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TWIN DISC

1. PARTS ND QTY REMARKS ITEM PARTS ND QTY REMARK ITEM PARTS ND QTY REMARK TEM PARTS ND QTY REMARK 154 N132420000 1 119 1 82642 4 84 N085710055 10 1 1 N085710035 6 L 35 116 117 118 119 120 121 122 123 54 53 52 5 158 159 155 370202815 1 120 1 83796 2 85 085710075 1 2 N085710040 1 L 40 56 5 48410 0 1 121 N422007350 2 86 085710110 S__ L 110 3 085710055 1 1255 157 1 55034 2 122 1 72996 C 2 87 No31010000 16 4 412006024 6 158 085708055 6 123 3 49168 2 88 1 78055 1 5 1 75149 p 2 n E 159 3 49161 1 124 1 12380 F 8 INCLUDED IN ITEM 19 111 89 N370162215 1 WASHER COPPER 6 083006000 2 160 N113808040 2 125 412018024 2 90 1 2996 1 7 1 8381e 1 161
2. ITEM PARTS NAME REMARKS HYDRAULIC 0 PUMP DRIVE SPECIFICATION 1 84447 SLEEB AS PUMP 1 89 2 89 TOTAL MASS APPROX 48 kg 2 NI13812035 BOLT SOCKET HEAD 4 L 35 AT ENGINE RATED SPEED 3 3 55197 ADAPTER e4 4 DIL PRESSURE CLUTCH OIL 1 1 1 4 MPa 600 2500 min DIL TEMP 65 70 C 0 3 60 5 OIL VISCOSITY SAE 40 MULTI GRADE DIL IS NOT APPROVED 01 01 WORKING TORQUE 200 L 26 N m E 449 449 L Length of pump spline 1 2 13UNC 22 DEEP CAPACITY OPERATING SPEED 600 2500 min 6 HOLES SHAFT ROTATION SAME AS ENGINE ROTATION ris P LO ACCEPTS 5 J744 SIZE PUMP 5 i N SHIESHING 0 5 X RATED ENGINE SPEED Jd Q RESTRICTION IN t 2 DP 16 32 13 Y P T H SHAFT 4 ROTATIONAL DIRECTION SPLINE DATA NOMINAL PITCH CIRCLE DIA 20 637 5 Elo eg PRESS ANGLE 30 un T 73 0 1 73 01 TIP DIA 19 050 2 ROOT DIA 22 258 0 032 0 064 DETAIL OF PTO MOUNT ARC TOOTH SPACE 2 494 0036 CSAE J744 SIZE B x3 e 3 m T B B 3m os ILS luu T T 12 TT
3. Cl 1 H M ul aj lt M lt 3H 4 gq 88 88 a 88 BE S 85 e FT FT 9 FT _ 28 C BURE 23 DEEP 9 85 8 g EG SPACED S 3 3 x uz a a PLAIN WASHERS o foe 8 HAVE BE PROVIDED 18 MO Q D i RR SNAP RING N 4 RODOV 41 6 5 15 sus 4 12 126 25 4 126 25 4 12 EQ SPACED 100 8 1256 a PLAIN WASHERS HAVE JL BE PROVIDED _ SNAP RING ui 6 613 5 EQ SPACED 14 EQ M RI E PLAIN WASHERS HAVE BE PROVIDED PLAIN WASHERS HAVE TD BE PROVIDED es LU SCALE 1 4 SCALE 1 4 SCALE 1 5 THIRD ANGLE P PROJECTION BOM NO 5205781 BOM NO 9Z05781 e2 BOM NO 5205781 4 SIMILAR 0 NOTE LEIGURES IN THE DRAWING SHOW TIGHTENED TORQUE FOR MAIN IMPORTANT BOLTS INPUT GROUP NOTICE THIS PRINT CONTAINS MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIETARY INFORMATION AND IS 041019 BRI INT DISC NOT BE USED IN ANY MANNER E x 2075 SCALE INCORPORATED DETRIMENTAL TO THE INTERESTS EAT REAT FIRST USE XX 3243 irigan RACINE WI 53403 USA TWIN DISC INCORPORATED assy ALL ANGULAR TOLERANCES 1 RACINE 53403 USA edid
4. zem METRIC THIRD ANGLE NOTES Dy PROJECTION LTIGHTENING TORQUE FOR MAIN IMPORTANT BOLTS SEE TABLE 2 LIVE P T O PUMP DRIVE FOUR SAE C und 2 CDAT LIQUID PACKING THE PORTION MARKEDQ AND ASSEMBLE THEM BOM 5706039 1 E MARKE BOLT TIGHTENING TORQUE NOTICE THIS PRINT CONTAINS MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE x vagas 22 CURAE Begg H TUIN DISE x2 M10x1 5 42 Nem DETRIMENTAL TO THE INTERESTS OF TIU FIRST UE xx 2028 L3 RACINE VI 53403 USA TWIN DISC INCORPORATED s ANCES 17 RN x3 M12x1 75 74 C K I c 060405 RACINE WI 53403 USA 5 homi ooninoto PER ANSI Y14 5M 1982 E x4 mexe 195 Nin bpa es 050290 ene m 7 39488 8 Q rinoue K I Massses 050621 GRANTED TO THE U S GOVERNMENT MARINE APPD BY APPD REV zone CH ND DATE RV zone cH DATE OR OTHERS BY CONTRACT MGX 65984A TRANSM SSTON SHEET 8 OF 16 REV C F E D C B AT ITEM PARTS NO NAME Q TY REMARKS 1 5 50858 BRACKET 2 2 085720060 BOLT 12 3 341720032 PIN KNOCK 4 02050 0000060 0
5. 2 020 lt BOTH SIDES 4 M10x1 5 lt BOTH SIDES 20 ITEM PARTS NO NAME Q TY REMARKS 1 3 52201 RUBBER VIB PROOF 2 2 5 52125 PLATE 2 3 085720065 BOLT 12 4 113912035 BOLT SOCKET HEAD 16 5 341720040 4 HOUSING PLATE 000 000 0000 000 0009 000 355 m 12 1 25 JIS 8 8 09 90 8950096 Q 09009 2 1 T o iD iD u u QS ua zm METRIC 5 Q EM 96N m CMlexl 75 JIS 8 8 SIUE INSTALLS RUBBER VIBRATION ISOLATOR BER VIBRATION ISDLATD RESILIENT MOUNT BRACKETS BOM 5706052 1 MATERTAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIE ran T ENFERNATIGN AND 15 DIMENSIONS ARE wos 7009 DISS NUT TO BE USED IN ANY MANNER un X 0 75 SCALE TNCORPORATED DETRIMENTAL TO THE NTERESTS OF nm 1 RACINE WE 53403 USA TWIN DISC INCORPORATED S assy ALL ANGULAR TOLERANCES 51 LEUR RACINE VI 53403 USA 2 me PER ANSI YIR ENT MEL Mene pt 7 39458 10 REV BY APPD RE
6. c p DYNAMIC TORSIONAL STIFFNESS UE DYNAMIC TORSIONAL STIFFNESS ee E DYNAMIC TORSIONAL STIFFNESS CENTAFLEX R 0 315 kNm 0 630 1 575 3 150 4 725 6 300 VULKARDAN E 5 00 kNm 0 50 kNm 1 25 2 50 3 75 5 00 VULASTIK L 8 00 kNm 0 80 kNm 2 00 4 00 6 00 8 00 6 kNn rad 12 74 115 178 32119 19 40 kNm rad 19 90 23 10 33 90 47 00 sails 28 5 kNn rod 36 0 4 amp 5 82 0 134 0 MOMENT OF INERTIA MAX NOMINAL MAX MAX WR MAX MAX wR MAX MAX COUPLING URQUE TORQUE MARINE GEAR COUPLING MARINE GEAR COUPLING MARINE GEAR UUTER PARTS INNER PARTS SPEED Nm Nm INPUT SPEED UUTER PARTS NNER PARTS SPEED INPUT SPEED DUTER PARTS NNER PARTS SPEED INPUT SPEED 0 220 kgm 0 98 kgm 0 286 kgm INCLUDES 3000 6 30 19 0 2500 min 71 0 24 kgm INCLUDES 2750 2500 min 108 0 708 kgm 2400 min 1 2500 min 1 16 oe 9 2 ITEM PARTS NAME Q TY REMARKS ITEM PARTS NL NAME Q TY REMARKS ITEM PARTS NAME Q TY REMARKS 1 N059010000 RING SNAP 1 1 N059010000 RING SNAP 1 1 532220000 BEARING TAPER ROLLER 1 2 N330120201 SPACER 1 2 N330120201 SPACER 1 2 N023713019 3 3 532220000 BEARING TAPER ROLLER 1 3 N53eee0000 BEARING TAPER ROLLER 1 3 085708020 BOLT 2 4 1 83785 SLEEVE AS DRIVE 1 4 1 83785 SLEEV
7. LIVE P T PUMP DRIVE SPECIFICATION ITEM PARTS NAME Q TY REMARKS TOTAL MASS APPROX 86 kg 1 1 84395 SLEEVE AS PUMP MAX 0 WORKING TORQUE 75 Nm 2 N113810055 BOLT SOCKET HEAD 3 0 CAPACITY 0 OPERATING SPEED 2500 min ACCEPTS J744 SIZE PUMP 3 3 55158 ADAPTER SAE DP 16 32 4 N113810180 BOLT SOCKET HEAD 5 DF TEETH 13 5 3 54577 B GEAR PUMP 45 SPLINE DATA NOMINAL PITCH CIRCLE DIA 20 637 6 183654 GASKET PRESS ANGLE 30 7 No48010023 RING D TIP DIA 19 oso 2021 8 NO4801004 RING D ROOT DIA 22 258 ose 9 085710095 BOLT ARC TOOTH SPACE 2 49418 0 42 Nem CM1Ox1 5 JIS 8 8 73 73 7 0 SHAFT ROTATIONAL DIRECTION Ja 1 2 13 UNC DEEP 9146 6 HOLES EQ SPACED 2 HOLES USE f 20 46 42 5 0 8 42 m 10 1 5 JIS 8 8 788 9 SECTION FOR REVERSE SHAFT AND MAIN PUMP NOTES El ms 1 FIGURES IN THE DRAWING SHOW TIGHTENED TORQUE FOR MAIN IMPORTANT BOLTS LIVE P 1 PUMP DRIVE FOR SAE B BOM 5706040 1 E MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIETARY INFORMATION AND IS DUNG ARE esie VA a DUSS Stob S rE 2 MEM E si i RACINE 53403 USA TWIN DISC INCORPORATED Te aae meraes PRES RACINE WI 53403 US
8. TABLE 2 MARKE BOLT TIGHTENING TORQUE 2235 8 1 25 22 x 0 15 4g Nm RIC x3 12 1 75 74Nn THIRD ANGLE ES x4 16 2 0 195 Nm PROJECTION TIGHTENING TORQUE FOR MAIN IMPORTANT BOLTS SEE TABLE 2 HYDRAULIC P T O PUMP DRIVECFOR SAE A 2 COAT LIQUID PACKING ON THE PORTION MARKEDQAND ASSEMBLE THEM BOM 0 5706142 MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIETARY INFURMATION AND IS one 11570 DISS NOT BE USED IN ANY MANNER SCALE INCORPORATED DETRIMENTAL TO THE INTERESTS OF aa TWIN DISC INCORPORATED assy ALL ANGULAR TOLERANCES 17 tokai RACINE WI 53403 USA GEOMETRIC TOLERANCING THIS NOTICE IS NOT INTENDED ppp 5598 E sik TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT 7 39488 15 TAKAI 050930 GRANTED TO THE U S GOVERNMENT BY REV DATE REV ZONE CH DATE OR OTHERS BY CONTRACT M G X 6 5 9 8 A TRANSMISSION YT REV Q C B
9. 23 Oil Pressures 24 Optional Equipment ec 27 Torque Values for Fasteners 28 33 Al FM a 33 General Overview of GP Valve with Electronic Interface 34 Hydraulic System with GP Control Valve 40 Preventative Maintenance 43 In boat Maintenance and Repair 43 General 44 Periodic Visual Inspection cce 46 Marine Transmission Service Manual 1022297 7 Table of Contents Twin Disc Incorporated Troubleshooting amem 49 Troubleshooting of Electric Control Valves 49 di rr 50 Troubleshooting of GP Control Valve with Electronic Interface 51 DISASSEIMONY Ems 55 Prepare Transmission for Disassembly 55 56 Remove External Parts me 58 P
10. 235 7 39488 13 MGX 6598A Live 236 7 39488 14 MGX 6598A Hydraulic 237 7 39488 15 MGX 6598A Hydraulic 238 7 39488 16 MGX 6598A Hydraulic PTO 239 Marine Transmission Service Manual 1022297 9 Table of Contents Twin Disc Incorporated NOTES 10 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc MGX 6598A marine transmissions 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 1022
11. LIVE P T O PUMP DRIVE SPECIFICATION ITEM PARTS NO NAME Q TY REMARK pe 1072 107 5 TOTAL MASS APPROX 7 5 kg 1 1 77162 EEVE AS PUMP 1 WORKING TORQUE 600 x L 40 gt 2 2 90 591 99 5 91 L Length of pump spline COVER CAPACITY PLO OPERATING SPEED 600 2500 nin 9 048002055 2 SHAFT ROTATION SAME AS ENGINE ROTATION 4 1 83770 COVER AS SUPPLY 1 72 13UNC TAP 26 DEEP E ape u ACCEPTS S AE J744 SIZE _ 5 1 70677 JT SPACER 1 DP 12 24 6 460200022 SHIM 1 8 11UNC 34 DEEP 2 usi 7 032010000 WASHER 8 E E 2 HOLES SPLINE DATA NOMINAL PITCH CIRCLE DIA 29 633 8 113810035 BOLT SOCKET HEAD 7 4 PRESS ANGLE 30 PT 9 113810175 BOLT SOCKET HEAD 1 Qa IIP DIA 27 591 0 10 087710035 BOLT 7 N X DIA 31 785 0 034 11 No32010000 WASHER 7 SHAFT ROTATIONAL DIRECTION ARC TOOTH SPACE 3 325 8802 ie 1020628 VALVE SEQUENCE 1 13 1 84105 SPACER 1 14 1 53392 PLUG HEX HEAD 3 15 N048002046 3 DETAIL OF PT UNI CSAE J744 SIZE 1 e 6 REVERSE DRIVING GEAR L L MASS ELASTIC SYSTEM l f zn LIVE PTO PUMP DRIVE L6 d 5 C1 0 50 0 191 0 044 z L Ci TORSIONAL RIGIDITY MNm rad MIN SHAFT DIA i5 lt ACTUAL SHAFT LENGTH m NIS H40 H 59118 259505550 LL
12. THIS NOTICE IS NOT INTENDED PER ANSI Y14 5M 1982 TAK TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT Me ks 39488 25 KSoto marasa 060407 GRANTED THE U S GOVERNMENT MARINE rev_ BY APPD REV zone No DATE zone DATE OR OTHERS BY CONTRACT 6598 TRANSMISSION YT SHEET 5 OF 16 REV F E D FOI ES Tq Su Item NO Ports NU Ports Nome Q TY 5 WREC kgm Note 3 49589 C FLANGE COMPANION 1 94 0 2588 e NO88920045 BOLT 12 20 1 5 12 20 1 5 DEEP 240 50 3 SS pepe 507N mCJIS 10 9 dio BOLTS HEXAGON HEAD SM i Ao D xs SE gt M f METRIC COMPANION FLANGE ASSEMBLY BOM No 5703157 4 BEBE SIMILAR TO NOTICE THIS PRINT CONTAINS MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIETARY INFORMATION AND IS 041020 aro uu DDISG NOT TO BE USED IN ANY MANNER n X 0 75 SCALE INCORPORATED DETRIMENTAL TO THE
13. 4 lt REMARKS N205034000 1 70034 K N204034000 1 128573 1 52382 73004500 74204521 0 0 085310030 085710025 Im I fe fe fe fe fe 3 54554 085710020 1 83638 1 78395 N319034000 1 83058 1 74238 5 085708020 BOLT 031008000 WASHER M M M IN PM 10 IA JO JH U Je J201513 220 422 2 SCREW DRIVE 81360 V eec 422 4 SCREW DRIVE 223 83251 224 4 SCREW DRIVE 225 93392 A R 226 048002046 RING O 227 96240 BJ 228 76553 229 76554 230 NO844 16000 METRIC e THIRD PROJECTION ANGLE SIMILAR TO NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE NTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE NOT INTENDED TU NULLIFY DR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT REV BY APPD REV ZONE CH NO DATE REV ZONE CH ND DATE OR OTHERS BY CONTRACT MATERIAL MASS kg wn HEAT TREAT FIRST USE 455 MODEL UN
14. 773 9 SECTION FOR REVERSE SHAFT AND MAIN PUMP THIRD ANGLE NOTES DY PROJECTION LFIGURES IN THE DRAWING SHOW TIGHTENED TORQUE FOR MAIN IMPORTANT BOLTS LIVE P T H PUMP DRIVE SAE A SAR TO BUM 9206040 E NOTICE THIS PRINT CONTAINS MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIETARY INFORMATION AND IS 4 MACHINED DIMENSIONS 05017 TW 0 N MISS ct LED d MEN ores at Sun i 13 RACINE WI 53403 USA IHEAT TREAT FIRST USE 0 13 TWIN DISC INCORPORATED assy ALL ANGULAR TOLERANCES 17 Den mre RACINE WI 53403 USA ms GEOMETRIC TOLERANCING THIS NOTICE IS NOT INTENDED 5 65984 Fas vias 1962 TO NULLIFY OR LIMIT RIGHTS SURF ACE TREATMENT bp 4 ES KSekiguchi a 51 1050930 GRANTED TO THE U S GOVERNMENT MARINE mV sv APPD REV zone DATE zone DATE OR OTHERS BY CONTRACT 6598 TRANSMISSION SHEET 12 OF 16 REV Q D C B
15. 24 059010000 1 1 77328 1 INCLUDED IN ITEM 20 143 031010000 2 108 60204522 1 SHIM 25 330120201 1 1 71042 1 144 1 68614 1 109 085708020 2 INCLUDED ITEM 104 26 532220000 1 J10205864 1 145 N048006043 1 110 1 74071 1 27 1 74238 1 1021658 1 146 N113810050 8 111 3 54663 1 jossenbly 28 085708020 2 1 53392 4 147 N032010000 8 WASHER 112 SEE TABLE 1 1 29 N031008000 2 WASHER 048002046 4 RING D 148 132416000 1 113 1 77222 1 30 023713019 3 JMA1052U 4 1149 N370162215 1 WASHER COPPER 114 N530317000 1 31 7 39427 1 SAE 1 1 83804 1 150 3 49199 F 1 115 1 77293 1 32 N408311100 1 N113810045 4 BOLT SOCKET HEAD 151 NI13808045 6 116 NO48115031 2 33 3 54677 1 sarassccr R 318 1017383 1 152 1 63573 1 INCLUDED IN ITEM 150 117 1 75494 D 2 34 1 83785 1 jassenbly JB1337G 1 153 1 63572 1 INCLUDED IN ITEM 150 118 1 8735 2 35 3 54676 1 36 113916040 16 37 N059011500 2 4 6 8 10 12 14 16 18 20 28 30 32 34 36 38 089411200 2 39 031012000 2 5 7 11 13 5 19 2 5 27 29 31 33 35 37 40 460208203 1 f 41 A 42 NO48010041 1 43 050010108 9 44 5 52278 1 45 075080016 4 46 1 79375 N 1 47 1 77226 G 1 9 181 82 183 84 48 N408001100 1 49 408701100 1 50 085712040 9 51 3 54666 1 Se 048020001 1 6 n H 53 N532218000 1 54 1 63757 1 iz SS 1 77277 1 Y 56 5 48306 1 57
16. Figure 13 Hydraulic Hose Removal 58 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 2 Drain oil from filter Remove the sending unit from the hydraulic filter housing 3 Remove the hydraulic oil filter from the main housing W00115A 00114 Figure 14 Hydraulic Oil Filter Removal Sequence Valve 1 Identify and remove the secondary clutch shaft sequence valve 2 Identify and remove the primary clutch shaft sequence valve Figure 15 Sequence Valve Removal 3 Protect the sequence valves from contaminants Marine Transmission Service Manual 1022297 59 Disassembly Twin Disc Incorporated GP Electronic Control Note To aid in assembly be sure to mark all wire connectors prior to removing the control 1 Disconnect the wiring 2 Loosen the four 6 capscrews retaining the electronic module 3 Remove the electronic module W00111 Figure 16 GP Control with Electronic Interface Removal Upper Valve he Remove the six M10 x 70 capscrews retaining the upper valve 2 Remove the upper valve from the lower valve Discard the gasket W00110 Figure 17 Upper Valve Removal 60 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Lower Valve 1 Remove four M10 x 50 socket head capscrews 2 Remove the lower valve from the main housing Discard the gasket WD005 Figure 18 Lower Valve Removal Ditch Plate 1 Remove the four M1
17. Inspect and correct cause of suction leak Inspect repair or replace control valve Overhaul marine transmission Remove marine transmission Replace worn or damaged coupling Select proper torsional coupling Overhaul marine transmission Check alignment of engine and transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine 53 Troubleshooting Twin Disc Incorporated Table 15 Troubleshooting Chart continued 1021658 and 1020941 GP Control Valves with Electronic Interface No neutral 6 1 Clutch plates warped Remove clutch plates Overhaul unit 6 2 Disengaged clutch has Replace Proportional apply pressure Valve Service transmission oil filter 7 Harsh engagement Faulty Proportional Valve Replace Proportional Valve Faulty Temperature Sensor Replace Temperature if equipped Sensor Profile Generator defective Replace Profile Generator or out of adjustment Adjust if proper equipment is available 8 Low lube oil pressure Pump flow output too low Replace pump Pump suction strainer Remove clean inspect plugged and install the suction Screen Air leak on suction side of Inspect and correct cause pump of suction leaks Lube relief valve Remove and clean or malfunction replace parts as necessary Broken piston rings Replace damaged piston rings Cil spilling out of Cil level too high Adjust oil level breather Wrong
18. 113806060 BOLT SOCKET HEAD 3 f 7 93114 J PUMP TRDCHUID m 8 52905 GASKET 5 9 84255 PIPING 5 f O 10 54942 STRAINER 11 048006043 RING O 5 2 Nm JIS 8 8 4 4 BOLTS HEXAGON SOCKET HEAD 11 Nm CJIS 8 3 BOLTS HEXAGON SOCKET HEAD I 3 2 SECTION FOR TRAILING PUMP SECTION FOR L_STRAINER ES METRIC _FIGURES IN THE DRAWING SHOW TIGHTENED TORQUE FOR MAIN IMPORTANT BOLTS Q C mew SIMILAR TO TRAILING PUMP BUM 5706036 nee RENE UT e We ER TUIN DISE DETRIMENTAL TO THE INTERESTS OF Xx 525 1 acne HEAT TREAT FIRST USE XXX 0 13 TWIN DISC INCORPORATED assy ALL ANGULAR TOLERANCES 15 PRN RACINE WI 53403 USA 2 me ORC IS nor NDME are HEE SEINE 7y 39488 7 REV BY APPD REV ZONE CH NO DATE REV ZONE CH DATE CRAIR OTHERS BY CONTRACT NT MGX 6598A TRANSMISSION MEL SHEET 7 OF 11 REV ___
19. LIQUID PACKING ON THE PORTION MARKED AND ASSEMBLE THEM YDRA P L P Y 0 5706039 3 24 25 ee 27 ee MEO T esser TURTON DDISG NOT BE USED IN ANY MANNER wnt MACHINED DIMENSIDNS SCALE INCORPORATE D DETRIMENTAL TO THE INTERESTS DF 2025 L3 DETAIL DF CIRCLE TWIN DISC INCORPORATED jid aaar menasan RACINE 53403 USA MGX 6598A GEOMETRIC TOLERANCING SCALE 1112 SECTION b KI b Masse 1060405 THIS NOTICE IS NOT INTENDED SAE ET BE A eS 7 39488 14 SCALE 115 TAKAI KS 050930 GRANTED TO THE US GOVERNMENT MARINE lap REV BY APPD REV ZONE CH NO DATE REV ZONE CH DATE OR OTHERS BY CONTRACT MGX 6598A TRANSMISSION 14 16 REV b F E D AT 20 5 8 6UNC TAP 20 DEEP 49 34 49 gt P T D SHAFT ROTATIONAL DIRECTION 20 5 ETAIL OF PTO MO SAE J744 SIZE HYDRAULIC PUMP DRIV SPECIFIC ATION TOTAL MASS APPROX 47 kg AT ENGINE RATED SPEED DIL PRESSURE CLUTCH DIL 1 1 1 4 MPa 600 2500 min DIL TEMP 65 70 C DIL VISCOSITY SAE 40 MULTI GRADE DIL IS NOT APPROVED CAPACITY WO
20. Marine Transmission Components MGX 6598A Document Number 1022297 Twin Disc Incorporated 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 Twin Disc Incorporated Document Number 1022297 December 2005 Marine Transmission Service Manual Twin Disc Incorporated 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 serv
21. 1 63760 2 INCLUDED IN TEM 150 126 5 52140 B 2 91 1 14833 1 8 1 53392 6 LI 221041657 2 INCLUDED IN TEM 150 127 3 49158 22 92 N048004030 1 9 NO48002046 6 RING 0 pny 163 2240002388 2 INCLUDED IN ITEM 150 128 3 49159 H 22 93 1 77481 D 1 ossenbly 10 048002055 12 164 085312030 4 129 3 49157 B 24 94 N085710035 11 11 1020628 2 165 1 51819 2 130 3 49157 2 FOR ADJUSTMENT 95 N031010000 11 12 1 84105 2 SPACER 166 1 64583 2 INCLUDED IN TEM 150 131 N421019000 2 96 3 54529 1 13 N113810095 2 1595 N 67 1 12573 1 132 113810030 4 97 085710095 1 14 113810055 1 1255 168 1 71197 1 133 N032010000 4 98 3023709019 1 15 032010000 3 on EE 169 1 71198 1 134 1 77337 1 39 K330085134 1 16 460200022 1 170 1 12573 B 1 135 NS06206H00 2 100 12006024 6 17 46020 522 1 sum 171 3 49365 1 136 1 55019 G 1 101 1 75332 1 18 530315000 1 72 1 63762 2 INCLUDED IN TEM 150 137 1 77498 1 102 085710030 1 19 3 54662 1 lassembly 1173 1 80389 1 138 059003000 1 103 048006035 1 20 1 83778 1 assembly 174 1 0316 1 139 N085710140 2 104 1 83651 A 1 21 SEF TABLE 1 1 175 175015030 1 140 N064010000 2 105 050051027 1 22 N422007000 1 SEC FOR HEAT EXCHANGER 1176 N370243415 L 141 1 70677 QT 1 106 1 51967 1 2 1 1722 1 SCALE 11 5 gt 177 1 e301 F 1 142 N085710030 2 107 N460200022 i
