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1. OMAR RANSMISSION LUBRICANT SERVICE CLASS USE S AE API SERVICE CLASS CD ENGINE L BY VEKTIR PASS 10 LEN Eur SS ee Ll IX SAE API SERVICE S Ce ENGINE Ly JA eene b UA D BASE SELE I N DN SUMP IEMP NS TARULCATED SL START UP STEADY RATON 117 SOF mo T gt C MIN 65 B5 C Sue 50 F MIN 1255 2001 SAF so 10 C MIN 805 2522 STEADY OPERA TON G OE oo OR ABOVE 3005151 Ie NOI RECOMMENDED Y WIN DISC 6 M RACING Oud B2415 Figure 3 Oil Specification Plate Example 24 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications O
2. BLIM POWER TRA IL CAPACITY CUSTOMER GAL MARINE RSANSMISSILIN UBRICAT ION PRESSURE WHEN CRUISING PSL VERY 10 SERVICE HLIURS UR DAILY CHECK DIL LEVEL WITH ENGINE RUNNING AND ARINE TRANSMISSION IN NEUTRAL RS SESS IS PROVIDED UBRICATE OUTPUT SHAFT SEALS WITH WATER PUMP GREASE PREVENT BILGE WATER FNTERING HOUSING VERY 1000 SERVICE HUURS UR 6 MUNTHS WHICHEVER CUMES RST DRAIN AND REFI USING WITH CLEAN OIL REMOVE AND REPLACE FILTER ELEMENT WHERE APPLICABLE CLEAN SUCTION SCREEN MPLIN WARRANTY IS VOID UNLESS TRANSMISSION IS LUBRICATED AND MAINTAINED AS e SPECIFIED T E SERVICE MANUAL AVAILABLE UN REQUEST REFER MARINE TRANSMISSIUN LUBRICANT PLATE SHIPPED WITH UNIT ES BILL OF MATERIAL NH MUST BE GIVEN WHEN ORDERING PARTS CU V V WIN DS MADE IN USA VEA 5 USA Figure 1 Nameplate for MG 5321DC Marine Transmission Marine Transmission Service Manual 1022294 17 Description and Specifications Twin Disc Incorporated Power Ratings The MG 5321DC transmission can be operated t
3. SEAL M201576A SEE NOTE 10 SLEEVE 1020606 RING 4291615 ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 8570 0 NOTES 1 THRU 10 ARE IN SS70BQ THESE STANDARDS APPLY 574 FASTENER TORQUE REQUIREMENTS 692 BEARING SHIMMING 765 TAPERED JOINT ASSEMBLY 2 NOTE 11 44 APPLY 908 INPUT SENSOR THREADS N4 SERIE ASSEMBLE SENSOR UNTIL CONTACTING PLATE 206063 418 SENSOR UNE FULL TURN NOTE 12 ASSEMBLE SENSOR UNTIL CONTACTING TIP OF GEAR TOOTH THEN BACK OUT SENSOR TWO FULL TURNS NOTE 13 PORT MARKED BE ASSEMBLED CLOSEST TO TRAILING PUMP OUTLET NOTE 14 SETSCREW 2041 2 SEE NOTE 9 SPRING A2704CN 32 gt ons GEAR 1016994 RING 2916 VALVE 1018162 PLATE 206067G 20 RING 2078 DETAIL SCALE FULL BACKPLATE 1020371 2 gt BEARING 1019971 2 CONE ASS Y 585 a7 4 Jh n CUP 590 SCREW 996 23 IV ZI 222 XS 4 GEAR 1016993 RING M2693T 2 N we Bene E SAE 4005 Nis Ed C3 Me PLUG MA1038D 2 TUBE 1017095 5 7 Nii
4. Leere eee ee ee eene nnn 13 e 13 Ordering Parts and Obtaining Services 14 Source of Service Information eere eee 15 T E 15 Description and Specifications 17 OOO e 17 S Ea E 18 Changing Rotatio i 18 OF 18 CODSITUCUONn EN INE 19 L brication Features 20 Flexible Torsional Input Coupling 21 Heal EX CAIN geeeec M 22 Specifications and Maintenance 23 25 Assembly Specifications 28 Optional 29 Torque Values for Fasteners 1 31 Clutch Plate Wear 22 222 33 Marine Transmission Service Manual 1022294 7 Table of Contents Twin Disc Incorporated Operation 35 General 35 GP Control Valve with Electronic Interface 1020941C 36 Hydraulic System with GP Control Valve
5. cee a commana 6 23 04 a e 5 20 03 A ATMOSPHERIC PRESSURE A ATMOSPHERIC PRESSURE LP INTERMEDIATE PRESSURE CLUTCH PRESSURE 20 UNLESS OTHERWISE SPECIFIED FIRST USE m e t o oo DENIES aG e 0415 1 11 02 025 XXX 013 2 0553 12 3 01 ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING PER ASME 14 5 1994 Oo SEE SHEET 2 OF 8 FUR VALVE ASSEMBLIES NOTICE THIS PRINT CONTAINS PRUPIETARY INFORMATION AND IS NOT USED IN ANY MANNER DETRIMENTAL TO THE INTEREST OF TWIN DISC INCORPORATE VALVE 4557 THIS IS NOT INTENDED NULLIFY OR LIMIT RIGHTS GRANTED THE US GOVERNMENT OR OTHERS BY CONTRACT CWITHOUT TROLLING VALVE PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND HYDRAULIC LOCK OPTIONAL CONDITION 6 WIRING DIAGRAM OPTIONAL MATING WIRING HARNESS 1017404 SERIES SPECIFY LENGTH THESE SOLENOID CONNECTIONS NOT POLARITY SENSITIVE CONNECTOR SHROUD 1001434 CONNECTOR PORT SOLENOID PORT SOLENOID D RING MA379CP RING A2916FT PLUG 1017389 5 1 EE NY 5 NAW SPOOL 1017433 2 4 SOLENOID ASS Y SEE CHART TORQUE 33 9 25 0 lbf ft5 e SCREEN 221336 VALVE BODY ASS Y 1017444 A BODY 1017443 BALL MA1034A 11
6. 41 Manual Control Valve 1017172 or 1017546 45 Electric Control Valve 1018084 47 Trolling Valve Optional 57 Power Take off Optional cere ee ee een 59 Trailing ODNONAN 60 FOWOF FIOW 60 Preventative Maintenance 65 In boat Maintenance and Repair 65 LUDHCAUON 65 General 66 Periodic Visual Inspection eese 68 Troubleshooting 71 Troubleshooting of Mechanical and Electric Control Valve 71 55 72 Troubleshooting of GP Control Valve with Electronic Interface 73 Disassembly 81 Prepare Transmission for Disassembly 82 Remove Transmission External Components and Sub ASSemblIBS 83 Remove Output NVRA SIME ND DS 88 Remove and Disassemble Manifold and Bearing Carrier 90 Remove Primary and Secondary Clutch Shaft Assemblies 9
7. TRANSMISSION MAIN amp LUBE LAY PORT SIZE 32 77 26 0 MAX 68 30 73 46 D 4 5 2 03 03 H E4 ECNI42 i 5 2 06 T Y c ci 1978 1 18 03 G 4091 4 25 61 View C SHOWING MOUNTING CONFIGURATION 665 7 16 03 5761 54 202 PA __ 45 ECN11639 6 13 03 E ECNI2317 4 5 4 8 ECN14244 6 20 06 LL ancuLar TOLERANCES st ev soer zme cu wo mare sheer zme vate sneer zoe cm no DATE MOUNTING SURFACE REQUIRES 28 FINISH F SEE NOTE 119 4 D 4 PLACES PLATE 1018175 SCREW 11008 DIMENSIONS ARE mm GEOMETRIC TOLERANCING PER ASME Y14 5M 1994 PLUG MA1038B M12x1 5 0 RING PURT MAIN PRESSURE CHECK BUDY 1020519 2 OPERATION TO BE TWIN DISC CONTROL SYSTEMS OR MODULES MANUAL DIRECTIONAL CONTROL VALVE OPERATION 1 WITH MANUAL DIRECTIONAL CONTROL VALVE CENTERED POSITION PUSH TO ENGAGE PORT A PROPORTIONAL CONTROL VALVE OPERATION 1 WARNING DO NOT CONNECT VALVE COIL DIRECTLY TO BATTTERY POWER SUPPLY VU ULATAGE VALVE 10210004 TORQUE TO 36 N m gt SCREW 960 40 1002144 zt NUT 1002145 GASKET 1020531 SEE NOTE D PISTON 1020939 Sa COVER 1020936 M6x1 0 16 0 DEEP
8. nu SCREEN 1020479 CL e be on SIDES D 3980 53 8 E 79 60 M8 X L25 6H TH D 191 DEEP 4 HOLES VIEW SCREW 1052 4 TORQUE 542 400 lbf ft NOTE INSTALL USING MA908 242 THREAD DOG POINT INTO DETENT GROOVE UNTIL SNUG BACK OFF 1 2 TURN CLUTCH ENGAGED FOR POSITION F WD NEU REV USE rng ENGAGED FOR 2 POSITION ENGAGED amp DISENGAGED USE COVER 1017324 RACE Me086DF SETSCREW M2038W BEARING MEUB ARD PISTON SEE CHART RACE M2086R SPRING ASSY SEE CHART GASKET B1334C PLATE SEE CHART CDVER ASSY 1017336 A CARRIER 1017335 SHIM SEE CHART BALL M1990Y 8 24 6 SEAL MA778 STEM SEE CHART Q SNAP RING A2915S SJE tN NOTE LEVER MAY BE LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 gt ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL M8 X 1 25 6H TH D SHIM SEE CHART e HDLES IK COVER 1017128 21 7 gt 35 5 N 7 NZ ae IN d LM A APE 23 3 OR 363 p C D SECTIUN A m A U RING A2916AT WASHER A2782AS SPACER 2885 GASKET 1017334 GASKET 1017130 BALL
9. Figure 55 Top Hydraulic Valve Body Assembly 104 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 3 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 if not previously removed Main Regulator Valve Body Pressure 7 Adjustment Figure 56 Main Regulator Hydraulic Valve Assembly 4 Remove the Manual Direction Control Valve with switch if equipped or the Plug Assembly from the Top Valve Body Override Valve with Neutral Switch Locking Pin Plug if applicable Figure 57 Manual Direction Control Valve or Plug Marine Transmission Service Manual 1022294 105 Disassembly Twin Disc Incorporated 9 Hemove the M6 1 00 x 16 Allen head capscrew the retaining plate and the proportional Valve Cartridges from the Top Valve A slight rotating motion while pulling will help to with the removal of the valves Figure 58 Remove Proportional Valve Cartridges 106 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 6 Remove the Main Pressure Regulator from the Main Regulator Valve body A Remove the regulator adjusting screw cap and loosen the jam nut Turn the adjusting screw counter clockwise to reduce the spring load on the valve Evenly loosen the four M8 x 25 capscrews and remove the cover assembly and gasket
10. Figure 67 Removing Roll Pin Retaining Shuttle Seat 21 Thread a M8 x 1 25 screw one of the cover screws works well into the seat and remove it from the valve body 22 Remove the shuttle ball from the valve body 12 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly Disassembly of Upper Valve Body Half electric section 1 Remove the Weatherpak connector from the valve body by sliding it in the direction of the opening in the shroud 2 Mark the wires with the location letters that are on the Weatherpak connector Open the end of the Weatherpak connector to allow removal of the pins and wires Remove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool Tool is Packard Electric P N 12014012 Figure 68 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them D Remove the third Neutral solenoid units with hydraulic lock or plug units without hydraulic lock Marine Transmission Service Manual 1022294 113 Disassembly Twin Disc Incorporated 6 Remove the filter screen from the Figure 69 Removing Filter Screen 7 Remove the two socket head O ring plugs from the bores in the end of the valve body 8 Remove the two spools from the valve body 9 Remove one dowel pin and spring from each of the spools hydraulic lock units only 10 Re
11. 45 PLUG MA1038F SCREW MA996G 9 SCREW 996 26 MA1039D 2 PLUG Me080CZ SEE NOTE 8 FITTING MA1053AA FITTING MA1053T SEE NOTE 11 GAUGE B3631AM TUBE ASS Y XB2301C SCREW MA960A 42 WASHER MA1039A 4 PLUG MA1040A UNLESS OTHERWISE SPECIFIED WEIGH R FIRST USE MATERIAL HEAT TREAT DIMENSIUNS ARE ASSY MACHINED DIMENSIONS x 0 75 MODEL NOTICE THIS PRINT CONTAINS PRUPIETARY INFURMATIUN AND IS USED IN 025 13 DETRIMENTAL THE TWIN DISC INCORPORATE ALL ANGULAR TOLERANCES 31 0 ANY MANNER To THE INTEREST OF SIMILAR TO THIRD ANGLE 1 APPT Cl A ee o CELLA S run B SENSOR 1020553 gt TAG 656 ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 5570 0 NOTES 1 THRU 10 ARE 5570 0 NOTE 11 APPLY MA908 TO INPUT SENSOR THREADS ASSEMBLE SENSOR UNTIL CONTACTING TIP OF GEAR TOOTH THEN BACK SENSOR ONE FULL TURN NOTE 12 ASSEMBLE SENSOR UNTIL CONTACTING TIP OF GEAR TOOTH THEN BACK OUT SENSOR TWO FULL TURNS NOTE 13 PORT MARKED BE ASSEMBLED CLOSEST TO TRAILING PUMP OUTLET NOTE 14 PORT MARKED 5 BE ASSEMBLED CLOSEST TO QUTPUT SHAFT TWIN Ise INCORPORATED 1 2 RACINE WI 53403 USA 10153394 ASSEMBLY INSTRUCTIONS OPTIONAL EQUIPMENT ASSEMBLE AND TEST PER 557000 VALVE ASSY 1018084P 24 V VALVE
12. Marine Transmission Components MG 5321DC Document Number 1022294 Twin Disc Incorporated makes no warranty or guaranty of any kind expressed implied or otherwise with regard to the information contained within this manual Twin Disc Incorporated has developed this manual through research and testing of the information contained therein Twin Disc Incorporated assumes no responsibility for any errors that may appear in this manual and shall not be liable under any circumstances for incidental consequential or punitive damages in connection with or arising out of the use of this manual The information contained within this manual is subject to change without notice Document Number 1022294 January 2006 Marine Transmission Service Manual Qu TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE 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 twenty four 24 months from the date of shipment by Twin Disc Incorporated to original customer but not to exceed twelve 12 months of service whichever occurs first This is the only warranty made by Twin Disc
13. f GEN LL 7 13 78 POWER TRAIN RD1006 MODEL 100 TON 6 3 3 STROKE J qM We 3 itin 4 1 INK v g 0023 DET e 7 GS 20023 4 20023 4 DET 2 IET 1 DET 4 20023 4 14 gt 53210 T eme lanus HEFTE E INS gr Atene ini Lue T umm Ads STU NBN UNE p E Pi Ic I POWER TEAM DOUBLE ACTING RAM 190 TENS 6625 STROKED a 13 4 4140 RoD s ma MEDEL F RO 1006 509 LUNG zu c CAD FILE 023 3 3 dl os n RETRACTED LENGTH OF PRESS RAM 15 12 DRILL 5 16 3125 DIA x 125 DP ees 2 00 TAP 3 8 16 100 DP 2 REQ D 180 USE FOR LIFTING 2 44 MID STROKE 0 50 TI NOTE UNLESS OTHERWISE SPECIFIED 2 BREAK ALL SHARP CORNERS NOTE ALL GRD DIA S amp SURFACES MUST BE SQUARE amp CONCENTRIC TO WITHIN 6B 6 005 ATN 7 N SEE SAT 3 FER CH H AES REVISION s SHT 3 8 1 MS PUSHER PLATE Supe 06 2 7 1 MS WASHER CARB amp HDN2 4 88 DIA x 56 THICK TYP a mam rm 4 00 38 DIA 2 ts 3e x 42 je ut uc wamm T nues 1 SEE SHT 3 PULLER N
14. 4 NOTE EE 40962 1017383 1017179 aezoeBC Me7o4U 2655 385 10171894 MA1038E e7 x 20 64 Be451B 1176 98 A INSTALL USING NASOS LOCTITE eee oe F j a T MAX TROLLING PRESSURE ERE 85 1007178 M TUR 20 689 BEASIB INE 2 or i 1017546F 41848 1018688 70740 A2707AD A2703AB 2000 290 10171298 MA1038E Me7 x 20 6H B2451B 5 A 5 EL EE r7546G 1016688 7072 7072 7 725 10171298 8 7 x BeASIB B de F E E PLATE 160 8 209 8 M8 X 1 25 6 TH D 191 DEEP 4 HOLES INSTALLATION NOTE 0 6 0 9 5 5 8 3 lb AT THE 46 0 41 812 R LOCATION OF THE 6 4mm 1 4 DIA HOLE IS REQUIRED TO OVERCOME DETENT REMOTE CONTROL ACTUATOR MUST PROVIDE 650mm 2 56 TOTAL LINEAR TRAVEL AT THE 6 4mm 174 DIA HOLE LOCATION VIEW SCREW 1052 4 TORQUE 54 2 N m 40 0 lbf f t5 INSTALL USING 908 242 THREAD DOG POINT INTO DETENT GROOVE UNTIL SNUG BACK OFF 1 2 TURN NOTE ADJUST SETSCREW SO THAT NOTE LEVER MAY BE LOCATED ANYWHERE RACE Me086DF 1017324 SETSCREW M2038W CAPSCREW M2000H LE
15. 566 1 09 06 D 1590 6 03 03 025 RACINE WI 53403 USA W ALL ANGULAR TOLERANCES 31 e FEES ECN13667 12 16 05 me 11452 5 22 03 WI 53403 USA qs GEOMETRIC TOLERANCING W Russell WIRE SPLICE TWIN DISC P N 1020282 GEOMETRIC TOLERANCIN AT DH DEUTSCH CONNECTOR 3723 05 B 1 ECNISeS 4 29 03 THIS NOTICE TS NOT INTENDED SURFACE TREATMENT NAME P Sehen SERIES MP METRIPACK CONNECTOR c a n oe a tcwrae 422 03 LIMIT RIGHTS CONTROL B PREV sHEET zone REV SHEET ZUNE CH DATE OR OTHERS BE CONTRACT D MG ETROLL MODULE A TWIN DISC PART NUMBER 1020585 POWER SUPPLY 12 or 24VDC NOMINAL WARNING DO NOT CONNECT VALVE COILS DIRECTLY d gt L Qe a 2 2 eH BATTERY POWER SUPPLY VOLTAGE 125 0 3 2 4 PLACES DEUTSCH CONNECTOR 1 PART NO DT04 2P DEUTSCH TERMINAL lt 2 PART 0460 202 16141 DEUTSCH WEDGE LOCK 0 PART NL WeP TEMP GND TEMP IN SUL SUL SUL B SUL B NIN OUTPUT NIN GND SOL POWER GND SOL POWER METRI PACK CONNECTOR PART 12162193 METRI PACK TERMINAL 4 gt PART 12124075 WIRE 18 AWG XLPE SAE 1128 TYPE GXL USE 1020282 SOLDER SHRINK CONNECTORS AS REQUIRED
16. BALL M1990Y 6 VALVE GASKET 1017136B 3 DITCH PLATE GASKET SEE CHART TRANSMISSION GASKET SEE CHART SECTION D D VALVE BODY ASSY 1018095 A BODY 1018094 BALL 1034 BALL 10340 2 BALL M1990H BALL 1990 52 e O OBSOLETE FOR PRODUCTION AND SERVICE A NOT SERVICEABLE SEPARATELY THESE PARTS ARE TO BE PACKAGED SEPARATELY AND SHIPPED WITH UNIT TUIN 9186 DATE 3 23 98 0 100 INCORPORATED RACINE 1 53403 USA oreo SA SERIES A HEAT TREAT CONTROL VALVE 1020942 SEE NOTE FILTER P10786 SEE NOTE C SECTION B B SCALE 2X U RING A2916K S S PLUG MA1038B di PDRT SCREW MA961X 6 U RING 8916H 7 2 V 2 2 gt f RING Ae QIGk V STAMP VALVE ASSEMBLY IDENTIFIER HERE PLUG M2051BA 11 0 THRU mM 4 HOLES FOR TRANSMISSION TRANSMISSION SUMP PORTS gt 3 iso e MAX SZ TRANSMISSION CLUTCH PORTS F 12 7 MAX PORT 4 4 il o CP SO OPTIONAL 5 2 M27 LUBE PORT SEE CHART 84 35 56 72 11 30 102 75 eT 199 1 a 1 SEMEN 4 TD 2 144 L 2 Q 104 27 TEMPERATURE SENSUR
17. THE 0 3 GOVERNMENT OR OTHERS CONTRACT SERVICE REFERENCE 1016502 FILTER CAPSCREW MA960M SEE NOTE 7 WASHER 1039 SERVICE REFERENCE B1974 GASKET FILTER 557 1020872 W O INDICATOR GEAR 1022349 KEY Meo3eF BEARING M1828 SHAFT 1021263 BEARING MA208 RING Me078CL PLUG MA1038F GASKET 1020996 PLATE 1080736 I N ee NE Naa N SS NN JuNJ 9 RING A2916HP COVER 2502 TUBE 1022350 212754 SCREW 996 WASHER 10390 STANDARD EQUIPMENT PROFILE MODULE 1022311A GAUGE B1703D E TROLL MODULE 1022307C B cOPTIONAL SCREW 1097 lt 45 WASHER M 1039J 4 VALVE 55 1020941C SCREW 1052 ACLOSURE 2067 2 EXCHANGER 1017051 ANODE 1017049 5 MA960D WASHER M2081D GASKET 1017050 PLATE 2415 SCREW M422B 85 SCREW 1052 4 GASKET 1021192 PLATE 1021148 SCREW MA1062M 8 PLATE 204098C FILL ENTIRE TAPPED HOLE WITH SILICON SEALANT ALLOW PROPER CURE TIME HOSE MA1147H SCREW MA996AH 2 HOUSING 1017037 iR i 7 RING A2916W e PLUG 1038 GASKET 1017047 PLATE 1019906 y GASKET 1019905 C ZZ AA qu PLUG MA1038F Gi ie e PLUG MA1038F SCREW MA996Z 4 WASHER MA1039D 4 SCREW 996
18. ae FHA RING A2916LV iY BODY 1020874 immi SPRING S SEE CHART PORT B 7 NZ 4 1225 2 ns VY 7 WASHER A2782AU X 7 SPOOL 1020876 Y LY Y 2 IL SSSSSSSN COVER 1020934 TON GASKET 1020935 VALVE FEMA SEE CHART 2 SECTION SCREW MA960A 4 3 RING A2916JT 2 MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH NOTES 1 SWITCHES ARE NORMALLY CLOSED WHEN MANUAL DIRECTIONAL CONTROL VALVE IS IN THE CENTERED POSITION AND OPEN WHEN LEVER IS ACTUATED FROM CENTERED POSITION 2 CURRENT 20 AMPS MAX 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE DRAWING D PRESSURE REGULATOR ADJUSTMENT 1 REMOVE 1002144 CAP AND LOOSEN 1002145 NUT CLOCKWISE ROTATION OF 1020939 PISTON INCREASES PRESSURE COUNTER CLOCKWISE DECREASES PRESSURE 3 LOCK PISTON IN PLACE USING JAM NUT AND REPLACE CAP PERFORMED WITH ONLY WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PULL TO ENGAGE PORT B 118 7 E REFER TO MARINE TRANSMISSION ASSEMBLY DRAWING OR BILL OF MATERIAL FOR VALVE MOUNTING AND SCREWS Q F SERVICE KIT K1550 UPDATES LOWER VALVE BODY TO INCLUDE 2051 ORIFICE TO ALLOW PUMP TO PRIME DURING INITIAL START UP 2 VALVE ASSEMBLY PRESSURE 2 SPRINGS TEMP PLUG PROPORTIONAL IDENTIFIER SENSOR VALVE PSD 1020941B 42605 172 250 PSI 201341YX 1016122A 1018528 250 1020941 4261
19. shorted together or low coil current Both red light 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 soeed 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 1022294 Twin Disc Incorporated Troubleshooting Table 17 Troubleshooting Chart 1021658 and 1020941 GP Control Valves with Electronic Interface Symptom 1 Low main oll pressure No oil pressure or erratic low pressure at control valve tap Cause 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 5 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 Marine Transmission Service Manual 1022294 Remedy Remove and clean oil strainer Adjust the Main Regulator Valve Replace the Main Regulator Valve spring Remove the collec
20. NES peces 1017000 SHAET IDETIREQ DESCRIPTION STOCK SIZE oa Ld _ y amp DET 8 ADDED OUTPUT FLANGE FIXTURE DEL terns pice SHT 3 ADDED amp MG 5301 CAD FILE 21433 ___ Tw DSC NG _ 21433 5 00 1 8 THREAD 100 1 274 DRILL 7 8 68795 DIA THRU 1 8 1 REQ D E DRILL 29 32 906 DIA THRU 03 x 45 06 x 45 52 REQ D FOR CLEARANCE 926 5 THREADED ROD REQ D FLAME HDN AS SHOWN 926 2 1498 1 498 5 NN J DRILL 1 1 8 11252 DIA THRU 5 REQ D FOR ROD CLEARANCE DRILL 2 00 DIA 82 REQ D FOR EASIER LIFTING KNURL 6 75 6 00 1018363 n BEARING ASS Y 1 62 M2950 BEARING ASS Y 12 x 30 7 00 DIA WELDMENT ASS Y 1 1018372 WELD NORMALIZE amp HARDEN M CAD FILE 21506 MAT DRILL ROD THREADED STOCK FLAME HDN FLAME HDN 0 62 SQUARE 03 x 45 PEN I 0 50 250 375 7 8 8 THREAD 7 25 8 06 1 00 DIA n U CUT 12 x 1 75 THREAD 3 ROD 5 REQ D MAT FIRM X FLAME HDN AS SHOWN GRDUND SURFACES MUST BE PARALLEL WITHIN 0005 DF EACH UNLESS DTHERWISE SPECIFIED BREAK ALL SHARP CDRNERS a ______ _________ 5 1 STK THREAD
21. T 36 00 Co 24 75 R4 69 6 00 01 R4 41 007 01 TARE WT 120 LB APPROX 2 TOL 1 16 X TOL 060 XX TOL 040 XXX TOL 010 20 53 C SINK FOR 172 FLT HD SCREW IAUTOCAD FILE14 19987 2 2 90 CH 5 00 9716 0 20 T CD 0 25 TL 1 1998 CAPACITY 200 LBS a onto us 201 WEST 155TH STREET SOUTH HOLLAND ILLINOIS mE HORIZONTAL GEAR LIFTER E E 944770 rA JPL reas LIFTING FIXTURE 1L MG e ee eee ee l 1 19987 2 wear SIZE 45 49 ft 1 4148 PLATE Re 45 49 91350 x 238 JE PULLER 2 x IBA 1 HYD CYCLINDER MOTION IND DRILL 00 94 THRU A HC 41045 REQ I EQUALLY SPACED DRILL THRU amp 3 4 SOC HI CAP SCREW 4 REQ D AS SHOWN DRILL 6042 DIA THRU TAP 1 13 UNC lt 1 71 0 39 DET 1 4140 HDN 45 49 DET 3 225 7 8 9 UNC FLANGE NUT 7 8 9 THD BOTH ENDS DET 2 MAT 4140 006 x 45 HIN 45 49 Rc HIER 00556437 1 00 __________________ 1 00 1 39 37 16 pm 4 TWIN DISS E INGEEPORATES INCH OUTPUT GEAR PULLER Rileungh 20023 4 S 7 MEX S32IE rm 20023 4 AUI ff Hoah 1
22. 126 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Preliminary Assembly 1 Lay the transmission housing on blocking with the rear side up 2 Install the chilled cups for the primary and secondary front tapered roller bearings into their respective bores in the front inner face of the housing Use driver T 18050 711 to press drive cups to the bottom of the bore It is important to maintain downward force as temperatures equalize to ensure that cup is at bottom of bore Figure 77 Front Pinion Bearing Cup Installation d Measure and record the distance from the machined surface of the housing to the bottom of the output shaft bearing cup bore where the oil distribution shield contacts dimension Measure and record the thickness of the oil distribution shield at the outer edge dimension B Measure and record the width of the bearing cup dimension 4 Install oil distribution shield into output shaft front bearing bore Be sure shield is properly centered Marine Transmission Service Manual 1022294 127 Assembly Twin Disc Incorporated 5 Install chilled front output tapered roller bearing cup into housing bore Use driver T 18050 771 to press drive cup to bottom of its bore Note Care must be taken to ensure that the shield remains centered Tighten puller rod to standard torque limit for thread size of puller rod or 275 Nm 200 ft lb whichever is less Maintain this to
23. 1990 PISTON 1399 SPRING A2702T SHIM 1020005 lt AS REQ D5 DITCH PLATE SEE CHART SCREW SEE CHART SCREW 1042 4 BY CLUTCH ENGAGED FOR POSITION CFWD NEU REV USE NEUTRAL FOR 3 POSITION CF WD NEU REV _USE DR DISENGAGED FOR 2 POSITION CENGAGED amp DISENGAGED USE APPLY 895 lt THREAD SEALANT WITH TEFLON 9 TO THREADS TORQUE TO 30 0 lbf ft 40 7 N m PLUG M2080A 34 28 M NUT M2027C R SCREW M2000L PORT DITCH VALVE SPRINGS CLUTCH SHIMS MOUNTING SCREWS DATE VALVE BOM DITCH TRANSMISSION ORIFICE x FIRST PLATE STEM PISTON CONSISTS OF kPa CPSD AND 2 GASKET GASKET ASSY ourer m ge m iii parT wo R x S x 1017172 40770 1017133 1017134 B1337F 10181638 1018688 7072 427072 7 1725 250 10171298 MA1038EQ7 X 20 60 24518 o 10171724 40772 1017383 10181638 1017179 A2707BD 2704 0 2415 350 1017129 10 8 7 x 20 69 B2451B 5 MG 6619RV 451 173 2 732 2 MG 540 msme 10171720 4083 1017383 10181638 1017179 Ae7t pu 2655 985 1017129A 10 8 7 x 20 68 B2451B 5 MG 6449 msme 071720 4150 1017383 101816
24. 236 1029941 Control Valve 237 102058S3E Troll 238 1020585 Profile Module eee eee 239 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc MG 5321DC marine transmission Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wisconsin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and application of the material in this manual will result in consistent performance from the unit and help reduce downtime Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Inc will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unacceptable maintenance working practices 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 resul
25. Max Min Act Min Act Min Act Max Temp kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa psi psi psi psi psi psi psi psi psi F lewe 2 310 285 2140 1960 100 380 lew o Jesl lal lel _ bala dol dio 150 0 0 40 65 000 1860 0 69 0 270 0 10 1 2000 0 1860 69 mI lal 255 310 0 20 140 al le ol lol l l l l _ Cooling Temperature Range Delvac 1110 oil 29 35 C 85 95 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 Faulty valve springs sticky valve pump flow too low wrong valve spring shims or quantity of shims leakage broken forgotten or cut seal rings Primary and 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 1860 270 8 19 8 8 5 0 5 0 6 6 26 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications Table 4 Limits for Marine Transmission Equipped with 1017546F or 1018084 Control and Trolling Valve with 2000 kPa 290 psi Spring Trolling valve in minimum trolling position amp control valve per shift given below 600 rpm in
26. The use of proper safety equipment is mandatory when working with high pressure hydraulic tools The parts may separate with extreme force 2 Install the oil injector into the output flange at the O ring plug location Note that the threads are 1 4 19 BSP Figure 32 Output Flange Oil Injection Plug Location 88 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 3 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature into the flange hub until the flange separates from the output shaft Remove the oil injection equipment Remove the capscrews washer shims and output flange Figure 33 Removing Output Flange Retainer Note Use caution to prevent damaging the taper of the output flange or shaft as the torque capacity can be reduced 4 Hemove 15 M16 x 40 capscrews and washers and remove the output seal carrier Figure 34 Removing Seal Carrier and Shims o Press the oil seals out of the seal carrier and remove the O ring from the seal carrier 6 Remove the output bearing cup and adjustment shims Marine Transmission Service Manual 1022294 89 Disassembly Twin Disc Incorporated Remove and Disassemble Manifold and Bearing Carrier 1 Remove four M12 x 40 capscrews and remove the primary shaft end cover plate and O ring 2 Remove 26 M12 x 60 and four M12 x 75 capscrews with washers that retain the manifold to the main housing Remove nine M12 x 35 capscrews
27. WASHER MA1039D A 7 ZA OPTIONAL FLANGE ASSEMBLY COMPANION i 2 1019642 W SHAFT BRAKE PINION 4557 1021191 lt gt HOUSING 1017013 gt 1017007 _ PINION 1017644 2 4 GEAR 1017643 5 961 RATIO 24T SHIELD 1017032 PINION ASS Y 1022516 2 G SHAFT 1017000 5 461 RATIO 26T SHE YA BEARING M2909 N A EN 4 961 RATIO 287 TA cc NE Nas TE PINION ASS Y 1017111 2 3 SEAL 1017085 2 gt CARRIER 1015340 SCREW 1041 152 RING A2916DA SHIM 1017038 SHIM 1017039 AS REQ D SEE NOTE 4 SHIM 1017040 GEAR 1022494 6 39 1 RATIO 115T GEAR 1022492 3 9611 RATIO 143T GEAR 1022517 5 461 RATIO 142T GEAR 1022489 A 4 961 RATIO 139T GEAR 1022490 BEARING M2950 4 4211 RATIO 137T HHE ASS Y MA585DC GEAR 1022491 590 4 061 RATIO 134 CN GEAR 1022493 3 3511 RATIO 154T PLUG MA1040A SCREW MA1052B 42 SEE NOTE 7 GEAR 1022348 CUSTOMER NOTES a gt OIL CAPACITY 37 9 L lb THIS UNIT CAN NOT BE USED WITH A LEFT HAND ENGINE c OPTIONAL EQUIPMENT REFER TO BOM PRODUCT LIST NOT SERVICEABLE SEPERATELY AREMOVE BEFORE OPERATING 2 PLACES CLOSURES REQUIRED FOR USE OF 1022307C E TROLL MODULE LI EQUIPPED WITH NEUTRAL SOLENOID 1 G F E WASHER B1504GF GEAR 1017107 x 1
