drain plug 1 an
127. rear bearing carrier The bearing cups must be removed for clutch shafts shimming procedure Use a bearing driver to remove the bearing cups Marine Transmission Service Manual 1022127 81 Disassembly Twin Disc Incorporated Primary and Secondary Clutch Shaft T Remove the two M8 x 20 capscrews that retain the pump drive to the secondary clutch shaft Remove the pump drive 316 5135 317 5135 Figure 45 Pump Drive Removal 2 Remove the spacer and S valve from the secondary clutch shaft A small wire with a hook on its end can be used to help pull the S valve 319 5135 320 5135 s eZ 321 5135 MOV 770F Figure 46 Secondary Clutch Shaft Spacer and 5 Valve Removal 82 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 3 Remove the plug from the center bore of the primary clutch shaft Figure 47 Primary Clutch Shaft Plug Removal 4 Remove the spacer and S valve from the primary clutch shaft A small wire with a hook on its end can be used to help pull the S valve 324_5135 325_5135 MCV_770F Figure 48 Primary Clutch Shaft Spacer and S Valve Removal Marine Transmission Service Manual 1022127 83 Disassembly Twin Disc Incorporated 5 Remove the two piston rings from the end of the secondary and primary clutch shafts 327 5135 Figure 49 Piston Rings Removal 6 Install an eyebolt in the end of the secondary and primary clutch shaf
128. remove the following parts Be sure the main housing is securely supported T Remove the twelve M12 x 35 mm capscrews securing the input housing 2 Remove the input housing from the main housing 5135_0630 Figure 53 Input Housing Cover Removal 86 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Front Output Cover T Thread a M10 1 5 eyebolt into the front output cover 2 Use a lever and a block of wood to pry on the capscrew to overcome the friction of the front cover O ring 3 Remove the front cover Discard the O ring 5135 0631 Figure 54 Front Output Cover Removal Marine Transmission Service Manual 1022127 87 Disassembly Twin Disc Incorporated Remove Output Gear and Shaft Output Gear Pan js Remove the four capscrews with sealing washers securing the output gear pan to the main housing 2 Remove the output gear pan through the top opening DCP 1034 Figure 55 Output Oil Pan Removal Separate Output Gear From Output Shaft Using SKF Procedure Note The MGX 5135SC transmission requires the use of a SKF THAP 300 Oil Injection Kit see Special Tools or similar device to separate the output gear from the output shaft T Place the main housing in the face down position to separate the output gear from the output shaft Be sure the main housing is securely supported 2 Remove seven capscrews and remove the output shaft seal carrier speed pickup bracket i
129. roove in the mandifold b Use two 10 24 UNC threaded rods to align the screw holes in the manifold with the holes in the bushing Deep freeze the bushings 51 C 60 F for at least two hours before installing them Use a bearing installation tool to install the bushing into the manifold 148 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Handle the bushings with care The bushings are extremely COLD d Apply Loctite 518 MA 1015 to the threads of the two 10 24 UNC x 5 8 flat head screws Use a bushing installation tool to install the bushing into the manifold 5135_0258 5135 0253 Figure 124 Primary Clutch Shaft Manifold Bushing Installation 2 If removed install a new secondary clutch shaft bushing in the manifold a Use two 10 24 UNC threaded rods to align the screw holes in the manifold with the holes in the bushing b Deep freeze the bushings 51 C 60 F for at least two hours before installing them Use a bushing installation tool to install the bushing into the manifold Handle the bushings with care The bushings are extremely COLD Marine Transmission Service Manual 1022127 149 Assembly Twin Disc Incorporated Apply Loctite 518 MA1015 to the threads of the two 10 24 UNC x 5 8 flat head screws Install the flat head screws and torque to 4 5 Nem 40 Ibein 5135 251 5135 0243 Figure 125 Secondary Clutch Shaft Manifold Bushing Instal