22. 1 77297 1 58 075080020 3 ft 9 H D j 59 N085310055 2 L 55 i i 60 1 77227 1 o SELECTOR VALVE _ 61 3 492207 1 62 3 49166 B 1 63 N460100019 1 64 SEE TABLE 1 1 65 NO85310050 9 L 50 66 085310035 12 1 35 97 98 99 100 101 102 103 104 185 6 188 67 N031310000 23 68 No31010000 30 L L 69 N085710035 30 Z0 1 12573 1 71 N420008000 1 72 1 70677 0 1 73 21316006 1 74 1 70677 GP 1 75 N085710150 5 NOTES 1 76 3 54577 1 L1ADJUST SPACES ANDOFOR EACH SHAFT WITH SHIMS 77 1 836954 1 SPACES AND SHOULD 0 05 0 05 mm 78 85710040 6 1 40 5 Gee SHOULD BE 0 0 05 mm 79 085710070 1 L 70 SPACE REFERS TO OTHER DRAWING 3 54745 z USE THICK SHIMCOVER 1mm ON THE SIDE OF GROOVE IF THERE IS A GROOVE PR eon 3 ee amp TIGHTENING TORQUE FOR MAIN IMPORTANT BOLTS SEE TABLE L 82 085710135 1 L 135 S MARKET P JSHU VS SEAT PACKINGS 031010000 1l 4 LIQUID PACKING ON THE PORTION MARKED D AND ASSEMBLE THEM S MARKED D SHOULD BE COATED WITH LOCTITE 277 lt RED gt M C R C 6 MARKED SHOWS SEAL WASHER C D E 7 CLUTCH PISTON STROKE IS SET TO 3 05 0 85 mm REFER TO OTHER DRAWING 3 55080 FOR DETAILS c PROJECTEN TABLE i TABLE 2 38 40 42 44 46 48 50 52 54 56 se 60 6e 64 66 68 70 72 74 GU ET ITEM 21 ITEM 112 ITEM 64 MARKE BOLT TIGHTENING TORQUE 39 43 45 47 49 51 53 55 57 59 61 63 65 67 69 7
23. L3 P Pr n 5 0 3 o o e 43 TABLE 2 MARKE BOLT TIGHTENING TORQUE x1 8 1 25 22 Nm 36 5 xe 10 1 5 42 RIC 3 M12x1 75 74Nm THIRD ANGLE NOTES x4 16 2 0 195 Nm PROJECTION LTIGHTENING TORQUE FOR MAIN IMPORTANT BOLTS SEE TABLE 2 HYDRAULIC PUMP DRIVECEUR SAE B 2 LIQUID PACKING ON THE PORTION MARKED L AND ASSEMBLE THEM BOM 5706142 1 MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE PEE TAS PRINT CONTAINS s 11971 DISS Ee a ME vets o a eel 5 1 RACINE 53403 USA TWIN DISC INCORPORATED PEAT ALL ena Tu RACES 7 takai RACHEL 53 GSR MGX 6598A UK THIS NOTICE IS NUT INTENDED SURFACE TREATMENT NAME 5 rakar 050930 RAN TED EO DE US GOVERNMENT MARINE 4 16 rev_ BY APPD REV zone No DATE zone DATE OR OTHERS BY CONTRACT 6598 TRANSMISSION YT SHEET 16 OF 16 REV O F E D C A 1022297 12 05 SY ANY TWIW DISC POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
24. NOTES 16 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Description and Specifications Description and Specifications General The MGX 6598A is a reverse and reduction Marine Transmission with an additional Quickshift feature The output shaft operates at a 10 down angle from the input shaft They offer conical helical gearing for quieter operation and are available in the following ratios 1 29 1 1 51 1 1 74 1 2 03 1 2 48 1 and 2 80 1 The MGX 6598A transmissions are controlled by hydraulics 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 7 39630 identifies the installation information for the MGX 6598A marine transmission Marine Transmission Service Manual 1022297 17 Description and Specifications 18 Nameplate Twin Disc Incorporated 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 25 QUICK SHIFT MARINE TRANSMISSION OIL OIL MODEL NO CAPACITY AT RATED RPM MINIMUM PRESSURE RATIO L MPa BOM NO CUSTOMER NO SERIAL NO LUBRICATION EVERY 10 HOURS OR DAILY CHECK OIL LEVEL EVERY 100 HOURS OR WHEN BOAT IS DOCKED OIL
25. WI 53403 USA MeL GEOMETRIC TOLERANCING THIS NOTICE NOT INTENDED PER ANSI 14 5M 1982 CHK Ks WA S EE dr Mi RINE pa seit REV BY APPD REV ZONE CH NO DATE REV ZONE CH DATE OR OTHERS BY CONTRACT MGX 6598A TRANSMISSION SHEET 11 OF 11 REV ___ E D C B 4 SHAFT ROTATIONAL DIRECTION 3 8 16 UNC 20 DEEP 6 HOLES EQSPACED 2 HOLES USE 9 at m 83 58 Sires p N in e o eo e 6 Si o Rtg N E LIVE P T O PUMP DRIVE SPECIFICATION PARTS NO NAME Q TY REMARK TOTAL MASS APPROX 25 kg 1 1 84395 SLEEVE AS PUMP 1 WORKING TORQUE 75 x L 19 N m NI13810055 BOLT SOCKET HEAD 3 L Length of pump spline P T 0 CAPACITY 0 OPERATING SPEED 2500 min 3 3 55158 ADAPTER 1 SAE P L ACCEPTS S AE J744 SIZE PUMP 4 N113810180 BOLT SOCKET HEAD 5 DP 16 32 5 3 54577 GEAR PUMP AS 1 ND TEETH 9 6 1 83654 GASKET 1 SPLINE DATA NOMINAL PITCH CIRCLE DIA 14 287 7 048010035 1 PRESS ANGLE 30 8 48010042 RING D 1 IIP DIA 19 7008 9 N085710095 BOLT 1 ROOT DIA 16 579 3 030 ARC TOOTH SPACE 2 494 0082
26. 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 the shaft diameter If the distance is less than this a flexible coupling may be necessary to isolate the engine vibration Marine Transmis
27. transfer gears clutch spiders are shrunk fit onto the primary and secondary shafts Do not remove these gears during service The output gear is mounted ona keyless taper Marine Transmission Service Manual 1022297 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 Li Dampen torsional vibrations Change the natural frequencies of a system to move critical frequencies out of the operating speed range Accommodate a certain amount of misalignment Absorb shock and reduce noise Minimize gear rattle The coupling has been selected based on the customer supplied engine information Final coupling selection must be confirmed by the packager based on the torque rpm ratings the result 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 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 raw or fresh water through the heat exchanger The heat exchanger is located in the transmission housing Replaceable zincs for corrosion protection are located on the heat exchanger front and rear end caps 22 Marine Transmission Service
28. 1022297 157 Assembly Twin Disc Incorporated 12 Seat the output gear onto the output shaft with 50 000 kPa 7 250 psi Hold the pressure for a minimum of five minutes Verify the spacer below the output gear can not rotate W00053 Figure 165 Output Gear Pressed onto Output Shaft 13 Remove all special tools 14 Verify the output gear advancement onto the output shaft a Measure the distance from the shaft shoulder near the output gear to the end of the shaft Record this dimension as dimension K Dimension K b Measure the distance from the edge of the output gear to the end of the output shaft Record this dimension as dimension L Dimension L The differences between these two dimensions L K should be 0 00 0 05 mm 0 00 0 002 inches d If the output gear requires further advancement reinstall the tools and reapply pressure to advance the output gear If the gear cannot be advanced the proper distance the shim pack thickness should be checked Checking the shim pack dimension will require disassembly e If the shim pack thickness is correct and the output gear cannot be advanced the proper distance consult the Product Service Engineering Department at Twin Disc 158 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 15 Install the spacer onto the output shaft W00054 Figure 166 Spacer Installation 16 Install the spherical roller bearing onto the output
29. 189 Assembly Twin Disc Incorporated Note See Specification Section for tubing fitting torque values wo0114 W00115 WO00116 Figure 216 Hydraulic Oil Filter Installation Grease Output Shaft Seals Fill the cavity between the two output shaft seals with grease as follows a Remove the pipe plug on the output shaft seal retainer housing The pipe plug is located on the opposite side 180 opposed of the grease fitting on the housing The pipe plug provides a place for air to escape while greasing the seal cavity b Use a grease gun to fill the cavity with grease When grease escapes the seal retainer through the pipe plug opening the cavity is filled Reinstall the pipe plug AAR328 6557 AAR329 6557 Figure 217 Grease Output Shaft Seals 190 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Input Coupling 1 Apply molydisulfide grease to the splines at the input end of the primary clutch shaft 2 Position the input coupling onto the shaft 3 Temporarily attach the input coupling to the front housing for shipping WO00117 Figure 218 Input Coupling Installation Note Following the repairs main pressure must be adjusted and the Sequence Valve adjustment must be accomplished with a Tekmeter or other instrumentation capable of measuring and recording pressure versus time The locations for pressure measurement are shown on the Installation Drawing that is located
30. 207 Applying Sealant 2 Place the top cover on the main housing Torque the eleven M10 x 35 capscrews with washers to 45 Nem 35 Ibeft W00104 W00105 Figure 208 Top Cover Installation 184 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Ditch Plate 1 Position a new ditch plate gasket onto the main housing 2 Install the ditch plate 3 Torque the four M10 x 45 socket head capscrews to 45 Nem 35 Ib ft W00106 Figure 209 Ditch Plate Gasket Installation Marine Transmission Service Manual 1022297 185 Assembly Twin Disc Incorporated Assembly of GP Control Valve with Electronic Interface 186 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 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 Ibeft 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 nptf 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 i
31. 7 39488 5 9 7 39488 6 9 7 39488 7 9 7 39488 8 9 7 39488 9 9 7 39488 10 MGX 6598A Marine Transmission Section MGX 6598A Marine Transmission Section MGX 6598A Marine Transmission Installation MGX 6598A Marine Transmission Input Groups MGX 6598A Marine Transmission Companion Flange MGX 6598A Marine Transmission Trailing Pump MGX 6598A Marine Transmission Live PTO MGX 6598A Marine Transmission Rigid Mounting MGX 6598A Marine Transmission Resilient Mounting Marine Transmission Operator s Manual 1022297 223 Engineering Drawings 224 7 39488 11 7 39488 12 7 39488 13 7 39488 14 7 39488 15 7 39488 16 Twin Disc Incorporated MGX 6598A Marine Transmission Heat Exchanger MGX 6598A Marine Transmission Live PTO MGX 6598A Marine Transmission Live PTO MGX 6598A Marine Transmission Hydraulic PTO MGX 6598A Marine Transmission Hydraulic PTO MGX 6598A Marine Transmission Hydraulic PTO Marine Transmission Operator s Manual 1022297
32. Disc to be used in salt water applications have zinc anode rods installed at the heat exchanger 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 anode rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or externally grounded electrical current If these conditions do not exits it is evident the corrosion is due to local electrolysis Ifthe zinc anode rods are corroded with foreign materials they should be cleaned with a wire brush Marine Transmission Service Manual 1022297 149 Assembly Twin Disc Incorporated 1 Install the heat exchanger base and gasket Torque the eight M10 x 50 socket head capscrews to 45 Nem 34 Ib ft W00036 Figure 150 Heat Exchanger Base Installation 2 Install a new gasket and heat exchanger core Install the core as it was marked on disassembly The gasket is placed between the flange on the heat exchanger and the base _ W00037 W00038 Figure 151 Heat Exchange Core Installation 3 Place the heat exchanger core in the main housing with the divider located horizontally in the housing 150 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 4 Install the divider a new gasket and rear cover Apply grease between the rear cover and gasket Atta
33. Install the external retaining ring Remove the clamps CA1018 Figure 99 Clutch Backing Plate Installation 12 Install the inner bronze thrust washer with eighteen radial grooves into the pinion with the grooves away from the gear teeth CA1019 Figure 100 Inner Bronze Thrust Washer Installation 120 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 13 Lubricate the area of the clutch shaft that contact the rear bronze thrust bushing Install the pinion Gently rotate the pinion as itis lowered into the clutch plates until the splines are fully engaged in all of the clutch plates CA1020 Figure 101 Pinion Installation 14 Slide the outer bronze thrust washer with 18 radial grooves on both sides onto the shaft CA1021 Figure 102 Outer Bronze Thrust Washer Installation Marine Transmission Service Manual 1022297 121 Assembly Twin Disc Incorporated 15 Install the round snap ring into the groove of the shaft to retain the outer bronze thrust washer Note The round snap ring groove will be visible above the rear bronze thrust washer if the pinion is fully engaged with all of the clutch plates CA1023 Figure 103 Round Snap Ring Installation 16 the clutch shaft over Install new bearing cone against the clutch housing a Heat the bearing cone to 120 C 250 F A WARNING Handle the bearing cone with care The bearing cone is HOT b Place t
34. Shaft e Apply air pressure to the large area of the clutch This is the passage between the seal rings nearest the clutch 116 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly f While maintaining air pressure on the clutch measure the distance from the end of the clutch shaft to the end of the special tool sleeve The clutch piston travel must be between 2 80 3 30 mm 0 110 0 130 in If the clutch piston travel is outside its limits use a combination of 2 2 mm 0 087 in and 2 6 mm 0 102 in steel clutch plates to achieve the desired amount Steel plate part number 349157A is 2 6 mm 0 102 in thick and part number 349157B is 2 2 mm 0 087 in thick g Remove the special tools and disassemble the components from the clutch housing 4 Slide the lower spring retainer and release spring onto the shaft CATDIO Figure 93 Lower Spring Retainer and Release Spring Installation Slide the top spring retainer and external snap ring onto the shaft CA1011 CA1012 Figure 94 Top Spring Retainer and External Snap Ring Installation Marine Transmission Service Manual 1022297 117 Assembly Twin Disc Incorporated 6 Slide the snap ring retainer thrust race onto the shaft with chamfered side facing the external snap ring CA1013 Figure 95 Upper Thrust Washer Thrust Race Installation 7 Use a special tool and seat the external snap ring into the groove of the shaft by applying a
35. Specifications Table 13 Tubing Nuts Torque Values for Tubing Nuts Recommended Torque Ibeft Nominal Tube Size Marine Transmission Service Manual 1022297 31 Description and Specifications Twin Disc Incorporated NOTES 32 Marine Transmission Service Manual 1022297 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 1022297 33 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 Valve_6598 Figure 2 GP Valve Assembly mounted on Marine Transmission 34 Marine Transmission Service Manual 1022297 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 m
36. bearing cones from the output shaft Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly A CAUTION Use the bearing puller properly to avoid damage to the bearing cones 13 Remove the output shaft seal carrier from the output shaft a Remove and discard the O ring from the inner diameter of the seal carrier b Remove the two seals from the seal carrier 14 Ifnecessary remove the output sensor gear from the output shaft Heat Exchanger Note Place the transmission with the output end facing up Be sure the transmission is securely supported 1 Remove the six M8 x 45 capscrews retaining the heat exchanger rear cover Remove the rear cover Discard the gasket Note The heat exchanger rear cover is equipped with a divider separating the inlet of the heat exchanger from the outlet of the heat exchanger 2 Mark the heat exchanger core at the top to ensure it will be replaced into the main housing correctly AR6557 18BE Figure 47 Mark Top of Heat Exchanger Core Marine Transmission Service Manual 1022297 81 Disassembly Twin Disc Incorporated 3 Pull the heat exchanger core from the main hosing Discard all gaskets and O rings WD030 Figure 48 Heat Exchanger Core Removal 4 Remove the eight M10 x 50 socket head capscrews retaining the heat exchanger base to the main housing Remove the base and discard the gasket Trailing Pump 1 Remove the external retaining ring fr
37. flexible couplings in the market today that solve a variety of problems Couplings to reduce noise and vibration Couplings to allow a permanent angular misalignment 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 1022297 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 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 ducting or conduit 2 Keep cable or harness away from hot surfaces moving parts and oil locations 3 Attach cable or harness to vessel making the connector th
38. force to the tool until the snap ring seats CA1014 Figure 96 Seat External Snap Ring into Groove 118 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 8 Install the clutch plates a Install one steel clutch plate next to the piston b Install one friction clutch plate CA1015 Figure 97 Steel Clutch Plate and Friction Clutch Plate Installation G Place one wave spring around the outer circumference of each friction clutch plate Be sure to install the wave spring around the circumference in a random manner Note Be sure the wave springs are not against the face of the friction clutch plates CA1016 RMVC028FGS Figure 98 Wave Spring 2 Installation Marine Transmission Service Manual 1022297 119 Assembly Twin Disc Incorporated d Install the remaining steel clutch plates friction clutch plates and wave springs in an alternating fashion until all clutch plates and wave springs have been installed 12 steel clutch plates 11 friction clutch plates and 11 wave springs 9 Install the clutch backing plate Press the plate firmly into the clutch housing to ensure the splines of the clutch are aligned 10 Position the internal retaining ring next to the clutch backing plate 11 Install two clamps on the clutch housing and the clutch backing plate Use the clamps to evenly compress the clutch until the internal retaining ring can be installed properly into the clutch housing
39. of the output shaft Fill the special tool with oil d Remove all air bubbles from the oil e Thread special tool 1 57215 hex head bolt into special tool 1 57214 A Marine Transmission Service Manual 1022297 77 Disassembly Twin Disc Incorporated f Use a thin pry bar between the gear and the front spherical bearing A prying force while applying expanding pressure will cause the bearing to move upward in the housing creating space to allow the shaft to separate from the gear As the bolt is tightened the pressure inside the special tool will begin to rise Continue to tighten the bolt while prying on the bar The front spherical roller bearing will begin to expand allowing it to move upward in the housing WD027 Figure 44 Initial Operation to Separate Front Spherical Roller Bearing from Output Shaft 78 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly To separate the output gear from the output shaft Note At the time of publication these tool drawings were not available Tools T214182 8 and T214182 18 should be used for these procedures Apply thread seal tape to the male threads of special tools 1 57214 D and 1 57215 Thread special tool 1 57214 D into the deep hole in the end of the output shaft Fill the special tool with oil Remove all air bubbles from the oil Thread special tool 1 57215 hex head bolt into special tool 1 57214 D As you tighten the bol