28. 22 NEUTRAL SOLENOID SPRING A2705AH 2 PIN A2711R 2 WITH OR WITHOUT HYDRAULIC LOCK SO SPRING ASSY SEE CHART PISTON B1399H BALL M1990M 12 SEN SS NS e SHIM SEE CHART 4 A PLATE SEE CHART SSS N ZN ES 56 N 2 1017128 Re SER NNNN 2 NRD T NA p HERA PS Bah SSS Nu SEN AA DN 1 STINE EN GASKET 1017334 GASKET 1017130 BALL M1990H SPRING A2702T SHIM 1020005 AS REQ D SECTION B m B SPRING 1801 SETSCREW A2870K LAO SECTION C gt BALL 1990 0 RING A2916DK 1927 SEAT 1017524 DITCH PLATE SEE CHART MAIN PRESSURE PICKUP PORT SWITCH 866 PORT 1 4 18 DRYSEAL APPLY MA895 THREAD SEALANT WITH TEFLON 9 TO THREADS Wace La 300 lbf ft NUT M2027C SCREW 1042 4 INSTALL USING MA908 LOCTITE SCREW M2000L 242 TOP OF SCREW MUST BE FLUSH WITH SURFACE 1 EE 8 E amp LEVER E X STR TH D D RING lt 1506149 MAIN PRESSURE DIL INLET WHEN INTERNALLY SUPPLIED THREAD SIZE AT PORT 1 4 18 WHEN 2052 REDUCER BUSHING IS SPECIFIED VIEW a
29. 47679 NOTE STAMP TOOL 18050 708 PART NO BREAK ALL SHARP 2205 T E TOLERANCE UNLESS OTHERWISE SPECIFIED 001 ON THREE PLACE DECIMAL DIMENSION 010 ON FRACTIONAL AND TWO PLACE DECIMAL DIMENSION CAD FILE T 18050 708 dwg 1 4 ANGULAR DIMENSION STAMP 1017005 PINIUN 06 R CI YP 1 18050 08BRG DRIVER tg A 0 75 sil i te pg 4 56 DIA 1 BEARING DRIVER 1 REQ D GROUND SURFACES MUST BE PARALLEL WITHIN 0005 UF EACH UTHER UNLESS UTHERWISE SPECIFIED BREAK ALL SHARP CURNERS Mose XU X 132 C x HD BEARING DRIVER 5 25 DIA x 168 DESCRIPTION STOCK SIZE TL p wenesepn PL ew sewer NAME BEARING DRIVER FUR 196446 0705 PINIDNISEET Ca vasso _____ 58057 HHee4346 BRG CONE 100502706 DESCRIPTION DATE TWIN DISC INC RACINE WIS 0 13 E 1 50 DIA 6 REQ D DRILL 5 16 31052 DIA THRU 3 8 16 UNC 2 REQ D DRILL 3 8 37 52 DIA THRU 1 HOLE USE FOR PICKING BRG DRIVER UP 2 79 138 KNURL FULL LENGTH OF SHAFT STAMP T 18050 711 BEARING DRIVER FOR INSTALLING 2 CUP 1017081 100 DIA 12 x 45 06 x 30 2 du oS m v Mw DIA 748 SF DIA S F DIA BEARING DRIVER lt 1 REQ D MAT CARB amp HDN2 NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005
30. CIRCULAR SPACE mmer MEASUREMENT BETWEEN vanacr nerl 9574 DIA WITH EL TU FLAT eD 2600 SPLINE DATA IN INCHES Ex S FITTING MA1053L 0 LOCATION OF PLUG A IN HOUSING SEE NOTE 1 PLATE A4480Q 8 SCREW 961 42 SPRING B1783N 7 HOUSING 1017824 RACE 202265 HOSE MA1147J PLATE 44814 7 SHAFT 1017827 PLATE 2012 A SEE NOTE 9 BACKPLATE 1017822 RING 1904 HOSE MA1147L SCREW M422 FITTING 10531 2 gt CLOSURE M2067B BEARING 2898 RING 1017826 RING 1048 RING M2916KD ADAPTER 1017821C SAE J744 No 38 45 BEARING M1989 RING 2915 Nh a 2 REN 29 4 E RA HHHH E 5 LEON e rant S HANS SS 5 AE A TS o t ENS 16 Tu NS 5 SS NN EA I A R Sask Ea E al z T 2m x 5 ES S PLUG 1945 1017823 ADAPTER 1017821 Ls SAE J744 No 32 4 7 238 00 PISTON 1017825 RING 1048 RING M1904L BEARING M2087P MANIFOLD FACE SCREW MA1062C lt 2 RING A2916FW RING M1904C ADAPTER 1017834 PLUG MA1038B lt 2 NUT MA947B 4 STUD 1049 45 Gee a rd A START THE PLUG INTO THE
31. FPN FuLL po men Ee T 21433 5 PULLER BASE D NEQ D UNLESS OTHERWISE SPECIFIED ALL GRD DIA S amp SURFACES MUST BE A eo ANGE FI RE ae MAT MS 45 49 RO BREAK ALL SHARP CORNERS SQUARE amp CONCENTRIC TO WITHIN Hr 005 OF EACH OTHER SHT 3 ADDED MG 5301 CAD FILE 21433 1 RETRACTED LENGTH 2 75 15 12 OF PRESS 12 x 45 DRILL 5 16 3125 DIA x 125 DP 3 8 16 x 100 DP REQ D 180 USE FOR LIFTING 25 R 06 x 45 244 MID STROKE 522 4 C em m _ 1 4 me e 7 7 1 o CTYP D 7 E EL T m 7 UNLESS OTHERWISE SPECIFIED REF BREAK ALL SHARP CURNERS NOTE REWORK DET 5 ALL GRD DIA S amp SURFACES MUST BE SQUARE amp CONCENTRIC WITHIN TO DIMS 005 OF EACH OTHER peur m FEEDS poem END N E LLL GN 45 49 1 ms PUSHER PLATE 67 x eod LG __ E REWORKED TO THIS DRWG SEE 5 2 5 1 5 PULLER s 5 soc HD SCREW x 175 80 MM LG SEE SHT 2 3 1 ja340H PULLER ROD
32. I 7 x HOUSING 10 5341 SS US WX MANIFOLD 1015338 ASSN RIS TUBE 1022350 2 EE MQ SHIM 1017041 LEA UP WD o OO VD SS NWA S O JTN GASKET 1017589 222 0 uuum N SHIN SERE as REQD SEE NOTE 4 SS N e E BEARING 1017081 8 HEY we Off WE SEK 7 S ee 10175844 CONE ASSY MASBSHN 7 77 A 2 NN SPACER 1017046 lt 2 SSS ZNN 0 a RING A2915CG 2 N Sg ZZ 7 wa i AG NN Y N 2 NIN N x N RING pm ETT 77772 7744 S SET N NN SS SEE DETAIL S INSEE NUN SONNO NIIS te te id ES e ASK SS Qo wu NSSSNNNNNEASNI EEE EX gt e Ne PLATE 1015518 VN mA 2 RRA sep SHAFT ASS Y 1019954 OOOO ADAYA RAE Sen 64 ANB 6 p 1019953 SS 22224 gt a p BALL 1034 Ae RING M2693S YY 2 SERE E du 5 5 S BEARING MA217K 2 Eo 222227224 RING MI904FS lt 2 Senn ero SCREW 996 4 SS PISTON 1019950 2 NS RING A2916HP RING Me059L lt 2 COVER B2502B PIN 1035 2 l ail VENUS H wf PLATE 212754B SN SRR SCREW 996 20 7 ae S TRA FLANGE 10170094 2225 Ces ux E SCREW MA996E 722 Y EE I
33. 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 148 Checking the Flywheel Pilot Ring Bore Eccentricity 186 Marine Transmission Service Manual 1022294 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 lf the length of the shaft from the last support bearing to the gearbox 15 excessive or a flexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Engine and Marine Transmission Proper alignment of an engine and marine unit 15 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 alig
34. Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil 75 Troubleshooting Twin Disc Incorporated Troubleshooting of GP Control Valve with Electronic Interface 76 General The transmission 15 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 16 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 low MG Units Only Valve coil leads coil current
35. SEE NOTES 8 amp 4 CUSTOMER SUPPLIED SOLENOID B ON RED LED ILLUMINATED INDICATES VALVE COIL COMMANDED ON CE EDS CUSTOMER SUPPLIED INE RED FLASHING INDICATES AN OPEN CIRCUIT IN AN ENERGIZED VALVE COIL CIRCUIT VALVE COIL LEADS SHORTED TOGETHER OR LOW COIL CURRENT GREEN A DTE WIRING DIAGRAM lt OPTION e RED LEDS FLASH SIMULTANEDUSLY AFTER ENTERING TROLL FROM NEUTRAL WITH BOTH VOLTAGE USED IF ELECTRONIC PROPULSION CONTROLLER AND CURRENT TROLL SPEED SIGNALS PRESENT OR WHEN POWER IS APPLIED TO SOLENOID A GREEN 1 PROVIDES SWITCHED BATTERY POSITIVE AND SWITCH INPUTS AT THE SAME TIME TAN TEMPERATURE SENSOR DIRECTION OUTPUTS RED ALTERNATELY FLASHING INDICATES EITHER OR BOTH SPEED SIGNALS MISSING FAN 200 250 CONTROLLER SHOWN AS EXAMPLE TAN 1 0 ENGINE SPEED SENSOR NOTE 1 WHEN TROLL SPEED CURRENT INPUT IS USED TO CONTROL TROLL SPEED RED THE ORANGE AND GREEN TROLL SPEED POTENTIOMETER INPUT WIRES MUST BE POWER OK BROWN ELECTRICALLY CONNECTED TOGETHER WITH A SOLDER SHRINK CONNECTOR AND SECURED GREEN LED PROPELLER SPEED 3 THE RED WIRE MUST BE INSULATED AND ALL 3 WIRES SECURED GREEN NOTE 2 WHEN TROLL SPEED VOLTAGE INPUT IS USED CONTROL TROLL SPEED BLACK DH i NORMALLY CLOSED THE VIOLET AND GREEN WIRES MUST BE INSULATED AND SECURED SURE SOLENOID A IN NEUTRAL RELAY NOTE 3 PROPELLER SPEED SENSOR MUST BE TWIN DISC SUPPLIED PART MP CLOSED IN NEUT
36. T 8050 771 m 5301 18050 771 STAMP 19330 MG 540 X 9882 A SPRING 2 08 1 2 CLEAN UP RING PLATE WELD 6 PLCS SYMBOL CHARACTERISTIC SYMBOL MODIFIER 27 FLATNESS M MMC MATERIAL Sma T 17710 38 PARALLELISM S CONDITION T 2 RFS REGARDLESS OF 20 PERPENDICULARITY EGARDLESS CONCENTRICITY CIRCULAR DATUM FEATURE SYMBOL NAME 001 ON THREE PLACE DECIMAL DIMENSION AA AUTO CAD F LE N 1 2 50 010 FRACTIONAL AND TWO TOTAL RUNOUT RS DECIMAL DIMENSION E 1 4 ANGULAR DIMENSION POSITION DIAMETER 1 4 20 THD X C 8 DEEP ee PECS A REV STAMP 19330 DET 2 X 9882 4 20 27 THRU MG 540 SPRING 42708 AM 58 C SINK 827 OS PLCS 3130 27 00 05 375 20 27 THRU 156 0 258 BC SINK 82 QF 6 r 3 PLCS Cj ae sk FN m SCR 1 4 20 THD X 10 3 3 ws SUPPORTBARS A 43 4 X 20 1 NAME SPRING DE COMPRESSER onic Goo POL e O O OOO CAD_DRAWING FOR DESCRIPTION E 7 que e 7 00 2 00 r 263 2 00 SECTION BY anh CA 675 3 00 E X 2 X 16 TUBE TYP ALL LUCATIUNS 18 25 277 3 16 D amp T 1 2 PLCS lt UEM E 45 9 g
37. 0 006 inch specification Arrange the shims such that the thinnest shims are in the center of the shim pack Remove lifting fixture Remove output seal carrier Install O ring in groove in O D of output seal carrier ih fru J A Figure 90 O ring Installed onto Output Seal Carrier Marine Transmission Service Manual 1022294 137 Assembly Twin Disc Incorporated 10 Install oil seals into output seal carrier using driver T 18050 713 per the following description A Install forward seal with spring loaded lip toward the inside of the transmission Start inner seal with flanged side of driver T 18050 713 facing down and complete its installation with tool inverted as shown below B Install rear seal with spring loaded lip of seal toward rear of the transmission Install flush with outer face of seal carrier with driver T 18050 713 NOTE START FIRST SEAL INTO CARRIER WITH SEAL DRIVER FLANGE DOWN INSERT THIS SEAL FIRST AS SHOWN SEAL CARRIER 7 OIL SEAL FLANGE DOWN PRESS 2 FLANGE UP PRESS SECOND SEAL Figure 91 Output Seal Driver T 18050 713 138 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 11 Pack area between the seals with NLGI No 2 grease example Mobilux 2 Figure 92 Packing Cavity Between Output Seals With Gre
38. 1016987 MODEL NUMBER MG 5301 10 x 45 0 75 NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CURNERS 1 CLUTCH PICK UP PLATE RERI NOTE GROUND SURFACES MUST BEPARALLEL MAT MS amp WITHIN 005 OF EACH UTHER CWO JERGENS 18504 OR EQUIV e oe extension SIA x 42515 1016987 CLUTCH SHAFT FE STAMP TOOL NO T 18050 715 NAME PART Nd 5301 T CLUTCH PICK UP FIXTURE rede RN CLIP W8 5301 0 709 ae 106987 SHAFT pu women CAD FILE T 18050 715 0wg MARK 18050 03 FUR PART 628 BEARING TO SHAFT 1016987 38 DIA 02 REQ D 06 45 1 00 ZZZZZZZZZZZZ N X L T Te __ IL i 272 777777 3 563 a 14 18 NOTE UNLESS OTHERWISE SPECIFIED EE dez BREAK ALL SHARP CORNERS p msg 1016987 SHAFT i NOTE GROUND SURFACES MUST BE 10 x 50 1017010 SHAFT PARALLEL WITHIN 0005 OF EACH OTHER 1 lt 1 REQ D 1016993 GEAR SEE DEITS FOR CARB amp HDN MS 7 475 THK 1016994 GEAR I TREAT sen is at ee ud __ DETIREGL MAT _____DESCRIPTIUN Stock SIZE 216987 SHAFT ee irum pup seii BEARING CONE DRIVER wr ors i lazo SHEET 1 OF 1 lorzoo 1016994 a OVER 02 50 6 HOLES THRU EQUALLY SPACED R
39. 15 METRIC PORT CONFORMS TO ISO 6149 PRIMARY CLUTCH SHAFT INPUT SPEED SENSOR 5 8 18 UNF THREAD RH ENGINE ROTATION DRIVEN THRU PRIMARY 733 4 3740 325 00 9 200 000 0025 PILOT 866 25 0 OUTPUT SPEED SENSOR LOCATION LESS OTHERWISE SPECIFIE DIMENSIONS ARE mm MACHINED DIMENSIONS x 10 75 FILTER CONTROL VALVE TRAILING PUMP TO DISPLAY LAYER TURNED ON LAYER TURNED OFF ___ pro HYDRAULIC LIVE PTO MANIFOLD CDVER ee 12 TWIN DISC SUPPLIED RAW WATER HEAT EXCHANGER FRESH WATER HE ROW WATER PME PLATE CUST HE RAW WATER HE FRESH WATER HE TWIN DISC SUPPLIED FRESH WATER FRESH WATER HE PLATE CUST HE HEAT EXCHANGER CUSTOMER SUPPLIED HEAT EXCHANGER RAW WATER PLATE CUST HE NO CLOG INDICATOR CLOG INDICATOR 7 CLOG INDICATOR 0 INDICATOR NO CLOG INDICATOR CLOG INDICATOR 1017172Q 1020941C 1018084 1020941C 1018084P 1018084Y amp 1017172Q 1018084AV 1018084 1020941C NO CLOGING INDICATOR CLOGING INDICATOR 1020941C NO TRAILING PUMP TRAILING PUMP TRAILING PUMP NO TRAILING PUMP NOTE FOR CLARITY BEFORE OPTIONAL LAYERS ARE TURNED ON TURN OFF DIMENSIONS NOTES LAYER 2 r 5 4 SAE 0 3 s HOUSING e 797 6 Me4 X 3 0 THREAD 40 0 DEEP
40. 2 APPLY MA895 THREAD SEALANT WITH TEFLON TO THREADS CEMER ss TORQUE 30 0 lof ft P MAIN PRESSURE PICKUP PORT 40 7 N m 1 4 18 DRYSEAL T __ 492 5 28 03 NOTICE THIS PRINT CONTAINS MATERIAL UNLESS OTHERWISE SPECIFIED 1 DIMENSIONS ARE mm us 31 98 s 1102 PRUPRIETARY INFORMATION AND IS DIMENSIONS ARE mn 4 eT VE ME MENS or m A XO ERES 10465 10 26 01 FIRST USE RACINE 17839097 05 STR TH D D RING 15061490 TWIN DISC INCORPORATED ASSY 1015207 ALL ANGULAR TOLERANCES 31 MAIN PRESSURE DIL INLET WHEN 6 20 01 RACINE WI 53403 USA GEOMETRIC TOLERANCING eS NOT INTERNALLY SUPPLIED PY 4 4 18 01 MODEL _MG S202DC PER ANSI 14 5 1982 THREAD SIZE AT PORT THIS NOTICE IS NOT INTENDED SURFACE TREATMENT NAME 1 4 18 N P T F WHEN 2052 257 0 5 4 TO NULLIFY OR LIMIT RIGHTS j EKIS REDUCER BUSHING IS SPECIFIED BOTTOM VIEW 6 30462 11 16 00 GRANTED 0 THE US GOVERNMENT VALVE ASS Y CONTROL Rev wa mare c OR OTHERS CONTRACT WITH TROLLING VALVE EX 4 F E D B MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp 10 00 TRANSMISSION IS IN NEUTRAL MAX I 20 A PLUG M2051K 2 ff
41. 20 HOLES 10 EACH SIDE USE ALL 20 HOLES FOR MOUNTING UNIT USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 5574 OR SERVICE MANUAL VALUE 7 27 05 TWIN DISC INCORPDRATED RACINE WI 53403 USA METRIC PP JM THIRD anae MG 5321DC 1015 339A F MARINE TRANSMISSION ALC ao A P PROJECTION B OPTIONAL TRAILING PUMP OPTIONAL TEMPERATURE SENSOR PORT M14 X 15 M14 X 15 L LUBE RELIEF VALVE PRIMARY SECONDARY 828 kPa CLUTCH CLUTCH 6 SPRING RELEASED CLUTCHES OPTIONAL HYDRAULIC PTO LUBE TUBE q Y PROPORTIONAL VALVE X I Q I 2 E a ga W i T PROPORTIONAL VALVE LLL 5 H Pg PROPORTIONAL VALVE 4 2 gt gt I Di a bo pm NE 1 d eu ti ERE vi 1 L 65 lt p 9 jj KP r1 REIT PRESSURE REGULATOR F 5 T2 i S 1 MANUAL DIRECTIONAL TWIN DISC OR CUSTOMER SUPPLIED BOR EDA AVE Ee HEAT EXCHANGER A
42. Assembly 7 Install clutch apply piston into piston bore in transfer gear Figure 94 Installing Clutch Piston Marine Transmission Service Manual 1022294 143 Assembly Twin Disc Incorporated Assembly of Clutch 1 Install clutch return springs A Install 16 clutch return springs into pockets in face of clutch apply piston Install spring retainer over springs with groove toward springs Working through holes in retainer use a small punch or probe to assure that all springs are in pockets in face of piston and that springs are aligned correctly stand straight up E u L x m Figure 95 Return Springs and Spring Retainer Ready for Installation 144 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly C Install external retaining ring over shaft to rest against spring retainer Move shaft assembly to press and install tool T 19330 Press down tool 19330 to compress springs and expose retaining ring groove of shaft Keep force on springs and install retaining ring into exposed groove of shaft Figure 96 Installing Spring Retainer Retaining Ring D Slowly release force on springs assuring that spring retainer counterbore covers retaining ring and prevents retaining ring from coming out of the groove Remove tool 19330 2 Install the pinion rear tapered roller bearing cone onto the shaft Note This bearing is a slip fit and will not require special too
43. E NE ADAPTER 10178354 SAE J744 No 32 4 MiG X 20 TAP THRU METRIC SAE J744 No 127 2 127 4 FLANGE AND ES 4 HOLES APPROVED INPUT TORQUE SAE 744 32 4 PUMP DRIVE ADAPTER PUMP ADAPTER IS 1187 N m c THIRD ANGLE SHOWN BELOW CENTERLINE A TuS PLUG IS USED DNUY FORC FACTORY INSTALLATIONS DF AN AUXILIARY ior eer TEMA NE aoa ee CARRIER 1015932 PUMP DRIVE WITHOUT AUXILIARY PUMP INSTALLED PUMP ADAPTER IS 592 N m ANERUBIC SEALANT M2828 TO PLUG OD PER S774 AND INSTALL PLUG CDNSULT SALES DEPT U RING A2916KD FLUSH WITH REAR SURFACE DF CARRIER den dM SECTION m A THIS PRINT CONTAINS MATERIAL ilL 75 ae 1 11 18 96 CAPSCREW 40 O MER USD IV AV AN DUET ERE BES TWIN DPE lt RACINE WI 53403 USA B TWIN DISC INCORPORATED DRN 742 46 uae S S sn assy 1017020 41 ANGULAR TOLERMCES a Bj i a9757 i12 1 99 THIS NOTICE IS NOT INTENDED 1 2 1 a we D I M E N S I N S A E 5 G 56 TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME G R U P MOUNTING FACE 2815910 1 2 GRANTED TB THE US GOVERNMENT APPD ev aer aer BY CONTRACT AUXILIARY PUMP DRIVE F E D CLUTCH ACTUATING LOCATION OF DRAIN HOLE 1 THREAD PORT CONFORMS ISO 6149 SCREW MA996D 8
44. EACH OTHER Ss er 1017085 OIL SEAL DET JREG DESCRIPTION STOCK SIZE 1017019 CARRIER sien ff SEAL DRIVER 5301 SHEET 1 ____ ee 18050 SED DRILL 21 32 6563 DIA THRU STAMP TOOL NUMBER 1805 714 374 10 UNC CD SHAFT NUMBER 101 000 MODEL NUMBER MG 5301 1 575 0 487 1 074 REWORK 2 NOTE SPOT WELD amp LOCATE SHLD ER EYE BOLT AS SHOWN 0 926 DRILL 1 2 5000 DIA THRU 5 REQ D AS DIMENSIONED 0 926 NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 12 45 450218 x NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF EACH OTHER PICK UP PLATE Reo MS CARB amp HDN2 REWORK JERGENS 18506 OR 2 1 PUR JERGENS SHDER EYE BOLT 374 10 UNC CARB amp STAMP TOOL 18050 714 I SHAFT PICK UP FIXTURE _ ee _ FUR 5201 ON THREE PLACE ceo ee eee 1017000 SHAFT CAD FILE 050 714 T 18050 714 NOTE SPOT WELD amp LOCATE DRILL 27 64 4019 DIA THRU SHD ER EYE BULT TAP 172 13 UNC CD REQ D WELD RUD TU DRILL 1 2 500 DIA THRU PLATE AS SHUWN C2 REQ D AS SHOWN AS UN EDGE ONLY BOTTOM 6 00 0 709 STAMP TOOL NUMBER T 18050 715 SHAFT NUMBER
45. Fine and Coarse Thread Capscrews Bolts and Nuts Thread NI ON L 6a sew 4816 79 970 1132 615 735 850 1000 1163 1355 9 16 82 98 111 132 120 140 163 190 Marine Transmission Service Manual 1022294 31 Description and Specifications Twin Disc Incorporated Table 13 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs WEN Diameter Diameter Op sme NO O1 NO O1 iN O 32 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications Table 14 Tapered Pipe Plugs with thread lubricant Torque Values for Lubricated Pipe Plugs Recommended Torque in Nm ft lb NPTF Size Installed in Cast Iron or Steel Installed in Aluminum 1 16 28 1 16 27 11 5 1 3 8 5 1 0 7 5 0 9 5 5 0 7 1 8 28 1 8 27 14 2 1 8 10 5 1 3 8 8 1 1 6 5 0 8 1 4 19 1 4 18 34 4 25 3 22 3 16 2 Note The lubricant is to John Crane insoluble plastic lead seal No 2 or equivalent or Loctite No 92 or equivalent and plugs are to be capable of removal with out damage Overtightening may cause initial leakage plus potential removal damage An option of a maximum of two full turns after finger tightening the plug may be used if required and if removal conditions are met Clutch Plate Wear Limits Clutch Steel Plates Maximum con
46. 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 transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine Remove clutch plates Check and adjust control Inspect repair or replace parts as Inspect repair or replace hydraulic lock spool Twin Disc Incorporated Troubleshooting Table 15 Troubleshooting Chart continueed Mechanical and Electric Control Valves 7 Harsh engagement 8 Oll spilling out of breather 9 Oil spilling out of breather Regulating piston or rate of rise piston stuck Orifice plate ball in control valve not seating properly Blown gasket on either side of orifice plate Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Marine Transmission Service Manual 1022294 Disassemble control valve Clean parts Replace parts if necessary Remove orifice plate cover Clean parts Replace parts if necessary Replace gasket Replace pump Remove clean inspect and install suction screen Inspect and correct cause of suction leaks
47. MG502 MG5005 MG5010 MG501 1 MG5012 MG5015 5020 e MG506 MG5061 MG5062 MG5065 MG5050 MGO cL e MG507 MG5081 MG5085 5090 MG5075 MOSUST e MG5112 MG5113 MG5085 MG5090 MG509 MG 5111 MG5114 MGX5114 e MG514C MG514M MG5141 MG514CHP MGX5135 MGX5145 5147 MG520 1 MG 5202 MG5203 MG5204 MG5205 MG6449 557 e MG530 MG530M MG5301 MG6650 MG6690 MG6848 MG6598 MG6600 MG6619 MG6620 MG6984 MG61242 MGX6650 MGX6690 erigi i EC e MG540 MG5506 MG5600 e MGN80 MGN232 MGN233 MGN272 MGN273 MGN332 MGN334 MGN335 MGN432 MGN433 MGN472 493 e MGN650 MGN800 MGN1000 MGN1400 m PUMP ALL MODELS e VALVE ALL MODELS November 30 2005 R amp R UNIT REBUILD CLUTCH REPAIR 8 0 11 0 12 0 17 0 29 0 28 0 32 0 32 0 32 0 62 0 32 0 62 0 BOTH PACKS 6 0 8 0 10 0 10 0 16 0 20 0 10 0 40 0 TDWP2003A rev 2005 Twin Disc Incorporated Table of Contents Table of Contents Introduction 11 General 11 Safety and General Precautions 11 Preventative Maintenance
48. OF EACH OTHER a 222 2222 21 4 1 PUR JERGENS WASHER 32004 NOTE UNLESS OTHERWISE SPECIFIED 3 1 stk soc SCREW 3 8 16 1016 OC E ee BREAK ALL SHARP CORNERS CANCELLED amp 1 1 MS BEARING DRIVER _ 875 DIA x 138 IREGL MAT DESCRIPTIIN STUCK SIZE 9 24 39 te te 23 96 e ew cates FULL BEARING DRIVER FOR cu FOR MG 5301 SHEET 1 OF 1 1017081 BRG CAD FILE 050 711 T 10050 7 DRILL 5 16 31252 DIA x 1 00 DP 3 8 16 UNC x 88 DP 1 REQ D 10 50 06 45 CTYPD DIA 1 05 REF 8 90 KNURL 12 12 R 9 54 06 R N X er 2 00 DIA 9 990 10 15 2 1 SEAL DRIVER CD REQ D DOUBLE DUTY DRIVER OTE PRESS SEAL INTO CARRIER WITH SEAL DRIVER FLANGE DOWN INSERT THIS SEAL FIRST AS SHOWN STAMP TOOL NUMBER T 18050 713 CARRIER NUMBER 10 019 SEAL NUMBER 1017085 MODEL NUMBER MG 5301 02 2 101 019 ES N 1017085 SEAL REQUIRED AS SHOWN FLANGE DUWN PRESS FLANGE UP PRESS IN FIRST SEAL IN SECUND SEAL NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CURNERS NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF
49. OQ DEUTSCH TERMINAL lt 2 TAN ENGINE SPEED SENSDR E ENGINE SPEED PART NO 0462 201 16141 RED 5V PROP SPEED DEUTSCH WEDGE LOCK lt 1 Z prop sPEED IN PART NH 25 012 ARANT srown LEN BEEN PROPELLER SPEED SENSOR Zeal ma DEUTSCH CONNECTOR lt 1 GREEN suas PART DT06 3S P012 BLACK 2 ss DEUTSCH TERMINAL 3 Js u NORMALLY CLOSED S ss em PART 0462 201 16141 BLACK SOLENOID A NOT IN NEUTRAL RELAY DEUTSCH WEDGE LOCK lt 1 CLOSED IN NEUTRAL ee PART W3S P012 5 SOLENOID CUSTOMER SUPPLIED Z METRI PACK CONNECTOR 2 RED B m PART NOL 12162193 METRI PACK TERMINAL lt 4 PART 12124075 SOLENOID A BLACK 200 mA MAXIMUM je WHITE OQ BLACK SOLENOID ENGAGE SWITCH YELLDW lt CUSTOMER SUPPLIED cS START SOLENOID ENGAGE SWITCH CIRCUIT CUSTOMER SUPPLIED TRANSMISSION Leal al ena SOLENOID RETURN OVERRIDE SWITCHES ME mE sene LUG RING Q E E E THOMAS BETTS 18 8 REF T D M2995K PINK TP CREE OUR 4 TROLL SPEED POTENTIOMETER 1K OHM aan eee LED INDICATORS ORANGE 0 0 TO 0 55 VOLT MINIMUM TROLL OPEN CRUISE MODE GREEN LED ILLUMINATED WHEN POWER IS GREATER THAN 9 0 VOLTS GREEN 4 9 50 VOLT MAXIMUM TROLL
50. PTO connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven whenever the engine is running Hydraulic Clutched Power Take off 1017820E The 1017820E model has internal splines and accepts an SAE J744 size C pump The hydraulic clutched PTO also allows accessories to be driven using engine horsepower Since the PTO 15 attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The PTO 15 engaged by closing a customer supplied switch The hydraulic clutched PTO operates with an engaged clutch pressure equal to that of the transmission s primary and secondary clutches The pressure is set by the main pressure regulator valve in the General Purpose Control Valve Marine Transmission Service Manual 1022294 59 Operation Twin Disc Incorporated Trailing Pump Optional The trailing pump is used to supply oil flow to the transmission lubrication circuit when the transmission is in a backdriving condition Backdriving Sometimes referred to windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller An optional mechanically driven trailing pump is available and is mounted on the lower left rear of the transmission Aserviceable suction screen is located below the trailing pump An optional electric motor driven trailing pump 15 available and oil
51. Pump Gear to Shaft 130 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Installation of Output Shaft and Gear 1 Clean tapered surface of output shaft and tapered bore of output gear Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Do not touch cleaned surfaces Loctite 7070 cleaner is recommended Before installing the output gear in the transmission housing confirm the potential advance is in compliance with the specification Place the output shaft into the output gear using T 18050 714 Seat shaft onto the taper of the gear using only the weight of the shaft Use gauge blocks and a feeler gauge to measure between the output gear and shaft shoulder This is the potential advance and it must be 9 45 mm to 11 00 mm 0 372 in to 0 433 in the shaft from the bore Figure 83 Measuring Output Gear Advance Note Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance CAUTION Tapered surface of shaft and matching tapered bore of gear must be completely free of grease oil dirt and solvent residue Failure to properly clean mating parts could prevent proper advance measurem
52. TWIN DISC SUPPLIED PART m MP CLOSED IN NEUTRAL NOTE 2 WHEN THE NOT IN NEUTRAL CIRCUIT IS NOT USED INSULATE AND SECURE THE A S EHE dp CUSTOMER SUPPLIED BLUE AND BLACK WIRES RED B MP NOTE 3 REMOVE WEATHER PACK CONNECTOR FROM EC200 250 SOLENOID HARNESS IF EC250 INSULATE AND SECURE THE BLUE AND BROWN WIRES OF THE BLACK 200 mA MAXIMUM zw ASM203452 HARNESS DEED DES MN BLACK BLACK WHITE SOLENOID DUTPUT SOLENOID HARNESS 200 1018045 SERIES YELLOW RED EC250 ASM203452 SERIES a GREEN SOLENOID OUTPUT SEE NOTE 3 START PART FACTORY SETTINGS CIRCUIT 2 TRANSMISSION MANUAL 1020585 SOLENOID RETURN OVERRIDE SWITCHES per 10205854 SEE PAGE 2 1020585B WIRING DIAGRAM 3 NOTE FOR USE ON NOMINAL 12 24 VDC SYSTEMS USED IF ELECTRONIC PROPULSION CONTROLLER PROVIDES SWITCHED BATTERY NEGATIVE DIRECTION OUTPUTS 185 THIRD ANGLE CONSULT TWIN DISC FOR MORE INFORMATION PRUSEN EN a C r p e l E mmm Ens nn 2 25 03 ECNI2521 NUT TO BE USED IN ANY MANNER SEE NOTE ka MAEHINED DINENSIENS k 1 EcNi3866 1 0 06 D t amp 2 1990 11 HEAT TREAT FIRST USE 422 WIRE SPLICE PART 1020282 J 1 _ ___ C i amp e 590 TWIN DISC INCORPORA assy Ae FEINER wma 1 Tr rouisea esto ispum ree au nur aen U RPS TO NULLIFY OR LIMI
53. Transmission Service Manual 1022294 123 Cleaning and Inspection Twin Disc Incorporated 124 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Assembly The MG 5321DC transmission requires the use of a SKF THAP 300 Oil Injection Kit See Special Tools or similar device to install the output gear onto the output shaft Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces The following discussion contains frequent reference to the transmissions parts and components Refer to Engineering Drawings Marine Transmission Service Manual 1022294 125 Assembly Twin Disc Incorporated Prior to Assembly Use the following reference The input side of the transmission 15 the front and the output side is the rear Left and right sides are determined by facing the output side of the transmission from the rear Identify and place the following bearing components an oven at 120 250 F for 30 minutes output shaft rear tapered roller bearing cone and the rear bearing cones for both clutch shafts Submerge all new friction clutch plates in transmission oil for a minimum of one hour prior to installation Identify and place the following bearing components a deep freeze 51 60 F for at least two hours prior to assembly front output bearing cup all pinion bearing cups and both pinion inner needle roller bearings
54. Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications Construction Features Housings The transmission has a one piece main housing Front housings in sizes SAE 0 and SAE No 00 are available A top cover bearing carrier and manifold sealed with gaskets complete the housing enclosure Bearings The primary and secondary clutch shafts and pinions are supported and located by a combination of straight and tapered roller bearings Bearing clearances for each clutch shaft and pinion assembly are set by use of a single shim pack at the rear tapered roller bearing on each shaft A combination of straight and tapered roller bearings support the output shaft and have bearing clearance adjusted by use of shims in the rear bearing carrier Gears All gears are helical carburized hardened and ground for smooth quiet operation All gears are in constant mesh The primary and secondary transfer gears and the output gear are mounted on keyless tapers Oil Pump and Drive The oil pump 15 driven by the secondary clutch shaft Marine Transmission Service Manual 1022294 19 Description and Specifications Twin Disc Incorporated Lubrication Features The lubrication tube in the transmission extends from the front to the rear of the inside of the housing Holes drilled in the tube force the oil to spray the transfer gears and the primary and secondary pinions Bearings and clutches on t
55. bearing cones on the shafts 7 Install the manifold gasket over the alignment studs and against the bearing carrier 8 Install the bearing spacers over the bearing cups Figure 107 Bearing Cups Spacers and Manifold Gasket Installed Rotate the shafts at least three revolutions to seat the bearing rollers while pressing down on both bearing spacers 10 Push the tapered roller bearing cups with bearing spacers firmly against the roller bearing cones Use adepth micrometer to measure from the top of manifold gasket to the shim retainers This distance is shaft endplay Use necessary shims to develop a shim pack for each shaft to reduce the endplay to 0 013 mm to 0 063 mm 0 0005 in to 0 0025 in Figure 108 Measuring to Determine Required Shim Pack Thickness 152 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 11 Remove one shim retainer and install the shim pack for that shaft directly over the bearing cup The thinnest of the shims should be in the center of the pack and the thickest shim should be against the bearing cup Repeat this process for the other shaft 12 Install the shaft seal rings into the grooves of both clutch shafts Center the seal rings in the grooves to prevent seal ring damage during manifold installation 13 Apply a coat of assembly grease or oil to the seal rings of both clutch shafts Figure 109 Install Seal Rings 14 Apply 908 threadloc
56. carrier Record this measurement as dimension B Subtract dimension B from dimension A and record this as dimension Build a trial shim pack having a thickness 0 05 to 0 15 mm 0 002 to 0 006 in less than dimension Install the trial shim pack over the bearing cup Marine Transmission Service Manual 1022294 135 Assembly Twin Disc Incorporated 4 Install the output seal carrier without output seals or O ring and torque the 14 M16 x 40 screws to 192 Nm 208 ft lb Figure 88 Output Bearing Shims Location 5 Install dial indicator onto the housing with finger resting on rear of output shaft or on lifting fixtures Zero the dial indicator and mark the spot where the reading was taken Figure 89 Measuring Output Shaft Endplay 136 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Using a hoist and tool 18050 714 exert 2225 N to 4000 500 Ibs to 900 165 of lifting force onto the shaft Minimum of 2224 500 105 lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 N 300 Ibs lifting force on bearing Rotate shaft several revolutions with lifting force applied Stop rotation with dial indicator finger on mark previously made continuing to hold lifting force Read shaft endplay on dial indicator Add or remove shims as necessary to bring output shaft endplay within the 0 05 to 0 15 mm 0 002 to
57. engine flywheel housing and the indicator stem is riding on the face of the flange Figure 145 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keeping a thrust in the same direction and note the face deviation of the engine flywheel housing flange The face deviation must not exceed the figures given in the table below Table 18 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations uc Eccentricity mm 0 41 0 016 SEEN NN 184 Marine Transmission Service Manual 1022294 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 Figure 146 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 thousandths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the surface to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter Figure 147 Checking the Flywheel Face Runout Marine Transmission Service Manual 1022294 185 Installation Twin Disc
58. flow from the trailing pump flows through a check valve into the transmission s lubrication circuit via one of the pressure test ports Power Flow 60 Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is mounted to the front end of the primary clutch shaft causing the primary shaft to rotate in engine direction during engine operation Power is transmitted to the secondary shaft by means of the transfer gear teeth on the outer diameter of the primary clutch housing These teeth are in constant mesh with gear teeth on the of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in anti engine direction Application of the secondary clutch locks the secondary pinion to the secondary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in engine direction Note he following power flow illustrations are shown merely as examples of power flow and may not pertain specifically to your unit Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operatio
59. followed by the spring s and spool D Remove the four M 8 x 25 capscrews from the opposite end 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 Figure 59 Remove Main Pressure Regulator Valve Components Marine Transmission Service Manual 1022294 107 Disassembly Twin Disc Incorporated Electric Selector Valve 1018084 and Mechanical Valve 1017172 Steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Loosen and remove four of M8 x 25 socket head capscrews and remove orifice plate cover and gasket Figure 60 Removing Orifice Plate Cover Gasket 2 Remove orifice plate Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket 108 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 5 Remove rate of rise piston Note that shims located between the piston and springs Figure 61 Rate of Rise Piston left and Regulator Springs right 6 Remove pressure regulating springs Remove pressure regulating piston with an external retaining ring pliers Figure 62 Removing Regulating Piston with Pliers 8 Remove external retaining ring from the lever end of the stem Loosen the cla
60. front bearings on primary pinion secondary pinion and output shaft are an interference fit in their respective bearing bores of the transmission housing Remove these parts only if replacement is required To remove these bearing cups weld a light bead around the I D of the bearing cup with an electric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced Marine Transmission Service Manual 1022294 95 Disassembly Twin Disc Incorporated Disassembly of Trailing Pump Drive Components 1 From inside the transmission remove the M8 x 20 retaining cap screw and washer from the gear end of the trailing pump shaft Figure 44 Removing Retaining Cap Screw and Washer 2 Remove the trailing pump driven gear key from the trailing pump shaft Remove the trailing pump or trailing pump cover if equipped and gasket from the transmission housing 4 Remove the internal retaining ring from the bore of the transmission housing Figure 45 Removing Internal Retaining Ring 96 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 9 Remove the trailing pump shaft assembly Figure 46 Removing Shaft Assembly 6 Press the bearings off of the trailing pump shaft only if replacement of parts is necessary Marine Transmission Service Manual 1022294 97 Disassembly Twin Disc Incorporated Disassembly of Primary and Secondary Clutch Shaf
61. 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 188 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Installation Engine and Marine Transmission Alignment 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 Not Recommended x ne 06 T 7 E rwr zi E a FI J Figure 150 Transmission Mounting Configurations When mounting the engine and transmission in the boat all of the mounting pads on both the engine and the transmission must be used Failure to do so may result in damage to the transmission Marine Transmission Service Manual 1022294 189 Installation 190 Twin Dis
62. 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 2 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 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 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 6 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 Asconsideration 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 with
63. spools cannot reach the clutch pressure passages in the transmission The main oil pressure regulator shuttle ball neutral pressure regulator and rate of rise functions remain exactly the same as when the valve is in the electric mode In the manual override position shifting is controlled by rotating the lever on the manual override stem In the Neutral position both clutches are vented to sump by two pockets in the stem Figure 20 Stem Pocket or Passage Main pressure oil can flow through the hole in the end of the stem to a narrow slot between the two pockets This slot does not connect to any other passages when the stem is in the Neutral position When the lever and stem are rotated to engage either the primary or secondary clutch main pressure oil flows through the slot in the stem to the appropriate clutch pressure port The opposite clutch port passage remains connected to sump by the same pocket in the stem as when the stem was in the Neutral position When the stem is rotated back to the Neutral position the main pressure oil slot in the stem is no longer aligned with either clutch port Both clutches are again vented to sump by the two pockets in the stem 56 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Trolling Valve Optional The trolling valve is used to reduce and control propeller soeed below that normally attained by operating the engine at low idle Actuating the trolling fu
64. spring regulator EE Orifice Ball and Spring Regulator Figure 11 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Control Valve Assembly in Primary or Secondary Pressurized oil is directed to one of the transmission s clutches to engage The pressurized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the passage to the opposite clutch The pressurized oil also forces the ball of the ball and spring regulator against its seat on the orifice plate stopping the flow of oil from the rate of rise chamber to sump Since oil continues to flow into the rate of rise chamber through the orifice the oil pressure in the rate of rise chamber increases This increased oil pressure forces the rate of rise piston to stroke over to its stop in the valve body compressing the pressure regulating springs even further yet Rate of Rise Peston Piston Against Stop Figure 12 Rate of Rise Piston in Neutral left and Rate of Rise Piston with Clutch Engaged right The travel rate of the rate of rise piston and resulting pressure rate of rise Is controlled by the orifice size regulator spring stiffness and the final main pressure after completion of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the rate of rise piston is against the stop pressure regulating springs a
65. that secure the manifold to the bearing carrier Install two of the removed screws into the threaded pusher screw holes of the manifold near the dowel pins Tighten the screws alternately and evenly to push the manifold off of the bearing carrier and dowel pins Remove the manifold and gasket Figure 35 Pusher Screws Installed in Manifold Removing Manifold 3 Remove the pump drive adapter from the secondary shaft Remove the shims and bearing spacers from the bearing bores of the bearing carrier Mark the shims and spacers for location identification 4 Figure 36 Remove Adapter Spacers and Shims 90 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 4 Remove the lubrication tube from the bearing carrier Figure 37 Lube Tube in Bearing Carrier 5 Install two of the removed screws into the threaded pusher screw holes of the bearing carrier near the dowel pins Tighten the screws alternately and evenly to push the bearing carrier off the housing and dowel pins Install an eye bolt in the bearing carrier and lift it from the housing Take care to prevent the bearing cups from falling out of the bores Figure 38 Pusher Screw Installed in Bearing Carrier Removing Bearing Carrier 6 Remove the bearing cups from the bearing carrier Mark the bearing cups for location identification Marine Transmission Service Manual 1022294 91 Disassembly Twin Disc Incorporated Remove Prim
66. the output side of the transmission from the rear Note Photos are intended to illustrate the procedure and may not be consistent with previous disassembly steps Marine Transmission Service Manual 1022294 81 Disassembly Twin Disc Incorporated Prepare Transmission for Disassembly Note During service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the old O rings gaskets and seals with the appropriate components being disassembled for future reference during the inspection and assembly process to make sure you do not forget the quantity size etc Drain the oil from the transmission sump by removing the hex plug from the bottom of the rear side of the housing Drain the water from the heat exchanger by removing the O ring plug from the bottom of the heat exchanger housing units with integral heat exchanger only A CAUTION Flat washers are used under all fasteners where the head of the fastener would otherwise contact 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 82 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly Remove Transmission External Components and Sub Assemblies Note The following steps of disassemb
67. the adapter such that the spring end of the stem exits the adapter first Note that the inner spring will come out with the stem Figure 73 Removing Stem and Adapter from Valve Body left and Removing Stem from Adapter right Remove the O ring from the groove the end of the stem Figure 74 Removing O ring from Stem Marine Transmission Service Manual 1022294 117 Disassembly Twin Disc Incorporated 10 Remove the inner spring and roll pin from the stem only if replacement of parts is necessary 11 Remove the washer from the bore of the valve body some models Note the washer may have been removed with the stem 12 Remove the outer spring and piston from the bore of the valve Note that there may be washer s in the bore of the piston some models Figure 75 Removing Spring and Piston from Valve Body 13 Remove the O ring from the groove and the oil seal from the end of the adapter Figure 76 Removing O ring from Adapter 880 Marine Transmission Service Manual 1022294 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 by steam cleaning Parts must be dried and oiled immediat
68. up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the 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 transmission The oil level should not be over the full mark at operating temperature Liquid sealant must cure for a minimum of 24 hours prior to contact with oil Marine Transmission Service Manual 1022294 67 Preventative Maintenance Twin Disc Incorporated Periodic Visual Inspection 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 forleakage Replace parts as required Inspect unit nameplates for looseness corrosion Tighten mounting screws that are loose and replace nameplates that are corroded Inspect and oil the exposed stem of the Manual Direction Control Valve for corrosion protection Torsional Coupling DO
69. 000 lt 290 10171298 7 x 20 6H 2451 52050 1018163C 1019791 707 A2707AD 270 2000 290 1019786 7 x eo em B2451B eto __ 2415 lt 350 10171298 1038 27 x 2 0 6 451 a MG 6848SC MERGE 1 10171727 10171726 1017172 1017172 1017172 1017172 10171720 1017172 10171727 017172P 41331 0171720 41577 0171725 41753 017172T 43678 Reese 509 mers SS 10171720 212 I T pev dl p __ _ 45 4 p __ ___ iT O E O 5d dol dl Hel x i uper dq cq ___ ___ ides dq El la less ce EL 0 21 1 y O ozuec o y O oe __ y O P y O 1114 1114 77441 41114 e une 1 f y amp GASKET 1017136B BALL
70. 017007 4 4211 RATIO 311 SCREW 996 5 PINION ASS Y 1017112 2 GEAR 1017108 HUB 1017007 4061 RATIO 33T PINION ASS Y 1017768 2 gt GEAR 1017767 1017007 3 35 46 SHEET CROSS SECTION 1 OF 6 AND PART NUMBERS SHEET CROSS SECTION 2 OF 6 AND PART NUMBERS SHEET CROSS SECTION 3 OF 6 AND PART NUMBERS 6 391 SHEET INSTALLATION 3 961 4 6 DRAWING 5 461 SHEET FLEXIBLE 4 9641 5 DF 6 COUPLING INPUTS GEAR RATIOS SCREW 104 4 SEE NOTE 7 4 4211 FETU MTU MONITORING GEAR 1021154 4 061 6 OF 6 3 351 1021153 MASS ELASTIC HEAT EXCHANGER HYDRAULIC A7119AG DIAGRAM 1 7 27 05 TUN 2086 INCORPORATED SENSOR 1020552C lt OPTIONAL M SEE NOTE 12 SCREW 96 2 WASHER 1039 2 F 3 mm em Tw TE PATER Fc Ecn13694 fi0 14 05 METRIC E 1 620 9 20 05 E 1 amp 5 ECNI3873 ALL ANGULAR TOLERANCES 21 zoe cuno zone cu wa xe Pen ASHE Vide 1994 D MAX INPUT SPEED 2400 rpm CONSULT SALES DEPT APPLICATION ENGINEERS FOR LIMITING CONDITIONS 3910153394 MuR DETRIMENTAL TU TE SIMILAR VIN DISC INCORPORATE e WS 1015339 MG 5321DC m MARINE TRANSMISSION ALC 6 E F B HEAT TREAT THIS NOTICE JS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS BRANTED
71. 147 7 1810 B CREP SAE J744 p 230 00 MIO c0 e70 DEEP M12 X 175 THREAD METRIC PORT CONFORMS TO ISU 6149 17 5 210 DEEP 4 HULES EQ SPACED INSTALLATION INSTRUCTIONS 12 REMOVE PLUG FROM HOUSING 2 gt PRESS THE 2 gt DOWEL PINS IN THE Se TIME THE PINS PROTRUDE 9 0 FROM END OF ASSEMBLE THE PISTON RING INTO THE ave OF THE ADAPTER AND INSTALL THE ADAPTER OVER THE DOWEL PINS IN THE SHAFT THE SHAFT WITH CAPSCREWS AND TORQUE PER 5574 OR SERVICE MANUAL VALUES 42 INSTALL THE 42 STUDS INTO THE MANIFOLD 5 2 INSTALL THE P T O ASSEMBLY ONTO THE MANIFOLD SO THAT THE SLOT IN THE PTO HOUSING ALIGNS WITH THE DRAIN HOLE IN THE MANIFOLD FASTEN WITH THE 42 NUTS AND TORQUE PER 5574 OR SERVICE MANUAL VALUES RINGS AND VALVE THE HOUSING WITH THE 452 SCREWS AND TORQUE PER 5574 COR SERVICE MANUAL VALUES REMOVE CLOSURES ASSEMBLE THE FITTINGS AND HOSES AS SHOWN FASTEN THE ADAPTER PRESSURE 30 SAE J744 NO INTERNAL SPLINE DATA 42056 FLAT T 42055 39 4 17 _ 18724 m een e 1555 CIRCULAR SPACE E rum 1327 1345 rn ar MEASUREMENT BETWEEN pa MAT WITH s INTERNAL SPLINE DATA PRESSURE ROOT ANGLE 30 NUMBER OF 14 12 24 214 er 11667 1 254 MAJOR DIAMETER 283 1317 VALVE ASSY 1015047
72. 2 Twin Disc Incorporated Inject oil with a viscosity of 300 5 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating Surfaces Advance gear to shaft shoulder stop with the portable press Release injection oil pressure between the mating surfaces and wait five minutes before lowering the press force and removing the assembly tool Remove the assembly tools from the output shaft and gear Install the pinion front bearing cones for primary and secondary shafts onto bearing cups previously installed in transmission housing Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Installation of Output Shaft Rear Bearing 1 Install heated rear output shaft tapered roller bearing cone Install with small O D of bearing to the rear Press drive bearing to shaft shoulder using special tool T 21506 to hold bearing in place while temperatures equalize Figure 87 Output Bearing Tool T 21506 2 Install output bearing cup into housing bore until it contacts bearing cone 3 Adjust the output shaft tapered roller bearing To determine the shim thickness required proceed as follows A E With a depth micrometer measure the distance from the housing face where the seal carrier contacts down to the tapered roller bearing cup Record this measurement as dimension A With a depth micrometer measure the pilot length of the output seal
73. 2 Remove Output Gear and Shaft 93 Disassembly of Trailing Pump Drive Components 96 Disassembly of Primary and Secondary Clutch Shafts 98 Disassembly of Control Valve sse 103 1017555 Trolling Valve Optional Equipment 115 8 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Table of Contents Cleaning and Inspection 119 ERR ETE 119 DEVS DC 121 125 Prior to uei 126 Preliminary 5660 127 Installation of Trailing Pump Shaft and Driven Gear 129 Installation of Output Shaft and Gear 131 Installation of Output Shaft Rear Bearing 135 Assembly of Primary and Secondary Shafts 140 Installation of Clutch Shafts Bearing Carrier and Manifold 150 Installation of Output Flange 155 Speed Sensors if equipped 159 Installation of Input Oil Seal Front Housing and Input 160 Installation of Exterior Components 162 Installa
74. 20 CH N pate UTHERS E e LX 2 E D INTERNAL SPLINE DATA SEE 435 PRESSURE o FLAT poor ANGLE _3O AUXILIARY PUMP DRIVE AND AUXILIARY PUMP INSTALLATION INSTRUCTIONS _FLAT __ a ee NUMBER OF 17 _ _ 12 24 12 REMOVE MA1038A PLUG FROM DRAIN HOLE IN MANIFOLD PITCH nra eer 14167 FURM 1 504 2 PRESS THE 2 DOWEL PINS IN THE SHAFT UNTILL THE PINS PROTRUDE 9 0 FROM END OF SHAFT 1 535 3 ASSEMBLE THE PISTON RING INTO THE GROOVE OF THE DRIVE ADAPTER AND AND INSTALL THE ADAPTER OVER THE DOWEL PINS IN THE SHAFT CIRCULAR SPACE 1327 FASTEN THE ADAPTER TO THE SHAFT WITH 2 CAPSCREWS AND WIDTH 1345 6 TORQUE PER 5574 OR SERVICE MANUAL VALUES MEASUREMENT BETWEEN 1 2052 42 ASSEMBLE THE NEW D RING AND THE AUXILIARY PUMP CARRIER ONTO THE 144 DIA PINS WITH MANIFOLD SO THAT THE 51 IN THE CARRIER BORE ALIGNS WITH NONE to riaT gt pe 1 2078 THE DRAIN HOLE IN THE MANIFOLD MAKE SURE THAT THE PLUG IS NOT INE DATA INSTALLED IN DRAIN HOLE lt 5 12 FASTEN WITH lt 42 CAPSCREWS AND TORQUE PER 5574 OR SERVICE MANUAL VALUES 92 ASSEMBLE THE SNAP RING INTO SPLINED ADAPTER AND INSTALL THE ADAPTER ONTO THE DRIVE ADAPTER NUMBER 14 12 24 62 INSTALL APPROPRIATE GASKET AND PUMP ONTO AUXILIARY PUMP CARRIER AND 11667 FORM DIA 1 254 DIMENSION TO SAE 0 HOUSING INTO SPLINED ADAPTER TORQUE FASTENERS PE
75. 3 37 v MACHINE ENS THIRD ANGLE MARINE TRANSMIS STON TE mU 6 0 THRU TOP SIDE ONLY 12 50 KNURL HANDLE 2 00 THREAD LENGTH 777792 ZA e 0 SSS 1 2 13 UNC SECTION A A NOTE LIFTING CAPACITY 305 PUUNDS 9 36mm DESCRIPTION ATERIAL 200 SQ X 25 X 1359 SQ X 25 VALL X 1350 UBE Feet NUT 3 3019118 McMASTER 1 2 13 X 200 THREADED ROD X 200 THREADED 21 213 NT 100 OD SID X139 150 200 50 25 VAL X 1756 50 X 25 WALL X 1756 TUBE 75 1259 150 59 75 250 250 590 NOTE ION O O HOLD DRILLED C BORED AND OR mbes rom Teese 7 coca TAPPED HOLES 005 s PA DET Se 0 AUTOCAD FILE T 506000 DWG REV DESCRIPTION DATE BY DISC ING mme vis 206000 0 69 48 02 mm 0 90 mm 7 813 mm 2 i m gt a a ar 5 Twin Disc Incorporated List of Engineering Drawings Engineering Drawings Engineering Drawings The following pages include the engineering drawings that are specific to this model 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 1015339A 1015339A 1015339A 1015339A A7119A
76. 300 500 WIRING DIAGRAM OPTION 1 SOLENOID B ON USED IF DIRECTION IS MECHANICALLY SWITCHED CRED LED 6 GREEN 4 TEMPERATURE SENSOR e DH POWER GREEN LED NORMALLY CLOSED NOT IN NEUTRAL RELAY CLOSED IN NEUTRAL CUSTOMER SUPPLIED 5 BLACK BLACK SOLENOID RED MP CRED LED WHITE ono BLACK SOLENOID ENGAGE SWITCH CUSTOMER SUPPLIED ee SOLENOID A ENGAGE SWITCH CIRCUIT CUSTOMER SUPPLIED TRANSMISSION MANUAL 7 SOLENOID RETURN OVERRIDE SWITCHES LUG RING THOMAS amp BETTS RA18 8 4 REF T D M2995K WIRING DIAGRAM lt OPTION 2 USED IF ELECTRONIC PROPULSION CONTROLLER EM PROVIDES SWITCHED BATTERY POSITIVE CRED LED DIRECTION DUTPUTS 200 250 CONTROLLER SHOWN AS EXAMPLE GREEN _ F TEMPERATURE SENSOR 2 DH LED INDICATORS GREEN LED ILLUMINATED WHEN POWER IS GREATER THAN 9 0 VOLTS RED LED ILLUMINATED INDICATES VALVE COIL COMMANDED DN SAVER ER ONE RED FLASHING INDICATES AN OPEN CIRCUIT IN AN ENERGIZED VALVE COIL CIRCUIT aca 3 VALVE COIL LEADS SHORTED TOGETHER OR LOW COIL CURRENT RED LEDS FLASH SIMULTANEQUSLY WHEN POWER IS APPLIED TO SOLENOID A AND SWITCH INPUTS AT THE SAME TIME BLACK CON EE Ee BLACK B SOLENOID NOT IN NEUTRAL RELAY NOTE 1 TEMPERATURE SENSOR MUST BE A
77. 38 1017179 550 370 10171298 1038 7 x 20 68 451 4 MG 6597 mvax 1017172 41866 1017383 10181633 1017179 ae7oes 2450 355 1017129A 0 x 20 6 Be451B 1017172F 10171726 41074 seas 1017172 017172 1017134 1017172 10185944 1018163C 1019791 2415 lt 350 1019786 MAI038EGe7 x 20 6 24518 Q O 10171721 41226 10181638 1018688 7072 427072 703 1725 250 gt 10171298 10 8 7 x 20 6 451 6 516 0 1017172 1018163B 1018688 27077 427072 2703 1725 250 gt 10171294 7 x 20 6 24518 6 520 S 1017172 41306 1017172 41725 10181638 1017179 A2707AD 2703 1860 lt 270 10171294 1038 x 20 6H 24518 6 51415 A2707AD A2703BA 1860 lt 270 1019786 7 x 20 6H 45 Az mc 10181638 1018688 2707 0 A2707AD 2703 2000 lt 290 10171298 7 x 20 6H 2451 66505 Mec 10181638 1018688 2707 0 A2707AD 2703
78. 8 10209412 44074 201341 201341 2 41 350 PSD 1020520 350 1020520 350 1020941 44079 172 250 PSD 201341YX 20515 1018528 250 201341 1020941F 44080 2 00 290 PSD 2013417B weosis 1020520 350 UNLESS OTHERWISE SPECIFIED WEIGHT WR FIRST USE 1020608 MATERIAL FET TREAT d m METRIC Of MACHINED DIMENSIONS na 557 X 10 75 0 25 DISC INCORPO ADJUSTMENT TOOL 1022474 INCORPORATED RACINE WI 53403 USA 515 03 TIN DISE 1020941 Ml ae ELM 6 neosee VALVE ASSEMBLY SERIES rr p taeda 8891 2 amp 4 GP VALVE E B 125 0 TWIN DISC ETROLL MODULE 1020583 POWER SUPPLY 12 or 24VDC NOMINAL SAE J1128 TYPE GXL PINK cm TWIN DISC RED 5V PART NUMBER USE 1020282 SOLDER SHRINK TROLL SPEED POTENTIOMETER 1K OHM 2212 CONNECTORS AS REQUIRED ORANGE 0 0 TO 0 5 VOLT MINIMUM TROLL OPEN CRUISE MODE GREEN 4 75 5 0 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 CUSTOMER SUPPLIED DEUTSCH CONNECTOR 1 CUSTOMER SUPPLIED 6 5 TRILL ENABLE PART NU DT04 2P VIOLET E GREEN Z 4 20 MA SEE NOTE D inr id 22 WIRING DIAGRAM OPTION 12 c WIE TET PART Lm _ a SEMSESRT SE MENS USED IF DIRECTION IS MECHANICALLY SWITCHED gt 1 GND A cwn DEUTSCH CONNECTOR lt 1 DH 7 TEMP IN PART NH DT06 2S P012 _
79. ALVE d al poe VALVE E mon TIT E posa c 2 e cce m i Hv pes i lt o nu a MANUAL DIRECTIONAL TWIN DISC OR CUSTOMER SUPPLIED CONTROL VALVE HEAT EXCHANGER AND CONNECTION LINES REFER TO INSTALLATION DWG OPTCONAL TEMPERATURE OPTIONAL TRAILING PUMP SENSOR PORT 14 15 REMOVE MA1038D X LS PLUG MANIFOLD PER MARINE TRANSMESSION NSTALLATION DRAWING PRIMARY amp SECONDARY AND NSTALL LUBE LINE SHAFT LUBE TO DIRECT FLOW INTO TRANSNESSION HYDRAULIC f CIRCUIT co d 5 z tb 2 CHECK Ag se uw VALVE 4 MS ed 4B kPa a af dy 2 U d d wg dg LOU Ll LE LEI LE Le jM Q TRAILING PUMP L LUBE RELIEF VALVE B2B kPa OPTCONAL INDICATOR OPTIONAL TEMPERATURE SENSOR PORT Ml4 X 15 Figure 8 Hydraulic Schematic GP control valve Marine Transmission Service Manual 1022294 43 Operation 44 Twin Disc Incorporated Manual Direction Control Valve Operation The manual direction control valve is locked in the NEUTRAL center position during normal operation There are three possible positions of the manual direction control valve stem If conditions exist that the operator wishes to manually operate the tra