130. s 383 529 kN 39 55 metric tons 500 706 kN 51 72 metric tons Figure 112 Pressing Output Gear Onto Output Shaft 136 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Remove the output gear advance tool Check the output gear advance The face of the gear should be flush with the shoulder on the shaft within 0 05 mm 0 002 in Heat the front bearing to 120 C 250 F for 30 minutes and press on output shaft until it is seated Be sure it is properly seated A CAUTION Handle the front bearing with care The front bearing is HOT 1B Carefully remove assembly from the press and place it on the output end of the output shaft Lower the assembly until the blocking can be removed Insert the gear pan into the main housing and rotate it around approximately in place Lower the assembly until the front output bearing is in place in its outer race Block the gear with wooden blocking material to hold the front bearing cone in its race Turn the housing over with the input end down Block the unit securely Heat the rear output bearing cone to 120 C 250 F for 30 minutes and install on the shaft Be sure it is properly seated A sleeve with a plate and the three capscrews can be used to seat the bearing against the shaft shoulder CAUTION Handle the rear bearing with care The rear bearing is HOT 20 21 Install the special output bearing ground cup onto the be
131. s and fasten the engine and transmission in place Then recheck the alignment and if satisfactory bolt the coupling together There are many types of flexible couplings in the market today that solve a variety of problems Couplings to reduce noise and vibration m Couplings to allow a permanent angular misalignment m Couplings that allow engines to be flexibly mounted and take out the momentary misalignment In some cases the proper alignment of these couplings requires an accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Marine Transmission Service Manual 1022127 Twin Disc Incorporated Installation Electrical Controls Installation All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connectors must be tight and free from corrosion It is strongly recommended that the Control Harnesses and Wiring guidelines be followed to ensure proper installation of all wiring Control Harnesses and Wiring guidelines Install all control wires and harnesses as follows 1 10 The connector end of each control cable or harness must be secured within twelve inches of control connectors other connectors and all other termination points The cable or harness must be secured to frame supports at sixteen inch intervals along its entire length unless installed in rigid
132. s Manual 1022127 199 PRIMARY amp SECONDARY PINION 2 REQ S GEAR OUTPUT 2 REQ S GP VALVE 1021658A NUMBER wine NUMBER R EL NUMBER PINION HUB BUSHING OF NUMBERS OF RATIO O O G x TEETH TEETH SEE CHART 19551 PX 11644 P 11638 11645 M 2073 DR 21 P 11637 61 2 90 1 M1990Q HH h PX 11643 P 11630 11642 M 2073 DR 23 P 11633 59 2 57 1190 m SS rere ot 11639 P 11639 7 M 2073 DR 27 11641 55 2 0411 BM CH WASHER 1 2706 ESR PTE 11655 11655 2 7 M 2073 DR 30 11656 52 1 7511 ae 9 D 1 erts 11657 P 11657 M 2073 DR 33 11658 49 1 4811 WS s I 039 4 8 1059 4 1 8 Px 11659 P 11659 2073 08
133. s could be caused by improperly assembled parts loose parts vibration or improperly torqued parts Bolts nuts bent worn or stripped threads Inspect the hub looking for the following Q Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found Marine Transmission Service Manual 1022127 57 Preventative Maintenance Twin Disc Incorporated Heat Exchanger Check Inspect heat exchanger oil lines for leaky connections kinks cracks or other damage Replace damaged lines Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days If over 50 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist itis evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush 58 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting of Electric Control Valve General The following charts are intended as a guide for determinin
134. sembly Twin Disc Incorporated Hydraulic Oil Filter Note Position the main housing with input end down Be sure the main housing is securely supported Remove the hydraulic oil filter 5135_405 Figure 30 Hydraulic Oil Filter Removal Suction Strainer 1 Remove the M12 1 5 capscrew with washer directly below the suction strainer plug Remove the clamp plate 2 Thread a M8 1 5 capscrew into the suction strainer plug and pull 3 Remove the plug and suction strainer 5135 0625 Figure 31 Suction Strainer Removal 74 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Oil Filter Bypass Cover Remove filter bypass valve cover DCP1010 Figure 32 Oil Filter Bypass Cover Removal Output Flange iP Remove the three M12 x 40 output flange clamp screws 2 Remove the output flange clamp plate 5135_0164 Figure 33 Output Flange Clamp Plate Removal Marine Transmission Service Manual 1022127 75 Disassembly Twin Disc Incorporated 2 Remove the output flange shim 5135_0165 Figure 34 Output Flange Shim Removal 4 Remove the output flange sealing ring 5135_0166 Figure 35 Output Flange Sealing Ring Removal 5 Using puller remove the output flange from the output shaft 5135 0167 5135 0168 Figure 36 Output Flange Removal 76 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly Remove Internal Parts Manifold