40. 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 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 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Preventative Maintenance Separation of rubber from flex plate on coupling plate or deterioration of the rubber to metal bond See above Deterioration of
41. place under the output flange Place wooden blocking under the output flange Allow approximately 70 mm 2 3 4 in of clearance between the wooden blocking and output flange Figure 42 Wooden Blocking Under Output Flange 76 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 3 Remove the external retaining ring and spacer from the output shaft _ WD026 Figure 43 External Retaining Ring and Spacer Removal 4 The end of the output shaft has two holes The deep hole is use to separate the output gear from the output shaft The shallow hole is used to separate front spherical roller bearing from the output shaft The following special tools are required Note At the time of publication these tool drawings were not available Tools T214182 8 and T214182 18 should be used for these procedures a 1 57214 A is required to separate the output gear from the output shaft b 1 57214 D is required to separate the front spherical roller bearing from the output shaft 1 57215 hex head bolt is required for both operations 5 It will require two separate operations to totally separate from the front spherical roller bearing from the output shaft The first operation will start to separate the output shaft from the front spherical roller bearing a Apply thread seal tape to the male threads of special tools 1 57214 A and 1 57215 b Thread special tool 1 57214 A into the shallow hole in the end
42. 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 versions of Electronic Profile or E Troll Module WARNING Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System Marine Transmission Service Manual 1022297 Twin Disc Incorporated Operation prof_gen Figure 6 Electronic Profile Module MGX non troll Solenoid A Red LED Power OK Green LED Solenoid B on Red LED Prof_gen_nts1 Figure 7 Electronic E Troll Module MGX E Troll Marine Transmission Service Manual 1022297 39 Operation Twin Disc Incorporated Hydraulic System with GP Control Valve 40 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
43. shaft a Heat the spherical roller bearing to 120 C 250 F WARNING Handle the spherical roller bearing with care The bearing is HOT b Lubricate the output shaft bore Use a bearing driver to install the spherical roller bearing onto the output shaft Verify the bearing is against the spacer W00055 WO00056 Figure 167 Spherical Roller Bearing Installation Marine Transmission Service Manual 1022297 159 Assembly Twin Disc Incorporated 17 Install the spacer and external retaining ring onto the output shaft W00057 Figure 168 Spacer and Retaining Ring Installation Heat Exchanger Front Cover Install the heat exchanger front cover to the main housing a Lubricate a new O ring and install the O ring over the front of the heat exchanger core b Install the spacer next to the O ring Lubricate a new O ring and install the O ring over the heat exchanger core next to the spacer d Install the front cover Torque the six M8 x 55 capscrews evenly to 23 Nem 17 Note Tighten the six capscrews evenly to prevent damage W00060 W00062 Figure 169 Heat Exchanger Front Cover Installation 160 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Input Shaft Seal 1 Apply MA1015 or equivalent sealer to the outside diameter of a new input seal 2 Use a seal installer to install the seal into the main housing flush with the housing 3 Apply grease to
44. temperature sensor if equipped and loosen the four M6 1 0 capscrews that retain the 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 Prof_gen Figure 81 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 2 73 Proportional E Valves Manuel p M12x 1 50 Override o ring plug Valve Top Valve Body Top_hydraulic_valve1 Figure 82 Top Hydraulic Valve Body Assembly Marine Transmission Service Manual 1022297 101 Disassembly Twin Disc Incorporated 9 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 assy1021658_lower Figure 83 Main Regulator Hydraulic Valve Assembly 1021658 102 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 4 Remove the Manual Direction Control Valve with switch or the Plug Assembly from the Top Valve Body Note Some applications have two identical switches located on the manual direction control valve Override Valve with Neutral Switch Locking Pin Plug if applicable Valve or plug1 Figure 84
45. the lip of the seal W00062 W00063 Figure 170 Input Seal Installation Input Drive Sleeve Note Place the transmission with the output end facing up Be sure the transmission is securely supported Allow enough clearance under the housing for the input sleeve about 203 mm 8 in Wrap the retaining ring groove of the input drive sleeve with electrical tape to protect the lip of the seal Install the input drive sleeve into the main housing Use a jack to support the sleeve in place Marine Transmission Service Manual 1022297 161 Assembly Twin Disc Incorporated Note Use care not to damage the lip of the input seal DO NOT position the input drive sleeve to far into the seal W00064 Figure 171 Supporting Input Drive Sleeve 2 Remove the protective tape from the input drive sleeve 3 Install the bearing cone onto the input drive sleeve a Heat the bearing cone to 120 C 250 F A WARNING Handle the bearing cone with care The bearing cone is HOT b Lubricate the input drive sleeve Use a bearing driver to install the bearing cone onto the input drive sleeve 00065 Figure 172 Bearing Cone Installation 162 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 4 Install the spacer and external retaining ring LAS WO00066 Figure 173 Spacer and Retaining Ring Installation 5 Remove the jack Use a tool to drive the input drive sleeve down unti
46. 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 or deformed This 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 Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found 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 b
47. you find one of these defects replace the bearing 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 110 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Cleaning and Inspection Gears 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 Parts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found Springs Inspect springs for broken or distorted coils Replace the spring if either o
48. 0 x 45 socket head capscrews retaining the ditch plate to the main housing 2 Remove the ditch plate Discard the gasket Figure 19 Ditch Plate Removal Marine Transmission Service Manual 1022297 61 Disassembly Twin Disc Incorporated Top Cover 1 Remove the eleven M10 x 35 capscrews with washers retaining the top cover to the main housing 2 Gently tap on the top cover to break the sealer bond from the main housing 3 Remove the top cover Figure 20 Top Cover Removal Oil Level Gauge Remove the oil level gauge from the main housing 62 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Lube Tube 1 Remove the and washer that retains the lube oil valve components inthe main housing 2 Remove the spring and piston Spring Washer Piston LubeOilValve Figure 21 Lube Oil Valve Removal Input and Output Speed Sensors Note Place the transmission with the output end facing up Be sure the transmission is securely supported dy Disconnect the input speed sensor connector and output speed sensor connector 2 Loosen the jam nut securing each sensor 3 Remove the sensors WD007 WD008 Figure 22 Input and Output Speed Sensors Removal Marine Transmission Service Manual 1022297 63 Disassembly Twin Disc Incorporated Hydraulic Oil Pump 1 Remove the six capscrews five M10 x 50 one M10 x 95 retaining the hydraulic oil pump to the pump mount Ide
49. 03 414 0 0 0 0 303 414 Table 3 Output Gear Advance 5 45 mm 0 215 RUM 6 75 mm 0 266 Table 4 Primary and Secondary Tapered Roller Bearing Preload End Play Maximum Preload Maximum Endplay 0 05 mm 0 002 in 8 77 0 05 0 002 Table 5 Output Bearing Endplay 0 00 mm 0 000 in 0 05 mm 0 002 in Marine Transmission Service Manual 1022297 25 Description and Specifications Twin Disc Incorporated Table 6 Runout Limits Record total indicator runout of the following max allowable shown Face of SAE 0 and SAE 1 housing from input spline 0 41 mm 0 016 in Pilot of SAE 0 and SAE 1 housing from input spline 0 30 mm 0 12 in Face of propeller flange near O D from main housing 0 10 mm 0 004 in Pilot of propeller flange from main housing 0 10 mm 0 004 in This note applies to a continuous 270 arc if the balance of the pilot is negative in readings otherwise it means all 360 Table 7 Sequence Valve Min Max psi psi om vw o 290 300 m m 7 290 300 Table 8 Clutch Piston Travel 2 80 mm 3 30 mm 0 110 in 0 130 in 2 80 mm 3 30 mm 0 110 in 0 130 in 26 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Description and Specifications Optional Equipment The following optional equipment is available for the MGX 6598A marine transmission
50. 058 Figure 183 Gear Pan Installation 168 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Bottom Cover 1 Apply MA1015 on the sealing surface of the main housing Be sure to apply enough sealant to adequately seal the bottom cover A IMPORTANT Be sure to seal the surface around the center two capscrews location on the main housing Leaks will result if the bottom cover is not properly sealed 2 Install the bottom cover Torque the two M10 x 55 nine M10 x 50 and twelve M10 x 35 capscrews with washers to 45 Nem 35 16 Note Apply nickel anti seize compound to the threads before installing the screws W00059 Figure 184 Bottom Cover Installation Marine Transmission Service Manual 1022297 169 Assembly Twin Disc Incorporated Manifold 1 Lubricate and install new O rings into the main housing W00076 Figure 185 O Ring Installation 2 Apply MA1015 sealant to the manifold and the main housing mating surfaces WO00077 Figure 186 Applying Sealant Insert the two dowel pin assemblies into the manifold 170 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 4 Position the manifold onto the main housing W00078 Figure 187 Manifold Installation 5 Loosen the dowel pin nuts on the manifold Drive the dowel pins into the main housing to properly locate the manifold Lightly tighten the dowel pin nuts to hold the manifold i
51. 1 73 E RATIO PINION AS F VD PINION AS REV GEAR 8 1 25 22 Nem x 1 99 3 54660 3 254661 5 52249 xe 10 1 5 42 Nm NOTICE THIS PRINT CONTAINS MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE cura asse an i qoe _ TIN DISE 1 74 3 54660 3 54661 5 52255 x4 M16x2 0 195 Nm DETRIMENTAL TO THE INTERESTS OF UE 2025 1 4 Sat Usa 2 0313 54660 C 3 54661 5 S2258 TWIN DISC INCORPORATED assy ALL Toverances en PRN an 2 48 3 24660 D 3 54661 D 15 52261 RACINE WI 53403 USA her GEDMETRIC TOLERANCING aK 2 80 13 54660 13 54661 15 52264 b SL b 060405 TU NULLIEY DR LIMIT RIGHTS SURFACE TREATMENT 7 39488 1 K S 060314 GRANTED TO THE U S GOVERNMENT MARINE REV BY APPD REV ZONE CH DATE REV ZONE DATE OR OTHERS BY CONTRACT MG X 6 5 984 TRANSMISSILIN YT SHEET 1 OF 16 REV _ F E D C B SECTION B B ou Qi I oS 05099 90509 206 208 216 217 218 624 eed 4226 227 VIEW A 5 1 MARKED P SHOWS SEAT 8 ee9 e30 INGS 1 I PARTS N
52. 1 Remove the special tool retaining the input sleeve Install the secondary clutch shaft front bearing cone in the main housing Apply a thin film of grease to the inner bore of the bearing cone W00073 Figure 180 Secondary Clutch Shaft Front Bearing Cone Installation 166 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 2 Lubricate the splined end of the primary clutch shaft with grease Install the primary clutch shaft into the main housing Carefully align the input drive sleeve and clutch shaft splines during installation Note In some instances it may be necessary to press the primary clutch shaft into the splines of the input drive sleeve A IMPORTANT Be sure the primary clutch shaft is fully engaged into the input drive sleeve before installing the secondary clutch shaft 00074 Figure 181 Primary Clutch Shaft Installation 3 Install the secondary clutch shaft into the main housing Note Assembly of the secondary clutch shaft will be difficult if the two shafts are not perfectly aligned Marine Transmission Service Manual 1022297 167 Assembly Twin Disc Incorporated Note The clutch shaft transfer gears will protrude 5 mm 0 20 in above the main housing WO00075 Figure 182 Secondary Clutch Shaft Installation Gear Pan 1 Position the gear pan over the output gear 2 Torque the two M10 x 140 capscrews with sealing washers to 42 Nem 31 Ibsft WO00
53. 12 PLACES BAS SL NI 2 PLACES N 0078 R DRILL 7 16 43755 DIA THRU PIPE TAP 1 4 16 NPTF 2 PLACES ee eek DRILL 37 64 lt 5791 DIA x 122 DP PISTON RING lt 1 REQ D PIPE TAP 3 8 18 NPTF 1 PLACE PREHARD Rc 28 32 DRILL THRU amp 1125 C BORE DEPTH SHOWN FOR M6 SOC HD CAP SCREW 16 PLACES STAMP PISTON RETAINER LD REQ D NAXINLM OPERATING PRESSURE 7250 PSI 5 PREHARD Rc 28 3 IN OD OF DETAILE 1 WITH MINIMUM 1 4 INCH HIGH LETERING NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE ALL GRD 026 5 amp SURFACES MUST BE SQUARE amp CONCENTRIC TO WITHIN 09 97 001 OF EACH OTHER RAM imi a ia 6000 CAD FILE T 2l482 2 DWG TWIN DM VIS ELREO MAT 1 4140 RAM SUPPORT HDN AND GRD DRILL 10 2mm THRU 1 4140 RAM BASE HRN AND GRD TAP 2 x 175 x 22 RETAINER SHAFT 2 PLCS FOR LIFTING SHCS DRILL d22mm THRU DRILL 485mm x rus TAP M10 x 381 x 5 PLCS FOR 20 1 55 BOLTS PLCS FOR 2 RAM BASE 1 REG D MAT 4140 HDN amp GRD SUPPORT XD REQ D T 4140 HDN amp GRD ZENS SWZ 12 e x 150 THREAD 12 7 G SPECIAL HIGH STRENGTH BOLT 52 REQ D MATERIAL HIGH STRENGTH STEEL UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE ALL GRD DIA S amp S
54. 23 N421003600 RING SNAP 1 L 24 1 8735 RING SQUARE 1 25 3 55157 SPRING 1 28 26 1 70677 RC RETAINER SPRING 1 B 27 N420003000 RING SNAP 1 d 28 1020628 VALVE SEQUENCE 1 E 1 29 1 84105 SPACER 1 1 30 1 53392 AR PLUG HEXHEAD 3 5 QE 31 048002046 RING 0 3 Ci 1 12573 PLUG TAPER 3 5 33 N113810045 BOLT SOCKET HEAD 5 L 45 4 34 N113810150 BOLT SOCKET HEAD 1 MARKED 150 n ej 35 N113810030 BOLT SOCKET HEAD 2 SECTION 30 2 D 36 NO32010000 WASHER 7 gt 5 37 091711000 5 38 87710035 BOLT 7 1 35 39 NO32010000 WASHER 7 40 J1015047B VALVE AS 1 41 N113810080 BOLT SOCKET HEAD 4 L 80 1620 6 2 42 032010000 WASHER 4 43 1 53392 PLUG HEX HEAD 1 44 N370121810 GSKET COPPER 1 45 1 53392 BB PLUG HEX HEAD 1 46 N370121810 GASKET COPPER 1 1 6 34 36 x 33 47 1 84478 PIPING AS 1 Xi x xel 48 1 60949 PLUG SEAL 1 49 048002058 RING 0 1 50 11 51116 PISTON 1 51 N175007036 SPRING 1 52 1 50867 PLATE 1 dr 53 422 SCREW DRIVE 2 TABLE 2 MARKE BOLT TIGHTENING TORQUE 5 1 8 1 25 22 595 xe 10 1 5 42 C R Es x3 12 1 75 74 EN THIRD ANGLE NOTES x4 M16x2 0 195 Nm Dy L T PROJECTION LTIGHTENING TORQUE FOR MAIN IMPORTANT BOLTS SEE TABLE 8 HINT eee SIMILAR TO
55. 297 Twin Disc Incorporated Assembly 2 Place the selected shim pack and the spacer from the output shaft into position on the trailing pump drive gear WO00043 W00044 Figure 156 Spacer and Shim Pack on Trailing Pump Drive Gear Install the output shaft thrust bearing cup into the bore of the housing next to the thrust cup spacer The bearing cup is a slip fit in the bore W00045 Figure 157 Output Shaft Thrust Bearing Cup Installation Marine Transmission Service Manual 1022297 153 Assembly Twin Disc Incorporated 4 Ensure the tapered surface of the output shaft is clean and free of grease and other contaminants Lightly grease the output shaft bore of the main housing and the O ring on the seal carrier Slowly lower the output shaft into the housing through the spacer shims trailing pump drive gear and output gear A CAUTION Carefully lower the output shaft into the main housing as the seal carrier is installed in the housing Damage to the seals could result if appropriate care is not taken during the installation process W00046 Figure 158 Output Shaft Installation Align the holes in the output shaft seal carrier with the holes in the main housing Gently tap the end of the output shaft with a dead blow hammer if necessary to guide the output shaft seal carrier into the housing Note There will be a slight interference fit between the output shaft seal carrier and main housing Note Wh
56. 297 11 Introduction 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 thread enga
57. 3 J 617 196 UC Ul ee eee 199 Electrical Controls Installation 205 Wiring 207 Special 211 List of Special TOONS mc 211 T 214182 8 High Pressure Removal Tool 213 T 214182 18 Adapter 214 1 214182 2 Hydraulic Ram ooo errem rennen enn enne eene 215 T 214182 63 Hydraulic Ram Base and Support 216 Engineering Drawings 223 List of Engineering Drawings 4 2 2 223 7 39488 1 MGX 6598A Marine Transmission Section 225 7 39488 2 MGX 6598A Marine Transmission Section 226 7 39488 3 MGX 6598A Marine Transmission Installation 227 7 39488 5 MGX 6598A Marine Transmission Input Groups 228 7 39488 6 MGX 6598A Marine Transmission Comp Flange 229 7 39488 7 MGX 6598A Marine Transmission Trailing Pump 230 7 39488 8 MGX 6598A Marine Transmission Live 231 7 39488 9 MGX 6598A Rigid Mounting 232 7 39488 10 MGX 6598A Resilient Mounting 233 7 39488 11 MGX 6598A Heat Exchanger 234 7 39488 12 MGX 6598A Live
58. 60 ORO O 4 62 BOTH SIDES 2 M20 BOTH SIDES 399N m 20 2 5 JIS 8 8 148 20 26969 N 4F e 2 M 20 1 J oe MA p 90 Lv LH Au NOTES FIGURES THE DRAWING SHOW TIGHTENED TORQUE FOR MAIN IMPORTANT BOLTS 370 370 MOUNT THE UNIT ON A COMMON BASE WITH ENGINE METRIC AFTER LOCATING BRACKETS WITH PINS 5 e THIRD ANGLE SIMILAR TO TS BOM ND 5706052 RIGID MOUNT BRACK NOTICE THIS PRINT CONTAINS MATERIAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIETARY INFORMATION AND IS 041019 aro 09 2186 m ux USED AIN ANT PANER n 0 75 SCALE INCORPORATED DETRIMENTAL TO THE INTERESTS Df ERT TENT FIRST USE 3 x 6 s 5 RACINE WI 53403 USA TWIN DISC INCORPORATED S assy ALL ANGULAR TOLERANCES 17 PRN Oom inato RACINE WI 53403 USA bet is GEOMETRIC TOLERANCING 2x THIS NOTICE INTENDED 5 EU Mi MARINE E S APPD REV BY APPD zone DATE REV zone CH NO DATE OR OTHERS BY CONTRACT MGX 6598A TRANSMISSION Yt SHEET 9 DF 11 REV ___ E D C B