80. ASSY 1018084Y 12 V VALVE 55 1018084AV 24 WO VALVE ASS Y 10171720 SCREW MA1068N lt 8 SCREW MA10S52L PLATE 1021149 GASKET 1018594 GASKET 1021193 _ 22 71 2 OPTIONAL MANUAL VALVE SCREW 996 145 CLOSURE M2067J 2 HOUSING 1017185 1017127 GASKET 1019905 1017121 PLUG 1038 GASKET 1017126 GASKET 1017124 SCREW MA1062D 12 OPTIONAL FRESH WATER HEAT EXCHANGER PLATE 1017127 GASKET 1019905 SCREW MA1062D 12 CLOSURE 2067 2 oami OPTIONAL DIICH PLATE CUSTOMER SUPPLIED HEAT EXCHANGER SCREW MA1052L PLATE 1021149 GASKET 1018594 GASKET 1021193 NOTES 1 THRU 10 ARE IN 5570 0 NOTE 11 APPLY MA908 TO INPUT SENSOR THREADS ASSEMBLE SENSOR UNTIL CONTACTING TIP OF GEAR TOOTH THEN BACK OUT SENSOR ONE FULL TURN NOTE 12 ASSEMBLE SENSOR UNTIL CONTACTING 8 TIP OF GEAR TOOTH THEN BACK OUT SENSOR TWO FULL TURNS NOTE 13 PORT MARKED TO BE ASSEMBLED CLOSEST TO TRAILING PUMP OUTLET NOTE 14 PORT MARKED S TI BE ASSEMBLED CLOSEST DUTPUT SHAFT SCREW MA1062N 85 53 Q 7 igs 27 p IC ee 7 7 PAW ERI eee V D ET OPTIONAL ELECTRIC CON
81. COVER BORE APPLY A THIN BEAD OF NOTE ANEROBIC SEALANT M2828 TO THE PLUG O D PER S774 AND INSTALL USE ALL 4 HOLES FOR MOUNTING A THE PLUG FLUSH WITH THE REAR SURFACE OF THE COVER MAX APPROVED INPUT TORQUE ee eg CUSTOMER SUPPLIED SUPPORT BRACKET APPLIES IU ES TH SAE 2744 No 38 4 SIZE MG 5321DC 1015339 m TO THE USE 8 8 PROPERTY CLASS MGX 6650SC 1002046 Mee ee NED INEU 9 WARNING DO NOT CONNECT VALVE COIL DIRECTLY QUALITY CAPSCREWS PER 150 898 1 AND MGX 6690SC 1020674 BUMP ADAPTER I 592 N n TO BATTERY POWER SUPPLY VOLTAGE VALVE COIL TORQUE TO 5574 OR SERVICE MANUAL CONSULT SALES DEPT BE OPERATED WITH ONLY TWIN DISC CONTROL STEN trs Condi SYSTEMS OR MODULES VALUES TRIN 9086 LT EE FEST USE INCORPORATED LE 0720F mM XXX mp X ose 1 zone cu pare chno erase vom ioo D MANUAL OVERRIDE START MG 59141SC 70 75 TROLLING 90 79 60 ff _ S S MIN TROLLING PRESSURE DITCH CLUTCH DATE V TN me ocn E E a E rs MR E rer em ar SCREEN 1020479 a emen
82. Cae SPRING 1801 SETSCREW A2870K ZPUAZ lt D D BALL 1990 0 RING A2916DK PIN 1927 1017524 SECTION B m B GASKET 1017553 GASKET 1017130 BALL M1990H PISTON B1399H SPRING A2702T 1020005 AS REQ D2 DITCH PLATE SEE CHART SCREW SEE CHART PORT LEVER POSITION SECTION ES TRANSMISSION GASKET SEE CHART SCREW 1042 4 NOTE INSERT SPRING A2701BN OVER ROLLPIN A A 3036 UNTIL FIRST SPRING COIL SECTION REMAINS LOCATED AGAINST STEM FACE RING 0916 WASHER 4078245 SPACER 2885 DITCH PLATE GASKET SEE CHART VALVE BODY ASSY 1018095 A BODY 1018094 BALL 1034 BALL 10340 2 gt BALL M1990H BALL M1990Y 5 gt INSTALL USING 908 2 242 TOP SCREW MUST BE FLUSH WITH SURFACE APPLY MA895 THREAD SEALANT WITH TEFLON gt TO THREADS TORQUE TO 30 0 lbof ft 40 7 N m N PLUG M2080A 34 28 NUT M2027C SCREW Me000L SCREW 1042 2 PORT HYDRAULIC DIAGRAM A7119Y d THIRD ANGLE PROJECTION ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE Ducum LP INTERMEDIATE PRESSURE THESE PARTS ARE BE PACKAGED CP CLUTCH PRESSURE SEPARATELY AND SHIPPED WITH UNIT SCREW 1042 2 58 93 5182 SWITCH MA866A
83. Disc Authorized Distributor Marine Transmission Service Manual 1022294 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services WARNING 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 Disc having stipulated the bill of material number on the units 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 ch
84. E ENGINE SPEED SENSOR RED sp POWER OK BRONN GREEN LED C PROPELLER SPEED SENSOR GREEN B lt BLACK Bin Pee NS NORMALLY CLOSED BLACK B SOLENOID A NOT IN NEUTRAL RELAY PED mE AUT CLOSED IN NEUTRAL aue SOLENOID B CUSTOMER SUPPLIED BLUE 0 MP SOLENOIDAON BLAK s ys EDITED WHITE BLACK BLACK WHITE gt SOLENOID OUTPUT SOLENOID HARNESS 200 1018045 SERIES YELLOW BED 24 EC250 ASM203452 SERIES o TO GREEN SOLENOID B OUTPUT SEE NOTE 6 START CIRCUIT oro TRANSMISSION MANUAL Ei SOLENOID RETURN OVERRIDE SWITCHES WIRING DIAGRAM OPTION 3 USED IF ELECTRONIC PROPULSION CONTROLLER PROVIDES SWITCHED BATTERY NEGATIVE DIRECTION OUTPUTS CONSULT TWIN DISC FOR MORE INFORMATION Figure 154 MG E Troll Wiring Diagram Marine Transmission Service Manual 1022294 197 Installation Twin Disc Incorporated WIRING DIAGRAM OPTION 1 SOLENOID B ON USED IF DIRECTION IS MECHANICALLY SWITCHED RED LED GREEN TEMPERATURE SENSOR 2 POWER GREEN LED BLACK TY VY NORMALLY CLOSED BLACK E SOLENOID A NOT IN NE
85. ED ROD 1 8 THREAD x 52516 4 5 5 FLANGE NUT 7 8 8 THREAD 3 5 100 DIA x 82516 x W e 1 MS TOP PLATE 500 DIA x 125 THK LL L 1 1 MS TOP PLATE 7 00 DIA x 75 THK 1 1 TUB TUBE DRIVER 700 OD x 5 WALL x 625 LG 1 1 22 Scale FULL Date 10 22 98 ____ BEARING DRIVER ______________________ __ 1018372 SHAFT MG 6650 SC T 21506 DESCRIPTIUN DATE BY TWIN DISC INC RACINE VIS STAMP TOOL ND PART ND BREAK ALL SHARP CDRNERS TOLERANCE UNLESS OTHERWISE SPECIFIED 001 ON THREE PLACE DECIMAL DIMENSION 010 ON FRACTIONAL AND TWO PLACE DECIMAL DIMENSION 1 4 ANGULAR DIMENSION KNURL THIS DIA THIS WIDTH 00 0 08 X 45 BOTH ENDS 1 00 LD AND D D 0 50 STAMP TOOL 121506 DET 6 PART 5301 SHAFT SEL A Ce 1 a SPACER RING Rc3e 3e TUBING 725 DD X 225 TL 1 1 SPACER RING TL Td 0 MG 9301 SHAFT 1 1 06 DESCRIPTION NYLON DRIVER SEAL 5 0 x 6 0 24693 X 0 683 3 90 23 89 2 1018476C COND oO STAMP 494 ege TS ine UM IET INE OR PORATED UNLESS ITHERVISE SPECIFIED 5 TOOL OUTSIDE VENDOR DRAWING NAME INCH 722155
86. EEL COOLER WATER 46 C 60 C 115 F 140 F3 ENGINE JACKET WATER 74 C 85 C lL6S F 1l amp S F gt STATE MIN ALSO MAX L min WATER FLOW INSTALLATION amp SERVICE REQUIREMENTS OIL LINES TRANSMISSION H E AND RETURN MAX VELOCITY IN FITTINGS PIPEHDSE AND TUBES 7 6m s Ceaft s BURST PRESSURE MIN 4 x PEAK DIL PRESSURE HOSE PER S597 E PROTECT LINES FROM MECHANICAL DAMAGE ZINC ANODES PROTECT HE RAW WATER PASSAGES FROM CORROSION CHECK amp REPLACE THEM FREQUENTLY Figure 2 Heat Exchanger Specification Information 22 Marine Transmission Service Manual 1022294 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 Dry Weight With SAE 0 housing 1 570 kg 3 458 Ibs With SAE 00 housing 1 620 kg 3 568 Ibs Maximum Input Speed MG 5321DC 2400 rpm Oil Capacity 37 9 liters 10 0 gal Type of Oil and Viscosity Note Multi viscosity oils e g 10W 20 should not be used in Twin Disc marine transmissions Marine Transmission Service Manual 1022294 23 Description and Specifications Twin Disc Incorporated Recommended oil is specified on the lubricant data plate mounted on the transmission housing
87. Figure 139 Installing O ring onto Adapter 2 Install a new O ring into the groove of the stem 3 Install the roll pin into the end of the stem if removed 4 Install the inner spring onto the roll pin in the stem end with a counterclockwise twisting motion The spring is to be installed onto the roll pin such that the first coil contacts the end of the stem 5 Apply assembly grease to the stem from the O ring to the reduced diameter end Install the stem into the adapter with the reduced diameter end entering the adapter first Adjust the position of the stem if necessary to bring the helical slot into alignment with the dog point setscrew hole 6 Install the large diameter washer used on some models inside the bore of the adapter and over the inner spring until it lays flat on the end of the stem 1 Install the small washer used on some models inside the piston washer must lie flat at the bottom of the bore in the piston Marine Transmission Service Manual 1022294 177 Assembly Twin Disc Incorporated 8 Apply assembly grease to the adapter where it contacts the trolling valve body and install the adapter into the valve body Be sure to align the setscrew holes in the adapter with those in the valve body Figure 140 Installing Trolling Valve Parts Into Trolling Valve Body Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back
88. G 1016473 1017177 1017820E 1017546 1017172 1018084 1020941 1020583 D O O 1020585 Marine Transmission Service Manual 1022294 sheet 1 of 6 Marine Transmission sheet 2 of 6 Marine Transmission sheet 3 of 6 Marine Transmission sheet 4 of 6 Marine Transmission Hydraulic Diagram Trailing Pump Assembly Auxiliary Pump Drive Group PTO Assembly Control Valve w trolling valve Control Valve w out trolling valve Control Valve w out trolling valve Control Valve E Troll Module Profile Module 225 ASS Y 1017025 COVER 1017024 PART NUMBERS ADAPTER 1966 INPUT OPTIONS SCREW 996 24 WASHER 1039 24 gt PLUG 20515 SEE SHEET 5 GASKET 1017028 HOUSING 1017014 BAFFLE ASS Y 1019068 SAE 4005 BAFFLE 1019067 NUT 1054 3 SCREW MA960D 35 WASHER M2081D lt 3 SEE NOTE 8 RING A2916W SCREEN MA993 BREATHER 1251 S LINK 2007 CHAIN M1072 1047 2 gt Soin COVER 1022685 CSAE 00 COVER B1973B LLQ CSAE 0 PEN GASKET 1021172 CARRIER 1019986 SCREW MA960M GASKET 1020188 I A A ea CLIP M1763A PLUG 1038 22 AALI
89. GHEGK ZirS DL Imm S E OIL OUT 1 2 14 THREAD INSTALL PLUGS FOR SHIPPING 0 25 kW 1725 rpm 118 FILTER REPLACEMENT ELEMENT SPON EE ORP ORATION 56558 REMOVABLE PLUG 2 OR SCREEN FOR CLEANING PARKER 925023 CROSS 119023 1 2 NPT QUICK DISCONNECT TYPICAL MARINE GEAR SECONDARY LUBE TEST PORT DRAIN PORT O gt lt o 3 4 NPT QUICK DISCONNECT 5 2 2 GE HD T ee INSTALL PLUGS FOR SHIPPING M OIL IN 3 4 14 N P T THREAD FEMALE PIPE SWIVEL PUMP FLOW RATE IS 110 l min 102 100 MESH INLET STRAINER REMOVABLE SCREEN M E Jh R 1 THIRD ANGLE 4 PROJECTION 1 LARGE HEX PLUG SIMILAR TO REMOVE THIS ENDCAP TO SMALL PIPE PLUG EXTRACT SCREEN FOR CLEANING REMOVE TO C WEIGHT DATE DBS DETRIMENTAL TO THE INTERESTS OF 4 INCORPORATED 3 65M POWER CORD D 2 5 29860 1 26 00 WEAT TREAT ERG USE 025 1 1 RACINE 53403 USA D Hiii gt 3 PRONG GROUNDING PLUG rc 29423 7 6 99 TWIN DISC INCORPORATED DRN mm 115 me RACINE WI 53403 USA MODEL GEDMETRIC TOLERANCING Gk 1 1 6475 mun B 1 29078 1 19 99 NOTICE IS NDT INTENDED COILED TIE WRAPPED TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME PJL 5 A 22103 1 4 38 GRANTED TO THE US GOVERNMENT PUMP ASSEMBLY TRAILING PPP ows seer 1071 rev D REV
90. 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 The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering B The exclusive remedy provided by Twin Disc Incorporated whether arising out of warranty within the applicable warranty period as specified or otherwise including tort liability shall at the sole option of Twin Disc Incorporated be either the repair or replacement of any Twin Disc Incorporated part or product found by Twin Disc Incorporated to be defective and 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 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 1 Complete parts
91. LOCK ON PLUG MA1038E 2 RACE M2086DF BEARING M2087AD RACE M2086R GASKET B1334C COVER ASSY 1017336 A CARRIER 1017335 BALL 1990 LEVER MAY LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTAL ROTATION 11 4mm AXIAL MOTION REQUIRED FOR CONTROL SOLENOID amp M8 X 1 25 6H TH D 2 HOLES 59 MANUAL OVERRIDE SUR NA OSE pany ELECTRIC 24 7 NEA 217 3 SEAL MA778 CONTROL M POSITION ro ____ __ ___ 1 4 DIA THRU 36 6 55 mE 1018163 9 SNAP RING A2915 PORT LEVER STU SCREW 1042 4 x RING 2916 SPRING 2705 WASHER A2782AS SECTION A aor i N SS VS NN LO i ANZ i rma T 1j is NT ZL NM RA SCREV SEE CHART PLUG M2051K 2 SCREEN 1020479 9 CONNECTOR SHROUD 1001825 CLIP CONNECTOR 1017322 SCREW MA1052P 4 TORQUE 542 40 0 2 NOTE INSTALL USING 908 242 THREAD DOG POINT INTO DETENT GROOVE UNTIL SNUG 1 2 TURN SETSCREW M2038W SPRING A2702BQ 24 HYDRAULIC LOCK ONLY SPOOL 1017432 2 HYDRAULIC LOCK ONLY PISTON SEE CHART 9 THESE SOLENOID CONNECTIONS ARE NOT POLARITY SENSITIVE BALL 19906 BALL M1990L
92. M1990G SWITCH MA866A APPLY MA895 THREAD SEALANT BALL M1990L WITH TEFLON gt THREADS BALL 1990 7 171 5 RNIN gt ASSI Dee es SESSIONS EMT SEIS 55 77 YZ Al SECTION SECTION B secum D TRANSMISSIUN GASKET SPRING 1801 SEE CHART 72 5 0 RING A29316DK DITCH PLATE GASKET PIN 1927 SEE CHART SEAT 1017524 VALVE BODY ASSY 1018095 A BODY 1018094 BALL MA1034A BALL 10340 25 BALL 1990 NOTE BALL 1990 5 INSTALL USING MA908 LOCTITE 2 242 TOP OF SCREW MUST BE FLUSH WITH OR SLIGHTLY BELOW BOTTOM FACE OF VALVE HYDRAULIC DIAGRAM A7119Y O OBSOLETE FOR PRODUCTION AND SERVICE ATMOSPHERIC PRESSURE A NOT SERVICEABLE SEPARATELY 6 A ATMOSPHERIC PRESSURE m LP INTERMEDIATE PRESSURE x THESE PARTS ARE TO BE PACKAGED E ER CLUTCH PRESSURE SEPARATELY AND SHIPPED WITH UNIT xX STR TH D RING 1506149 MAIN PRESSURE PICKUP PORT MAIN PRESSURE OIL INLET WHEN u owes T ewodegm 26 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS X 0 75 DATE 2 12 97 SCALE TZIN DUSE INCORPORATED MATERIAL WEIGHT a ES T INTERNALLY
93. Marine Transmission Service Manual 1022294 163 Assembly 164 Twin Disc Incorporated Assemble oil filter differential bypass valve parts into oil filter head and torque the O ring plug to 108 Nm 80 ft lb Install the oil filter head onto transmission and torque the attaching screws to 80 Nm 59 ft lb Install O ring filter element and filter housing onto filter head and torque the bolt to 81 Nm 60 ft lb with its threads and washer oiled Figure 125 Oil Filter Installed 6 If the transmission is not equipped with an optional trailing pump install the trailing pump port cover Insert the cover mounting washers and screws and torque them to 112 Nm 83 ft Ib Install O ring on suction screen cavity cover Install cover and secure it with clamp plate washer and M12 x 30 hex head screw Torque to 112 Nm 83 ft lb If the transmission is equipped with an optional trailing pump install the trailing pump tube and associated fittings Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Installation of Top Cover Assembly Heat Exchanger and Oil Gauge 1 Turn transmission over and block securely in upright position 2 Attach oil baffle to top cover if removed Install the sealing washers onto the screws apply MA908 threadlocker to the screw threads and grease to the sealing washers and torque the three M8 x 30 screws to 33 Nm 25 ft lb Install top cover assembly with its gasket Ins
94. Mechanical Valve 10171 72 1 Install the steel shuttle ball into its bore in the valve body 2 Install the O ring onto the shuttle ball seat 3 Apply lubricant such as Dow Corning 200 30 000cSt fluid to the O ring and install the seat into the valve body Be sure to align the roll pin holes in the seat with the holes in the valve body One of the valve s M8 x 1 25 cover screws threaded into the seat can be used to adjust the seat location in the valve body 4 Install the roll pin to retain the shuttle ball seat Drive the roll pin in until it is flush with the gasket surface of the valve body Figure 134 Installing Shuttle Ball Seat Roll Pin Install the stem into the valve body aligning the slot in the stem with the threaded hole in the valve body for the dog point setscrew Be sure the slot in the stem is aligned with the setscrew hole in the valve body to prevent damage to the stem and valve body Marine Transmission Service Manual 1022294 173 Assembly 174 Twin Disc Incorporated 6 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn Figure 135 Installing Dogpoint Setscrew 7 Install the steel detent ball into the valve 8 Install the detent spring over the detent ball Apply 908 threadlocker to the threads of the hollow setscrew and install into the threaded hole Astepped Allen wrenc
95. ND LINES REFER INSTALLATION DWG 2z OPTIONAL GP TRANSMISSION CONTROL VALVE or v ae HYDRAULIC REFER TEMPERATURE SENSOR I PRODUCT LIST OPTIONAL TEMPERATURE OPTIONAL TRAILING PUMP SENSOR PORT M14 X 15 mz D CU DM C REMOVE MA1038D M18 X 15 PLUG FROM MANIFOLD PER MARINE TRANSMISSION ae EUR INSTALLATION DRAWING PRIMARY amp SECONDARY AND INSTALL LUBE LINE SHAFT LUBE DIRECT FLOW INTO PRIMARY SHAFT TRANSMISSION HYDRAULIC 3 CIRCUIT FILTER BY PASS uico um OPTIONAL xL x PU CHECK 9 INDICATOR ag 5 S Eg as ele XQ valve x 48 kPa N sed d amp g alg ms EJ 22 m 77 I WF Q 1 Lt L i B 4 f TRAILING PUMP 21 T 4 976197976727 us ccu QE lt gt OPTIONAL OPTIONAL INDICATOR TEMPERATURE 2 SENSOR PORT m I 2 x gt ECNI3404 7 28 05 m 0 112 gt GRAPHICAL ISO SYMBOLS CGP VALVE SHOWN 4 48 8 E 109 u MG 5321DC x HYDRAULIC SCHEMATIC SECONDARY SHAFT STRAINER ES STRAINER NATGE RIS PRINT CINTANS MATERIAL WEIGHT vee UNLESS
96. 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 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 68 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Preventative Maintenance When inspecting the flexible coupling look for evidence or conditions identified in the following steps Cracks in the surface of the rubber May be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate deterioration of the rubber to metal bond See above Deterioration of the rubber element as evidenced by sponginess or by black carbon like dust on rubber surf
97. OTHERWISE SPECIFIED PROPRIETARY INFORMATION AND IS il mn NOT BE USED IN MANNER 0 75 DETRIMENTAL TO THE INTERESTS OF 0 25 HEAT TREAT FIRST USE 0 13 RACINE WI 53403 USA GEOMETRIC TOLERANCING MG 5321DC LIC DINE S RATHS JS Ear HYDRAULIC LINE DIAGRAM GRANTED THE US GOVERNMENT PICTORIAL ED Ie DER SCHEMATIC nEDRAULIE B THIRD ANGLE PROJECTION DATE SCALE DRN x A7119AG APPD sweet lur A TWIN DISE INCORPORATED RACINE WI 53403 USA 589 CENTER LABEL 1018729 CAUTION MAX TEMP 100 REDUCE SHAFT SPEED IF EXCEEDED 6 S S N N N N N N N N N N N N N N N N N N h Oz N gje N AA SINGLE PHASE CAPACITOR TYPE C THERMALLY PROTECTED DUAL VOLTAGE DUAL ROTATION 8 LEAD NZ wit Wg N Ol x 28 5 ege N N N N S RN HEAT EXCH S N Lil N Ww N u N N N f N 2o N N gt N me N N m N S 5 VON S MH 8 N N N N IN li I gp PART a eth RED PILOT LIGHT LIT WHEN MOTOR Dx IS OPERATING 8 CI n a CUR e MERC SUED re FILTER WITH 172 kPa BYPASS OIL TO AIR HEAT EXCHANGER PRESSURE ALARM SWITCH 6 25 MICRON 4 15 8 41 4 kPa SETTING Bice SANE 4 SEE TOP VIEW FOR
98. R 5574 OR SERVICE MANUAL PITCH RIB SAREE MIN MOUNTING FACE CAPSCREW 10625 4 SEE 5 435 PRESSURE FLAT poor ANGLE _ O SAE J744 127 2 127 4 FLANGE AND E MHUNTING A NENNEN CIRCULAR SPACE SAE J744 No 38 4 PUMP DRIVE ADAPTER 4 BOLT PUMP REPLACE AS A SHOWN ABOVE CENTERLINE 7800 THESE SCREWS WITH STUDS DIA PINS WITH OF ADEQUATE LENGTH TO WE ADAPTER 10178344 MOUNT BOTH THE PUMP AND SPLINE DATA CARRIER SECURE PUMP AND IA IN INCHES 5 RING M1904L 19508 CARRIER WITH NUTS MALY e FIN MALOSSB 22 z _ ED RING 2669 pss ADAPTER 10178364 2744 No 38 4 _ M N b 30 Ta 2E D y N NS A 0 06 Xr NN Se SPLINE 33902 SAE J744 No 38 4 PUMP DRIVE ADAPTER ZAAFA N ON 0 03 4 AE HH E 7 Na O N rz E REESE DNL Y T T SOS SLUG DRAIN HOLE Ec pA V LAM 161 9 A Pa k L A a 058 REF HC Ee SAE 744 127 4 gt ae 55 1810 2 a REF H C N SAE J744 No 127 4 PTZ PLUG 1945 KS ee
99. RAL NOTE 4 TO INITIATE TROLL WITHOUT THE 0 5 VOLT DEAD BAND AT MINIMUM TROLL A SOLENOID B CUSTOMER SUPPLIED ADD A 100 OHM RESISTOR BETWEEN THE POTENTIOMETER AND THE GREEN WIRE RED B NOTE 5 WHEN THE NOT IN NEUTRAL CIRCUIT IS NOT USED INSULATE AND SECURE THE ua NOTE 6 REMOVE WEATHER PACK CONNECTOR FROM EC200 250 SOLENOID HARNESS CRED LED WHITE BLACK g5 IF 250 INSULATE AND SECURE THE BLUE AND BROWN WIRES OF THE E Uu 200 1018045 SERIES Deae YELLOW RED _ M 250 ASM203452 SERIES eis FACTORY SETTINGS GREEN dentis E 1 TRANSMISSION ON ee 1020583 SOLENOID RETURN OVERRIDE SWITCHES WIRE 18 AWG XLPE 1020583A 1020583B SEE PAGE 2 10203583C 10205830 NOTE FOR USE NOMINAL 12 24 VDC SYSTEMS HENRI CERE EC aS SS WIRING DIAGRAM lt OPTION 3 METRIC USED IF ELECTRONIC PROPULSION CONTROLLER PROVIDES METRIC SWITCHED BATTERY NEGATIVE DIRECTION OUTPUTS rece MORE INFORMATION CUNSULT TWIN DISC FUR fT e 6 30 04 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS ____ __ 11890 10 15 03 NOT TO BE USED IN ANY MANNER 1 SIMILAR TO PUN DUSE MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED due DIMENSIDNS ARE mm SEE MACHINED DIMENSIONS 7 16 02 ps enoe X 075 NCORPORATED rk 1
100. SUPPLIED SUNY Ve RENO eso qo 3 HEAT TREAT FIRST USE XXX 013 T a o RACINE 53403 USA GEOMETRIC TOLERANCING REDUCER BUSHING IS SPECIEI 11 16 00 W 1494 5 28 03 PER ANSI YLASM 1988 CHK REDUCER BUSHING IS SPECIFIED o 556 THIS NOTICE B NOT INTENDED See aE BE RM SERIES BOTTOM VIEW 30289 8 30 00 V 970 8 9 02 GRANTED THE US GOVERNMENT VALVE ASS Y CONTROL fares REV ZONE REV ZONE CH ND Be HESS BY CUNIROC WITHOUT TROLLING VALVE TBC SHEET 1 oF REV W F E D B A WIRING DIAGRAM 273 4 CONNECTOR MANUAL OVERRIDE NEUTRAL START 146 00 PORT SOLENOID C MAX I 20 NEUTRAL SOLENOID OPTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH 78 8 BOTH SIDES s38 BOTH SIDES ELECTRIC CONTROL MODE SWITCH CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE MAX I 20 A PLATE 1018312 NOTE SECURE LEVER IN THE DEPRESSED ELECTRIC CONTROL MODE POSITION BY LOOPING PLASTIC STRAP THRU 1 4 HOLE IN LEVER amp M8 THREADED HOLE BEHIND PULL TIGHT TRIM END SHORT TOP VIEW STRAP M2942B THESE SOLENOID CONNECTIONS ARE NOT POLARITY SENSITIVE PIN A2711AC 2 N Y HYDRAULIC
101. T RIGHTS 2974 114 05 1 FS ECNII4I8 SB GR LIMIT RIGHTS CONTROL Pre nt SERIE prev smeet zone pare sneer zone cu mar DR OTHERS BY CONTRACT MG PROFILE MODULE MB Gee SHEET 1 OF 2 F E D 1022294 01 06 d POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
102. TROL VALVE C INDICATOR 557 1020836A FITTING MALOS3AA SERVICE REFERENCE GASKET 5 SERVICE REFERENCE 1016502 FILTER 4 TUBE 1022342 FITTING Me483J VALVE 1137 SEE NOTE 13 FILTER ASS Y 1020872 WITH INDICATOR NIPPLE M2053BA 3 PUMP 1020513 SEE NOTE 14 FITTING 2988 FITTING Me052AG GASKET 1020996 SCREW 960 lt 45 PLUG 2051 STRAINER B2130A i OPTIONAL MOUNTED TRAILING PUMP TWIN DISC 1 2 INCORPORATED REPE 2 2224 MARINE TRANSMISSION ALC 6 F GEOMETRIC TOLERANCING MAIN PRESSURE PORT 12 1 5 THD CONFORMS TO ISO 6149 SEE NOTE SEE NOTE A PROPORTIONAL CONTROL VALVE OPERATION 1 WARNING DO NOT CONNECT VALVE COIL DIRECTLY BATTTERY POWER SUPPLY VULATAGE 2 OPERATION TO BE PERFORMED WITH ONLY TWIN DISC CONTROL SYSTEMS OR MODULES MANUAL DIRECTIONAL CONTROL VALVE OPERATION WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PUSH TO ENGAGE PRIMARY CLUTCH WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PULL TO ENGAGE SECONDARY CLUTCH MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH 1 SWITCH IS NORMALLY CLOSED WHEN MANUAL DIRECTIONAL CONTROL VALVE 15 THE CENTERED POSITION AND OPEN WHEN LEVER IS ACTUATED FROM CENTERED POSITION CURRENT 20 AMPS 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE DRAWING 1020941C CONTROL VALVE TEMPERAT
103. UCE WODE GREEN 4 75 TO 5 0 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 CUSTOMER SUPPLIED SOLENOID B ON CUSTOMER SUPPLIED RED LED VIOLET TROLL SPEED CURRENT INPUT 4 20 MA SEE NOTE 1 l WIRING DIAGRAM OPTION 1 1 PERATURE SENSOR USED IF DIRECTION IS MECHANICALLY SWITCHED 2 TAN S ENGINE SPEED SENSOR RED ee ea POWER OK BROWN GREEN LED C PROPELLER SPEED SENSOR GREEN N BSIDH BLACK ZA NORMALLY CLOSED BLACK SOLENOID A NOT IN NEUTRAL RELAY RED A NMP ___ a CLOSED IN NEUTRAL SOLENOIDE CUSTOMER SUPPLIED BLUE MP SOLENOIDAON BLACK Ns RED LED 22 WHITE BLACK SOLENOID B ENGAGE SWITCH c CUSTOMER SUPPLIED BATT m TO START SOLENOID A ENGAGE SWITCH CIBCUIT CUSTOMER SUPPLIED EMEN CO o TRANSMISSION MANUAL SOLENOID RETURN OVERRIDE SWITCHES BATI OO EINE BATT oo 8 RED 45V TROLL SPEED POTENTIOMETER 1K OHM 22 ERSNGE 0 0 TO 0 5 VOLT MINIMUM TROLL OBEN CRUISE MODE GREEN 4 75 TO 5 0 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 CUSTOMER SUPPLIED SOLENOID B ON CUSTOMER SUPPLIED RED LED VIOLET NE TROLL SPEED CURRENT INPUT WIRING DIAGRAM OPTION 2 ep MA SEE NOTE USED IF ELECTRONIC PROPULSION CONTROLLER GREEN PROVIDES SWITCHED BATTERY POSITIVE TAN TEMPERATURE SENSOR DIRECTION OUTPUTS ane 2 212 u EC200 250 CONTROLLER SHOWN AS EXAMPL
104. UI WELDMENT Pas snc soc cae x 475 Ce o NUT WITH HANDLES eee rea 1016523 HSG THREAD SIZE 2 4 1 2 UNC GRADE 8 a at 1017009 FLANGE 194 GRADE 2H HEAVY HEX FULL NUT m ee Se A INAME DET 8 REPACES DET 1 amp 2 OUTPUT FLANGE FIXTURE DET 5 REWORKED 21 97 JPL YC 5301 SHEET 1 OF 3 T 21433 SHT 3 ADDED CAD FILE 21433 26 50 06 2 00 4 1 2 UNC DIA THREADS TO BE GROUND 6 19 2 000 AFTER HEAT TREAT 1250 HEX FLATS CENTERED BELL CENTER 10 x 452 06 x 45 BOTH ENDS PULLER ROD 1 REQ D MAT SAE 4340 H CAIRCRAF QUILITYD HEAT TREATMENT HARDEN amp TEMPER Il Rc 44 48 CHECK HARDNESS UN 2 000 DIA UNLY DU NUT TOUCH THREADS INSPECTION CHECK ALL SURFACES WITH MAGNIFLU EQUIPMENT 1 749 1 740 2 495 DIA DRILL 5 16 3125 DIA x 105 DEEP TAP 3 8 16 x 100 DEEP REQ D DRILL 31 64 64844 DIA THRU 03 32 187 DIA x 94 DP 52 REQ D FOR x 175 BOLTS DRILL 5 16 31855 DIA x Leo DEEP 1 PUSHER PLATE 1 REQ D 3 8 16 x 100 DEEP MAT M S 45 49 Ro SEE DET 5 REV D uui Ee 3 1 j340H PULLER ROD 68 DIA k 27 00 LG Lp cc ober 2 903 DIA 2 908 DIA 101653 HSG Eo OM ZETREG MAT DESCRIPTION STUCK SIE 1017009 FLANGE i i Date 10 12 96 JPL
105. URE PORT SAE 0 HOUSING E PRESSURE PORT 14 X 15 METRIC PORT CONFORMS TO 150 6149 FOR USE WITH OPTIONAL TRAILING PUMP EYEBOLTS 2 FOR LIFTING MARINE TRANSMISSION ONLY EQUALIZE LOAD ON BOTH EYEBOLTS TO LIFT MARINE TRANSMISSION WATER OUT FROM HEAT EXCHANGER M4e X 2 0 METRIC PORT CONFORMS ISO 6149 WATER TO HEAT EXCHANGER M42 X 2 0 METRIC PORT CONFORMS 150 6149 EN Y 59 SECONDARY CLUTCH PRESSURE PORT 15 METRIC PORT CONFORMS TO ISO 6149 LUBE PRESSURE PORT 18 X 15 METRIC PORT CONFORMS TO 150 6149 LUBE PORT lt AUXILLARY Me7 X 2 0 METRIC PORT CONFORMS TO ISO 6149 M14 X 15 METRIC PORT CONFORMS TO ISO 6149 WATER DRAIN M10 X 1 0 METRIC PORT CONFORMS TO 6149 SECONDARY CLUTCH SHAFT DIL STRAINER OUTPUT SHAFT 6 245 THRU 14 HOLES EQUALLY SPACED Mie X 1 75 THREAD 33 0 DEEP 8 HOLES 4 EACH SIDE V p Tee EE LUBE PRESSURE PORT Mi8 X 15 METRIC PORT CONFORMS TO ISO 6149 OIL DRAIN M33 X 20 METRIC PORT CONFORMS TO ISO 6149 LAYER DISPLAY UPTIONS OPTION FRONT HOUSING PTO GROUP SAE 0 HOUSING MAIN PRESSURE PORT 2 15 METRIC PORT CONFORMS ISO 6149 CONNECT OIL PRESSURE GAGE LINE HERE M PRIMARY CLUTCH PRESSURE X 15 METRIC PORT CONFORMS ISO 6149 TEMPERATURE PORT M14 X
106. UTRAL RELAY GEB pl Mq CLOSED IN NEUTRAL A BED CUSTOMER SUPPLIED BLUE MP SOLENOID BLACK 200 mA MAXIMUM RED LED BLACK SOLENOID B ENGAGE SWITCH CUSTOMER SUPPLIED GT BATT 87A START SOLENOID A ENGAGE SWITCH CIRCUIT CUSTOMER SUPPLIED TRANSMISSION MANUAL SOLENOID RETURN OVERRIDE SWITCHES BATE WIRING DIAGRAM OPTION 2 USED IF ELECTRONIC PROPULSION CONTROLLER SOLENOID B ON PROVIDES SWITCHED BATTERY POSITIVE RED LED DIRECTION OUTPUTS EC200 250 CONTROLLER SHOWN AS EXAMPLE GREEN TEMPERATURE SENSOR POWER GREEN LED BLACK Vv YO NORMALLY CLOSED BLACK E SOLENOID A NOT IN NEUTRAL RELAY BED um ACT CLOSED IN NEUTRAL A SED SOLENOID CUSTOMER SUPPLIED BLUE MP SOLENOID BLACK 200 mA MAXIMUM EDITED WHITE BLACK BLACK WHITE SOLENOID e OUTPUT SOLENOID HARNESS EC200 1018045 SERIES BED EC250 ASM203452 SERIES GREEN gt SOLENOID OUTPUT SEE NOTE 3 START CIRCUIT TRANSMISSION MANUAL SOLENOID RETURN OVERRIDE SWITCHES WIRING DIAGRAM OPTION 3 USED IF ELECTRONIC PROPULSION CONTROLLER PROVIDES SWITCHED BATTERY NEGATIVE DIRECTION OUTPUTS CONSULT TWIN DISC FOR MORE INFORMATION Figure 155 MG Profile Module Wiring Diagram 198 Marine Transmission Service Manual 1022294 Twin Disc Inco