135. so be accomplished by the use of chain hoists or properly placed jacks Adjustable shims also are available and can simplify the alignment process particularly for future realignment It may also be necessary to move the engine and transmission to one side or the other on the engine bed to obtain horizontal alignment This can be done with a jack placed horizontally between the engine and the foundation At the same time a straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE MALE FEMALE Se ed STRAIGHT EOGE Figure 159 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1022127 Twin Disc Incorporated Installation As the engine and marine transmission come into their aligned position it will be possible to mate the output flange and propeller coupling and prepare for bolting together Care should be taken not to burr or mar this connection because the fit is very critical Place a 0 05 mm 0 002 in feeler gauge between the flanges of the coupling Move slide the feeler gauge completely around the coupling Rotate the marine transmission flange coupling in 90 degree increments and move the feeler gauge around the flange in each successive position The feeler gauge will fit snugly with the same tension all around the flange coupling in all four positions if the alignment is correct If the alignment varies
136. so hot air is ported out of the housing Visually inspect the element after the first 100 hours of operation and every 2000 hours thereafter or every six months whichever comes first Torsional vibration misalignment degradation by contaminants oil heat ultraviolet radiation and excessive system torque can cause cracks or other signs of distress to appear on the surface of the rubber The above described items affect the life of the coupling element Perform a complete inspection whenever the transmission is removed from the engine for any reason When inspecting the flexible coupling look for evidence or conditions identified in the following steps Cracks in the surface of the rubber be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate or deterioration of the rubber to metal bond See above Marine Transmission Service Manual 1022127 Twin Disc Incorporated Preventative Maintenance Deterioration of the rubber element as evidenced by sponginess or by black carbon like dust on rubber surface may be caused by contaminants or excessive heat either external or internal to the coupling Cracked bent or otherwise damaged flex plate or coupling plate Bolt holes in flex plate or coupling plate elongated deformed Thi
137. special brackets allow either live PTO connection or clutchable PTO and no PTO as well In case of remote mounting the heat exchanger should be installed in a location convenient to both engine coolant and marine transmission oil WATER IN WATER OUT Figure 2 Heat Exchanger Marine Transmission Service Manual 1022127 23 Description and Specifications Twin Disc Incorporated Table 1 Heat Exchanger Requirements HEAT EXCHANGER H E REQUIREMENTS PERMISSIBLE OIL TEMPERATURE INTO HEAT EXCHANGER 2 22 cuc MIN HEAT TRANSFER CAPACITY KW BTU MIN PER ENGINE RTD APPLY APPROPRIATE SERVICE FACTOR CONTINUOUS DUTY amp INT DUTY FOR FRESH AND RAW WATER 026 1 484 022 1 272 APPROX OIL FLOW TO H E 2 3 L MIN 61 GPM PER 100 ENGINE R P M 1965 KPa 205 PSI MAX ALLOWABLE OIL PRESSURE DROP ACROSS H E WITH 207 KPa 66mm sec 300 SUS OIL AT RATED ENGINE R P M 30 PSI WATER FLOW TO H E USE 1 5 TO 3 0 TIMES OIL L MIN GPM H E WATER PRESSURE RATING MIN 1 5 X H E INLET WATER KPa PSI DATA H E PURCHASER MUST ALSO TELL VENDOR STATE IF RAW OPEN CHANNEL amp SEA OR FRESH CLOSED ENGINE JACKET AND OR KEEL COOLER WATER WILL COOL H E STATE MAX WATER TEMP INTO H E TYPICAL RAW WATER 29 C 32 C 85 F 90 F KEEL COOLER WATER 46 C 60 C 115 F 140 F ENGINE JACKET WATER 74 C 85 C 165 F 185 F STATE MIN ALSO MAX L MIN GPM OF WATER FLOW TO H E H E INSTALLATION amp SERVICE