59. 7 Twin Disc Incorporated Assembly Install External Parts Primary Clutch Shaft Rear Cover 1 Lubricate and install new O rings on the manifold 00089 Figure 195 Primary Clutch Shaft Rear Cover O Ring Installation 2 Apply MA1015 sealant to the cover and manifold mating surfaces 3 Install the primary clutch shaft rear cover W00090 W00091 Figure 196 Primary Clutch Shaft Rear Cover Installation 4 Install and torque the following manifold capscrews to 45 Nem 35 Ib ft Six M10 x 35 Capscrews One M10 X 40 Capscrew One M10 x 55 Capscrew Marine Transmission Service Manual 1022297 177 Assembly Twin Disc Incorporated Pump Mount 1 Install the bushing into the pump mount a Deep freeze the bushing to 51 C 60 F for at least two hours before installing it WARNING Handle the bushing with care The bushing is extremely COLD b Heat the pump mount to 120 C 250 F Handle the pump mount with care The plate is HOT Use guide pins to align the bushing with the mount d Torque the two M8 x 20 capscrews to 23 Nem 27 Ib ft 2 Lubricate and install new O rings on the manifold 9 Apply MA1015 sealant to the pump mount and manifold mating surfaces 4 Install the pump mount Figure 197 Pump Mount Installation 5 Torque the six M10 x 40 capscrews to 45 Nem 35 Ibeft 178 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Suction Strainer 1 Instal
60. 7 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 or steam cleaning Parts must be dried and oiled immediately to prevent corrosion Examine all parts carefully for grit dirt and abrasives and reclean them if necessary Q Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent 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 1022297 107 Cleaning and Inspection Twin Disc Incorporated 108 Cleaning Bearings DO NOT remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease A CAUTION Never dry bearings with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preven
61. A RR GEOMETRIC TOLERANCING eon naso Lee 17 39488 13 REV BY APPD REV ZONE CH NO DATE REV ZONE CH DATE OR OTHERS BY CONTRACT MGX 6598A TRANSMISSION E SHEET 13 OF 13 REV ___ D C B MGX 6598A TEM PARTS NAME Q TY REMARKS HYDRAULIC PUMP DRIVE S
62. E AS DRIVE 1 4 031008000 WASHER 2 5 023713019 3 5 023713019 3 9 1 74238 E COVER 1 6 085708020 BOL 2 6 085708020 BOL 2 6 7 393652 HOUSING FRONT 1 7 N031008000 WASHER 2 7 031008000 WASHER 2 7 1015474 VULASTIK 1 8 1 74238 COVER 1 8 1 74238 COVER 1 8 3 54676 A FLANGE INPUT 1 9 7 394207 HOUSING FRONT 1 9 7 39427 HOUSING FRONT 1 9 085820070 BOL 16 10 3 54677 CENTAFLEX R 1 CF R 318 14 T1 10 3 498028 NERTIA 1 10 1 837852 LEEVE DRIVE AS 1 11 N113216040 BOLT SOCKET HEAD 16 11 J1016217 VULKARDAN E 1 11 NO22010000 RING SNAP 1 12 059011500 RING SNAP 2 12 059011500 RING SNAP 1 12 N330120201 WASHER 1 1313 54676 FLANGE INPUT 1 13 085816060 BOL 16 13 059011500 RING SNAP 2 14 085 710035 BOL 30 14 3 49445 A FLANGE INPUT 1 14 085710035 BOL 16 15 031010000 WASHER 30 15 085710035 BOL 30 15 085710045 BOL 14 16 N082708020 BOL 4 16 031010000 WASHER 30 16 1 74238 F COVER 2 17 N031008000 WASHER 4 17 085708020 BOL 4 17 031008000 WASHER 6 18 1 74238 S COVER 2 18 N031008000 WASHER 4 18 085708020 BOL 6 19 1 74238 S COVER 2 19 031010000 WASHER 30 9 m C 0 92 OOOOO OD 9 9 6 amp 9 69 G9
63. ER R3 8 85 85 105 FUR MDUNTING UNIT METR I C 448 126 MOUNT THE UNIT ON A COMMON BASE WITH ENGINE 120 120 DUTLET TO FORWARD CLUTCH 680 5 AFTER LOCATING BRACKETS WITH PINS 42 C cl PROJECTION DIL DRAIN FLANGE eco Eco OMNE ROSE TN AREA DETAIL DF DUTPUT FLANGE pp 91 244 244 91 DRAIN PLUG VITH MAGNET 14 1 5 PLUG SO 6149 TH D gt MARKED S SHOWS STAINLESS STEEL BOLTS R3 8 340 340 MATERIAL MASS UNLESS OTHERWISE SPECIFIED PROPRIE ran T INFIRMA TION AND 15 MENS ARE wos 7009 DISS DETRIMENTAL TH THE INTERESTS OF is X 0 28 ME 5 a 0 25 i RACINE WE 53403 USA GREASE DRAIN PLUG TWIN DISC INCORPORATED 7 RACINE 53403 USA 2 ooninato To NULLIEY OR LIMIT RIGHTS SURFACE TREATIENT GENERAL VIEW ks 7 39488 3 GRANTED THE U 5 GOVERNMENT JAPPD REV BY APPD REV ZONE CH NO DATE REV ZONE CH DATE OR OTHERS BY CONTRACT MGX 6598A MARINE TRANSMISSION Y T SHEET 3 OF 11 REV ___ F E D C B
64. INTERESTS OF 0 25 r25 RACINE WE 53403 USA HEAT TREAT FIRST USE X XX 0 13 TWIN DISC INCORPORATED assy ALL ANGULAR TOLERANCES 17 PRN RACINE WI 53403 USA B GEOMETRIC TOLERANCING THIS NOTICE INTENDED K S WAS EE dr Mi MARINE APPD REV BY APPD zone CH DATE REV zone CH NO DATE OR OTHERS BY CONTRACT MGX 6598A TRANSMISSION Yt SHEET 6 OF 11 REV ___ E D C B XH L W 09590909 o 09096 09090 e O D 7 EEING FROM STERN SCALE 1 4 PARTS NAME Q TY REMARKS 1 01012 VALVE NON RETURN 2 71198 A GASKET 6 3 77337 GASKET 5 4 11017 C COUPLING OLDHAM K 5 1 77901 MOUNT AS PUMP 6
65. LESS OTHERWISE SPECIFIED DIMENSIONS ARE m MACHINED DIMENSIONS X x E X XX 0 13 ALL ANGULAR TOLERANCES 1 GEDMETRIC TEL ERANCING ANSI Yl4 5M 198 DATE 041019 Di RN oominoto TUIN DISE SCALE INCORPORAT 4 RACINE WE 53403 USA CHK SURFACE TREATMENT 7 39488 2 SHEET 2 OF 11 REV C MARINE MGX 6598A TRANSMISSION A MGX 6598A MARINE GEAR SPECIFICATIONS SEE NOTE GEAR RATID 1 09 1 51 1 74 2 03 248 2 80 HH DISTANCE REQUIRED 710 cles TOTAL MASS DRY APPROX 475 kg SEE NITE no REMOVE GEAR PUMP 304 BASIC UNIT DRY APPROX 440 kg MASS INPUT HOUSING 13 kg INPUT COUPLING AND FLANGE 22 o SEQUENCE VALVE REVERSE SOLENOID 5 Eq SUL h e gt REESE TU BE USED FOR LIFTING APPROX Sea wee ALENT o FORWARD SOLENOID MARINE GEA
66. Limits for Marine Transmission Equipped with 1021658C Control Valve and 2415 kPa 350 psi Proportional Valve 1000 pem Current Valve Inlet Inlet Primary Secondar Lube 2206 2414 2206 200 600 y 320 350 320 i 29 87 2206 2414 0 2206 200 600 a 320 350 200 9 8 2206 2414 0 0 320 350 0 0 2103 2206 2103 0 69 193 y 305 320 305 0 10 28 i 2103 2206 2103 69 193 Y 305 320 305 10 28 Cooling temperature range Delvac 1110 Oil at 29 35 C 85 95 F or Mobilkote501 at 32 39 C 90 100 F Required Primary lube pressure secondary lube pressure within 21 kPa 3 psi ALL SHIFTS MUST BE DONE AT OR BELOW 1800 rpm A reading outside limiting range could mean Valve Inlet Pressure Sticky valve pump flow too low leakage broken forgotten or cut seal rings Primary amp Secondary Pressure Broken seal ring at collectors or piston Lube Pressure Out of tolerance or missing orifice broken rear seal ring faulty lube relief valve or check valve 24 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Description and Specifications Table 2 Limits for Marine Transmission Limits for Marine Transmission Equipped with 1021658C Control Valve and 2415 kPa 350 psi Proportional Valve and 320 mA Supply Current in M Min Max Range k kPa Pa i psi psi psi ax Pa k 3
67. M10 x 35 capscrews and fourteen M10 x 45 capscrews 2 The front housing is equipped with three pusher screw locations near the housing dowel pin locations to assist in the removal of the housing a Lubricate three M10 1 5 x 60 mm fully threaded screws b Thread the screws into the front housing to push the front housing away from the main housing A IMPORTANT Always lubricate the pusher screws before use 3 Remove the front housing from the main housing WD022 Figure 39 Front Housing Removal 74 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Heat Exchanger Front Cover 1 Remove the six M8 x 55 capscrews retaining the heat exchanger front cover to the main housing 2 Remove the front cover spacer and two O rings Note The front cover uses a spacer to locate the heat exchanger core correctly in the main housing WD023 ARO37 6557 Figure 40 Heat Exchanger Front Cover Removal Marine Transmission Service Manual 1022297 75 Disassembly Twin Disc Incorporated Output Gear and Output Shaft 1 Be sure the trailing pump or cover has been previously removed Use a pry bar to apply downward pressure to the driven gear of the trailing pump to move the gear toward the wall of the main housing This will allow clearance to remove the output gear from the output shaft WD024 Figure 41 Moving Trailing Pump Gear 2 Support the main housing to allow for a wooden block to be
68. MPo gt 1 0 MPa e MAX ALLOWABLE OIL PRESSURE DROP ACROSS H E AND DIL 8 048015031 0 1 LINE MARINE GEAR H E AND RETURN WITH 66 mm s 0 2 MPa 9 1 80241 B COVER HEAT EXCHANG 1 SUS 300 2 AT RATED ENGINE min 10 N085708030 BOLT 6 MAX ALLOWABLE WATER PRESSURE DROP ACROSS H E 0 1 MPa H E WATER PRESSURE RATING MIN 1 5 x H E INLET WATER MPo H E INSTALLATION amp SERVISE REQUIREMENTS DIL LINES TRANSMISSION H E AND RETURN 1 BURST PRESSURE MIN 4 x PEAK DIL PRESSURE H E PROTECT LINES FROM MECHANICAL DAMAGE ZINC ANUDES PROTECT H E RAW WATER PASSAGES FROM CORROSION CHECK amp REPLACE THEM FREQUENCY 42 Nm CJIS 8 8 el Nm CJIS 8 8 242 17 DIL OUTLET _1 09090 KA m d e 4 gt oe ol 1 in Wy e T T KA BR DIL INLET a 2 HEAT EXCHANGER Xt NPTF 1 2 SECTION SCALE 1 2 42 Nm METRIC me cl THIRD ANGLE PROJECTION N 5 SIMILAR FIGURES IN THE DRAWING SHOW TIGHTENED TORQUE FOR MAIN IMPORTANT BOLTS CUSTOMER SUPPLIED HEAT EXCHANGER BOM ND 5206051 MATERTAL MASS UNLESS OTHERWISE SPECIFIED DATE PROPRIE ran T INFERNATION END 15 DIMENSIONS ARE ano 009 DISS NOT TO BE USED IN ANY MANNER kg x 0 75 SCALE INCORPORATED DETRIMENTAL TO THE NTERESTS OF FIRST USE t Mm i n 15 RACINE WI 53403 USA TWIN DISC INCORPORATED S assy ALL ANGULAR TOLERANCES 17 PRN om inato RACINE
69. Manual 1022297 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 The MGX 6598A has an oil capacity of 18 Liters 4 75 US Gal The transmission should be warmed to operating temperature when oil is checked Oil Pump Capacity 72L 19 GPM 1800 RPM Minimum Oil Pressure When Cruising Check your unit s identification plate The MGX 6598A has a minimum oil pressure at rated engine rpm located on the nameplate of 2200 kPa 319 psi non trolling mode Maximum Input Speed 2500 rpm Dry Weight Approximately 475 Kg 1047 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 Manual 1022297 23 Description and Specifications Twin Disc Incorporated 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 6598A rear view for location of oil pressure checkpoints Table 1 2415 kPa 350 psi Transmission Oil Pressure Specifications
70. Manual Direction Control Valve or Plug Marine Transmission Service Manual 1022297 103 Disassembly Twin Disc Incorporated 5 Remove the M6 1 00 x 16 socket head capscrew the retaining plate and the proportional Valve Cartridges from the Top Valve Bogy A slight rotating motion while pulling will help to with the removal of the valves Solenoid A Solenoids Figure 85 Remove Proportional Valve Cartridges 104 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 6 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 M 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 4 Temperature 127 7 Check Valve 4 Valve_body Cover with Adjustment components Figure 86 Remove Main Pressure Regulator Valve Components Marine Transmission Service Manual 1022297 105 Disassembly Twin Disc Incorporated NOTES 106 Marine Transmission Service Manual 102229
71. N273 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 amp MG360 1 0 Twin Disc Incorporated Table of Contents Table of Contents Introduction NR T OTT 11 General Information numina 11 Safety and General Precautions 11 Preventative 12 Backdriving OF Towing 13 Ordering Parts and Obtaining Services 14 Source of Service 15 UL rng E 15 Description and Specifications 17 CTI A 17 Power Ratings MEE 19 Changing Rotation mm 19 Direction of 19 Construction Featul amp 8 id ignc Fa FEAR P RUE 20 Lubrication 21 Specifications and Maintenance
72. PECIFICATION 11 84329 P10 1 SIOZ 222 OZ ca TITA MASS APPROX 430 2 059005500 RING SNAP 1 BT ENGINE RATED SPEED 3 1 70677 EQ WASHER 1 OIL PRESSURE CLUTCH DIL 11 14 MPa 600 2500 mn 1 DIL VISCOSITY SAE 40 MULTI GRADE DIL IS NOT APPROVED 506211000 e 13UNC 26 DEEP WORKING TORQUE 600 x L 40 S l 4 HOLES L Length of pump spline 6 N41e0063e4 RING DIL SEAL 2 CAPACITY OPERATING SPEED 600 2500 min 7 1 84398 HSG AS 1 12 1 75 21 DEEP ON Ts 2 E P Ln SHAFT ROTATION SAME AS ENGINE ROTATION 8 048002055 RING O 2 4 HDLES ACCEPTS S A E J744 SIZE PUMP PEN z 5 SECTION A A SHIF TING Gu RESTRICTION 05 X RATED ENGINE SPEED 10 1 84435 BEARING NEEDLE 1 LNMegoo m 12 24 11 N420002200 RING SNAP 1 2n od ND DF TEETH 14 12 1 83770 COVER AS SUPPLY 1 5 T TION SPLINE DATA NOMINAL PITCH CIRCLE DIA 29 633 1 IONAL DIRECTIO 14 460200022_ SHIM 1 PRESS ANGLE 30 IIP DIA 27 591 E 127 15 412010224 RING DIL SEAL 1 ROOT DIA 31750 0145 16 1 84477 PISTON AS CLUTCH 1 DETAIL OF PI UNI 7 22 0040 17 1 8735 F RING SQUARE 1 ARC TOOTH SPACE 3 325 0 SAE J744 SIZE 18 3 8088 R PLATE FIBER 7 GM T 19 3 8089 F PLATE STEEL 6 3 5 3 14 20 1 75643 PLATE BACK 1 E Go 3 9 2 22 059005000 RING SNAP 1
73. R ONLY DIL PRESSURE LUBE DIL 0 2 0 6 MPa 70 c a SIL DIL VISCOSITY SAE 840 MULTI GRADE DIL IS NOT APPROVED OUTLET REVERSE CLUTCH DIL amp GREASE THE FIRST DIL CHANGE AT 100 HDURS DF DIL PRESSURECLARGE AREA CHANGE INTERVAL LUPERATION AND SUBSEQUENTLY EVERY 1000 a OF CLUTCH PISTON HOURS DF OPERATION M14x1 5 PLUG 5 6149 TH D L fk STRAINER WIRE NETTING NOTES ad DIL INLET AND BREATHER SHIFTING SHIFT TO FORWARD OR REVERSE FROM NEUTRAL A PROPORTIONAL CONTROL VALVE OPERATION GEAR PUMP RESTRICTIDN AND SHIFT ACROSS NEUTRAL SHALL BE MADE TO BATTERY PDMER SUPPLY VOLTAGE inis ENGINE SPEED ER THAN 50 THE RATED SPEED 2 OPERATION TO BE PERFORMED WITH ONLY TWIN DISC min CONTROL SYSTEMS OR MODULES NAME PLATE HEAT EXCHANGER TEMPERATURE DF COOLING WATER 3e MANUAL DIRECTIONAL CONTROL VALVE OPERATION A BIL PRESSURE SECTIONAL VIEW DWG NO l CENTERED POSITION PUSH TH ENGAGE SECONDARY Mi4xl 5 PLUGCISD 6149 TH D gt GEAR PUMP TOOTH WIDTH 44 mm SHAFT CLUTCH NAME PLATE LUBRICANT WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PULL TO ENGAGE PRIMARY SEQUENCE VALVE WHITE SHAFT FLHTEH o MOHE 6 30 VDC MAX CURRENT 100 mA 2 POLE C MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH DUTLET FOR THERMOMETER CONTROLER NCCRED PRESSURE SWITCH PDINT Q 28 9 9 MPa l DIRECTIONAL CONTROL
74. RANSMISSION MANUAL E ud CUSTOMER SUPPLIED OVERRIDE SWITCHES SOLENOID RETURN Figure 230 E Troll Wiring Diagram SOLENOID RETURN or O TRANSMISSION MANUAL OVERRIDE SWITCHES lt WIRING SCHEMATIC un I Io TO START CIRCUIT SOLENOID A ON RED LED BLACK WHITE 200 mA MAXIMUM WHITE SOLENOID B ON BLACK Ad NORMALLY CLOSED RED LED SOLENOID A IN NEUTRAL RELAY B lt CLOSED IN NEUTRAL MP CUSTOMER SUPPLIED RED A lt SOLENOID B RED POWER OK MP GREEN LED BLACK o o RED CUSTOMER SUPPLIED aet SOLENOID A SWITCH CUSTOMER SUPPLIED Figure 231 Profile Module Wiring Diagram Marine Transmission Service Manual 1022297 209 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 210 Marine Transmission Service Manual 1022297 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 following page T 214182 8 High Pressure Removal Tool 214182 18 Adapter 214182 2 Hydraulic Ram T 214182 63 Hydraulic Ram Base and Support Note At the time of publication all tool drawings were not available They will be added at a
75. REMOVE AND REPLACE FILTER ELEMENT NOTE WHEN TROLLING OPERATE ACCORDING TO INSTRUCTI OPERATOR S MANUAL IMPORTANT WARRANTY IS VOID UNLESS TRANSMISSION IS LUBRICATED AND MAINTAINED AS SPECIFIED REFER TO THE MARINE TRANSMISSION LUBRICANT PLATE MOUNTED ON THE UNIT FOR APPROVED OIL VISCOSITIES ORDERING PARTS MADE IN JAPAN SUPPLIED BY X U S PATENT NO 6 443 286 LUBRICATE OUTPUT SHAFT SEALS WITH WATER PUMP GREASE TO PREVENT BILGE WATER FROM ENTERING THE HOUSING IF APPLICABLE EVERY 1000 HOURS DRAIN AND REFILL HOUSING WITH CLEAN SERIAL AND BILL OF MATERIAL NUMBERS MUST BE GIVEN WHEN TWIN DISC INCORPORATED TWIN DISC NICO CO LTD A TWIN DISC SUBSIDIARY ONS IN 1 81360 V Nameplate MGX6598A Figure 1 Example of MGX 6598A Nameplate Marine Transmission Service Manual 1022297 Twin Disc Incorporated Description and Specifications Power Ratings Changing The MGX 6598A transmissions 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 ei
76. REVENTION FILTER DIFFERENTIAL 14 1 5 PLUGCISU 6149 TH D REMOVE OTL FILTER PRESSURE SWITCH CORROSION PREVENTION RUBBER HOSE 16 n HE DIL LEVEL GAUGE 24 573 2 OVERALL LENGTH 545 gocce chon DIL FILTERCRI 2 AUT DISTANCE REQUIRED USING ATTACHED PLAT URGES a REMOVE DIL LEVEL GAUGE FIR INSTALL 12 912 EQ SPACED D CF R 318 PLAIN WASHERS HAVE TO BE PROVIDED CENTER OF GRAVITY s OUT f 09690908 15 5500060 COOLING WATER INLET min P 208 AND OUTLET FLANGE E B DUTLET TD REVERSE lo CLUTCH DIL PRESSURE N v SMALL AREA OF B ye CLUTCH PISTON 1 Ks od od 14 1 5 PLUG 7 MID lt 150 6149 gt VT A Pes D 97 A TANE T i 45_ 2 012 e D e 5 0 e o gt CENTER OF GRAVITY a ip E x n e gt Ne 9 e IHICKNESS 0 EMERGENCY BOLTCR1 2 PLUG 8 2 H gt a CSECONDARY SHAFT CLUTCH ME AIN FLA 78 70 2 014 28 170 0 020 25 MAIN PUMP STRAINER C REJAM 20 2 DRILL THRU m l 2 20 REAM 20 DEEP 12 HOLES DISTANC REQUIRED TO BOTH SIDES EG SPACED amp GREASE NIPPLE REMOVE STRAINER 6 M20x2 5 TH D 43 DEEP IE ao E i F Y Fas THREAD ENGAGEMENT B 3 5 5 g 5 LENGTH 40 MIN COOLING WATER INLET AND OUTLET FLANGE 2 p BOTH SIDES OUTPUT SHAFT DIRECTION as OIL DRAIN PLUG FOR USE ALL 12 HOLES OF ROTATION IN FORWARD HEAT EXCHANG
77. RKING TORQUE 75 x L 20 5 N L Length of pump spline OPERATING SPEED 600 2500 min 7 SHAFT ROTATION SAME AS ENGINE ROTATION P LD ACCEPTS S AE J744 SIZE PUMP SHIFTING 05 X RATED ENGINE SPEED De 16 32 TEETH 9 SPLINE DATA NOMINAL PITCH CIRCLE DIA 14 287 PRESS ANGLE 30 IIP DIA 12 700 9 ROOT DIA 16 579 ARC TOOTH SPACE 2 494 10082 5 255 254 905555604 hilt NY A 40 EX m CX SSS ci 5524 xe ABE 9 002024 CELA 5 50 0 050 59 x lt A e 500 x 000 2550 e 90 25 55 252505 5 25 5 SS 5 9 5 25 gt 5 5 5 55 522050 555 550 10604064 05070707 550 5 i a ITEM PARTS REMARKS 1 1 84448 LEEVE AS PUMP 3 3 55196 2 113812030 BOLT SOCKET HEAD
78. URFACES MUST BE ae Lid D Vn RAM SEE TOOL DRAWING T 21482 2 HYD RAM Twin Disc Incorporated Special Tools This page reserved for additional tools when available Marine Transmission Service Manual 1022297 217 Special Tools Twin Disc Incorporated This page reserved for additional tools when available 218 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Special Tools This page reserved for additional tools when available Marine Transmission Service Manual 1022297 219 Special Tools Twin Disc Incorporated This page reserved for additional tools when available 220 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Special Tools This page reserved for additional tools when available Marine Transmission Service Manual 1022297 221 Special Tools Twin Disc Incorporated This page reserved for additional tools when available 222 Marine Transmission Service Manual 1022297 Twin Disc Incorporated List of Engineering Drawings Engineering Drawings 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 7 39488 1 7 39488 2 9 7 39488 3
79. V ZONE CH Na DATE REV ZONE CH DATE OR OTHERS BY CONTRACT MGX 6598A TRANSMISSION YT SHEET 10 OF 11 REV ___ C B A HEAT EXCHANGER E REQUIREMENTS ITEM PARTS ND NAME Q TY REMARKS 62022905 69099205 PERMISSIBLE OIL TEMPERATURE INTO HEAT EXCHANGER 1 N085710065 BOLT 2 L 65 0205000 05205020 RORORORO RORORORO RATIO DIL VISCOSITY MAX MIN 085710040 BOLT 4 L 40 ALL RATIOS SAE 40 90 162 F 65 C 117 F eres BRACKET MIN HEAT TRANSFER CAPACITY kW PER ENGINE RATED kW 4 1 12573 PLUG TAPER 1 APPLY APPROPRIATE SERVICE FACTOR CUNT amp MED DUTY INT LIGHT amp PC DUTY 5 N113810050 BOLT SOCKET HEAD 2 FOR FRESH AND RAW WATER 0 035 0 030 6 1 12573 PLUG TAPER 1 1 mut APPROX DIL FLOW TO 40 L min PER 100 ENGINE min X 9 PEAK DIL PRESSURE PROOF TEST AT 1 5