107. VER 2103 THE TORQUE REQUIRED OVERCOME DETENT IS 11 17 Nm 10 15 lbf In UN ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTALD ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL BEARING M2087AD RACE M8086R GASKET B1334C COVER ASSY 1017336 CARRIER 1017335 BALL 1990 SEAL 778 1018163 du SNAP RING A2915S INSTALL USING MA908 PISTON SEE CHART LECTITE 242 SPRING ASSY SEE CHART PLATE SEE CHART SHIM SEE CHART NUT Me0e7C BALL M1990U SPRING 10504 GASKET 1017136B BALL 19900 BALL MI1990L BALL M1990M M8 X 125 6 TH D STEM 1017901 2 HOLES SHIM 2057 CAS REQ D2 SETSCREW M2041AB VALVE BODY 1017529 SEAL 5591 ADAPTER 1017530 SETSCREW 10370 SCREW IN UNTIL X 125 6H 191 DEEP 2 HOLES 1 BOTTOMS THEN LOOSEN H INSTALL USING MA908 5 S LOCTITE 242 gt NN 36 6 KA RING 2916 lt lt NE na m E 012274 4d 55 lt D NA n RING A2916DD INN m Tr A 3036 STs NE IZ SPRING A2701BM 5 3 7 22 bu PRN E SEE EN 2 8 EER SPRING A2701BN S RRS REIN oar PISTON P 10491 2
108. ace 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 damage Replace any defective parts including defective fasteners that are found Marine Transmission Service Manual 1022294 69 Preventative Maintenance Twin Disc Incorporated Heat Exchanger Check Inspect heat exchanger oil lines for leaky connections kinks cracks or other damage Replace damaged lines Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days If over 50 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist it is evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned
109. al 1022294 93 Disassembly Twin Disc Incorporated 4 Install eyebolts into the end of the output shaft and into the main housing mounting pads 5 Thread a heavy strap through the eyebolts the output shaft and the strap to the eyebolts in the main housing The strap will restrain the output shaft during disassembly Figure 42 Heavy Strap Restraining Output Shaft WARNING Always use retainer bolts or a safety strap to hold parts being separated with oil pressure Oil pressure applied between the two parts for disassembly can reach 300 Mpa 43500psi The use of proper safety equipment is mandatory when working with high pressure hydraulic tools The parts may separate with extreme force 6 Inject oil with a viscosity of 900 5 900 cSt at room temperature dismounting fluid into the output shaft until the shaft and gear separate Note Use caution to prevent damaging the taper of the output gear or shaft as the torque capacity can be reduced 7 Lift the output shaft out of the transmission using tool 18050 714 94 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly Remove four M10 x 25 sockethead capscrews and remove the trailing pump drive gear from the output gear Remove output gear assembly from transmission housing Tool T 19987 2 can be used to ease removal of gear from housing Figure 43 Removing Output Gear Assembly 10 Tapered roller bearing cups for
110. anges will not be covered by a Twin Disc warranty Marine Transmission Service Manual 1022294 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 1022294 15 Introduction Twin Disc Incorporated NOTES 16 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications Description and Specifications General The MG 5321DC 15 a reverse and reduction transmission It is enclosed a nodular iron housing and is available either with or without torsional input coupling freestanding The output shaft is parallel to the input shaft The transmission is controll
111. ary and Secondary Clutch Shaft Assemblies 1 Lift out primary and secondary shafts Disassembly of the primary and secondary shafts are covered later in this section Use caution with the front pinion bearing cones They are loose on the pinion diameter and should remain in the housing On some ratios the diameter of the output gear will allow the bearing to come out with the shaft and it could easily fall off causing damage Set the shafts aside for further disassembly Figure 39 Lifting Out Primary or Secondary Clutch Shaft Assembly 2 Remove front pinion tapered roller bearing cones that were pulled off by output gear as primary and secondary shafts were removed Note Tapered roller bearing cups of front bearings on the primary and secondary shafts are an interference fit in the housing Removal of these bearing cups should not be attempted unless replacement of the bearing is necessary 92 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly Remove Output Gear and Shaft 2 Use a hoist to lift the output shaft and gear assembly until the gear contacts the housing Place blocks under the gear to support the gear and shaft assembly in position Figure 40 Supported Gear and Shaft Assembly 3 Connect oil injection equipment to the 1 4 19 BSP threaded port on the rear end of the output shaft Figure 41 Oil Injection Equipment Connected to Output Shaft Marine Transmission Service Manu
112. ase 12 Apply a coat of assembly grease or oil to the O ring on the seal carrier 13 Install grease fitting if not previously installed 14 Install shim pack over bearing cup 15 Install assembled output seal carrier onto housing Use caution to avoid damaging the O ring Install attaching screws and torque to 112 Nm 83 ft Ib 16 Remove 18050 714 from output shaft Marine Transmission Service Manual 1022294 139 Assembly Twin Disc Incorporated Assembly of Primary and Secondary Shafts 140 Installation of Transfer Gear Rear Bearing and Clutch Piston 1 Assemble transfer gear to secondary shaft A Clean taper on secondary shaft and tapered bore in transfer gear using OSHA approved cleaner Do not touch cleaned surfaces Loctite 7070 cleaner is recommended Determine if secondary shaft and transfer gear can be advanced properly a Hold secondary shaft in a vertical position standing on its front end b Use a depth micrometer and measure distance from the rear end of the shaft to the shaft shoulder at small end of taper Record this distance as dimension A Install secondary transfer gear on secondary shaft taper small diameter of tapered bore up Seat gear on shaft taper with 445 N to 890 N 100 Ibs to 200 Ibs of force d Use a depth micrometer and measure distance from rear end of shaft to machined face of transfer gear at small diameter of tapered bore Record this distance as dim
113. ate of rise piston Neutral main pressure of approximately 40 psi is maintained by relieving excess oil behind the rate of rise piston through the ball and spring regulator Orifice Ball and Spring Regulator Figure 14 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Control Valve Assembly in Primary or Secondary Pressurized oil is directed to one of the transmission s clutches to engage tt The pressurized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the passage to the opposite clutch The pressurized oil also forces the ball of the ball and spring regulator against its seat on the orifice plate stopping the flow of oil from the rate of rise chamber to sump Since oil continues to flow into the rate of rise chamber through the orifice the oil pressure in the rate of rise chamber increases This increased oil pressure forces the rate of rise piston to stroke over to its stop in the valve body compressing the pressure regulating springs even further yet PRIMAR ro SECONDARY See gt Rate of rise piston Figure 15 Rate of Rise Piston in Neutral left and Rate of Rise Piston with Clutch Engaged right The travel rate of the rate of rise piston and resulting pressure rate of rise is controlled by the orifice size regulator spring stiffness and the final main pressure after completion
114. ator Adjust if proper equipment is available Replace pump Remove clean inspect and install the suction screen Inspect and correct cause of suction leaks Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil See Paragraph 1 Replace Proportional Valve Verify that green voltage supply light and red clutch energized lights are bright 79 Troubleshooting Twin Disc Incorporated 80 Marine Transmission Service Manual 1022294 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 The physical size and weight of many of the parts for this transmission assembly are such that adequate lifting devices and procedures are necessary for safety considerations This requires that the transmission assembly be adequately supported and properly positioned as identified in the following paragraphs Note These transmissions require the use of a SKF 300 Oil Injection Kit as seen in Special Tools or similar device to service the output flange and output gear Use the following reference The input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing
115. brown wires of the ASM203452 harness Plug the appropriate connectors from the Profile Generator into the appropriate Proportional Valves Plug the appropriate connectors from the Profile Generator into the Engine Speed sensor and the Propeller soeed sensor if equipped Plug the appropriate connectors from the Profile Generator into the Temperature sensor if equipped To initiate troll without the 0 5 volt dead band at minimum troll add a 100 ohm resistor between the potentiometer and the green wire When troll soeed current input is used to control trolling speed the orange and green troll soeed potentiometer input wires must be electrically connected together with a solder shrink connector The red wire must be insulated and all three wires secured When troll speed voltage input is used to control trolling speed the violet and green wires must be insulated and secured Marine Transmission Service Manual 1022294 Twin Disc Incorporated Installation PINK o n 0 RED 45V TROLL SPEED POTENTIOMETER 1K OHM 5202 ORANGE 0 0 TO 0 5 VOLT MINIMUM TROLL OPEN CA
116. c Incorporated It is 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 oteel 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 future realignment It may also be necessary to move the engine and transmission to one side or the other on the engine bed to obtain horizontal alignment This can be done with a jack placed horizontally between the engine and the foundation At the same time a stra
117. cations Loctite 242 to the threads of the input speed sensor pickup Install the pickup Turn the speed pickup until it touches the gear tooth O D and back off one complete turn Tighten the jam nut to 2 Nm 20 ft Ib If no speed pickup is used install the plug and O ring and torque to 88 Nm 65 ft lb n 1 11 i V Qm MN Figure 119 Install Input Speed Sensor Pickup Marine Transmission Service Manual 1022294 159 Assembly Twin Disc Incorporated Installation of Input Oil Seal Front Housing and Input Coupling 1 Apply a thin coat of M2828 anaerobic sealer to the 0 of the oil seal and also to the housing input oil seal bore Install the input oil seal with the driver of tool T 21553 37 Remove any excess M2828 sealant from the seal Figure 120 Installing Input Oil Seal 2 Install the front housing onto the transmission Torque the attaching screws to 112 Nm 83 ft lb 3 Check front housing runout Mount dial indicator on the input shaft with the probe on the front housing machined face Rotate the input shaft and note the total indicator runout The face runout must not exceed 0 41 mm 0 016 in for both SAE 0 and 00 housings Figure 121 Measuring Front Housing Face Runout 160 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly B Move the dial indicator s probe so it m
118. ce The initial pre filled 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 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 Note Installations with this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 75 or better Besides the valve s requirement on filtration the filter must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1022294 A Operation Twin Disc Incorporated va ANUAL DIRECTIONAL CONTROL VALVE FILTER BY PASS OPTIONAL CNOJCA TOR Figure 7 Hydraulic Schematic GP control valve 42 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation PRIMARY SECONDARY CLUTCH CLUTCH SPRING RELEASED CLUTCHES OPTIONAL HYDRAULIC v PROPORTIONAL V
119. cifications D Tighten the jam nut to a torque of 20 Nm 15 ft Ib install the protective cap and torque it to 14 Nm 10 ft Ib Marine Transmission Service Manual 1022294 171 Assembly Twin Disc Incorporated 172 Assembly of Electrical Control Valve 1018084 Upper Body Half 1 Install one dowel pin large diameter into each of the two bores of the valve body 2 Install one spring into each of the two bores of the valve Figure 133 Dowel Return Spring Spool and Plug 3 Install one spool into each of the two bores of the valve 4 On units equipped with the hydraulic lock feature install one spring followed by one pin small diameter into each of the spools 9 Install the two O ring plugs into the valve body and tighten to 85 Nm 63 ft lb 6 Apply lubricant such as Dow Corning 2009 30 000cSt fluid to the O rings of the solenoids and plug plug used on units without hydraulic lock Install solenoids and plug if equipped into the valve body and torque them to 34 Nm 25 ft Ib 7 Insert the wires pins into the Weatherpak connector according to the location markings made at disassembly Close the end of the Weatherpak connector to lock the wires in position Install the Weatherpak connector onto its retaining clip on the top of the valve body Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Lower Half Electric Valve 1018084 and
120. clutches to engage at a controlled rate The control valve allows only one clutch to be engaged at a time 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 Control Valve Assembly in Neutral 46 Some of the main pressure oil from the oil inlet chamber flows through a passage to the orifice in the orifice plate The small flow of oil through this orifice fills and begins to pressurize the rate of rise chamber Both clutches are connected to sump when the control valve is in Neutral Since there is no pressure acting on the shuttle ball from either clutch the passage behind the ball and spring regulator is also connected to sump This allows the oil pressure in the rate of rise chamber to be regulated by the ball and spring since the overage oil can flow to sump The oil pressure in the rate of rise chamber acting on the rate of rise piston causes it to stroke over partially which compresses the pressure regulating springs additionally This additional spring compression further resists the movement of the pressure regulating piston resulting in a force balance between the area at the pressure regulator the springs and the area behind the rate of rise piston Neutral main pressure of approximately 40 psi is maintained by relieving excess oil behind the rate of rise piston through the ball and
121. crew using four M8 x 25 capscrews Evenly tighten the capscrews and torque to 23 Nm 17 Ft Ib Install the cap onto the adjusting screw finger tight as the main pressure must be set at the time of installation or testing Marine Transmission Service Manual 1022294 167 Assembly Twin Disc Incorporated Figure 127 Assemble Main Pressure Regulator Components 2 Assemble the Top Valve Body Install the two proportional valve assemblies into the valve body install the retaining plate and torque the 6 1 00 16 socket head capscrew to 9 5 Nm 7 ft lb Install the Manual Direction Control Valve into the body and torque to 27 20 Ft Ib Install the M12 x 1 50 o ring plug into the valve body and torque to 16 Nm 12 ft lb Connect the wires for the Neutral Switch E Proportional Valves Manual M12x 1 50 m Override o ring plug Valve Top Valve Body h 4 ff Figure 128 Assemble Valve Body Components 168 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 3 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 pscrew
122. d Joints E For previously sealed joints scrape surfaces to remove old gasket material or silicone E Clean surfaces with solvent to remove oil and grease residue Test clean surfaces by applying few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface film If the water puddles or forms beads use fresh solvent and reclean Marine Transmission Service Manual 1022294 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 and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will cause loss of press 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 solvent Inspect machined surfaces for burrs scratches nicks and foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part Inspect ground tapers for burrs nicks If you cannot remove the defect with a soft stone replace the part Inspect ground tapers for scratches galling scoring damage If any of these the defects replace the part Inspect threaded openings for damage
123. d 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 damage Replace defective dowels This applies where a matched set of parts is not involved 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 1022294 121 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 rollers Inspect for scored scratched cracked pitted or chipped races If 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 bu
124. dded 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 marine transmissions MG both with and without the trolling E Troll feature All electrical wiring for the marine transmission system controls are routed through this interface module The vessel battery power 12 vdc or 24 vdc is supplied to the electronic interface only and never directly to the hydraulic proportional valves Two red led lights are used to identify the proportional cartridge valve that is energized and a green led is used to identify when power 15 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 required for some marine transmission MG models Engine speed and Propeller speed sensors are required for transmissions with E Troll The following figures show the various versions of the Electronic Profile or E Troll Module i VI A HN ING Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System Marine Transmission Service Manual 1022294 39 Operation Twin Disc Incorporated Figure 5 Electronic Profile Module MG non troll Solenoid on Red LED Power
125. e 210 T 18050 723 Bearing cone and transfer gear driver 211 T 18050 771 Front output bearing cup driver 212 T 19330 Spring retainer compressor 1 213 T 19987 2 Output gear lifting fixture 214 T 20023 4 Output gear installing fixture 215 T 21433 Output flange installing fixture 218 T 21506 Output shaft bearing driver 221 1 21533 37 Input seal driver and protection sleeve 223 T 506000 Lifting Bracket for Clutch Removal in Boat 224 Engineering Drawings 225 1015339A Marine Transmission 226 A7119AG Hydraulic Diagram 230 1016473 Trailing Pump Assembly 231 1017177 Auxiliary Pump Drive Group 232 10170206 PTO Assembly ESPRIME 233 1017546 Control Valve w trolling valve 234 1017172 Control Valve w out trolling valve 235 1018084 Control Valve w out trolling valve
126. e 0 20 mm 0 008 inch Clutch Friction Plates Maximum cone 0 25 mm 0 010 inch Minimum thickness 3 48 mm 0 137 inch Marine Transmission Service Manual 1022294 33 Description and Specifications Twin Disc Incorporated 34 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Operation General The Control Valve is used to obtain neutral 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 provides a rapid smooth clutch engagement There are three different valves that can be used to control the transmission They will be discussed individually in the following pages Marine Transmission Service Manual 1022294 35 Operation Twin Disc Incorporated GP Control Valve with Electronic Interface 1020941C 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 Figure 2 GP Valve Assembly mounted on Marine Transmission typical 36 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation GP Control Valve Hydraulic Portion The hydraulic portion of the GP Control Valv
127. e 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 Transmission Service Manual 1022294 183 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
128. e body bore and main oil pressure is not reduced The trolling valve is actuated by sending a controlled amount of current through the 5 coil As the current is increased the orifice progressively opens allowing oil pressure from the rate of rise chamber to escape to sump Since oil is always flowing into the rate of rise chamber through the orifice in the orifice plate the pressure in the rate of rise chamber is controlled by how much oil is allowed to exit through the trolling 5 variable orifice Since the oil pressure in the rate of rise chamber is reduced clutch pressure is reduced which allows the clutch plates to slip The amount of clutch slip is controlled by the current flow amps through the 5 coil Decreasing the current through the valve s coil will increase clutch pressure and therefore reduce clutch slip Main oil pressure is always the same as the oil pressure in the engaged clutch with this type of trolling valve The 1017170 valve contains no user serviceable parts and is available only as an assembly Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Power Take off Optional There is a separate manual part number 1020075 which describes the operation installation troubleshooting and service of the optional Power Takeoffs PTO for this marine transmission Live Power Take off 1017177 The live PTO drives accessories using engine horsepower Since the live
129. e is made up of two blocks a lower main regulator valve body and an upper valve body These valve bodies contain two electrically actuated proportional cartridges a hydraulic pressure regulator and a manual direction control cartridge valve 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 that is closed when the valve is in the neutral position Separate identical proportional cartridges are used for the primary and secondary clutch actuation When the primary or secondary clutch is selected by the operator the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate of rise profile is controlled electronically by the GP Control Valve Electronic Interface Profile or E Troll Module to provide a rapid smooth oil pressure increase in the clutch hydraulic passages during engagement i C AU TION 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 this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 2 75 or better Besides th
130. e 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 152 Checking Output Flange Face Runout Marine Transmission Service Manual 1022294 191 Installation 192 Twin Disc Incorporated Figure 153 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 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 ou
131. e valve s requirement on filtration the filter must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1022294 37 Operation Twin Disc Incorporated Proportional Valves Manual Override Valve Top Valve Body EMEN 3 Figure 3 Top Hydraulic Valve Body Assembly ATTE Regulator Valve Body Pressure Adjustment Figure 4 Main Regulator Hydraulic Valve Assembly 38 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation GP Control Valve Electronic Control Interface Profile or E Troll Module Note Some installations will consist of the hydraulic portion of this valve and the Electronic Control Interface will be replaced by an appropriate electronic control system The electronic portion of the GP Control Valve fastens to the hydraulic portion of the GP Control Valve and is located on the top surface im VARNING 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 embe
132. easures the O D of the front housing pilot diameter Rotate the input shaft and note the total indicator runout The pilot runout must not exceed 0 30 mm 0 012 in for both SAE 0 and 00 housings Should total indicator runout exceed the allowable limits contact the Product Service Department of Twin Disc Inc for information and recommendations On units using Vulkan or Centa input couplings the input shaft splines are aslip fit If the transmission is to be shipped with the input coupling installed it must be attached to prevent it from sliding off and causing damage Be sure the internal retaining ring is installed into the correct groove of the input hub on units using a Vulkan input coupling refer to transmission assembly drawing The torque specification for the M20 screws that attach the coupling element to the coupling hub is 530 Nm 391 ft lb with lubricated threads On free standing units install the input hub The spline fit with this hub is a tight fit therefore it is recommended to heat the coupling to 66 C 150 F to ease installation The use of silicone spray lubricant on the shaft is also recommended Install the retainer washer and capscrews with torque of 112 Nm 83 ft Ib The torque specification for the M22 x 1 5 screws that attach the coupling element to the coupling hub is 820 Nm 605 ft lb with lubricated threads Marine Transmission Service Manual 1022294 161 Assembly Twin Disc Incorporated Insta
133. ed as specified above contact the Product Service Department at Twin Disc Incorporated for information Marine Transmission Service Manual 022204 11111111111 14 Assembly 142 Twin Disc Incorporated Install heated tapered roller bearing cone onto shaft against clutch housing Install bearing with large O D toward transfer gear Use driver T 18050 723 and hydraulic press to ensure bearing is fully seated against transfer gear Install the external retaining ring onto the shaft with the tapered edge side away from the bearing Install clutch piston inner seal ring into groove in secondary shaft Apply a coat of assembly grease or oil to seal ring Install multi piece seal ring in groove in O D of clutch apply piston as follows A Install the expander into the piston seal ring groove Install the first seal ring section into the groove over the expander ring Install the second seal ring section into the groove over the expander ring with the ends rotated 180 from the ends of the first seal ring Install the third seal ring section into the groove over the expander ring with the ends rotated 90 from the ends of the first seal ring Install the fourth seal ring section into the groove over the expander ring with the ends rotated 270 from the ends of the first seal ring Apply a coat of assembly grease or oil to the seal ring Marine Transmission Service Manual 1022294 Twin Disc Incorporated