138. ss of gasket B Desired preload Bearing height orginal cup Bearing height ground D Shimpack needed including spacer A B C D Secondary Shaft Housing rear to rear of bearing cup A Thickness of gasket B Desired preload C Bearing height orginal cup Bearing height ground cup D Shimpack including spacer needed A B C D Output Shaft Housing rear to rear of shim spacer A Thickness of gasket adjusted for crush B Desired preload C Bearing height orginal cup Bearing height ground cup D Shimpack needed A B C D 9 Remove the Special Ground Bearing Cups from the three shaft locations Marine Transmission Service Manual 1022127 143 Assembly Twin Disc Incorporated Rear Bearing Cups 1 Install a new output bearing cup in the housing a Deep freeze the bearing cup to 51 C 60 F for at least two hours before installing it Handle the bearing cup with care The bearing cup is extremely COLD b Lubricate the bore of the housing Use a bearing installation tool to install the bearing cup into the housing 2 Install a new output shaft seal in the seal carrier a Apply MA1015 sealer to the outside of the new output shaft seal b Use a seal installation tool to install the seal into the carrier Lip of the seal must face away from the seal carrier 3 Install a new O ring in the pilot diameter groove a Coat the O ring with grease b Install the O ring in the gro
139. ssing instructions This module contains the electronic circuitry to control the proportional cartridges that are used to engage the clutches based on the commands from the operator Clutch apply pressure rate of rise profile is factory set with the use of internal circuitry The initial fill level is factory set with an adjustment screw that is embedded in the bottom surface of the Profile or E Troll Module and sealed This can be field adjusted if necessary by authorized personnel with the proper instrumentation There are different control module types for Quickshift marine transmissions MGX both with and without the trolling E Troll feature All electrical wiring for the marine transmission system controls are routed through this interface module The vessel battery power 12 vdc or 24 vdc is supplied to the electronic interface only and never directly to the hydraulic proportional valves Two red led lights are used to identify the proportional cartridge valve that is energized and a green led is used to identify when power is provided to energize one of the clutches Flashing lights are used in troubleshooting Signals are provided to power a customer supplied relay to allow engine starting only when in neutral A Transmission oil temperature sensor is not required for the Quickshift marine transmission MGX models Engine speed and propeller speed sensors are required for transmissions with E Troll The following figures show the various
140. t pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when the unit is in the secondary position TOI PEE DIES ud Operation mg5135sc S1 Figure 16 Example of Power Flow with Secondary Clutch Engaged Marine Transmission Service Manual 1022127 51 Operation Twin Disc Incorporated NOTES 52 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance In boat Maintenance and Repair Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures are Q Removing and installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Removing and installing the control valve Removing and installing the manifold D D DO D DO Service clutch pack assemblies Note Further disassembly reassembly of the primary or secondary shafts will require removal from the engine and the use of tools and equipment normally not available on board the vessel Marine Transmission Service Manual 1022127 53 Preventative Maintenance Twin Disc Incor
141. t 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 July 1 2004 TDWP2004 rev 2004 TWIN DISC INCORPORATED FLAT RATE HOUR ALLOWANCE MARINE PLEASURE CRAFT TRANSMISSION Hourly Labor Rates Must Be Acceptable to Twin Disc Incorporated MODEL SERIES R amp R UNIT REBUILD MG340 0 0 0 0 MG502 MG5005 MG5010 MG5011 MG5012 MG5015 MG5020 8 0 MG506 MG5061 MG5061 MG5061 MG5062 MG5065 MG5050 MG5055 11 0 MG507 MG5081 MG5085 MG5090 MG5075 MG5091 MG5112 MG5113 MG5085 MG5091 MG5090 MG509 MG 5111 MG5114 MGX5114 MG514C MG514M MG5141 MG514CHP MGX5135 MGX5145 MGX5147 MG516 MG5161 MG5170 MG520 1 MG 5202 MG5203 MG5204 MG5205 MG6449 MG6557 MG530 MG530M MG5301 MG6650 MG6690 MG6848 MG6598 MG6600 MG6619 MG6620 MG6984 MG61242 MGX6650 MGX6690 MGX6848 MGN80 MGN232 MGN233 MGN272 MGN273 MGN332 MGN334 MGN335 MGN432 MGN433 MGN472 MGN493 MGN650 MGN800 MGN1000 MGN1400 MGN1600 PUMP ALL MODELS EXCEPT MG340 amp MG360 1 0 VALVE ALL MODELS EXCEPT MG340 MG360 1 0 J