80. VALVE I IN THE CENTERED CHEAT EXCHANGER INLET Sp TEMP o ELECTRIC SELECTOR VALVE POSITION AND OPEN WHEN LEVER IS ACTUATED FROM Were eae m DETAIL OF CLOGGING INDICATOR 2 CURRENT 20 AMPS MAX 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE HA DUTLET TO LUBE OIL PRESSURE DRAWING B 14 1 5 PLUG 5 6149 D CONTROL VALVE GENERAL PURPOSE VALVE DISTANCE REQUIRED TO EMERGENCY BOLT R1 2 PLUG INPUT SHAFT DIRECTION REMOVE HEAT EXCHANGER WARNING PLATECHOOK PRIMARY SHAFT CLUTCH OF ROTATION 347 510 5 WARNING PLATE OIL FILTER DUTLET TO FORWARD CLUTCH SUPPORT HEAT EXCHANGER DIL PRESSUREC LARGE AREA DISTANCE REQUIRED ZINC STICK FDR CLDGGING INDICATUR DF CLUTCH PISTIN ZINC STICK FOR FILT LO V CORROSION P
81. a clutch pack has been damaged causing heavy drag the prop shaft must be locked in a place to prevent backdriving The dragging clutch can produce high amounts of heat and further damage can occur Add an optional trailing oil 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 1022297 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services 14 All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you Note Do not order parts 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 Di
82. a more complete listing of stainless steel fastener torque values Metric Coarse Thread Stainless Steel Capscrews Bolts and Nuts Recommended Torque Thread Size lb ft 12 8 5 28 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Description and Specifications Table 11 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 14 2 1 8 10 5 1 3 8 8 1 1 6 5 0 8 115 13 85 10 75 9 55 7 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 off removal without damage Overtightening may cause intial leakage plus potential removal damage Note 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 1022297 29 Description and Specifications Twin Disc Incorporated Table 12 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Ib ft Nominal Nm lb ft Thread Thread 2 or 596 or 596 or 5 Diameter Diameter 108 30 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Description and
83. ain 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 The hydraulic pressure regulating valve Assembly 1021658 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 The manual direction control cartridge valve contains a switch some have two identical switches 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 arapid smooth oil pressure increase in the clutch hydraulic passages during engagement 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 Installations with t
84. al of ground point used by point as the control s if equipped the engine battery the gear controller or power ground signal the engine control Solenoid B Connect to the Connect to the output Connect to the Switch positive terminal of the in the gear controller control s Solenoid B engine battery through that is used to positive driver output the switch contacts engerize Solenoid B used to energize Solenoid B Solenoid Return Connect to the Connect to the Connect to the negative terminal of sameground point control s solenoid the engine battery used by the gear negative output controller or the circuit engine control Solenoid A Connect to the Connect to the output Connect to the positive terminal of the in the gear controller control s Solenoid engine battery through that is used to positive driver output the switch contacts engerize Solenoid A used to energize Solenoid A 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 contacts of the manual direction control switch closed in neutral must be wired in series with the energizing coil of the not in neutral relay Q Plug the appropriate connectors from the Profile Generator into the appropriate Proportional Valves Q Plug the a
85. arings The 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 spline driven by the secondary clutch shaft Marine Transmission Service Manual 1022297 Twin Disc Incorporated Description and Specifications Lubrication Features The MGX 6598A transmission bearings and clutches on the primary and secondary shafts are lubricated through oil passages drilled in the shafts The transfer gears the primary and secondary pinions and output shaft 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 canister style filter is located between the oil pump outlet and the selector valve in the hydraulic circuit The replacement element should be replaced at 1000 hour or six month intervals whichever comes first The replacement filter part number is 1 83058A Gears All gears are helical carburized hardened and skived or ground for smooth quiet operation All gears are in constant mesh The primary and secondary
86. assembly 9 Remove the steel thrust race CD1009 Figure 64 Inner Steel Thrust Race Removal 10 Remove the external snap ring When the snap ring is opened it will release with some force Protect hands from injury Fi i E CD1010 CD1011 Figure 65 External Snap Ring Removal Marine Transmission Service Manual 1022297 91 Disassembly Twin Disc Incorporated 11 Remove the release spring with the two spring retainers CD1012 Figure 66 Spring and Retainer Removal 12 Thread two M8 1 25 capscrews into the clutch piston Remove the clutch piston CD1013 Figure 67 Clutch Piston Removal 92 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 13 Disassemble the clutch piston Remove the seal ring internal seal ring backup ring and external O ring Discard these components CA1002 Figure 68 Clutch Piston Assembly Marine Transmission Service Manual 1022297 93 Disassembly Twin Disc Incorporated Secondary Clutch Shaft 1 Position the secondary clutch shaft with the output end facing up Remove and discard the six piston seal rings CD1001 Figure 69 Piston Seal Ring Removal 2 Remove the rear bearing cone Note Only remove the rear bearing cone 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 on the rear sho
87. ated in the Engineering Drawing Section of this manual Note that the subscript refers to the primary clutch first or small area and the subscript refers to the primary clutch second or larger area of engagement ls Disconnect the wires from the primary and secondary proportional valves 2 With an input speed of 600 rpm and continuously recording clutch pressure at Z and 2 versus time engage the primary clutch with the manual override valve 3 The recorded pressure plateau at 7 must be 2241 2310 kPa 325 335 psi See the pressure plateau example that follows 4 If the pressure plateau falls below or above the range specified in step 3 adjust the primary sequence valve and repeat step 2 until the pressure plateau is within the acceptable range 5 Record the pressure plateau for Z in the test records 6 Repeat steps 2 through 5 for the secondary sequence valve using pressure points Z and Z Step3 Pressure plateau Se E plateau Min Max kPa 1 51 51 51 Sequence Valve 325 335 325 335 Marine Transmission Service Manual 1022297 193 Assembly Twin Disc Incorporated ia w le d e Figure 220 Pressure Plateau Example Marine Transmission Service Manual 1022297 Twin Disc Incorporated Installation Installation Prior to Installation A CAUTION Most Twin Disc products mount directly onto the flywheel of the engine
88. ation 15 Install the bearing carrier onto the shaft a Heat the bearing carrier to 120 C 250 F WARNING Handle the bearing carrier with care The bearing carrier is HOT b Place the bearing carrier onto the clutch shaft Press the bearing carrier firmly against the outer thrust washer 130 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Note Be sure to seat the bearing carrier against the outer thrust washer as the bearing carrier cools CA1024 Figure 120 Bearing Carrier Installation 16 Turn the clutch shaft over Install a new bearing cone against the clutch housing a Heat the bearing cone to 120 C 250 F A WARNING Handle the bearing cone with care The bearing cone is HOT b Place the bearing cone onto the clutch shaft Press the bearing cone firmly against the clutch housing Note Be sure to seat the bearing cone is against the clutch housing as the bearing cone cools 18 Install six new piston seal rings onto the shaft CA1027 Figure 121 Piston Seal Ring Installation Marine Transmission Service Manual 1022297 131 Assembly Twin Disc Incorporated Main Housing If removed install new primary clutch shaft front bearing cup into the main housing a Deep freeze the bearing cup to 51 60 F for at least two hours before installing it WARNING Handle the bearing cup with care The bearing cup is extremely COLD b Lubricate
89. ch the gasket to the rear cover with grease W00039 Figure 152 Heat Exchanger Rear Cover Installation 5 The heat exchanger core position can be verified by viewing the core through the inlet outlet ports The divider should not be out of position when viewed through the ports AAR313 6557 Figure 153 Viewing Divider through Inlet Outlet Ports 6 Torque the six M8 x 45 capscrews to 23 Nem 17 16 Note Improper tightening of the rear cover capscrews could cause damage to the cover Marine Transmission Service Manual 1022297 151 Assembly Twin Disc Incorporated 7 Install the inlet outlet covers using new gaskets Torque the four M12 x 30 capscrews to 80 Nem 59 Ibeft WO00041 Figure 154 Inlet Outlet Covers Installation Output Gear A CAUTION The tapered surface of the output 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 onto the shaft and adversely affect torque carrying capacity of the assembled joint 1 Ensure the output gear bore is clean and free of grease and other contaminants Place the output gear in position in the main housing with the trailing pump drive gear towards the rear side of the housing Align the output gear with the output shaft bore in the housing 00042 Figure 155 Output Gear Installation 152 Marine Transmission Service Manual 1022
90. ches 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 1022297 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 5 amps DO NOT connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System The cu
91. e circumference of the pump mount The three readings should be identical Record this dimension Pump Mount Pilot Dimension Calculate the correct shim pack required to set the secondary clutch shaft rear bearings a Subtract the secondary clutch shaft rear cover dimension from the transmission housing to rear bearing cup dimension Bearing Bore Dimension Cover Dimension Pinion Shaft Clearance Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly b Calculate the shim pack thickness required to obtain 0 05 preload to 0 05 mm 0 002 preload to 0 002 inches clutch shaft clearance when the shim pack is installed 4 The calculated shim pack will be installed on the secondary clutch shaft between the bearing cup and the pump mount 1 tom 00085 W00086 Figure 192 Determine Secondary Clutch Shaft Bearing Adjustment Primary Clutch Shaft Shim Pack 1 Install the spacer next to the bearing cup 2 Install the shim pack next to the spacer Place the thickest shims toward the bearing cup W00087 Figure 193 Primary Clutch Shaft Shim Pack Installation Marine Transmission Service Manual 1022297 175 Assembly Twin Disc Incorporated Secondary Clutch Shaft Shim Pack Install the shim pack next to the bearing cup Place the thickest shims toward the bearing cup WO0088 Figure 194 Secondary Clutch Shaft Shim Pack Installation 176 Marine Transmission Service Manual 102229
92. e highest point of the wire If not possible install cable or harness with drip loop 4 Protect cable or harness with grommet loom or flex guard at any rub point particularly when passing a sheet metal hole 5 Locate cable or harness away from potential hazards For example capscrew cutting through the jacket and shorting a conductor to the chassis welding drilling heat exhaust burrs sharp edges etc 6 Prevent the cable from becoming a step or handrail 7 Make sure connectors will mate properly Locate use the connector orientation key 8 Circular connectors must be hand tightened and lock wired if possible 9 Cable or harness bend radius must not be less than eight times the cable diameter Marine Transmission Service Manual 1022297 205 Installation 206 10 11 12 19 14 15 16 17 18 19 Twin Disc Incorporated Avoid twisting or winding the cable along its axis during installation or removal 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 exits the boot Cables must not be installed in a manner which puts strain on the connector or results in more than twenty four in
93. e 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 STRAIGHT Figure 227 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1022297 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 during rotation additional alignment is necessary or the marine transmission and shaft couplings should be checked for proper face runout Runout must n
94. e spring onto the shaft CA DIO Figure 110 Lower Spring Retainer and Release Spring Installation 5 Slide the top spring retainer and external snap ring onto the shaft CA1011 1012 Figure 111 Top Spring Retainer and External Snap Ring Installation 126 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 6 Slide the snap ring retainer thrust race onto the shaft with the chamfered side facing the external snap ring CA1013 Figure 112 Upper Thrust Washer Installation pA Use a special tool and seat the external snap ring into the groove of the shaft by applying a force to the tool until the snap ring seals CA1014 Figure 113 Seat External Snap Ring Into Groove Marine Transmission Service Manual 1022297 127 Assembly Twin Disc Incorporated 8 Install the clutch plates a Install one steel clutch plate next to the piston b Install one friction clutch plate CA1015 Figure 114 Steel Clutch Plate and Friction Clutch Plate Installation 6 Place wave spring around the outer circumference of each friction clutch plate Be sure to install the wave spring around the circumference in a random manner Note Be sure the wave springs are not against the face of the clutch plates CA1016 RMVCO28FGS Figure 115 Wave Spring 2 Installation d Install the remaining steel clutch plates friction clutch plates and wave springs in an alternating fashion until al
95. eal Carrier Pilot 134 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 2 Using a fixture assemble the two output shaft taper roller bearings W00006 W00007 Figure 126 Output Shaft Taper Roller Bearings Assembly Measure the depth of the two taper roller bearings Measure the depth in three evenly spaced locations around the circumference of the assembly If all three readings are identical record the dimension as Dimension B If the readings are not identical adjust the bearings and measure again W00008 Figure 127 Measuring Depth of Taper Roller Bearings Marine Transmission Service Manual 1022297 135 Assembly Twin Disc Incorporated 4 If removed install the three roll pins that locate the thrust bearing spacer in the bore of the main housing Be sure the pins are in far enough to be below the face of the spacer WOO009 Figure 128 Inner Taper Roller Bearing Cup Support Pins Installation 5 Apply grease to the nine springs and install them into the housing Install a coil spring in each of the pockets in the bore of the main housing Ensure each spring is firmly held in its pocket W00010 Figure 129 Springs Installation 136 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 6 Install the thrust bearing spacer over the springs and pins 7 Measure the distance to the thrust bearing spacer in three evenly spaced locations Record this d
96. ed joint 142 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 2 Calculate for required shim pack a Measure the distance from the end of the output shaft to the spacer Measure in three locations around the circumference of the output shaft The three readings should be identical Record this dimension as Dimension E 00021 Figure 139 Measuring Distance from End of Output Shaft to Spacer b Measure the distance from the end of the output shaft to the shoulder on the shaft Measure in three locations around the circumference of the output shaft The three readings should be identical Record this dimension as Dimension F y 00022 Figure 140 Measuring Distance from End of Output Shaft to Shoulder Marine Transmission Service Manual 1022297 143 Assembly Twin Disc Incorporated Place the output gear and pump driven gear on a flat plate W00023 Figure 141 Output Gear on Flat Plane d Drive the pins into the output gear that retain the pump driven gear Place the pump driven gear on the output gear Seat the pump driven gear to the output gear W00026 W00027 Figure 142 Pump Driven Gear to Output Gear Installation 144 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly e Measure the depth of the output gear and pump driven gear Measure in three location around the circumference of the bore in the output gear The three reading shou
97. eed sensor and the output speed sensor gear to 1 3 1 7 mm 0 05 0 07 in 00100 Figure 204 Output Speed Sensor Adjustment 4 Secure the output speed sensor with the two jam nuts Torque the jam nuts to 49 Nem 36 Ib ft Input Speed Sensor Note Place the transmission in the upright position Be sure the transmission is securely supported 1 Apply MA1015 sealant to the threads of the input speed sensor 2 Thread the input speed sensor into the main housing until it contacts a tip of a gear tooth W00101 00102 Figure 205 Input Speed Sensor Installation 182 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 3 Back out the input speed sensor one full turn 4 Apply MA908 Locktite 242 thread locking adhesive to the threads of the input speed sensor jam nut Secure the input speed sensor in position with the jam nut Torque to 49 Nem 36 Ib ft Lube Valve ls Clean the lube oil valve bore of the main housing 2 Install the piston and spring 3 Install the cap and washer Torque cap to 54 Nem 40 ftelb Spring Washer Piston LubeOilValve Figure 206 Lube Oil Valve Installation Marine Transmission Service Manual 1022297 183 Assembly Twin Disc Incorporated Oil Level Gauge Install the oil level gauge in the main housing Top Cover 1 Apply MA1015 sealant to the top cover and main housing mating surfaces Figure