134. ed by hydraulics both the primary and secondary clutches are operated by main pressure oil supply Bearings clutches and gears are lubricated and cooled with low pressure oil Helical gearing provides quiet operation and is currently available in the following ratios 6 39 1 5 96 1 5 46 1 4 96 1 4 42 1 4 06 1 and 3 35 1 Components of transmission are identified on drawing no 1015339A Nameplate The nameplate identifies the model bill of material BOM and the serial number of the unit These numbers are necessary to identify the correct parts for your transmission a
135. ely to prevent corrosion Examine all parts carefully for grit dirt abrasives and reclean them if necessary Clean all oil passages by working piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent to flush oil pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or in the vicinity of all pusher screw locations Marine Transmission Service Manual 1022294 119 Cleaning and Inspection Twin Disc Incorporated 120 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 Never dry bearings with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently itis important to keep bearings clean Do not remove grease from new bearings Keep the wrapper on new bearings until they are installed Do not expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Seale
136. ension B Calculate expected advance Expected advance Calculated advance must be 2 67 mm to 3 71 mm 0 105 to 0 146 If calculated advance 15 not within the range recheck all measurements and calculations for errors If no errors are found contact the Product Service Department at Twin Disc Incorporated for information set secondary transfer gear on fixture T 18050 723 with large diameter of tapered bore up Move fixture and transfer gear toa press with at least 667 KN 75 tons capacity Install secondary shaft front end up into tapered bore of transfer gear Seat shaft in tapered bore of gear by applying 445 N to 890 N 100 Ibs to 200 Ibs downward force on shaft Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Center fixture gear and shaft under ram of press and apply approximately 391 KN to 543 KN 44 tons to 61 tons of force on front end of secondary shaft Release pressure and turn fixture shaft and gear 180 Reapply pressure to complete advance Figure 93 Pressing Clutch Shaft Into Transfer Gear Note Using a depth micrometer measure distance from rear end of shaft to face of transfer gear Record as dimension C Transfer gear face should be within 0 05 mm 002 in of the shaft shoulder at the small diameter end of the taper Actual advance C B must be 2 67 mm to 3 71 mm 0 105 in to 0 146 in If transfer gear has not been advanc
137. ent of gear on shaft and adversely effect torque carrying capacity of the assembled joint Both parts must be at the same temperature Marine Transmission Service Manual 1022294 131 Assembly Twin Disc Incorporated Install the front output bearing cone into the cup in the housing Install the output gear in the housing Use special tool 19987 2 to position gear into the correct location Be sure the gear is centered on the bearing cone q Figure 84 Installing Output Gear in Housing 4 132 Working through the output bearing opening in the housing install the trailing pump drive gear onto the output gear Insert two M10 x 40 dowel pins in output gear Place drive gear on dowel pins and attach the gear with four M10 x 25 sockethead screws Torque the screws to 75 55 ft lb Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 5 Install the output shaft into the output gear and bearing cone in the transmission housing using T 18050 714 Seat shaft onto the taper of the gear using only the weight of the shaft Figure 85 Installing Output Shaft 6 Connect the oil injector to the output shaft 7 Use portable press with 1340 150 ton capacity and fixture T 20023 4 to seat hub using 1340 N 300 Ibf load Figure 86 Output Gear Advancing Tools Installed Marine Transmission Service Manual 1022294 133 Assembly 134 10 11 1
138. er valve section and O rings Remove eight M12 by 35 capscrews and one M10 x 20 capscrew and remove ditch plate and gasket Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 11 Remove the oil filter assembly A Remove the oil filter element B Remove four M12 x 50 capscrews and washers and remove the filter head Remove the filter bypass cartridge valve from the filter head Figure 30 Remove Oil Filter 12 Remove the M12 x 25 capscrew washer and securing clamp plate for suction strainer cover Remove suction strainer cover with O ring and suction strainer Figure 31 Removing Suction Strainer 13 Remove the oil level gauge and tube assembly from the housing 14 Rotate the transmission Block and support the transmission with the output side facing up Use caution to avoid damaging the primary shaft Marine Transmission Service Manual 1022294 87 Disassembly Twin Disc Incorporated Remove Output Flange 1 Loosen each of the five M12 x 45 output flange retaining washer capscrews approximately six revolutions resulting in a 9 mm 0 35 inch gap below each screw head capscrews and washers will be used to restrain the output flange when it separates from the output shaft WARNING Always use retainer bolts or a safety strap to hold parts being separated with oil pressure Oil pressure applied between the two parts for disassembly can reach 300 Mpa 43500psi
139. ess away from potential hazards For example a capscrew cutting through the jacket and shorting a conductor to the chassis welding drilling heat exhaust burrs sharp edges etc Prevent the cable from becoming a step or handrail Make sure connectors will mate properly Locate and use the connector orientation key Circular connectors must be hand tightened and lock wired if possible Cable or harness bend radius must not be less than eight times the cable diameter Avoid twisting or winding the cable along its axis during installation or removal Marine Transmission Service Manual 1022294 193 Installation 194 11 12 13 14 15 16 17 18 19 Twin Disc Incorporated Whenever mating connectors always inspect each for damage or defects For example bent pins pushed back sockets broken keys etc Boots must be secured to cable or harness with cable tie to prevent boot from sliding off connector Cable tie must be installed over cable or harness and butted up against boot where the cable or harness exits the boot Cables must not be installed in a manner which puts strain on the connector or results in more than twenty four inches of excess length Be sure that metal clamps and cable ties do not cut through cable installation Check that all circular connectors are hand finger tight Check that oure Seal connectors have clip clamps in place Check that Weather Pack Metri Pack and Deu
140. ether The secondary input pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when the unit is in the secondary position om FS URS ME Minne apiri gtd mu ie Figure 24 Example of Power Flow with Secondary Clutch Engaged Marine Transmission Service Manual 1022294 63 Operation Twin Disc Incorporated 64 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance In boat Maintenance and Repair Certain transmission maintenance repair procedures be accomplished in the boat provided sufficient soace exists to work These procedures are Removing and installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Hemoving and installing the control valve Removing and installing the manifold Note Further disassembly reassembly of the primary or secondary shafts will require removal from the engine and the use of tools and equipment normally not available on board the vessel Lubrication Grease the oil seals on the output end of the output shaft th
141. external retaining ring to retain pinion on shaft S 3 gt 4 E h Figure 101 Installing External Retaining Ring Onto Clutch Shaft Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 8 Assemble primary shaft Repeat previous procedure steps assembly procedure for primary shaft is the same as for the secondary shaft and also includes the following Applicable to primary shaft only A Place two spacers about a half inch thick on the face of hte pinion Heat the input oil seal sleeve and place it on the shaft until it rests on the spacers Note that the groove for the O ring is over the undercut area of the shaft Allow the seal sleeve to cool to avoid injury Install the O ring over the shaft and work it into the groove inside the seal sleeve Hemoe the spacers Use tool 21553 39 and drive the seal onto the shaft making sure that the O ring remains in its groove The setscrew holes will now align with the machined groove in the shaft Apply MA9068 threadlocker to two 10 24 x 3 8 inch setscrews and secure the sleeve to the shaft Torque the screws to 18 Nm 13 ft lb Figure 102 Installing Sleeve on Primary Shaft Marine Transmission Service Manual 1022294 149 Assembly Twin Disc Incorporated Installation of Clutch Shafts Bearing Carrier and Manifold 1 Install clutch shaft assemblies into the transmission housing Use ca
142. f the large diameter ball at each switch location Install the pressure regulating piston into valve body with spring pocket Out Marine Transmission Service Manual 1022294 175 Assembly 22 23 24 Twin Disc Incorporated Install pressure regulating springs into valve body and into piston spring pocket Install the shims that were removed into the bore of the rate of rise piston Install the rate of rise piston over the springs and into valve body Install neutral pressure regulating spring into the pocket of valve body Figure 138 Neutral Pressure Regulating Spring Location 25 26 27 28 29 176 Install orifice plate gasket onto valve Install orifice plate and steel ball against spring onto valve body Install orifice plate cover and gasket onto valve body Install cover capscrews and torque to 23 17 ft lb Install gasket over lower valve body half Set upper valve body half over lower valve body half Insert the valve attaching screws through valve body halves to keep parts in alignment until installation onto the transmission When installing the valve onto the transmission torque the screws to 54 Nm 40 ft lb Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Assembly of Trolling Valve optional equipment 1 Press a new oil seal into the counterbore in the end of the adapter Install a new O ring into the groove of the adapter
143. fter or more often if conditions warrant For a rebuilt transmission check the filter element and or screen after eight hours of operation If the filter and or screen is clean install a new filter element and then change the oil and filter element after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the filter is clean and then change the oil and filter after 1000 hours of service or more often if conditions warrant Marine Transmission Service Manual 1022294 Twin Disc Incorporated Preventative Maintenance Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Use a 38 mm wrench to loosen the drain plug Oil Suction Strainer Hemove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located in the manifold below the pump oee Engineering Drawings for suction strainer location See discussion under oil change interval Type Oil Recommended oee Description and Specifications Filling Remove the filler breather in the top of the transmission Fill the transmission s sump with the proper weight and type oil See Description and Specifications for oil recommendations otart the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level
144. g Replace a worn or damaged coupling Excessive torsional vibration Select proper torsional coupling Worn or damaged gears Overhaul marine transmission Improper alignment Check alignment of engine and transmission output flange to propeller shaft Correct as necessary Damaged propeller 5 6 Repair propeller Misfiring engine 5 7 Repair engine 78 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Troubleshooting Table 17 Troubleshooting Chart continued 1021658 and 1020941 GP Control Valves with Electronic Interface 6 neutral Harsh engagement Low lube oil pressure Oil spilling out of breather Low Clutch Apply Pressure 6 1 Clutch plates warped Disengaged clutch has apply pressure Faulty Proportional Valve Faulty Temperature Sensor if equipped Profile Generator defective or out of adjustment Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Low Main Pressure Defective Proportional Valve Low voltage to Profile Generator Marine Transmission Service Manual 1022294 Remove clutch plates Overhaul unit Replace Proportional Valve Service transmission oil filter Replace Proportional Valve Replace Temperature Sensor Replace Profile Gener
145. h or one wrapped with tape will ease the installation of the hollow setscrew Tighten the setscrew until it is flush with the gasket surface of the valve body Check the stem rotation and detent action Figure 136 Installing Detent Ball Setscrew Marine Transmission Service Manual 1022294 Twin Disc Incorporated 10 11 12 13 14 Assembly Install the thrust washer over the end of the stem Press the oil seal into the cover assembly until flush with the adjacent cover surface Install the O ring into the counterbore in the cover assembly Apply grease to the stem O ring and oil seal lip Install cover assembly and gasket onto valve body Be sure to align the oil drain hole in the gasket with the hole in the valve body Figure 137 Holes in Gasket and Cover Must be Aligned 15 16 17 18 19 20 21 Install cover capscrews and torque to 23 Nm 17 ft lb Install washer over stem and against oil seal Install spring over stem against washer Install lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew may be damaged Torque the lever s attaching screw to 9 5 Nm 7 ft Ib Install external retaining ring onto stem Install the steel balls and electrical switches into the bores in the sides of the valve body if equipped Note that the small diameter ball is inboard o
146. he primary and secondary shafts are lubricated through drilled passages in the shafts Output shaft bearings are gravity and splash lubricated Suction Screen A serviceable suction strainer located below the oil pump between the Sump and oil pump in the hydraulic circuit The strainer can be replaced 11 necessary Filter Assembly An canister style filter is located between the oil pump outlet and the selector valve in the hydraulic circuit The replacement element is Twin Disc part number 1016502 This should be replaced at 1000 hour or six month intervals whichever comes first 20 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications Flexible Torsional Input Coupling The purpose of the torsional coupling is to transmit power from the engine to the marine transmission through a rubber or silicone element that will Dampen torsional vibrations Change the natural frequencies of a system to move critical frequencies out of the operating speed range Accommodate a certain amount of misalignment Absorb shock and reduce noise Minimize gear rattle several couplings are available from Twin Disc and are selected based on the customer supplied engine information Final coupling selection must be confirmed by the packager based on the torque rpm ratings and the results of the system torsional vibration analysis TVA and on engine rotation Care must be taken w
147. he shim pack and retainer washer onto the output shaft Install the screws and torque them to 112 Nm 83 ft lb Figure 117 Installing Output Flange Retainer Washer and Shims 16 Attach dial indicator to housing with probe resting on face of output flange Locate indicator probe as close to O D of flange as possible Check flange face runout by rotating flange Total indicated runout must not exceed 0 10 mm 0 004 in Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 17 Attach dial indicator to housing with probe resting on O D of output flange pilot Check pilot runout by rotating output flange Total indicated runout must not exceed 0 10 mm 0 004 in Note Should total dial indicator runout exceed 0 10 mm 0 004 in the flange must be removed and reinstalled on the shaft taper 18 Install the O ring plug into the oil injection port of the output flange and torque to 16 Nm 12 ft Ib Speed Sensors if equipped E Troll units only Apply anaerobic sealant meeting 908 specifications Loctite 242 to the threads of the output soeed sensor pickup Install the pickup Turn the speed pickup until it touches the gear tooth O D and back off two complete turns Tighten the jam nuts to 27 Nm 20 ft lb 9 ea i MINE 1 Figure 118 Install Output Speed Sensor Pickup 2 On E Troll units only Apply anaerobic sealant meeting MA908 specifi
148. hen servicing that replacement couplings are matched to this criteria Marine Transmission Service Manual 1022294 21 Description and Specifications Twin Disc Incorporated 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 HEAT EXCHANGER H E REQUIREMENTS PERMISSIBLE OIL TEMPERATURE INTO HEAT EXCHANGER RATIO ALL RATIOS 65 CC150 F ALL RATIOS SAE 50 93 C 200 F Eq _ _______ _ MIN HEAT TRANSFER CAPACITY kwW amp BtuzZmin3 PER ENGINE RTD APPLY APPROPRIATE SERVICE FACTOR CONT amp MED DUTY INT LIGHT amp P C DUTY FOR FRESH ANB RAW WATER 035 L484 O30 1 272 APPROX DIL FLUW H E 2 91 L minglo6b FER 100 ENGINE rpm PEAK DIL PRESSURE PROOF TEST AT 15 X kPa psi 690 lt 100 psi ALLOWABLE OIL PRESSURE DROP ACROSS HE WITH 207 kPa 66mm s 300 SUS DIL RATED ENGINE rpm 30 psid MAX ALLOWABLE WATER PRESSURE DROP ACROSS HE 15 psd WATER FLOW TO HE USE 18 TO 3D TIMES OIL LZnmin gpm WATER PRESSURE RATING MIN 15 X HE INLET WATER DATA HE PURCHASER MUST ALSO TELL VENDOR STATE IF RAW OFEN CHANNEL amp SEA FRESH CCLUSED ENGINE JACKET AND OR KEEL COOLER WATER WILL COOL STATE WATER TEMP HE TYPICAL RAW WATER 29 C 32 C BS F 90 F gt K
149. hrough either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation when viewing rear of engine This transmission cannot be driven by a left hand rotation engine Contact an authorized Twin Disc distributor for more information Transmission clutches are hydraulically applied using main oil pressure All bearings clutches and gears are lubricated and cooled with low pressure oil Always reference the Bill of Materials BOM or specification number when ordering service parts Changing Rotation These units can be used only with engines of R H rotation Direction of Drive The primary input clutch shaft and driving transfer gear always rotate 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
150. ic Lock Units The resulting reaction is a force on the spool that overcomes the 5 return spring force Should the solenoid become de energized while the spool has its clutch pressurized oil pressure will keep the spool in that position This keeps the transmission in gear as long as the engine 15 running 54 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation The hydraulic lock is disabled when either the engine is stopped or the neutral solenoid is energized When the neutral solenoid is energized it sends pressurized oil to the dowel pins at the return spring end of each spool Since the dowel pin used at the return spring side of the spool is larger in diameter than the dowel pin inside the spool the hydraulic force acting on the larger pin forces the spool to connect the clutch passage to sump with assistance from the return spring Dowel pin Return spring Figure 19 Neutral Solenoid Engaged Marine Transmission Service Manual 1022294 55 Operation Twin Disc Incorporated Manual Override Operation The control valve has a manual override feature which is a lever operated selector When the manual override lever is rotated counterclockwise and pulled outwards the upper portion of the valve is disabled because the connecting slots in the manual override stem are no longer aligned with the oil passages in the valve body Oil pressure from the solenoid operated pilot valve controlled
151. ight 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 FEMALE MALE STRAIGHT EDGE Figure 151 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1022294 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 not exceed 0 10 mm 0 004 in Excessive face runout on the marine transmission output flange can usually be corrected by repositioning the coupling on its spline or taper Excessive shaft coupling runout is usually due to inaccuracy of th
152. il Pressures Table 1 Limits for Marine Transmission equipped with 1020941C Control Valve and 2415 kPa 350 psi proportional valve and 1000 mA supply current P 5 Neutral Valve Inlet Primary Secondary Cooling Hm Act Min Act Min Act Min Act Temp kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa psi est ps psi psi psi m psi psi Cooling Temperature Range Delvac 1110 29 35 C 85 95 F Required Primary lube pressure secondary lube pressure within 21 kPa 3 psi A reading outside limiting range could mean Valve inlet pressure Faulty valve springs sticky valve pump flow too low forgotten or cut seal rings Primary and 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 Table 2 Limits for Marine Transmission equipped 1020941C Control Valve with 2415 kPa 350 psi Proportional Valve and 320 mA supply current Min kPa psi Act kPa psi Max kPa psi Min kPa psi Act kPa psi Max kPa psi Marine Transmission Service Manual 1022294 25 Description and Specifications Twin Disc Incorporated Table 3 Limits for Marine Transmission equipped with 1017172Q 1017546F or 1018084 Control Valve 2000 kPa 290 psi Spring P primary S Secondary N Neutral Vane Ta Cooling Min Act
153. ing into the bore of the control valve if removed Marine Transmission Service Manual 1022294 179 Assembly Twin Disc Incorporated 16 Install the steel ball onto the neutral pressure regulating spring Figure 143 Installing Neutral Pressure Regulating Spring and Ball 17 Install the orifice plate gasket orifice plate trolling valve gasket and trolling valve onto the control valve Install the attaching screws and torque them to 23 Nm 17 ft lb E Figure 144 Installing Orifice Plate left and Trolling Valve onto Valve Body right 180 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Installation of Electric Control Valve 1 Install control valve ditch plate and gasket Torque the ditch plate attaching capscrews to 112 Nm 83 ft lb 2 Install control valve and gasket Torque the attaching capscrews to 54 Nm 40 ft lb Marine Transmission Service Manual 1022294 181 Assembly Twin Disc Incorporated 182 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Installation Installation Prior to Installation A CAUTION Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be mad
154. ker to two M12 x 35 sockethead screws and attach the pump adapter to end of secondary shaft with them Torque screws to 130 Nm 95 ft Ib Figure 110 Attach Pump Adapter Marine Transmission Service Manual 1022294 153 Assembly Twin Disc Incorporated 15 Install the manifold over the bearing carrier and gasket Use a soft hammer near the dowels to seat the manifold against the gasket and over the dowels Figure 111 Install Manifold 16 Install 26 M12 x 60 manifold attaching screws and torque to 112 Nm 83 ft Ib Figure 112 Manifold Attaching Screws 154 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Installation of Output Flange If removed during disassembly install the speed pickup gear onto the rear of the output flange with the internal chamfer of the gear towards the flange Apply MA908 Locktite to the capscrew threads and torque the four M8 x 16 socket head capscrews to 37 Nm 27 lb ft Clean tapered surface of output shaft and tapered bore of output flange Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Do not touch cleaned surfaces Loctite amp 7070 cleaner is recommended Tapered surface of shaft and matching tapered bore of flange must be completely free of grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance measurement of flange on shaft and adversely effect t
155. late and remaining gasket Remove one M8 x 30 capscrew that retains the anode to the housing only if the anode must be replaced Units with optional fresh water heat exchanger A Remove 14 M12 x 160 capscrews and remove housing heat exchanger and gasket Remove 12 M12 x 45 capscrews and remove ditch plate gasket Note that removal of this plate also pertains to units with a customer supplied heat exchanger Heat Exchanger Control Vave Figure 29 Heat Exchanger and Control Valve Marine Transmission Service Manual 1022294 85 Disassembly 86 10 Twin Disc Incorporated Remove control valve assembly Remove mechanical valve assembly 1017172 A Remove four M10 x 120 sockethead capscrews and remove cover and valve assembly with gaskets Remove one M10 x 45 sockethead capscrew and eight M12 x 55 sockethead capscrews Remove ditch plate and gasket Remove electric valve assembly 1018084 A B Remove four M10 x 150 sockethead capscrews and remove both valve sections with gaskets Remove one M10 x 45 sockethead capscrew and eight M12 x 55 sockethead capscrews Remove ditch plate and gasket Remove GP control valve assembly A Loosen four M10 x 10 capscrews and remove control module if it was not left with the engine Remove six M10 x 70 capscrews and remove top valve section and gasket Remove four M10 x 35 capscrews and remove low
156. lectrical loads should be connected to this circuit Wiring Options The following power connection schematics show the possible configurations for connecting Electronic Profile or E Troll Module to the power source for the three possible wiring options LJ Option 1 connections are used when the Profile or E Troll Module direction control is mechanically switched LJ Option 2 connections are used when the Profile or E Troll Module direction control is from an electronic controller that provides switched battery positive direction outputs Option 3 connections are used if the electronic propulsion controller provides switched battery negative direction outputs Twin Disc must be consulted for additional information Marine Transmission Service Manual 1022294 195 Installation 196 Twin Disc Incorporated Make the following Connections 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 When the not in neutral circuit is not used the following wires must be insulated and secured 0 Profile Module Black and White wires All others Blue and Black wires 200 250 applications Remove weather pack connector from the control s solenoid harness If EC250 insulate and secure the blue and