142. ted Disassembly 5 Remove the M6 1 00 x 16 Allen head capscrew the retaining plate and the proportional valve cartridges from the top valve body A slight rotating motion while pulling will help to with the removal of the valves Proportional Valve A Figure 89 Remove Proportional Valve Cartridges Marine Transmission Service Manual 1022127 109 Disassembly Twin Disc Incorporated 6 Valve Assembly 1020729 Remove the main pressure regulator pilot relief valve and main valve from the main regulator valve body Figure 90 Remove Main Pressure Regulator Valve Components 110 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 7 Valve Assembly 1021658 Remove the main pressure regulator from the main regulator valve body a Remove the regulator adjusting screw cap and loosen the jam nut b Turn the adjusting screw counter clockwise to reduce the spring load onthe valve Evenly loosen the four 8 x 25 capscrews and remove the cover assembly and gasket followed by the spring s and spool d Remove the four M 8 x 20 capscrews and remove the cover and gasket e Remove the orifice and screen assembly for cleaning f Remove the ball check assembly only if necessary Removal will require destruction and replacement of the assembly Temperature Sensor Port C Filter WD Check Valve 4 Figure 91 Remove Main Pressure Regulator Valve Components Cover Cover
143. ted Installation Installation Prior to Installation A CAUTION Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be made before the driven component is installed After installation of the driven component the crankshaft endplay should be measured again The endplay at the second measurement should be the same as the first A difference in these two endplay measurements could be an indication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage caused by engine to Twin Disc component interference regardless of the cause of interference This engine crankshaft endplay check is considered mandatory The transmission housing flange and pilot the engine flywheel and the flywheel housing must be checked for trueness Clean the engine flywheel and flywheel housing mounting surfaces thoroughly before any measurements are made Note To isolate engine vibration and prevent transferring it to the hull through the propeller shaft the distance from the marine gear output flange to a fixed stuffing box or the first fixed bearing must be a minimum of 20 times
144. ted and is in lieu of any and all other warranties express or implied including the warranties of merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc Incorporated This warranty applies only to private non commercial non revenue marine pleasure craft The original customer does not 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 of 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 a guarantee of performance Twin Disc Incorporated cannot be held liable or responsible for incorrect information supplied or deviations from specifications provided by customer The exclusive remedy provided by Twin Disc Incorporated whether arising out of warranty within the applicable warranty eriod as specified or otherwise including tort liability shall at the sole option of Twin Disc Incorporated be either the repair or replacement of any Twin Disc Incorporated part or product found by Twin Disc Incorporated to be defective For all models except MG340 and MG360 this include the labor to perform that work and to remove and reinstall
145. the shaft diameter If the distance is less than this a flexible coupling may be necessary to isolate the engine vibration Marine Transmission Service Manual 1022127 169 Installation Twin Disc Incorporated Alignment also reference SAE J 1033 and J 617 ls Bolt a thousandths increment dial indicator or gauge to the engine flywheel so that the indicator is perpendicular to the face of the engine flywheel housing and the indicator stem is riding on the face of the flange ee Figure 153 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keeping a thrust in the same direction and note the face deviation of the engine flywheel housing flange The face deviation must not exceed the figures given in Table 19 Table 19 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations Eccentricity mm 1 00109 NN 0019 0370072 CETT 170 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Installation 3 With the indicator mounted as in the previous paragraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing ce y a Engine F yswhenol Housing Figure 154 Checking Flywheel Housing Bore Eccentricity 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the previous Table for allowable tolerances 5 Bolt a