98. en the output shaft is installed a small gap may be present between the output shaft seal carrier and main housing This gap is a result of the nine coil springs between the main housing and bearing cup 154 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 6 Torque the nine M12 x 40 capscrews evenly to 80 Nem 59 Ib ft 00047 Figure 159 Output Shaft Seal Carrier Capscrews Installation Note Place the transmission with the input end facing up Be sure the transmission is securely supported Align the trailing pump driven gear with the trailing pump drive gear W00048 Figure 160 Trailing Pump Gears Alignment Marine Transmission Service Manual 1022297 155 Assembly Twin Disc Incorporated 8 Install ram base special tool onto the output shaft W00049 Figure 161 Ram Base Special Tool 9 Install ram special tool over ram base special tool Connect a hydraulic power supply to the tool W00050 Figure 162 Installation of Ram Special Tool 156 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 10 Install ram support special tool on top of ram special tool A W00051 Figure 163 Ram Support Special Tool 11 Secure ram support to the output shaft using the five M18 1 5 capscrews Torque the lubricated capscrews to 440 Nem 325 Ib ft W00052 Figure 164 Secure Ram Support Marine Transmission Service Manual
99. engine speed Remove and clean strainer Check oil level and correct Correct cause of air leak Disassemble and repair as required Remove clean or replace the Main Regulating valve Replace oil pump Replace heat exchanger Marine Transmission Service Manual 1022297 Twin Disc Incorporated 3 4 5 Troubleshooting Table 15 Troubleshooting Chart continued 1021658 and 1020941 GP Control Valves with Electronic Interface High main oil pressure or erratic main pressure High temperature Excessive noise Main Regulator Valve is out of adjustment Main Regulating Valve orifice and ball check passages blocked 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 Marine Transmission Service Manual 1022297 Adjust Main Regulator Valve Replace orifice valve and ball check cartridge 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 transmission oil filter Overhaul marine transmission
100. ent 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 9 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 9 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 1022297 109 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 Bearings 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
101. except where noted through the nearest authorized Twin Disc distributor Optional Trailing Pump A trailing pump kit is available that bolts onto the rear of the marine transmission A drawing is included in the Engineering Drawings Power Take off A live Pump Mount power take off and a hydraulically clutchable power take off are available and mount on the rear of the transmission They rotate at the same speed and direction as the engine Mounting Brackets Fabricated mounting brackets are available Torsional Input Coupling Several models of torsional input couplings are available Companion Flange The companion flange assembly consists of the companion flange and mounting hardware Marine Transmission Service Manual 1022297 27 Description and Specifications Twin Disc Incorporated 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 9 Metric Coarse Thread Capscrews Bolts and Nuts Property Class 8 8 Property Class 10 9 Property Class 12 9 o9 T T Table 10 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
102. f 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 1022297 111 Cleaning and Inspection Twin Disc Incorporated NOTES 112 Marine Transmission Service Manual 1022297 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 the 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 manufac
103. from the engine flywheel and wire in place on transmission for shipping 56 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly EMERGENCY BOLT R1 2 PLUG PRIMARY SHAFT CLUTCH OUTLET TO FORWARD CLUTCH CLOGGING INDICATOR OIL PRESSURE LARGE AREA OF CLUTCH PISTON V PRESSURE SWITCH M14 x 1 5 PLUG ISO 6149 TH D OUTLET TO REVERSE CLUTCH OIL PRESSURE SMALL AREA OF CLUTCH PISTON M14 x 1 5 PLUG ISO 6149 TH D OUTLET TO FORWARD CLUTCH OIL PRESSURE SMALL AREA OF CLUTCH PISTON M14 x 1 5 PLUG ISO 6149 TH D EMERGENCY BOLT R1 2 PLUG SECONDARY SHAFT CLUTCH OUTLET TO REVERSE CLUTCH OIL PRESSURE LARGE AREA OF CLUTCH PISTON M14 X 1 5 PLUG ISO 6149 TH D 009076 00000000 00090900 0909090 OUTLET TO LUBE OIL PRESSURE M14 X 1 5 PLUG ISO 6149 TH D OUTLET TO CLUTCH OIL PRESSURE M14 X 1 5 PLUG ISO 6149 TH D MGX6598 001 Figure 11 Oil Pressure Checkpoints Marine Transmission Service Manual 1022297 57 Disassembly Twin Disc Incorporated Remove External Parts Note Place the transmission in the upright position to remove the following parts Be sure the transmission is securely supported Input Coupling If not previously removed remove the input coupling from the input drive sleeve WD001 Figure 12 Input Coupling Removal Hydraulic Oil Filter 1 Remove the hydraulic hose between the hydraulic oil pump and oil filter WD002
104. gement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Preventative Maintenance 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 12 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Introduction Backdriving or Towing 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 prolonged backdriving conditions the transmission does not receive proper lubrication Conditions where backdriving may occur Vessel is being towed One or more engines on a multiple transmission vessel are shut down while under way Sailboat under sail with auxiliary engine shut down Q Vessel tied up or docked in 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 WARNING If
105. gs should be identical Record this dimension Rear Cover Pilot Dimension Calculate the correct shim pack required to set the primary shaft rear bearings a Subtract the primary shaft rear cover and spacer dimension from the transmission housing to rear bearing cup dimension Bearing bore dimension Cover Dimension Primary Shaft Clearance b Calculate the shim pack thickness required to obtain 0 05 preload to 0 05 mm 0 002 preload to 0 002 inches clutch shaft clearance when the shim pack is installed Marine Transmission Service Manual 1022297 173 Assembly Twin Disc Incorporated The calculated shim pack will be installed on the primary shaft between the spacer and the rear cover W00084 Figure 191 Determine Priamry Clutch Shaft Bearing Adjustment Determine Secondary Clutch Shaft Bearing Clearance 1 Measure the depth of the secondary clutch shaft tapered roller bearing cup in the transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing cup Measure in three locations around the circumference of the bearing bore The three readings should be identical If the dimensions are not identical realign the bearing cup Record this dimension Bearing Bore Depth Measure the length of the pump mount pilot Measure from the bearing contact point to the rear mounting surface of the cover Measure in three locations around th
106. gulator Assembly 1021658 Marine Transmission Service Manual 1022297 37 Operation Twin Disc Incorporated GP Control Valve Electronic Control Interface Profile or E Troll Module 38 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 harnessing 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
107. h Shafts Shims Remove the shims from the primary and secondary clutch shafts 2 Tag the shims with proper identification WD012 WD013 Figure 28 Primary and Secondary Clutch Shaft Shims Removal Marine Transmission Service Manual 1022297 67 Disassembly Twin Disc Incorporated Remove Internal Parts Manifold 1 Remove the 16 capscrews ten M10 x 55 one M10 x 75 five M10 x 110 and three socket head screws with washers two M10 x 95 one M10 x 55 retaining the manifold to the main housing Identify all screws for proper assembly 2 The manifold is equipped with two pusher screw locations near the dowel pins to assist in the removal of the manifold a Lubricate two M10 1 5 x 60 mm fully threaded screws b Tighten the nuts on the dowel pins to aid in removal Thread the screws into the manifold to push the manifold away from the main housing A IMPORTANT Always lubricate the pusher screws before use Be sure to tighten the pusher screws in an even manner 072 6557 Figure 29 Pusher Screws 68 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 3 Remove the manifold from the main housing A CAUTION Use caution in removing the manifold from the main housing The clutch shafts rear bearing cups could fall out of the manifold as it is being removed WD014 Figure 30 Manifold Removal 4 Remove the primary and secondary clutch shafts rear bearing c
108. he bearing cone onto the clutch shaft Press the bearing cone firmly against the clutch housing Note Be sure to seat the bearing cone is against the clutch housing as the bearing cone cools 17 Install six new piston seal rings onto the shaft 122 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Secondary Clutch Shaft 1 Assemble the clutch piston a Lubricate and install a new seal ring on the outer diameter of the clutch piston b Lubricate and install a new internal seal ring CA1001 CA1002 Figure 104 Seal Ring and Internal O Ring Installation Ci Install a new backup ring d Lubricate and install a new external O ring between the backup ring and the top end of the piston as shown in the photo CA1003 Seal Ring Figure 105 Backup Ring and External O Ring Installation Marine Transmission Service Manual 1022297 123 Assembly Twin Disc Incorporated 2 Lubricate the clutch piston bore of the clutch housing with a thin film of grease Install the clutch piston into the clutch housing Gently push the clutch piston by hand until it is fully engaged into the clutch Note Ifthe clutch piston is difficult to install by hand remove the clutch piston and inspect the seal rings CA1005 Figure 106 Clutch Piston Installation 3 Calculate the clutch piston travel a Place the 12 steel clutch plates and 11 friction clutch plates in the clutch housing Be sure all steel clutch p
109. he control valve Removing and installing the manifold D D DO D DO Service clutch pack assemblies Marine Transmission Service Manual 1022297 43 Preventative Maintenance Twin Disc Incorporated General Maintenance 44 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 Lubrication Grease the oil seals on the output end of the output shaft through the grease fitting with water pump lithium soap based NLGI No 2 grease Apply grease every 100 hours or when the boat is docked No other lubrication is needed 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 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 and c
110. his 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 filler must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1022297 35 Operation Twin Disc Incorporated SEQU VALVE 24 SECONDARY CLUTCI a TO CLUTCH TO CLUTCH 4 PROPORTIONAL VAL po gt W r gt gt PROPORTIONAL VALVE Le c 15 EP e 1 N E esl i a Dp ANN 041 t i i SUMP e e e FROM PUM ae PRESSURE REGULATOR ANUAL DIRECTIONAL CONTROL VALVE Geese L L 1 NS 7 u il u u u pc T 1 ETT N TEMPE T S TE r1 1 T 2 m PRIMARY amp SECONDARY E PL SHAFT LUBE Figure 3 Hydraulic Schematic GP control valve Assy 1021658 36 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Operation Proportional Valves 12 1 50 Manual 4 Override A o ring plug Top Valve Body top hydraulic valve1 Figure 4 Top Hydraulic Valve Body Assembly assy1021658 lower Figure 5 Main Re
111. ht flash MG Units Power is applied to After entering troll from neutral simultaneously solenoid 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 alternately missing Marine Transmission Service Manual 1022297 51 Troubleshooting Table 15 Troubleshooting Chart Twin Disc Incorporated 1021658 and 1020941 GP Control Valves with Electronic Interface 1 Low main oil pressure 2 No oil pressure or erratic low pressure at control valve tap 52 Partially clogged oil strainer Improper adjustment of main pressure regulating valve Weak or broken springs in the Main Regulator Valve Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Engine idle speed too low Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Main Regulating Valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Remove and clean oil strainer Adjust the Main Regulator Valve Replace the Main Regulator Valve spring Remove the collector and inspect piston rings Replace damaged or worn oil pump assembly pump is not serviceable Raise
112. ice whichever occurs first This is the only warranty made by Twin Disc Incorporated 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 earning marine pleasure craft applications delivered by Twin Disc Incorporated to the original customer on or after May 1 1995 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 Incorporaed be either the repair or replacement of any Twin Disc Incorp
113. imension as Dimension C Figure 130 Measure Beaing Cup Support Depth 8 Install the inner taper roller bearing cup W0001 Figure 131 Inner Taper Roller Bearing Cup Installation Marine Transmission Service Manual 1022297 137 Assembly Twin Disc Incorporated 9 Calculate the shim pack required to set the output shaft bearing clearance a Add the pilot length of the output shaft seal carrier and the length of the two taper roller bearings Dimension A 4 Dimension B Dimension D b Subtract Dimension D from the depth to the thrust bearing spacer Dimension C Dimension D Dimension C Calculate the shim pack thickness required to obtain 0 to 0 5 mm 0 000 to 0 002 in bearing clearance when the shim pack is installed d Label the shim pack for use when assembling the output shaft Output Shaft 1 Install the output speed sensor gear onto the output shaft a Heat the output speed sensor gear to 120 C 250 F WARNING Handle the gear with care The gear is HOT b Use a special tool to seat the output speed gear against the shoulder on the output shaft WO00014 Figure 132 Output Speed Sensor Gear Installation 138 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 23 Apply a thin film of grease to the output shaft surface from the midpoint of the shaft to the seal sleeve shoulder Slide the oil seal sleeve onto the output shaft with the counterbore end towa
114. in the Engineering Drawing Section of this manual Note that the subscript refers to the primary clutch first or small area and the subscript gt refers to the primary clutch second or larger area of engagement Marine Transmission Service Manual 1022297 191 Assembly Twin Disc Incorporated Adjustment of Main Pressure Valve Assembly 1021658 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 assy1021658_lower Figure 219 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 Ibeft install the protective cap and torque it to 14 Nem 10 Ib ft 192 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Sequence Valve Adjustment Procedure Note Following the repairs main pressure must be adjusted and the Sequence Valve adjustment must be accomplished with a Tekmeter or other instrumentation capable of measuring and recording pressure versus time The locations for pressure measurement are shown on the Installation Drawing that is loc
115. ine Transmission Service Manual 1022297 97 Disassembly Twin Disc Incorporated 10 Remove the release spring with the two spring retainers CD1012 Figure 77 Spring and Retainer Removal 11 Thread two M8 1 25 capscrews into the clutch piston Remove the clutch piston CD1013 Figure 78 Clutch Piston Removal 98 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 12 Disassemble the clutch piston Remove the seal ring internal seal ring backup ring and external O ring Discard these components CA1003 CA1004 Figure 79 Clutch Piston Disassembly Marine Transmission Service Manual 1022297 99 Disassembly Twin Disc Incorporated 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 hydraulic pressure regulator valve Assembly 1021658 is serviceable and contains an orifice filter plug anda ball check valve assembly that are replaceable Valve on trans1 Figure 80 GP Valve Assembly mounted on Marine Transmission 100 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Disassembly 1 Disconnect the connectors at the proportional valves the neutral switch and the
116. 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 1022297 199 Installation Twin Disc Incorporated INDICATOR INDICATOR STEM MARINE GEAR SUPPORT BRACKET BEDRAIL Figure 225 Marine Gear Alignment Set the indicator gauge at zero 0 Lift the marine gear with a hoist or other 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 be
117. l tight against the spacer Figure 174 Seating Input Drive Sleeve 6 Use a special tool special tool to retain the input drive sleeve position during rotation of the main housing Be careful not to damage the lip of the input seal Marine Transmission Service Manual 1022297 163 Assembly Twin Disc Incorporated A CAUTION DO NOT damage the input drive sleeve plug when installing the special tool The primary clutch shaft end and plug are precision ground Figure 175 Retain Input Drive Sleeve Front Housing Note Place the transmission with the input end facing up Be sure the transmission is securely supported 1 Apply MA1015 or equivalent sealer around the output shaft bore of the main housing W00069 Figure 176 Applying Sealant 164 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 2 Position the front housing onto the main housing W00070 Figure 177 Positioning Front Housing 3 Install the three dowel pins to locate the front housing into the main housing W00071 Figure 178 Dowel Pin Installation Marine Transmission Service Manual 1022297 165 Assembly Twin Disc Incorporated 4 Torque the thirty M10 x 35 capscrews with washers to 45 Nem 35 Ib ft W00072 Figure 179 Front Housing Capscrew Installation Note Place the transmission with the input end down Be sure the transmission is securely supported Primary and Secondary Clutch Shafts
118. l clutch plates and wave springs have been installed 12 steel clutch plates 11 friction clutch plates and 11 wave springs 128 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 9 Install the clutch backing plate Press the plate firmly into the clutch housing to ensure the splines of the clutch are aligned 10 Position the internal retaining ring next to the clutch backing plate 11 Install two clamps on the clutch housing and the clutch backing plate Use the clamps to evenly compress the clutch until the internal retaining ring can be installed properly into the clutch housing Install the external retaining ring Remove the clamps CA1018 Figure 116 Clutch Backing Plate Installation 12 Install the inner bronze thrust washer with eighteen radial grooves into the pinion with the grooves away from the gear teeth CA1019 Figure 117 Inner Bronze Thrust Washer Installation Marine Transmission Service Manual 1022297 129 Assembly Twin Disc Incorporated 13 Lubricate the area of the clutch shaft that contact the rear bronze thrust bushing Install the pinion Gently rotate the pinion as it is lowered into the clutch plates until the splines are fully engaged in all of the clutch plates CA1020 Figure 118 Pinion Installation 14 Slide the outer bronze thrust washer with 18 radial grooves on both sides onto the shaft CA1021 Figure 119 Outer Bronze Thrust Washer instal