157. llation of Exterior Components 1 Install new O rings onto the plugs used for the clutch and lube pressure test ports Lubricate the O ring and threads and install the plugs Torque each plug as indicated below Torque Size 7 Wa Pesus T X Wi2x 18 Pun Clutch First Pressure M14 x 1 5 20 Primary Clutch Second Pressure M12x 1 5 16 9 Primary Clutch Lube M18 x 1 5 34 25 Secondary Clutch First Pressure M14 x 1 5 20 15 Secondary Clutch Second Pressure M12x 1 5 16 9 Secondary Clutch Lube M18 x 1 5 34 25 2 Install suction strainer into bore in manifold Apply assembly grease or oil to the suction screen cover O ring and install O ring into groove in the cover Install suction screen cover in housing and secure with clamp plate and screw Torque attaching M12 x 25 screw to 112 Nm 83 ft lb Figure 122 Install Suction Strainer 162 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 3 Install O ring into groove in face of manifold at primary shaft Install cover onto manifold at primary shaft Install attaching screws and torque to 112 Nm 83 ft lb Figure 123 O ring Installed left and Cover Installed right 4 Install the oil pump gasket and oil pump Mesh drive tang on pump shaft with drive slot in secondary shaft drive adapter Install four M12 x 45 attaching screws and torque to 112 Nm 83 ft lb Figure 124 Oil Pump Installed
158. ls for installation 3 Beginning with a friction plate alternately install 10 friction plates and 9 steel plates into clutch housing transfer gear against clutch apply piston Marine Transmission Service Manual 1022294 145 Assembly Twin Disc Incorporated 4 Install clutch backplate and internal retaining ring Figure 97 Installing Clutch Backplate Assemble Pinion A Use tool T 18050 708 to install chilled tapered roller bearing cup into rear of pinion for secondary shaft Bearing is installed with small 1 0 of taper toward the front and seated against shoulder of bore in clutch hub of pinion Figure 98 Installing Tapered Roller Bearing Cup Into Pinion 146 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly B Use tool 18050 705 to install chilled needle roller bearing into bore at front of pinion with the rounded edge of the outer race entering the pinion first Figure 99 Needle Roller Bearing Installed C Install internal retaining ring into groove in pinion bore Figure 100 Installing Internal Retaining Ring Into Pinion Marine Transmission Service Manual 1022294 147 148 Assembly Twin Disc Incorporated 6 Align plates in clutch pack and install pinion on secondary shaft so that external teeth on clutch hub mesh with internal teeth of steel plates in clutch pack Assure that clutch hub is in mesh with all clutch plates 7 Install
159. ly can be accomplished with transmission standing upright 1 Remove the torsional coupling and hub from the primary shaft spline if not previously removed The coupling hub is a slip fit on the spline Note the position of the internal retaining ring inside the hub it must be reinstalled in that position at reassembly Note Some models may have a retaining plate with capscrews to clamp the input coupling adapter to the input shaft Figure 26 Removing Torsional Coupling if equipped 4 Support front housing with a hoist Remove M12 x 45 capscrews 20 with SAE 0 housing 23 with SAE 00 housing and remove the front housing from the main housing 5 Hemove two M10 x 20 capscrews and remove output sensor if equipped Loosen aam nut and remove input sensor if equipped Marine Transmission Service Manual 1022294 83 Disassembly Twin Disc Incorporated 6 Remove 24 M12 x 45 capscrews and washers and remove the top cover and gasket Figure 27 Remove Front Housing if equipped Top Cover ie Remove hose from pump and housing 8 Remove four M12 x 45 capscrews and remove the oil pump and gasket Figure 28 Remove Oil Pump and Related Components 84 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 9 Remove the heat exchanger assembly Units with standard raw water cooler A Remove 12 M12 x 155 capscrews and remove the housing with anode Remove gasket p
160. mber to sump This reduces the oil pressure in the rate of rise chamber Since oil is always flowing into the rate of rise chamber through the orifice in the orifice plate the pressure in the rate of rise chamber is controlled by how much oil is allowed to exit through the trolling 5 variable orifice The trolling valve lever position determines the pressure in the rate of rise chamber which determines main oil pressure Main oil pressure is always the same as the oil pressure in the engaged clutch with this type of trolling valve 1017554 Electric Trolling Valve 58 This trolling valve is a variable orifice that controls the pressure in the rate of rise chamber The pressure in the rate of rise chamber determines the rate of rise piston position which ultimately controls the main and clutch pressures for the transmission The only difference between the electric trolling valve and the previously described mechanical trolling valve is that the electric trolling 5 orifice size is controlled by electrical current instead of a lever When the trolling valve is in the cruise non trolling mode the orifice in the trolling valve is closed Oil cannot exit from the rate of rise chamber through the trolling valve s orifice and the rate of rise chamber is fully pressurized the ball and spring regulator is blocked when either clutch is engaged This full pressure causes the rate of rise piston to remain against its stop in the valv
161. ment Location total indicator reading Face of SAE 0 and SAE 00 housing 0 41 mm 0 016 from input spline Pilot of SAE 0 and SAE 00 housing 0 20 mm 0 012 in from input spline in propeller flange near O D 0 10 mm 0 004 in from main housing Pilot of propeller flange from main housing 0 10 mm 0 004 in This note applies to a continuous 270 degrees arc if the balance of the plot is negative in readings otherwise it means all 360 degrees Marine Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications Table 10 Drag Limit Drag Limits 600 rom Ratio Check Gear input speed in neutral 1800 rom Ratio Max Pull Tangent Output rpm 281 7 at 320 0 mm 12 8 in dia Output flange hole circle Optional Equipment Trailing Pump Two types of trailing pumps are available 115 VAC electric powered trailing pump identified as part number 1016473 An engineering drawing is included in this manual Mechanically driven trailing pump identified as part number 1020513 or 10205134 Power Take off A live pump mount PTO is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 A clutchable pump mount PTO is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 Marine Transmission Service Manual 1022294 29 Description and Specifications Twin Disc Incorporated 30 Metric to NPTF Adapter Kit Adapter kits are available to con
162. move the spool return spring and dowel pin from the bottom of each of the spool bores in the valve body Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly Trolling Valve 1017555 Optional Equipment 1 Remove the trolling valve attaching screws i 1 G p Le i Figure 70 Removing Trolling Valve Attaching Screws oteel ball is under pressure from the spring Care must be taken when removing the trolling valve and orifice plate to prevent loss of steel ball 2 Remove the trolling valve from control valve 3 Remove the gaskets orifice plate and steel ball from control valve 4 Remove the screw and nut clamping the lever to the stem o Remove the lever from the stem It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged Marine Transmission Service Manual 1022294 115 Disassembly Twin Disc Incorporated 6 Remove the detent setscrew spring and detent ball Figure 71 Removing Detent Setscrew left and Detent Spring and Ball right 7 Remove the dog point setscrew from the valve body Figure 72 Removing Dogpoint Setscrew 116 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 8 Slide the stem and adapter out of the valve body together as one piece Push the stem out of
163. mping nut and remove the control lever from the stem may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 10 Remove the washer and spring from the stem Marine Transmission Service Manual 1022294 109 Disassembly Twin Disc Incorporated 11 Remove four of M8 x 25 socket head capscrews 12 Remove the cover assembly with gasket from the valve 13 Remove the O ring and oil seal from the cover assembly Figure 63 Removing O ring from Cover 14 Remove the two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body some models 15 Remove the detent setscrew spring and steel ball from the valve body Figure 64 Removing Detent Setscrew and Spring 10 Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 16 Remove the dog point setscrew Note that the setscrew is retained with 908 threadlocker Figure 65 Removing Dogpoint Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 66 Removing Thrustwasher Marine Transmission Service Manual1022204 1n Disassembly Twin Disc Incorporated 19 Remove the stem from the valve body 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers
164. n Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine Fe xm n sli muon E 4 i Figure 22 Example of Power Flow in Neutral Marine Transmission Service Manual 1022294 61 Operation Twin Disc Incorporated 62 Primary When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel plates are spline connected through the clutch hub assembly to the pinion Because the primary input pinion is in mesh with the output gear the output gear and shaft will rotate in anti engine direction The secondary input pinion will be backdriven engine direction when the unit is in the primary position E re EN 5 Ei _ E NEN pre Figure 23 Example of Power Flow with Primary Clutch Engaged Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Secondary secondary the same parts are turning that were turning in neutral When the secondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates tog
165. n Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Owner s Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment WARNING Under the conditions described below the prop shaft must be locked in place to prevent backdriving Failure to do this can damage the marine transmission due to lack of component lubrication Backdriving also called windmilling occurs when an engine is shut down and the propeller shaft is being driven by the flow of water across the propeller which in turn rotates the components in the marine transmission During backdriving conditions the transmission does not receive proper lubrication Conditions where backdriving may occur Vessel is being towed more engines on multiple transmission vessel shut down while under way Sailboat under sail with auxiliary engine shut down 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 4 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
166. nction reduces clutch apply pressure to reduce the propeller speed E Troll Electronic Interface An E Troll electronic interface module is available for use with the GP Control Valve 1017555 Mechanical Trolling Valve This trolling valve is a variable orifice that controls the pressure in the rate of rise chamber The pressure in the rate of rise chamber determines the rate of rise piston position which ultimately controls the main and clutch pressures for the transmission When the trolling valve lever is in the detent non trolling position the orifice in the trolling valve is closed Oil cannot exit from the rate of rise chamber through the trolling valve s orifice and the rate of rise chamber is fully pressurized the ball and spring regulator is blocked when either clutch is engaged This full pressure causes the rate of rise piston to remain against its stop in the valve body bore and main oil pressure is not reduced Detent position Trolling mode orifice closed orifice opened Figure 21 Mechanical Trolling Valve Marine Transmission Service Manual 1022294 57 Operation Twin Disc Incorporated Rotating the trolling valve lever into the trolling mode opens the variable orifice allowing some of the oil to escape from the rate of rise cha
167. nd the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance Connect the oil injector to the output flange Install tool 21433 onto the output shaft to advance the flange onto the shaft Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating Surfaces Advance flange onto shaft with the portable press Figure 116 Advancing Output Flange Onto Output Shaft Marine Transmission Service Manual 1022294 157 Assembly 13 14 15 Twin Disc Incorporated Release injection oil pressure between the mating surfaces and wait five minutes Remove T 21433 from the transmission Note It is possible to advance the flange using the retainer washer and its five retaining screws The screws must be tightened evenly in small increments and in an alternating star pattern to advance the flange squarely onto the shaft New screws must be installed if the old screws were over torqued during the advancing process Measure the distance from the output flange shoulder to the end of the output shaft Record this as dimension D Dimension D must be the same as dimension minus dimension within 0 05 mm 0 002 inch Create a shim pack that is 0 05 mm to 0 15 mm 0 002 to 0 006 inch less than dimension D Install t
168. ng in the bore of the front end of the pinion is an interference fit and will likely be destroyed during removal Remove the straight roller bearing with the use of a puller behind the roller ends Remove the tapered roller bearing outer race from the bore the rear of the pinion if bearing requires replacement This bearing race is an interference fit in the pinion bore To remove it use an electric welder to weld a light bead around the I D of the bearing race This will shrink the bearing race to facilitate removal Bearings removed with this method must be replaced oi Remove the internal retaining ring at the front of the clutch housing and remove the clutch backing plate Figure 50 Clutch Backing Plate and Retaining Ring Removed 6 Hemove the clutch plates 9 steel 10 friction maintaining their respective order for inspection purposes Remove the tapered roller bearing cone from the shaft Bearing supports rear of pinion This bearing is a slip fitand should remove easily 100 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly 8 Remove the clutch apply piston A Place the clutch in a press input side up Use special tool T 19330 to compress the clutch release springs and expose the round retaining ring Figure 51 Removing Spring Retainer Retaining Ring B Remove the retaining ring Slowly release the pressure and remove the shaft from the press Remove special t
169. nment 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 1022294 187 Installation Twin Disc Incorporated INDICATOR INDICATOR STEM MARIME GEAR SUPPORT BRACKET A M 73 ERGINE aqu Se eee Le CREEL de 1 Figure 149 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 between each mounting bracket and engine bed rail Add shims between the brackets and bed rails to equal the feeler gauge readings Carefully release the lifting force on the marine gear while observing the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading
170. nsmission 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 The manual direction control valve has an integral switch with contacts that are closed only when the manual direction control valve is in the NEUTRAL position This switch must be wired such that the engine cannot be started while clutch A or clutch B is engaged i C AU TION Engagement of a clutch with the Manual Direction Control Valve should only be done with the engine at idle speed Locking Pin RS Figure 9 Manual Direction Control Valve Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Manual Control Valve 1017172 or 1017546 Note The mechanical control valve 10171 72 is basically the mechanical override portion of the 1018084 electric control valve The 1017546 includes the trolling valve Hydraulic System with Manual Control Valve The oil pump draws oil through the strainer from the oil sump and discharges it through the oil filter Filtered oil enters the control valve through the inlet port The incoming oil forces the pressure regulator piston against the springs to open the path to the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the heat exchanger to the lubricati
171. of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the rate of rise piston is against the stop pressure regulating springs are compressed the most the main oil pressure reaches approximately 290 psi When the control valve is shifted to Neutral the clutch that was engaged is vented to sump within the valve As a result the passage behind the ball and spring regulator is vented to sump and induces a high differential pressure between the rate of rise chamber and the passage behind the ball and spring oince the pressure in the rate of rise chamber is much greater than the pressure itis to be regulated at the ball unseats from the orifice plate allowing main oil pressure to return to the neutral pressure level rapidly and again be regulated by the ball and spring regulator The ball returns to the pressure regulating position once the spring force is equal to force induced by the pressure at the rate of rise piston Marine Transmission Service Manual 1022294 51 Operation Twin Disc Incorporated 52 Electric Operation The transmission normally operates with the control valve in the electric mode Two spools each controlled by a solenoid operated pilot valve control clutch engagement When a solenoid is energized it opens the pilot valve and allows main pressure oil to flow to the end of the spool The pressure acting on the end of the spool overcomes the return spring at the oppo
172. off 1 2 turn The end of the setscrew should protrude approximately 3 mm from the valve body when the dog point of the setscrew is fully engaged in the helical slot Figure 141 Installing Dogpoint Setscrew 10 Check the action of the stem in the trolling valve If the stem does not rotate 90 smoothly loosen the dog point setscrew 1 8 turn and recheck the action of the stem 178 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 11 Install the detent ball and spring into the remaining hole in the valve body Apply MA908 threadlocker to the threads of the detent setscrew and install until flush with the valve body ee Figure 142 Installing Detent Ball Spring and Setscrew 12 Check the torque required to overcome the detent The torque should be 1 1 1 7 Nm 10 15 in lb Adjust the detent setscrew if necessary to achieve the proper torque to rotate the lever out of the detent position 13 Install the lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 14 Rotate the lever if necessary on the stem to the position shown on the valve installation drawing see Engineering Drawing Section of this manual Install the screw nut to clamp the lever to the stem Tighten the screw and nut to 9 5 Nm 7 ft lb 15 Install the neutral pressure regulating spr
173. ok Green LED Solenoid on Red LED Figure 6 Electronic E Troll Module MG E Troll 40 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Hydraulic System with GP Control Valve The oil pump draws oil through the strainer from the oil sump and discharges it through the heat exchanger to the oil filter Filtered oil enters the control valve through the inlet port The incoming oil is supplied to the main pressure regulating relief pilot cartridge and the main regulating valve cartridge satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit 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 engage the selected clutch pack The rate of rise is controlled electronically and pre fills the engaging clutch at a predetermined level and then increases to full pressure following a predetermined timing sequen
174. on oil circuit in the transmission to lubricate and cool the clutches and bearings There is a lubrication oil pressure relief valve to limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation The pressure in the rate of rise chamber is controlled by a ball that is spring loaded against the orifice plate The passage behind the ball and spring is connected to the sump atmosphere in Neutral and to main pressure when either clutch is engaged A shuttle ball connected to both clutch pressure ports permits pressurizing this passage with oil from the engaged clutch without allowing oil to flow to the disengaged clutch Shuttle Ball Figure 10 Location of Shuttle Ball Marine Transmission Service Manual 1022294 45 Operation Twin Disc Incorporated When the control valve is shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively increases the clutch engaging pressure causing the
175. ool 19330 and spring retainer Remove the clutch release springs from the pockets in face of the piston Remove the clutch piston by applying air to the hydraulic pressure port between the seal ring grooves forcing the piston from the bore Use caution to avoid damaging the piston Figure 52 Removing Clutch Piston Marine Transmission Service Manual 1022294 101 Disassembly 102 Note Twin Disc Incorporated Remove the piston ring from the ring groove in the shaft seals of clutch piston Remove the multi piece piston ring from ring groove outer diameter in O D of clutch piston Do not separate clutch housing transfer gear from the secondary shaft unless the shaft or the clutch housing must be replaced and the mating parts remain serviceable Use the following procedure to separate the housing transfer gear from the shaft Place a sleeve over the front end of shaft with an I D only slightly larger than the O D of the large end of the shaft taper 101 6mm 4 00 in Place the shaft and clutch housing on a press front end down Rest the end of the sleeve on a heavy wood block while the other end supports the inner face of the clutch housing Apply press force to rear end of shaft to separate the shaft from the clutch housing Take care to protect and restrain the shaft to prevent damage as the tapered joint separates Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembl
176. orque carrying capacity of the assembled joint Both parts must be at the same temperature 4 Measure the length of the tapered bore of the output flange using a depth micrometer The flange must be placed on a flat surface and the length being measured is to the inner shoulder of output flange Record this distance as dimension A Figure 113 Measuring Output Flange Bore Length Marine Transmission Service Manual 1022294 155 Assembly Twin Disc Incorporated 5 With a depth micrometer measure the output shaft height This is the distance from the end of the output shaft down to the rear tapered roller bearing cone Record this distance as dimension B Figure 114 Measuring From Output Shaft Height 6 Seat flange onto the taper of the shaft using only the weight of the flange 7 With a depth micrometer measure distance from inner shoulder of output flange to end of output shaft Record this distance as dimension C Figure 115 Measuring Output Step Height 156 Marine Transmission Service Manual 1022294 Twin Disc Incorporated 10 11 12 Assembly Calculate the output flange advance which is dimension B plus dimension C minus dimension A This is advance must be 4 85 mm to 7 04 mm 0 191 in to 0 277 in Note Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found a
177. out 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 Onlya 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 right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit November 30 2005 TDWP2003 rev 2005 52 TWIN DISC INCORPORATED FLAT RATE HOUR ALLOWANCE COMMERCIAL MARINE TRANSMISSION Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated COMMERCIAL MARINE TRANSMISSIONS ALL RATIOS MODEL SERIES e
178. plate cover Clean parts Shim as required Raise engine speed Remove and clean strainer Check oil level and correct Correct cause of air leak Disassemble and repair as required Remove disassemble clean and repair the regulating valve Replace oil pump Replace heat exchanger Remove clean regulating valve Shim as required Inspect repair or replace parts as necessary 73 Troubleshooting 4 5 6 74 Twin Disc Incorporated Table 15 Troubleshooting Chart continueed Mechanical and Electric Control Valves High temperature 4 1 Excessive noise No neutral Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Worn or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Clutch plates warped Control valve incorrectly indexed Solenoid malfunction units equipped with electric selector valve Hydraulic lock piston stuck units equipped with electric selector valve Marine Transmission Service Manual 1022294 Check and fill or drain with proper oil to correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch Overhaul marine transmission
179. put With the trolling valve in the non trolling position valve inlet primary secondary and lube pressures must be the same as charted in Table 3 Table 5 Limits for Marine Transmission equipped with Hydraulic Clutch PTO PTO Control Vlave Disengaged PTO Control Valve Engaged kPa psi Note With hydraulic PTO lube pressure may be less than values charted on table 1 by following amounts 34 kPa 5 psi less in primary neutral or secondary at 1800 rpm 14 kPa 2 psi less in primary neutral or secondary at 600 rpm but not less than 10 kPa 1 5 psi Table 6 Limits for Marine Transmission equipped with mounted Trailing Pump Input rom Min kPa psi Act kPa psi Max kPa psi Marine Transmission Service Manual 1022294 27 Description and Specifications Twin Disc Incorporated Assembly Specifications 28 Table 7 Advance Specifications Minimum Maximum Component i mm in mm in Primary Transfer Gear Advance 2 67 0 105 3 71 0 146 0 Secondary Transfer Gear Advance 2 67 0 105 3 71 0 146 Output Gear Advance 9 45 0 372 11 00 0 433 Output Flange Advance 8 13 0 320 9 91 0 390 Table 8 Bearing Shimming Adjustment Primary and Secondary Tapered Roller Bearing Endplay 0 013 mm 0 0005 in 0 063 mm 0 0025 in Output Shaft Bearing Endplay 0 05 mm 0 002 0 15 mm 0 006 in Table 9 Front Housing Maximum Runout Limits Maximum allowable Measure
180. r ee LOCATION NOT oe CRITICAL DET 3 7 64 26 00 LEM 1 00 EI t mu T 217 PS TYP 2 TYP 4 DRILL 5 16 THRU 3 8 16 X 1 00 THD j lt 2 HOLES FOR LIFTING N Me gt E E N i X Y x EN 2 00 227 1850 NN m M NN iu MEM EDT ai A ZEN Zi unes E wer e 3 82 L 2 20 00 E E a L S exem E E L 125 WE MS gt 2 R0 50 INDUCTION OR FLAME HD N RADIUS or SRE GE aw uen Ies MAS90CD BEARING ee ge 54973 TAPER INDEX BUSHING 1 8 STEEL THREADED INSERT 1 8 DRILL ROD X 18 3 4 LGTH BLOCK 2 x 2 X 20 1 BASE 13 DIA X 1 1 2 MAT DESCRIPTION TUCK LZ Deteg a 99 By amo p e E TL 1 1 BEARING DRIVER FOR CUP DESCRIPTIUN DATE BY TWIN DISC INC RACINE WIS SHEET 1 OF 1 erate MG 5301