146. the four M10 capscrews to 46 Nem 34 Ibeft 2 Install and tighten the heat exchanger hoses 5135 0002 5135 0001 Figure 143 Heat Exchanger Installation Speed Sensors If Equipped 1 Apply MA908 Locktite 242 to the threads of the output sensor 2 2 Assemble the output speed sensor until it contacts tip of a gear tooth 3 Back out the output sensor two full turns 4 Secure the output sensor in place with two jam nuts 5 Apply MA908 Locktite 242 to the threads of the input sensor 1 6 Assemble the input speed sensor until it contacts tip of a gear tooth 160 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 7 Back out the input sensor one full turn 8 Secure the input sensor in place with two jam nuts DCP_1000 Figure 144 Input Speed Sensor 1 and Output Speed Sensor 2 Installation Marine Transmission Service Manual 1022127 161 Assembly Twin Disc Incorporated Assembly of GP Control Valve with Electronic Interface Prior to assembly all parts must be properly cleaned Carefully inspect all o rings for any damage and replace as necessary Lubricate all o rings and replace both gaskets 1 Valve Assembly 1020729 Assemble the Main Regulator Valve body a Install the Main Pressure pilot relief valve into the valve body and torque to 27 Nem 20 Ib ft b Install the Main Valve into the valve body and torque to 33 Nem 24 Ib ft Install the 3 8 npt
147. thousanaths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the surface to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter Figure 155 Checking the Flywheel Face Runout Marine Transmission Service Manual 1022127 171 Installation Twin Disc Incorporated 6 With the indicator mounted as in the paragraph above adjust the indicator tip so that it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot bore eccentricity of the engine flywheel should not exceed 0 13 mm 0 005 in maximum total indicator reading Thrust on the flywheel should be in one direction at all times to obtain a correct reading Figure 156 Checking the Flywheel Pilot Ring Bore Eccentricity 172 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Installation Alignment Propeller Shaft Before any attempt to align the engine and gearbox to the propeller shaft proper alignment of the propeller shaft must be determined This includes alignment of the propeller shaft through all struts and intermediate bearings Failure to properly align the propeller shaft may result in premature wear on bearings vibrations or possible damage to other components If the
148. to LH rotation install an engine rotation plate Arrow to indicate the new direction of rotation Direction of Drive The primary input clutch shaft and driving transfer gear always rotates in engine direction The secondary clutch shaft and driven transfer gear always rotate in anti engine direction because the driven transfer gear is meshed with the driving transfer gear on the primary clutch shaft When the primary clutch is engaged the primary input pinion rotates in engine direction The output gear which is secured to the output shaft is meshed with the primary input pinion and so the output gear and shaft are driven in anti engine direction When the secondary clutch is engaged the secondary input pinion rotates in anti engine direction The output gear is meshed with the secondary input pinion and therefore the output gear and shaft are driven in engine direction Marine Transmission Service Manual 1022127 19 Description and Specifications Twin Disc Incorporated Construction Features 20 Housings The MGX 5135SC transmission has a one piece main housing with a bolt on SAE 1 or SAE 0 engine housing adapter A manifold and a top cover sealed with gaskets bolts onto the housing An end cover is located on the primary shaft and a pump located on the secondary shaft completes the housing enclosure Taper Roller Bearings The primary and secondary clutch shafts are supported and located by tapered roller bearings The