119. l the suction strainer and spring into the pump mount Note Use caution not to crush the suction strainer W00093 Figure 198 Suction Strainer Installation 2 Install the suction strainer cover and new O ring 100094 Figure 199 Suction Strainer Cover Installation 3 Torque the one M10 x 30 capscrew to 45 Nem 35 Ib ft Marine Transmission Service Manual 1022297 179 Assembly Twin Disc Incorporated Hydraulic Oil Pump 1 Drive the pin into the pump drive sleeve W00095 Figure 200 Pump Drive Sleeve Pin Installation 2 Place the pump drive sleeve onto the end of the secondary clutch shaft E W00096 Figure 201 Pump Drive Sleeve Installation Position a new gasket onto the pump mount 4 Install the pilot sleeve into the pump mount 180 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 5 Install the hydraulic oil pump It may be necessary to rotate the pump to align the spline Figure 202 Hydraulic Oil Pump Installation 6 Torque the five M10 x 150 and one M10 x 95 capscrews to 45 Nem 35 Ib ft Output Speed Sensor 1 Apply MA908 Locktite 242 thread locking adhesive to the threads of the output speed sensor 2 Thread the sensor into the bracket W00099 Figure 203 Output Speed Sensor Installation Marine Transmission Service Manual 1022297 181 Assembly Twin Disc Incorporated Adjust the gap between the output sp
120. later date Marine Transmission Service Manual 1022297 211 Special Tools Twin Disc Incorporated 212 Marine Transmission Service Manual 1022297 Smm C197 DIA THRU D REQ D DRILL 10 25mm 4035 DIA x 3 95 DEEP TAP 18M x 175 x 75mm 295 DP 1 4 BPT 1 HYDRAULIC KNOCK OUT TOOL MS 0 REQ D thee H HYDRAULIC KNOCK OUT TOOL WITH 12 1 75 FULLY THREADED BOLT a i STK 16 x 175 x 75mm LONG HH pus carr mac iri ma 1 GRADE 8 8 1 REG D ui FULLY THREADED oo HYDRAULIC KNOCK OUT TOOL ME 655756 amp MG 6557A L d MG 660 amp MG 6619 SERIES T 21482 8 CAD FILE 21482 8 _ Twm DISC ING RACINE WIS 1 4 CF EMALE2 omm DIA THRU 1975 MALE 1 000 2 952 101 5mm 25272052 a URAULIC PRESSURE E KAT oe MOS SIE 0 EUIS Mey S622 7 Sst DE db EST BREAK ALL SHARP CURNERS CAD FILE 21492 18 j TVIN DISC INC HYDRAULIC PRESSURE ADAPTER 1 26 98 JPL 77 21482 18 MN 44 X 45 DRILL Snn 61968 DIA 5 PLACES x 62 DE 6 10 x 6 DEEP 2 PLACES Pw g N 4 IE DRILL Snn 61968 DIA s DRILL amp Snm 63346 DIA x 142 IP x 835 DEEP TAP 0 x 81 DP ENSN 10 15 x 59 DEEP
121. lates measure 2 2 mm 0 87 in thick b Install the backing plate and internal retaining ring CA1006 1007 Figure 107 Preparing to Calculate Clutch Piston Stroke 124 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly C Slide the special tool sleeve for measuring the clutch piston stroke over the shaft through the clutch backing plate steel clutch plates and friction clutch plates The sleeve must be against the clutch piston CA1008 Figure 108 Piston Stroke Adjustment Special Tool d Measure the distance from the end of the clutch shaft to the end of the special tool sleeve CA1009 Figure 109 Measuring Distance of Sleeve from End of Clutch Shaft e Apply air pressure to the large area of the clutch This is the passage between the seal rings nearest the clutch Marine Transmission Service Manual 1022297 125 Assembly Twin Disc Incorporated f While maintaining air pressure on the clutch measure the distance from the end of the clutch shaft to the end of the special tool sleeve The clutch piston travel must be between 2 80 3 30 mm 0 110 0 130 in If the clutch piston travel is outside its limits use a combination of 2 2 mm 0 087 in and 2 6 mm 0 102 in steel clutch plates to achieve the desired amount Steel plate part number 3491574 is 2 6 mm 0 102 in thick and part number 349157B is 2 2 mm 0 087 in thick 4 Slide the lower spring retainer and releas
122. ld be identical Record this dimension as Dimension G W00025 Figure 143 Measuring Depth of Output Gear and Pump Driven Gear f Caculate the correct shim pack required to set the output gear advance on the output shaft as follows Dimension E Dimension F Dimension H Dimension Dimension G 0 00 0 1 mm 0 00 0 004 in Shim Dimension 3 Calculate for expected gear advance a Place the output gear onto the output shaft with pump driven gear facing down Seat the gear onto the shaft by tapping it with a dead blow hammer Marine Transmission Service Manual 1022297 145 Assembly 146 Twin Disc Incorporated b Measure the distance from the end of the output shaft to the output gear face Measure in three locations around the circumference of the output shaft The three readings should be identical Record this dimension as Dimension J 00028 Figure 144 Measuring Distance from End of Output Shaft to Pump Driven Gear Calculate the expected gear advance as follows Dimension F Dimension J Expected gear advance The expected gear advance should fall into the range of 5 45 6 75 mm 0 215 0 266 in If the calculated advance falls outside the range given above check to ensure all measurements calculations are correct If no errors are found it will be necessary to change parts Contact the Product Service Department of Twin Disc Incorporated Marine Transmission Service Ma
123. lean 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 screen after eight hours of operation If the filter and screen are clean install a new filter element and then change the oil and filter element after 1000 hours of service If the filter is Marine Transmission Service Manual 1022297 Twin Disc Incorporated Preventative Maintenance 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 Draining Drain the transmission by removing the drain plug with the magnet at the rear side of the bottom cover Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located at the lower end of the pump See Engineering Drawings for suction strainer location Type Oil Recommended See Description and Specifications Filling 1 Remove the filler breather in the top of the transmission 2 Fill the transmission s sump with the proper weight and type oil See Description and Specifications for oil recommendations 3 Start the engine and let it idle with transmission in neutral until oil i
124. n place W00079 Figure 188 Dowel Pin Installation Marine Transmission Service Manual 1022297 171 Assembly Twin Disc Incorporated 6 Install and torque the following manifold capscrews with washers to 45 Nem 35 Ib ft Ten M10 x 55 Capscrews One M10 x 75 Capscrew Five M10 x 110 Capscrews Two M10 x 95 Socket Head Capscrews One M10 x 55 Socket Head Capscrew 7 Install the primary and secondary clutch shaft rear bearing cups WO00080 W00081 Figure 189 Primary and Secondary Rear Bearing Cones Installation 8 Use a special tool to lightly press the bearing cones into manifold W00082 Figure 190 Seating Bearing Cones 172 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Determine Primary Clutch Shaft Bearing Clearance 1 Measure the depth of the primary shaft tapered roller bearing cup in the transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing cup Measure in three locations around the circumference of the bearing bore The three readings should be identical If the dimensions are not identical realign the bearing cup Record this dimension Bearing Bore Depth Measure the length of the primary shaft rear cover pilot Measure from the bearing contact point to the rear mounting surface of the cover Measure in three locations around the circumference of the rear cover The three readin
125. ne Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Primary Clutch Shaft Input Seal Use a seal remover to drive the primary clutch shaft input seal from the main housing Discard the seal Output Shaft Front Spherical Roller Bearing Use a special tool to drive the output shaft front spherical roller bearing from the main housing Main Housing Bearing Cups 1 If the main housing bearing cups require replacement weld a bead midway around the circumference of the bearing cup with an electric welder This will cause the bearing cup to shrink allowing it to be removed weld bearing cup1 Figure 54 Example of Welded Bearing Cup Marine Transmission Service Manual 1022297 85 Disassembly Twin Disc Incorporated 2 If the output shaft inner bearing was removed remove the inner taper bearing spacer and nine coil springs from the bore in the main housing W00012 Figure 55 Inner Taper Bearing Spacer and Coil Spring Removal 86 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Primary Clutch Shaft 1 Position the primary clutch shaft with the output end facing up Remove and discard the six piston seal rings CD1001 Figure 56 Piston Seal Ring Removal 2 Remove the rear bearing cone Note Only remove the rear bearing cone if it needs to be replaced If removed a new bearing must be installed during assembly a Cut off the bearing cage and remo
126. ng cone onto the output shaft a Heat the thrust bearing cone to 120 C 250 F Handle the bearing cone with care The bearing cone is HOT b Place the thrust bearing cone onto the output shaft with the large diameter of the bearing toward the previously installed bearing cone C Use a special tool to drive the thrust bearing cone onto the shaft until it contacts the previously installed bearing cone W00020 Figure 138 Thrust Bearing Cone Installation Marine Transmission Service Manual 1022297 141 Assembly Twin Disc Incorporated 8 Slide the spacer onto the output shaft 9 Use a special tool to ensure the components are properly seated onto the output shaft Preliminary Output Shaft Gear Advancement Verification 1 Clean and inspect the output gear tapered bore a Prepare the gear tapered bore surface 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 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 effect torque carrying capacity of the assembl
127. ng 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 1022297 201 Installation 202 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 also 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 futur
128. ntify all screws for proper assembly 2 Remove the hydraulic oil pump Discard the gasket Figure 23 Hydraulic Oil Pump Removal Suction Strainer 1 Remove the one M10 x 30 capscrew retaining the suction strainer cover 2 Remove the cover Discard the O ring 3 Remove the suction strainer and spring from the pump mount WD00094 Figure 24 Suction Strainer Removal 64 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Pump Mount 1 Remove the six M 10 x 40 capscrews retaining the pump mount to the main housing 2 Gently tap on the pump mount to break the sealer bond from the main housing 3 Remove the pump mount Figure 25 Pump Mount Removal 4 Remove and discard the O rings 5 Remove the pilot sleeve from the pump mount Marine Transmission Service Manual 1022297 65 Disassembly Twin Disc Incorporated Primary Clutch Shaft Rear Cover 1 Remove the eight capscrews six M10 x 35 one M10 x 40 one M10 x 55 retaining the primary clutch shaft rear cover to the main housing Identify all screws for proper assembly 2 Gently tap on the rear cover to break the sealer bond from the main housing 3i Remove the rear cover WDO11 Figure 26 Primary Clutch Shaft Rear Cover Removal 4 Remove and discard the O rings W00089 Figure 27 O Ring Removal 66 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Primary and Secondary Clutc
129. nto 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 Valve_body Cover Spool Spring components Figure 210 Assemble Main Pressure Regulator Components Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 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 Nem 20 lbeft Install the M12x1 50 o ring plug into the valve body and torque to 16 Nem 12 Ib ft Connect the wires for the Neutral Switch 7 Proportional 12 1 50 ses Manual Override o ring plug Valve Valve Body Top hydraulic valve Figure 211 Assemble Top Valve Body Components Install a new gasket and 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 bottom_valve Figure 212 Install Regulator Valve Body
130. nual 1022297 Twin Disc Incorporated Assembly Install Internal Parts Trailing Pump Note Place the transmission with the output end facing up Be sure the transmission is securely supported 1 Lubricate the bearing bore in the main housing 2 Install the trailing pump drive shaft through the bearing bore in the main housing 3 Use a special tool to retain the trailing pump drive shaft in position in the main housing W00029 Figure 145 Trailing Pump Drive Shaft Retained in Main Housing 4 Place the first trailing pump ball bearing onto the trailing pump drive shaft Use a special tool to drive the ball bearing onto the drive shaft 00030 W00033 Figure 146 First Trailing Pump Ball Bearing Installation Marine Transmission Service Manual 1022297 147 Assembly Twin Disc Incorporated 5 Install the spacer and the second ball bearing onto the drive shaft using the special tool W00031 W00032 Figure 147 Spacer and Second Ball Bearing Installation 6 Install the external retaining ring onto the trailing pump shaft W00034 AAR204E 6557 Figure 148 Trailing Pump Shaft Retaining Ring Installation 148 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 5 Install the trailing pump cover and gasket Torque the four M10 x 30 capscrews to 46 Nem 34 Ib ft Figure 149 Trailing Pump Cover Installation Heat Exchanger Note The heat exchangers furnished by Twin
131. of the psiton as shown in the photo CA1000 CA1004 Seal Ring Figure 88 Backup Ring and External O Ring Installation 114 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly 2 Lubricate the clutch piston bore of the clutch housing with a thin film of grease Install the clutch piston into the clutch housing Gently push the clutch piston by hand until it is fully engaged into the clutch Note Ifthe clutch piston is difficult to install by hand remove the clutch piston and inspect the seal rings CA1005 Figure 89 Clutch Piston Installation 3 Calculate the clutch piston travel a Place the 12 steel clutch plates and 11 friction clutch plates in the clutch housing Be sure all steel clutch plates measure 2 2 mm 0 87 in thick b Install the backing plate and internal retaining ring CA1006 1007 Figure 90 Preparing to Calculate Clutch Piston Stroke Marine Transmission Service Manual 1022297 115 Assembly Twin Disc Incorporated Slide the special tool sleeve for measuring the clutch piston stroke over the shaft through the clutch backing plate steel clutch plates and friction clutch plates The sleeve must be against the clutch piston CA1008 Figure 91 Piston Stroke Adjustment Special Tool d Measure the distance from the end of the clutch shaft to the end of the special tool sleeve CA1009 Figure 92 Measuring Distance of Sleeve from End of Clutch
132. om the trailing pump shaft Figure 49 Training Pump Retaining Ring Removal 82 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 2 Use a drift to remove the trailing pump shaft from the ball bearings and to remove the ball bearings and spacer from the main housing WD032 Figure 50 Trailing Pump Shaft and Ball Bearing Removal Input Drive Sleeve 1 Remove the special tool that was used to retain the input sleeve in position 2 Raise the input drive sleeve with a jack Raise the input drive sleeve enough that the primary clutch shaft front bearing cone no longer contacts the bearing cup WD034 Figure 51 Supporting Input Drive Sleeve Marine Transmission Service Manual 1022297 83 Disassembly Twin Disc Incorporated 8 Use drift to drive the bearing cone onto the input drive sleeve Drive the bearing cone enough to provide a space between the spacer and external retaining ring WD035 Figure 52 Providing Space Between Spacer and Retaining Ring 4 Remove the external retaining ring and spacer Figure 53 Retaining Ring and Spacer Removal B Replace the jack from under the input drive sleeve with wooden blocking Use a special tool to drive the input drive sleeve from the bearing cone Note DO NOT remove the plug from the end of the input drive sleeve It is difficult to remove without damaging it 6 Remove the front bearing cone from the main housing 84 Mari
133. orated Secondary Clutch Shaft Front Bearing Cone Remove the secondary clutch shaft front bearing cone from the main housing WD018 Figure 35 Secondary Clutch Shaft Front Bearing Cone Removal Retain Input Drive Sleeve Use a special tool to retain the input drive sleeve position during rotation of the main housing Be careful not to damage the lip of the input seal the special tool will keep the bearing cone seated in the cup DO NOT damage the input drive sleeve plug when installing the special tool The primary clutch shaft end and plug are precision ground WD019 Figure 36 Retain Drive Sleeve 72 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Trailing Pump Cover 1 Remove the four M10 x 30 capscrews retaining the trailing pump cover to the main housing 2 Remove the cover Discard the gasket Figure 37 Trailing Pump Cover Removal Output Shaft Seal Carrier 1 Remove the nine M12 x 40 capscrews retaining the output shaft seal carrier to the main housing WD021 Figure 38 Output Shaft Seal Carrier Capscrews Removal Marine Transmission Service Manual 1022297 73 Disassembly Twin Disc Incorporated Front Housing Note Place the transmission on the output side Be sure the transmission is securely supported 1 Remove the thirty M10 x 35 capscrews with washers retaining the front housing to the main housing Note SAE 0 housings are retained by sixteen
134. orated 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 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
135. ot 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 228 Checking Output Flange Face Runout Marine Transmission Service Manual 1022297 203 Installation 204 Twin Disc Incorporated Figure 229 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 shims and fasten the engine and transmission in place Then recheck the alignment and if satisfactory bolt the coupling together There are many types of
136. ppropriate 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 208 Marine Transmission Service Manual 1022297 Twin Disc Incorporated WIRING SCHEMATIC TROLL ENABLE SWITCH CLOSED TROLL MODE OPEN CRUISE MODE CUSTOMER SUPPLIED Installation PINK SEE MODULE POWER CONNECTION CHART RED 5V TROLL SPEED POTENTIOMETER 1K OHM ORANGE 0 0 TO 0 5 VOLT MINIMUM TROLL GREEN 4 75 TO 5 0 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 SOLENOIDBON L GREEN CUSTOMER SUPPLIED RED LED VIOLET TROLL SPEED CURRENT INPUT GREEN 4 20MA SEE NOTE 1 TAN ig TAN 3e ENGINE SPEED SENSOR RED 2 6 BROWN GREEN LED c lt l PROPELLER SPEED SENSOR GREEN BLACK DH bm NORMALLY CLOSED BLACK SOLENOID NOT IN NEUTRAL RELAY MP S CLOSED IN NEUTRAL RED Ad ovo BER CUSTOMER SUPPLIED BLUE MP SOLENOIDAON 5 BLACK 200 mA MAXIMUM QY RED LED S wane BLACK X SOLENOID B SWITCH N YELLOW CUSTOMER SUPPLIED C TO 28 START Be SEE MODULE POWER CIRCUIT CONNECTION CHART SOLENOID A SWITCH T