181. rated Mounting Fluid LHMF 300 and Dismounting Fluid LHDF 900 SKF LHMF 300 and LHDF 900 are recommended when using SKF hydraulic equipment like hydraulic pumps HMV nuts oil injection equipment etc The fluids contain anticorrosives and are non aggressive to seal material like nitrile rubber Buna Perbunan chrome leather PTFE etc SKF LHMF 300 and LHDF 900 are available in 5 liter 5 3 qt cans Designation LHMF 300 5 and LHDF 900 6 Figure 151 SKF LHMF 300 and LHDF 900 Note Order Through Your Local Authorized SKF Distributor 204 Marine Transmission Service Manual 1022294 2 50 KNURL 1 69 85 15 2 940 3 720 12 x 06 DP 12 15 MARK 18050 705 BRG DRIVER k 217 CAGED ROLLER 217 BEARING CCAGED RULLER 1017005 GEAR 1 BEARING DRIVER 1 REQ D MAT MS HDNO NOTE UNLESS ETHER WISE SPECIFIED BREAK ALL SHARP CURNERS To ee 7 NOTE GROUND SURFACES MUST BE PARALLEL Canne eee WITHIN 0005 EACH OTHER BEARING DRIVER CAGED ROLLER PART ND BREAK ALL SHARP CORNERS TOLERANCE UNLESS OTHERWISE SPECIFIED FOR 4406 SHEET 1 OF 1 001 ON THREE PLACE DECIMAL DIMENSION 10 DN FRACTIONAL AND PLACE 217 BRG m 1 Q 0 5 0 __ 7 0 5 CAD FILE 1 18050 705 dwa CHANGE DESCRIPTIUN DATE TWIN DISC INC RACINE WIS 1 4 UN ANGULAR DIMENSION BEARING CUP MAS90B CUST
182. re compressed the most the main oil pressure reaches approximately 290 psi When the control valve is shifted to Neutral the clutch that was engaged is vented to sump within the valve As a result the passage behind the ball and spring regulator is vented to sump and induces a high differential pressure between the rate of rise chamber and the passage behind the ball and spring oince the pressure in the rate of rise chamber is much greater than the pressure itis to be regulated at the ball unseats from the orifice plate allowing main oil pressure to return to the neutral pressure level rapidly and again be regulated by the ball and spring regulator The ball returns to the pressure regulating position once the spring force is equal to force induced by the pressure at the rate of rise piston Marine Transmission Service Manual 1022294 47 Operation Twin Disc Incorporated Electric Control Valve 1018084 Hydraulic System with Electric Control Valve 48 The oil pump draws oil through the strainer from the oil sump and discharges it through the oil filter Filtered oil enters the control valve through the inlet port The incoming oil forces the pressure regulator piston against the springs to open the path to the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the heat exchanger to the lubrication oil circuit in the transmission to lubrica
183. rogressively increases the clutch engaging pressure causing the clutches to engage at a controlled rate The control valve allows only one clutch to be engaged at a time 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 1022294 49 Operation 50 Twin Disc Incorporated Control Valve Assembly in Neutral Some of the main pressure oil from the oil inlet chamber flows through a passage to the orifice in the orifice plate The small flow of oil through this orifice fills and begins to pressurize the rate of rise chamber Both clutches are connected to sump when the control valve is in Neutral Since there is no pressure acting on the shuttle ball from either clutch the passage behind the ball and spring regulator is also connected to sump This allows the oil pressure in the rate of rise chamber to be regulated by the ball and spring since the overage oil can flow to sump The oil pressure in the rate of rise chamber acting on the rate of rise piston causes it to stroke over partially which compresses the pressure regulating springs additionally This additional spring compression further resists the movement of the pressure regulating piston resulting in a force balance between the area at the pressure regulator the springs and the area behind the r
184. rough 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 required beyond the daily oil check Marine Transmission Service Manual 1022294 65 Preventative Maintenance Twin Disc Incorporated General Maintenance 66 Overhaul Interval A complete overhaul and thorough inspection of the unit should be made at the same time as the scheduled engine overhaul Refer to Cleaning and Inspection for more detailed inspection instructions Oil System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil in it With the engine running at low idle and the transmission in Neutral check the oil again The oil level should be near the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval Maximum Note A suction screen is located in the suction line to the pump and the oil filter 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 clean the suction strainer screen within the first 50 hours of operation Change oil and filter element and clean the screen after each 1000 hours therea
185. rporated Installation Final Checks sure the transmission is filled with oil before starting See Description and Specifications and Preventative Maintenance for proper oil and filling procedure Marine Transmission Service Manual 1022294 199 Installation Twin Disc Incorporated 200 Marine Transmission Service Manual 1022294 Twin Disc Incorporated List of Special Tools Special Tools 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 18050 705 T 18050 708 L D 1 18050 711 1 18050 713 1 18050 714 1 18050 715 D 1 18050 723 1 18050 771 1 19330 T 19987 2 Marine Transmission Service Manual 1022294 Recommended Pump Set and Fluids THAP 300SKF Air driven Pump Set Bearing driver for pinion needle roller bearings Bearing cup driver Bearing cone driver primary and secondary shafts Output seal driver Shaft lifting fixture output shaft Shaft lifting fixture primary and secondary shafts Bearing cone and transfer gear driver primary and secondary shafts Front output bearing cup driver opring retainer compressor coil spring units Output gear lifting fixture 201 Special Tools Twin Disc Incorporated T 20023 4 Output gear installing fixture sheet 1 of 3 T 20023 4 Output gear installing fixture
186. rque until bearing cup and housing temperatures equalize approx 10 minutes Figure 78 Installing Output Shaft Bearing Cup Remove I 18050 771 Measure and record the distance from the machined surface of the housing to the top of the bearing cup dimension D Dimension D must equal dimension A minus dimension B minus dimension within 0 025 mm 0 001 in 128 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Installation of Trailing Pump Shaft and Driven Gear 1 Press the bearings onto the trailing pump shaft by pushing on the inner race of the bearing Use a driver with an inside diameter only slightly larger than the shaft diameter to push bearings on until they are stopped by the shaft shoulder Figure 79 Installing Trailing Pump Shaft Bearings 2 Install the trailing pump shaft and bearings into the transmission housing using a soft hammer if necessary Figure 80 Installing Trailing Pump Shaft Marine Transmission Service Manual 1022294 129 Assembly Twin Disc Incorporated 3 Install internal retaining ring into housing over bearing Figure 81 Installing Internal Retaining Ring 4 Install key and trailing pump driven gear onto trailing pump shaft 5 Install washer x 20 hex head screw onto trailing pump shaft to retain driven gear Apply MA908 threadlocker to the threads and torque to 33 Nm 25 ft lb Figure 82 Securing Trailing
187. rrs 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 122 Marine Transmission Service Manual 1022294 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 of these defects is found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses Clutch Plates Inspect clutch plates for signs of overheating pitting or excessive wear of the friction and splined surfaces Replace the clutch plates if one of these defects is found Refer to wear limits in Description and Specifications Marine
188. s Figure 129 Install Regulator Valve Body to Transmission 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 Nm 34 ft lb es Figure 130 Install Valve Body onto Regulator Valve Assembly Marine Transmission Service Manual 1022294 169 Assembly Twin Disc Incorporated 9 Install the Electronic Profile or E Troll Module on the top Valve and torque the four M6 1 0 capscrews to 9 5 Nm 7 ft lb Po j b E Figure 131 Place Profile 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 170 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Adjustment of Main Pressure Valve Assembly 1020941 Install a main pressure gauge into the port on top of the Top Valve body 2 Hemove protective cover cap located at the end of the adjusting stem This will expose a slotted adjustment stem Loosen the jam nut on the stem Figure 132 Main Pressure Regulating Valve Assembly 1020941 9 otart 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 Spe
189. s 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 Figure 25 Test kit 42168 72 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Low main oil pressure No oil pressure or erratic low pressure at control valve tap 3 High main oil pressure Table 15 Troubleshooting Chart Troubleshooting Mechanical and Electric Control Valves Partially clogged oil strainer Stuck pressure regulator Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Incorrect linkage adjustment to control valve assembly Clogged or plugged orifice in orifice plate of control valve assembly Shimming required between regulator springs and rate of rise piston Engine idle speed too low Oil pump strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Regulating valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost overboard Regulating valve stuck Improperly shimmed Lube relief valve malfunction Marine Transmission Service Manual 1022294 Remove and clean oil strainer Disassemble the valve Remove the collector and inspect piston rings Replace damaged or worn oil pump assembly Adjust linkage so that valve stem is indexed properly by detent Remove orifice
190. sheet 2 of 3 T 20023 4 Output gear installing fixture sheet 3 of 3 T 21433 Output flange installing fixture sheet 1 of 3 T 21433 Output flange installing fixture sheet 2 of 3 21433 Output flange installing fixture sheet 3 of 3 T 21506 Output shaft bearing driver sheet 1 of 2 T 21506 Output shaft bearing driver sheet 2 of 2 T 21533 37 Input seal driver and protection sleeve T 506000 Lifting Bracket for Clutch Removal in Boat SPX Power Team RD1006 100 x 6 375 inch stroke double acting ram no drawing SPX Power Team 554 electric over hydraulic pump no drawing Two SPX 9764 hoses drawing Two SPX 9795 couplers no drawing 202 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Special Tools Recommended Pump Set and Fluids Twin Disc recommends the following products for use in the assembly and removal of tapered shafts using the oil injection method THAP 300 Air Driven Pump Set This set consists of the air driven pump with accessories such as an adapter block pressure gauge high pressure pipe or pressure hose with quick connection couplings and connection nipples The set includes one of each air driven pump THAP 300 adapter block 226402 pressure gauge 1077589 and high pressure pipe 2m 6 5 ft 227957 Figure 150 THAP 300 Air driven Pump Set Marine Transmission Service Manual 1022294 203 Special Tools Twin Disc Incorpo
191. site end causing the spool to stroke over and connect the clutch passage with main pressure passage Figure 16 Pilot Spool Passages Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation Main pressure oil flows from the spools above to the clutch passages of the transmission below via connecting slots in the manual override stem These connecting slots are aligned with passages in the valve body when the valve is in the electric mode Figure 17 Flow Path in Override Spool Main pressure from the energized solenoid operated pilot valve also acts ona pin on the return spring side of the opposite spool to ensure the opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Marine Transmission Service Manual 1022294 53 Operation Twin Disc Incorporated Hydraulic Lock Feature Some models Some control valve models have a hydraulic lock feature and are identifiable by athird solenoid operated pilot valve This feature keeps the engaged clutch pressurized as long as the engine remains running should electrical power fail or malfunction occur while the clutch is engaged The hydraulic lock is accomplished by allowing pressurized oil from the pressurized clutch passage to flow inside the spool Oil pressure inside the spool forces the dowel pin against the O ring plug Neutral solenoid Spring HYDRAULIC LOCK UNITS Figure 18 Hydraul
192. t 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 WARNING 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 WARNING 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 WARNING 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 Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Transmission Service Manual 1022294 Twin Disc Incorporated Introductio
193. t 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 1022294 Twin Disc Incorporated Installation Electrical Controls Installation All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connectors must be tight and free from corrosion It is strongly recommended that the Control Harnesses and Wiring guidelines be followed to ensure proper installation of all wiring Control Harnesses and Wiring guidelines Install all control wires and harnesses as follows 1 10 The connector end of each control cable or harness must be secured within twelve inches of control connectors other connectors and all other termination points The cable or harness must be secured to frame supports at sixteen inch intervals along its entire length unless installed in rigid ducting or conduit Keep cable or harness away from hot surfaces moving parts and oil locations Attach cable or harness to vessel making the connector the highest point of the wire If not possible install cable or harness with drip loop Protect cable or harness with grommet loom or flex guard at any rub point particularly when passing a sheet metal hole Locate cable or harn
194. tall attaching 24 M12 x 45 capscrews and torque them to 112 Nm 83 ft lb Install the two lifting eyebolts Figure 126 Installing Top Cover Install breather filler cap 4 Install oil gauge tube assembly and oil level gauge Marine Transmission Service Manual 1022294 165 Assembly Twin Disc Incorporated Install the heat exchanger The use of M12 x 1 75 guide studs will ease the installation of the heat exchanger Units with Remote Heat Exchanger Install the adapter plate and gasket Torque the attaching sockethead capscrews to 80 Nm 59 ft lb Install protective plugs to prevent contaminants from entering into the transmission s lubrication oil circuit Units with Integral Fresh Water Heat Exchanger Install the adapter plate and gasket Torque the attaching sockethead capscrews to 80 Nm 59 ft Ib Install heat exchanger element and gasket over adapter plate Install heat exchanger cover and gasket and torque the attaching screws to 112 Nm 83 ft Ib Install protective plugs into cover to prevent the entrance of contaminants into the transmission s water circuit Install the M10 x 1 O ring water drain plug and torque to 12 Nm 9 ft lb Units with Integral Raw Water Heat Exchanger Install stiffener plate and gasket Install two O rings into counterbores of stiffener plate Install heat exchanger element and cover gasket over adapter plate and O rings Install anode into cover with gasket screw and sealing
195. te and cool the clutches and bearings There is a lubrication oil pressure relief valve to limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation Marine Transmission Service Manual 1022294 Twin Disc Incorporated Operation The pressure in the rate of rise chamber is controlled by a ball that is spring loaded against the orifice plate The passage behind the ball and spring is connected to the sump atmosphere in Neutral and to main pressure when either clutch is engaged A shuttle ball connected to both clutch pressure ports permits pressurizing this passage with oil from the engaged clutch without allowing oil to flow to the disengaged clutch Figure 13 Location of Shuttle Ball The electric control valve can be used in a manual override mode in the event of an electrical power failure When the control valve is energized or shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This p
196. tion of Top Cover Assembly Heat Exchanger OI GaU Mcd 165 Assembly of Control Valve eere esee eere 167 Adjustment of Main Pressure 2 1 1 171 Assembly of Trolling Valve optional equipment 177 Installation of Electric Control Valve 181 Installation 183 Prior to Installation ETE 183 Alignment also reference SAE J 1033 and J 617 184 7 0 187 Electrical Controls Installation 193 ConneeliloliS 195 Marine Transmission Service Manual 1022294 9 Table of Contents Twin Disc Incorporated Special Tools 201 Recommended Pump Set and Fluids 203 T 18050 705 Bearing driver for pinion needle roller bearings 205 T 18050 708 Bearing cup driver 206 T 18050 711 Bearing cone driver 207 T 18050 713 Output seal driver 208 T 18050 714 Shaft lifting fixture output shaft 209 T 18050 715 Shaft lifting fixtur
197. tor and inspect piston rings Replace damaged or worn oil pump assembly pump is not serviceable Raise 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 77 Troubleshooting Twin Disc Incorporated Table 17 Troubleshooting Chart continued 1021658 and 1020941 GP Control Valves with Electronic Interface 3 High main oil Main Regulator Valve is out of 3 1 Adjust Main Regulator Valve adjustment Main Regulating Valve orifice Replace orifice valve and ball and ball check passages check cartridge blocked 4 High Improper oil level Check and fill or drain with proper temperature oil to the correct level Faulty heat exchanger Inspect repair or replace heat exchanger Clutches slipping 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 Bearing failure Overhaul marine transmission Air leak on suction side of pump Inspect and correct cause of suction leak Control valve malfunction Inspect repair or replace control valve 5 Excessive Bearing failure Overhaul marine transmission Noise Worn or damaged input Remove marine transmission couplin
198. ts Primary Shaft Only Loosen two 10 24 x 3 8 set screws and remove the wear sleeve from the front end of the primary shaft Figure 47 Remove Oil Seal Sleeve with O Ring from Shaft 1 Remove three piston rings from the rear end of the shaft Figure 48 Removing Piston Rings From Shaft 98 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Disassembly Note Do not remove the rear bearing unless it must be replaced The bearing is an interference fit with the shaft and will be destroyed during removal 2 the rear bearing must be removed do this A Remove the external retaining ring from the shaft B With a hammer and chisel cut the cage off the bearing to remove the cage and rollers Use split type bearing puller cheese cutter to grip the flange at the small end of the tapered inner race D With a hydraulic jack push the rear end of the shaft while pulling the inner race of the bearing 3 Position the shaft upright with the input end up 4 Remove and disassemble the pinion Remove the round retaining ring from the input end of the shaft and remove the pinion from the shaft Figure 49 Removing Round Retaining Ring from Input End of Shaft Marine Transmission Service Manual 1022294 99 Disassembly Twin Disc Incorporated B Remove the internal retaining ring from the front end of the pinion and remove the straight roller bearing Note The straight roller beari
199. tsch 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 1022294 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 WARNIN DO NOT connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System The customer supplied selector switches for each of the transmission clutches and for troll if equipped must be connected directly to the wires of the Profile or E Troll Module and connected to the power source as shown in the table that follows No other e
200. ution to prevent damaging the shafts gears and bearings Use tool 18050 715 for lifting the primary and secondary shafts 2 Install bearing carrier gasket over dowels onto rear face of housing Figure 103 Installing Clutch Shaft Assembly 3 Install the lube relief valve cartridge into the housing Figure 104 Lubrication Oil Pressure Relief Cartridge Installed Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly 4 Install two alignment studs into the face of the transmission housing Install the bearing carrier over the studs and onto the dowels in the housing face Use a soft hammer near the dowels to seat the carrier against the gasket and over dowels Figure 105 Install Bearing Carrier D Install the lube tube through the keyed hole in the bearing carrier and into the machined pocket in the front inner face of housing Rotate the tube so the elongated key fits into the corresponding in the bearing carrier When properly installed the lube tube will be flush with the rear face of bearing carrier Figure 106 Key Orientation of Lube Tube in Bearing Carrier Marine Transmission Service Manual 1022294 151 Assembly Twin Disc Incorporated 6 Install cups for rear tapered roller bearings on the primary and secondary shafts into their respective bores in the bearing carrier Tap the cups down gently with a soft hammer or brass drift to seat them against the
201. vert the oil drain plug opening the pressure test ports and the heat exchanger connections from metric to NP TF threads Kit K1195 is for units with an integral heat exchanger and kit K1245 is for units with a remote heat exchanger Mounting Brackets Steel fabricated mounting brackets for rigid mounting are available under Twin Disc part number 1016428 AC Torsional Input Coupling several models of torsional input couplings are available including Vulkan VL3411S and CF R couplings in both SAE 0 and SAE 00 sizes Companion Flange Two different companion flanges are available For non propeller shaft brake applications the flange assembly is Twin Disc part number 1017084 For disc type propeller shaft brake applications the Twin Disc part number is 1019642 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Description and Specifications Torque Values for Fasteners Note Lubricate all threads and bearing face with light oil film prior to assembly Use Grade 5 and Property Class 8 8 specs when threading into aluminum Table 11 Metric Coarse Thread Capscrews Bolts and Nuts pos Property Class 8 8 Property Class 10 9 Property Class 12 9 0 1 2 25 29 5 34 40 70 80 14 16 16 18 21 25 23 26 84 40 32 36 43 49 44 51 60 68 12 59 s CMEC 9 14 35 714 820 987 1113 1235 1421 1674 1926 1475 1697 2000 2301 Table 12 U S Standard
202. washer torquing screw to 18 Nm 13 ft lb Fill the remaining threads in the anode below the screw with RTV silicone sealer Be sure sealer has proper curing time before exposing it to water Install heat exchanger cover and torque the attaching screws to 80 Nm 59 ft lb Install protective plugs into cover to prevent the entrance of contaminants into the transmission s water circuit Install the M10 x 1 O ring water drain plug and torque to 12 Nm 9 ft lb Marine Transmission Service Manual 1022294 Twin Disc Incorporated Assembly Assembly of Control Valve Assembly of GP Control Valve with Electronic Interface Prior to assembly all parts must be properly cleaned Carefully inspect all o rings for any damage and replace as necessary Lubricate all o rings and replace both gaskets 1 Assemble the Main Regulator Valve body A Install the filter into the threaded hole of the valve body and torque to 7 5 Nm 5 5 Ft Ib If removed install a new check valve assembly into the bore of the valve body and drive it with a drift until it is flush with the face of the body Install the 3 8 pipe plug or optional temperature sensor into the valve body and torque to 23 Nm 17 Ft Ib Install the gasket and cover without the adjustment screw to the valve body with four M8 x 25 capscrews and torque to 23 Nm 17 Ft Ib Install the spool with washer and spring into the bore Install the gasket and cover with the adjustment s
203. with a wire brush 70 Marine Transmission Service Manual 1022294 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting of Mechanical and Electric Control Valve General Note Some troubleshooting procedures may vary depending on the type of control valve that is installed on the transmission A thorough understanding of the valve operation is important to properly troubleshoot the problem that is occurring 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 15 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 1022294 71 Troubleshooting Twin Disc Incorporated Pressure Test Kit The Digital Pressure Transducer Kit BOM 42168 provides two pressure transducers 0 to 500 psi with hydraulic quick couplings a power supply box for the transducers and cables needed to connect the transducers to the power supply box and the signals out of the power supply box to a customer supplied digital volt meter Contact the Twin Disc Service Department Racine Wisconsin for specific information concerning this test kit One principle of troubleshooting i
204. y Disassembly of Control Valve GP Control Valve with Electronic Interface The GP Valve is made up of a non serviceable electronic interface and two valve body assemblies The top valve body is made up of 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 Lower Valve body contains the pressure regulator valve an orifice filter plug and a ball check valve assembly that are replaceable Figure 53 GP Valve Assembly mounted on Marine Transmission Marine Transmission Service Manual 1022294 103 Disassembly Twin Disc Incorporated 1 Disconnect the connectors at the proportional valves the neutral switch and the temperature sensor if equipped and loosen the four M6 1 0 capscrews that retain the Electronic Interface Module to the Hydraulic portion of the valve assembly If the Electronic Interface is not being replaced it can be set aside without disconnecting the remaining wires from the installation Figure 54 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 Siam Proportional Valves a Ta EE Manual Override Valve d LAG _ Valve M BA E Jn Ud

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