149. ts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found Springs Inspect springs for broken or distorted coils Replace the spring if either of these defects is found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses Clutch Plates Inspect clutch plates for signs of overheating pitting or excessive wear of the friction and splined surfaces Replace the clutch plates if one of these defects is found Refer to wear limits in Description and Specifications Marine Transmission Service Manual 1022127 117 Cleaning and Inspection Twin Disc Incorporated NOTES 118 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly General Assembly Note Photos are intended to illustrate the procedure and may not be consistent with previous assembly steps During service of this unit all O rings gaskets and seals must be replaced Refer to cleaning and inspection information in this manual prior to assembly It is good practice to compare the new parts with those being replaced during the assembly process to make sure you don t mistake the quantity or size Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Unless otherwise specified all torque values listed are for capscrews that have been lubricated on th
150. ts Note When servicing a 1 1 ratio transmission it is necessary to remove or install both the primary and secondary clutch shaft assemblies at the same time 1 to 1 spacer Figure 50 Primary and Secondary Clutch Shaft Removal 1 1 Ratio Transmissions 84 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Disassembly 7 Lift the secondary clutch shaft from the main housing The front bearing carrier will slide off the shaft and remain in the main housing The spacer may also come off the shaft 5135 628 5135 629 Figure 51 Secondary Clutch Shaft and Primary Clutch Shaft Removal 8 Install an eyebolt in the end of the primary clutch shaft 9 Lift the primary clutch shaft from the main housing The front bearing carrier will slide off the shaft and remain in the main housing The spacer may also come off the shaft Marine Transmission Service Manual 1022127 85 Disassembly Twin Disc Incorporated Front Bearing Ti Reach inside the main housing and remove the primary clutch shaft front bearing and spacer if it did not remain on the shaft Tag the components with identifying information 2 Reach inside the main housing and remove the secondary clutch shaft front bearing and spacer if it did not remain on the shaft Tag the components with identifying information 383 5135 Figure 52 Front Bearing Carriers Removal Input Housing Note Place the main housing in the upright position to
151. ts the boot Cables must not be installed in a manner which puts strain on the connector or results in more than twenty four inches of excess length Be sure that metal clamps and cable ties do not cut through cable installation Check that all circular connectors are hand finger tight Check that Sure Seal connectors have clip clamps in place Check that Weather Pack Metri Pack and Deutsch connectors are snapped together Check cable or harness tiedowns Keep cable securely fastened to vessel frame Check the condition of the cable or harness at any rub point and wherever the cable or harness passes through a sheet metal hole and wherever clamps or metal cable ties are used Check cable or harness for cracks effects of vibration abrasion brittleness or abuse Visually inspect for evidence of moisture or corrosion Marine Transmission Service Manual 1022127 Twin Disc Incorporated Installation Wiring Connections General The vessel wiring for the Profile or E Troll Module must be of sufficient size to prevent excessive voltage drop no greater than 0 5 Vdc between the battery connections positive voltage and ground and the Profile or E Troll Module The modules operate from nominal 12 VDC or 24 VDC batteries The battery power connection must be protected by an electrical over current protection component fuse or circuit breaker as required by the vessel s approval agency The minimum current capacity should be
152. uly 1 2004 TDWP2004A rev 2004 Twin Disc Incorporated Table of Contents Table of Contents Introduction cesses rideau mau RUSO vH Ud 11 General Information 11 Safety and General Precautions 11 Preventative nennen nnn nnn nnn nnns 13 I 13 Ordering Parts and Obtaining Services 14 Source of Service 15 Warranty OD TU 15 Description and Specifications 17 MEME Em 17 Power E 19 Changing Rotation mee 19 Direction of DEVE cs ia db bags CHA DER DR 19 Construction 20 Lubrication KOCH Na 21 Heat 23 Specifications and Maintenance 25 enBU RE TIU 27 Optional Equipment eee 28