137. pusher screws used in the disassembly of this transmission are threaded through aluminum parts ALWAYS LUBRICATE the threads 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 1022297 55 Disassembly Twin Disc Incorporated Prior to Removal 1 Remove drain plug and drain oil from transmission DRAIN PLUG WITH MAGNET MGX 6598A 002 Figure 10 Drain Plug 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
138. rd the output flange Note The oil seal sleeve must contact the shoulder on the output i shaft W00015 Figure 133 Oil Sleeve Installation Install the output shaft seal carrier onto the output shaft a Wrap the shoulder of the output shaft with electrical tape to protect the seals from damage during assembly b Slide the output shaft seal carrier onto the output shaft with the counterbore end toward the output flange W00016 Figure 134 Output Shaft Seal Carrier Installation Marine Transmission Service Manual 1022297 139 Assembly Twin Disc Incorporated 4 Slide the previously selected shim pack onto the output shaft WO00017 Figure 135 Shim Pack Installation 5 Slide the outer taper roller bearing cup onto the output shaft W00018 Figure 136 Outer Taper Roller Bearing Cup Installation 6 Install the outer bearing cone onto the output shaft a Heat the bearing cone to 120 C 250 F A WARNING Handle the bearing cone with care The bearing cone is HOT b Place the thrust bearing cone onto the output shaft with the small diameter end of the bearing facing the bearing cup 140 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly C Use a special tool to drive the thrust bearing cone onto the output shaft until it contacts the shoulder of the oil seal sleeve W00019 Figure 137 Outer Bearing Cone Installation 7 Install the thrust beari
139. rimary and Secondary Clutch Shafts Shims 67 Remove Internal Hee 68 Primary Clutch 87 Secondary Ol tch ae 94 Disassembly of GP Control Valve with Electronic Interface 100 BIL Cri p l 101 Cleaning and Inspection 107 hime 107 Pe S 109 113 General ee 113 Primary Shaft 114 Secondary Clutch SIM 123 uri m 132 Output Shaft Assembly E MEETS 133 rct Parts T 147 Install External 177 Assembly of GP Control Valve with Electronic Interface 186 Adjustment of Main Pressure 1 11 sees eeeeeeeeeeeeeeeeees 192 Sequence Valve Adjustment Procedure 193 8 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Table of Contents TS VAN e 195 195 Alignment also reference SAE J 103
140. rush Marine Transmission Service Manual 1022297 47 Preventative Maintenance Twin Disc Incorporated NOTES 48 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting of Electric Control Valves General The following charts are intended as a guide for determining 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 1022297 49 Troubleshooting Twin Disc Incorporated Pressure Test Kit 50 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 Q
141. s 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 4 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 oil 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 1022297 45 Preventative Maintenance Twin Disc Incorporated Periodic Visual Inspection 46 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 Inspect unit nameplates for looseness and corrosion Tighten mounting screws that are loose and replace nameplates that are corroded Inspect and oil the exposed stem
142. sc having stipulated the bill of material number on the unit s nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old 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 1022297 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 1022297 15 Introduction Twin Disc Incorporated
143. shipment to the date placed in service The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc 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 D 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 E Twin Disc Incorporated reserves the righ
144. sion Service Manual 1022297 195 Installation Twin Disc Incorporated Alignment also reference SAE J 1033 and J 617 1 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 Figure 221 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keeping a thrustin 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 22 Table 16 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations and Bore Eccentricity mm in ee OE 0 48 0 019 40 0 41 0 016 _ 1420 0 36 0 014 1 2 0 30 0 012 2 0 28 0 011 196 Marine Transmission Service Manual 1022297 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 A Flywheel Housing Figure 222 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 thousanaths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular
145. stomer 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 1022297 207 Installation Twin Disc Incorporated Table 17 Module Power Connection Chart Troll enable Connect to the Connect to the same Connect to the same switch return negative termin
146. t the pressure inside the special tool will begin to rise Continue to tighten the bolt The output gear will begin to expand allowing the output gear to separate from the taper of the output shaft Repeat steps c through f if necessary Note Tightening the bolt with an air tool may be advantageous WD028 Figure 45 Separate Output Gear from Output Shaft Marine Transmission Service Manual 1022297 79 Disassembly Twin Disc Incorporated To finish separating the front spherical roller bearing from the output shaft follow the procedure in Step 5 The weight of the shaft should provide sufficient force to remove the bearing while the pressure is increased on the tool Figure 46 Final Operation to Separate Front Spherical Roller Bearing from Output Shaft 8 10 11 12 80 Raise the housing off the output shaft using caution to properly support the output shaft to avoid damage If the bearing cup slides out collect the nine springs that may come out of the housing that are between the housing and thrust bearing spacer Support the housing and remove the output gear from the main housing Remove the front spherical bearing from the housing If necessary remove the trailing pump drive gear from the output gear Note Identify the shims that are located between the trailing pump gear and the spacer and the shims between the seal carrier and the rear bearing cup Use a press or puller to remove the two taper
147. t to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials F 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 November 30 2005 TDWP2004 rev 2005 adi f 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 MG360 0 0 0 0 MG5050 SERIES MG5010 SERIES MG5011SERIES MG5012 SERIES MG5015A MG5020SC MG506 MG506 1 MG6051SC MG5061 SERIES MG5065SERIES MG5050 MG5055A MG507 MG5081 MG5085 MG5075SERIES MG5085SERIES MG5082SERIES MG5091SC MG5112 MG5113 MG5091 MG5090 MG5090A MG509 MG 5111 MG5114SERIES MGX5114A 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 MG
148. ter 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 Some have two identical switches 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 or 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 override_valve3 Figure 8 Manual Direction Control Valve Marine Transmission Service Manual 1022297 41 Operation Twin Disc Incorporated NOTES 42 Marine Transmission Service Manual 1022297 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 Removing and installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Removing and installing t
149. the bearing bore in the main housing Use a bearing installation tool to 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 W00001 Figure 122 Primary Clutch Shaft Front Bearing Cup Installation 132 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Output Shaft Assembly Oil Seal Sleeve 1 Lubricate the surface of a new O ring with grease 2 Install the O ring into the groove in the inner bore of the oil seal sleeve W00002 Figure 123 Oil Seal Sleeve O ring Installation Output Shaft Seal Carrier 1 Apply MA1015 or equivalent sealer to the outside diameter of two new output shaft seals 2 Use seal installer to install the new seals into the output shaft seal carrier with lip of the seals facing out 3 Apply grease to the lip of the seals and fill the cavity between the seals with grease Marine Transmission Service Manual 1022297 133 Assembly Twin Disc Incorporated 4 Lubricate and install a new O ring on the output shaft seal carrier woo003 00004 Figure 124 Output Shaft Seals O Ring Installation Output Shaft Bearing Shimming Procedure 1 Measure the length of the output shaft seal carrier pilot in three evenly spaced locations around the circumference of the pilot Record the distance as Distance A 00005 Figure 125 Measuring Output Shaft S
150. ther forward or reverse This unit is designed for right hand rotation For left hand rotation engines consult Twin Disc Incorporated 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 1022297 19 Description and Specifications Twin Disc Incorporated Construction Features 20 Housings The MGX 6598A series transmissions have a one piece main housing Front housings in sizes SAE No 1 and SAE No 0 are available A top cover a bottom cover and a manifold complete the housing enclosure The pump mounts on the secondary shaft and the primary shaft has a cover Taper Roller Bearings The primary and secondary clutch shafts are supported and located by tapered roller be
151. through the inlet port The incoming oil is supplied to the main pressure regulating valve 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 and cascading all remaining oil flow into the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil 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 S valve that is located in the clutch shaft or externally on the housing 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 capaci
152. ting 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 1022297 Twin Disc Incorporated Cleaning and Inspection Inspection Housings Cast Parts and Machined Surfaces Replace cast parts or 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 sanding or grinding This will cause loss of fit of bearings or races Inspect oil 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 solv
153. to Transmission Marine Transmission Service Manual 1022297 187 Assembly Twin Disc Incorporated 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 Ibeft 6_capscrews Figure 213 Install Top Valve Body onto Regulator Valve Assembly 5 Install the Electronic Profile E Troll Module on the top Valve Body and torque the four M6 1 0 capscrews to 9 5 Nem 7 16 Clamping_screws2 Figure 214 Place Profile or E Troll Module onto Valve and tighten screws 6 Connect the electrical wires to the proportional valves and connect any other wires that were removed during disassembly 188 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Assembly Sequence Valve 1 Apply lubricant to the O ring and threads of the primary and secondary sequence valves 2 Install the primary clutch shaft sequence valve 3 Install the secondary clutch shaft sequence valve 4 Torque the sequence valves to 33 9 Nem 25 Ibeft 00112 W00113 Figure 215 Sequence Valve installation Hydraulic Oil Filter le Install a new O ring on the hydraulic oil filter connector 2 Thread the hydraulic oil filter into the main housing 3 Install the sending unit into the oil filter housing 4 Connect the hydraulic oil hose between the hydraulic oil pump and oil filter Marine Transmission Service Manual 1022297
154. 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 223 Checking the Flywheel Face Runout Marine Transmission Service Manual 1022297 197 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 224 Checking the Flywheel Pilot Ring Bore Eccentricity 198 Marine Transmission Service Manual 1022297 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 length of the shaft from the last support bearing to the gearbox is excessive or a flexible stuffing box
155. turers 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 Locktite Primer N MA1012 Avoid getting sealant into the O ring counter bores 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 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 Marine Transmission Service Manual 1022297 113 Assembly Twin Disc Incorporated Primary Clutch Shaft 1 Assemble the clutch piston a Lubricate and install a new seal ring on the outer diameter of the clutch piston b Lubricate and install a new internal seal ring CA1001 CA1002 Figure 87 Seal Ring and Internal O Ring Installation p Install a new backup ring d Lubricate and install a new external O ring between the backup ring and the end
156. tween 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 200 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Installation Engine and Marine Transmission Alignment A CAUTION 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 or the engine flywheel housing Recommended Accepted a m i 14 Figure 226 Transmission Mounting Configurations When mounti
157. ty 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 mechanical 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 S valve through a passage in the shaft or housing 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 atime 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 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Operation Manual Direction Control Valve Operation The manual direction control valve is locked in the NEUTRAL cen
158. ty 2 46 9o Marine Transmission Service Manual 1022297 Figure 9 Test kit 42168 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 problems 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 only 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 14 LED Light Status Light Status Profile Generator E troll Module Non trolling Green light on Supply voltage gt 9 0 volts Supply voltage gt 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 leads current shorted together or low coil current Both red lig
159. type of oil Draw and refill with recommended oil Low clutch apply Low Main Pressure See Paragraph 1 pressure Defective Proportional Replace Proportional Valve Valve Low voltage to Profile Verify that green voltage Generator supply light and red clutch energized lights are bright 54 Marine Transmission Service Manual 1022297 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
160. ulder of the inner bearing cone CD1002 Figure 70 Rear Bearing Cone Removal 94 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 3 Position the primary clutch shaft with the input end facing up Use a hydraulic jack and a cheese cutter type puller to remove the bearing carrier forward bronze thrust washer and pinion from the clutch shaft CD1015 Figure 71 Bearing Carrier Outer Thrust Washer and Pinion Removal 4 Install two clamps on the backing plate to compress the clutch wave springs Tighten the clamps and compress the clutch wave springs Remove the external retaining ring CD1006 Figure 72 Retaining Ring Removal Marine Transmission Service Manual 1022297 95 Disassembly Twin Disc Incorporated 5 Remove the two clamps Remove the clutch backing plate CD1007 Figure 73 Clutch Backing Plate Removal 6 Remove the 12 steel clutch plates 11 friction clutch plates and 11 wave springs CD1008 Figure 74 Steel Clutch Plates Friction Clutch Plates and Wave Springs Removal 96 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly T Remove the steel thrust race CD1009 Figure 75 Inner Steel Thrust Race Removal 9 Remove the external snap ring When the snap ring is opened it will release with some force Protect hands from injury Fi i _ CD1010 CD1011 Figure 76 External Snap Ring Removal Mar
161. ups from the manifold Note The primary and secondary clutch shafts rear bearing cups are different from each other Tag the bearing cups with proper identification 5 Remove and discard the manifold O rings W00076 Figure 31 O Ring Removal Marine Transmission Service Manual 1022297 69 Disassembly Twin Disc Incorporated Bottom Cover 1 Remove the 21 outer capscrews nine M10 x 50 twelve M10 x 35 retaining the bottom cover to the main housing Remove the two M10 x 55 capscrews near the center of the bottom cover Identify all screws for proper assembly A IMPORTANT The bottom cover capscrews are stainless steel 2 Install two guide screws before removing all of the capscrews d Remove the bottom cover from the main housing gt WD015 Figure 32 Bottom Cover Removal 70 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly Gear Pan 1 Remove the two M10 x 140 capscrews with sealing washers retaining the gear pan 2 Remove the gear pan 00058 Figure 33 Gear Pan Removal Primary and Secondary Clutch Shafts Remove the secondary clutch shaft then the primary clutch shaft using lifting scissors Note Set the primary and secondary clutch shafts aside until further disassembly is required E gt gt WD016 WD017 Figure 34 Primary and Secondary Clutch Shaft Removal Marine Transmission Service Manual 1022297 71 Disassembly Twin Disc Incorp
162. ve the rollers b Use a cheese cutter type puller on the rear shoulder of the inner bearing cone CD1002 Figure 57 Rear Bearing Cone Removal Marine Transmission Service Manual 1022297 87 Disassembly Twin Disc Incorporated Position the primary clutch shaft with the input end facing Remove the round snap ring y CD1003 Figure 58 Round Snap Ring Removal 4 Remove the forward bronze thrust washer Note The outer bronze thrust washer has 18 radial grooves on both sides for lubrication purposes CD1004 Figure 59 Forward Bronze Thrust Washer Removal 88 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Disassembly 5 Slide the pinion assembly from the shaft CD1005 Figure 60 Pinion Assembly Removal 6 Install two clamps on the backing plate to compress the clutch wave springs Tighten the clamps and compress the clutch wave springs Remove the external retaining ring CD1006 Figure 61 Retaining Ring Removal Marine Transmission Service Manual 1022297 89 Disassembly Twin Disc Incorporated 7 Remove the two clamps Remove the clutch backing plate CD1007 Figure 62 Clutch Backing Plate Removal 8 Remove the 12 steel clutch plates 11 friction clutch plates and 11 wave springs CD1008 Figure 63 Steel Clutch Plates Friction Clutch Plates and Wave Spring Removal 90 Marine Transmission Service Manual 1022297 Twin Disc Incorporated Dis

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