153. use of a Special Ground Bearing Cup Due to limited access through the manifold opening the depth micrometer measurement may be the desireable method on this transmission 1 Install two Special Tools TD 21552 101 or equivalent tool at the primary shaft with the two 1 4 20 threaded rods or screws to load the bearing cup a Locate the two tool halves such that a load can be applied to the bearing cup in two locations 180 apart b Clamp the tools to the housing using the appropriate capscrews with washers Torque the capscrews to the standard torque valve as shown in Description and Specifications Depth Micrometer Figure 118 Special Tools TD 21552 101 Marine Transmission Service Manual 1022127 141 Assembly Twin Disc Incorporated 2 Apply 10 Ibein of torque to the load screw to apply a force to the rear of the bearing cup and rotate shaft three complete turns Repeat torquing 10 Ib in followed by rotating the shaft until the applied torque remains on the screws 3 Measure the depth from the housing rear to the rear of the bearing cup and note measurements 4 Repeat steps 1 through 3 for the secondary shaft 5 Repeate steps 1 through 3 for the output shaft except torque the load screws to 30 Ibein 6 Measure the thickness of the gasket and record this dimension 142 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly Primary Shaft Housing rear to rear of bearing cup A Thickne
154. utch housing to ensure the splines of the clutch are aligned 6 Place the internal snap 6 ring next to the clutch back plate AAR6557 069 6557 1012 Figure 104 Clutch Back Plate 5 and Internal Snap Ring 6 7 Adjust clutch pack clearance as follow a Temporarily instal the pump drive adapter using two M8 1 25 x 20 mm socket head screws Install hose clamp over the shaft next to the bearing to block the 8 mm 0 315 in sump passage in the shaft Place the shaft vertically with the backplate at the top of the clutch assembly Apply a load of 100 200 N 23 45 to the backplate Using a dial indicator zero the bottom position for the backplate Apply air pressure to the clutch apply hole located between the seal ring grooves at the shaft end Observe the measurement of the clutch clearance on the dial indicator Clutch clearance must be between 2 30 3 20 mm 0 091 0 126 in If clutch clearance is out of specified range shim clutch using steel plates 2 34 2 38 mm 0 092 0 094 in thick friction plates 3 07 3 20 mm 0 121 0 126 in thick or cores from friction plates 1 54 1 57 mm 0 061 0 062 in thick Marine Transmission Service Manual 1022127 129 Assembly Twin Disc Incorporated When shimming using friction or core plates the addition plate must be located between the backplate and last active friction plate When shimming using a steel plate the additional plates must be located betwee
155. ver with Adjustment Figure 146 Assemble Main Pressure Regulator Components Marine Transmission Service Manual 1022127 163 Assembly Twin Disc Incorporated 2 Assemble the Top Valve Body Install the two proportional valve assemblies into the valve body install the retaining plate and torque the M6 1 00 x 16 socket head capscrew to 9 5 Nem 7 Ib ft Install the Manual Direction Control Valve into the valve body and torque to 27 N m 20 Ib ft Install the M12 x 1 50 O ring plug into the valve body and torque to 16 N m 12 Ib ft Connect the wires for the Neutral Switch M12x 1 50 Manual Override A o ring plug Proportional Valves Valve Top Valve Body Figure 147 Assemble Top Valve Body Components 9 Install new gasket the Main Regulator Valve Assembly to the transmission or ditch plate using the four twelve point capscrews Torque the capscrews to the level specified for the appropriate sized capscrew into aluminum threads See the torque specifications in Description and Specifications Capscrews Figure 148 Install Regulator Valve Body to Transmission 164 Marine Transmission Service Manual 1022127 Twin Disc Incorporated Assembly 4 Install a new gasket and the Top Valve Body Assembly on the Main Regulator Valve Assembly using six M10 1 50 x 70 hex head capscrews and torque to 46 Nem 34 Ib ft Figure 149 Install Top Valve Body onto Regulator Valve Assembly 5 Inst

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