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Service Manual Marine

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1. 1 bL 1111 LJ 1 D D bL bL DL LL fo 1 D bI DL bL bL bL bL DL LL LJ 0 LI 1111 1 1 1 L LI bL LL LI 1 TEST VALVES PER TEST SPEC NO 2408 CONTAINED IN VALVE SPECIFICATION 1 E 1st CLUTCH ENGAGED INSTALLATION DATA M8 1 25 TAP THRU 5 2 HOLES 5 1 VALVE SUITABLE FOR UP 95 L min 2 CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 255 AND 296 kPa 3 44 89 AT THE 55 9 R LOCATION OF THE 6 4 9 HOLE IS REQUIRED TO OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR M PROVIDE 35 8 LINEAR TRAVEL FROM NEUTRAL AT THE 6 4 Hoke LOCATION WHEN EE LE CONTROLS ARE USED THE DETENT SPRING AND PIN MAY BE D THEN THE FORCE WILL BECOME 13 31 N 22 THE DETENT FEATURE 15 SROVIDED IN THE FULL FORWARD FULL REVERSE AND NEUTRAL LEVER POSITIONS i CONTROL e MOUNTING i Md BOLTS INSTALL M2067X PLUGS IN MOUNTING BOLT COUNTERBORES i NEUTRAL POSITION MA960K _ 5 CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK i pas 2 7 TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION PRESSURE LINE GAUGE LOCATION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS jM2067X 4 o THAT REQUIRE FULL POWER TO THE PROPELLER i 4 6 4 DRILL i po ili SEE NOTE 5 i 1
2. 3 8 16 X 2 5 p X 3 38 OD SEE SHT EHARD ROD Rc 32 36 2 98 1 ws LEG 5x1 1 STRAP 912 WELDMENT ASSY IS PREHARD ROD 32 56 WAS 24 28 amp 18 125 pe1eJodjo2u 2510 UIML t 10 US 22002 1 Alquiassy 40 9 1299 1ndino 561 5100 19 4 76 SESOZOL enuen IUEN 45 49 Rc amp SPLIT 2 75 100 25 03 R Ww 45 06 03 x 45 TYP foo 8 787 7 150 8783 7 00 59 e 128 25 Be RILL CT BORE 500 REAM SLFIT 6 TAP 2 PLACES 400 gt 62 50 j elle 03 x 454 106 DIA THRU 1 416 1 1 172 100 1 Ud 00 94 DIA THRU 100 Mc 45 50 Rc THIS LENGTH 3 Audi 7 8 9 THREAD 1 8 THREAD Gsm sesso a140 ROD 00 DIA x 2750 1 a spacer 52 56 Re zr psa uas ima
3. wo jeersories vac az707A0 A2707AD eros emn 712 8 esee Bee c 40842 1017133 1017134 1537 1018688 759 24 voc xa2707z 7072 725 ces 10171298 x 8245 8 2 2 wc seoesc 5279 Ims ims ras paersei voe AUI EN tos PEL DL ees DER ELECTRIC CONTROL MODE SWITCH lt CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE 20 SCREW MA1052P 4 een 10180845 40954 1018584 1018594 117 1018688 xwe7sorMe4 vnc xae7o7z 427072 7 1725 eso tot71e9A x 20 6 24518 lt 7 MG 540 TORQUE 542 N m 0955 1067363 i179 beraad ea 96 6 NOTE M09 Orr sese per e se co mes paene ee aces SECURE LEVER IN THE DEPRESSED TOP VIEW Hoe ELECTRIC CONTROL MODE POSITION eee 7 BY L DPING PLASTIC STRAP THRU 2 427072 1 5 1 4 HOLE IN LEVER amp THREADED HOLE BEHIND PULL TIGHT TRIM 1 END SHORT STRAP M2942B NO
4. CUSTOMER INSTALL 8 29 2205 E m a 2 55 442 5 CSEE MARINE TRANSMISSION 4 y LN CUSTOMER TD BEARING N INSTALLATION DRAWING lee ae cae alee PH SHAFT BS 7 LE a E Selene LINE FRONT amp REAR BEARING PINION amp CLUTCH LUBE 7540 MARINE SHOWN ENGAGED oeoa a KPa TRANSMISSION E NEUTRAL LUBE RELIEF VALVE i t 690 1 A LUI 5 UNN ee EKA 3 00 SENS 0000 01000000000 L _______ ZS NN PAARL uw OPTIONAL TROLLING VALVE CUSTOMER SUPPLIED HEAT EXCHANGER AND CONNECTION LINES INSTALLATION DRAWING AND Wi Nig NN 5 OE o icc NS ra EE RM IT WW RSS _ PORTION ENCLOSED WITHIN OPTIONAL AUXILIARY LUBE SYSTEM USER lt S lt cen KD THESE LINES 15 REQ D FOR Ds 5 AND INS VR YE ro opus M Sie d oo N IS INN N SS MARINE TRANSMISSION REF XA7600 MO NM OCC PEE METRE EXTINGUISHING AND FIRE RESISTANT CONTROL VALVE AND XA7601 r i REQUIREMENTS ALSO IDENTIFICA
5. B FLAME HD N RADIUS PitHH923610 TDWMASS0EZ TR REAM PRESS T MAS90EZ BEARING A FIT BUSHING gt 18050 772 12500 005 150 5202 DC 6 1002695 a a Base 98 ma 1 72 REGI DESCRIPTIO IX Si y Tv p petes nn BEARING DRIVER F R CUP F R pe E ee E s 1518050775 rev BY TWIN misc wc RACING VIS SHIELD 1001421 HOUSING ASS Y 101523 HOUSING 1015235 TUBE Special Tools Twin Disc Incorporated Notes 202 Marine Transmission Service Manual 1020538 5 AS E Ors 02 PLCS DET 1A 97 8 THRU DETS 1B amp 1C 11 2 SQ TUBING 5 8 stk A q EN cc 41 15 3 8 AN 11 SYMBOL CHARACTERISTIC SYMBOL MODIFIER A FLATNESS MAX MATER PARALLELISM CONDITION PERPENDICULARITY RFS REGARDLESS OF FEATURE 5121 2 CONCENTRICITY SMOL CIRCULAR RUNOUT CAZ DATUM FEATURE 2 010 ON FRACTIONAL AND TWO PLACE ZY RUNOUT 1 4 ANGULAR DIMENSION POSITION 9 DIAMETER USS XXX XXX NELLY AKKKX KKK KKK KKK KKK KKK KKK KK HY EXXXXXXXXXXXXXXXA XXXXXXXXXXXXXXY AUTOCAD FILE T 19987 DXX
6. 186 Seal Driver 1800 120 187 Bearing Seat Driver T 18050 152 188 Bearing Driver 1 18050 607 189 Driver T 18050 609 190 Bearing Driver T 18050 610 612 191 Spring Retainer Hold Down T 19998 192 Output Gear amp Shaft Puller for Assembly T 20023 Sh 1 of 4 193 Details for Puller T 20023 Sh 2 of 4 194 Details for Puller T 20023 Sh 3 of 4 195 Spacer for SKF Hydraulic Assembly T 20023 Sh 4 of 4 196 Sleeve for Runout Check T 21302 1 197 Oil Seal Protector T 21347 198 Seal Driver T 21347 1 eet ebat bbb 199 Lifting Bracket for Clutch Removal in Boat 200 Bearing Driver T 18050 772 201 Output Gear Lifting Fixture 19987 203 eene 205 List of 205 M 206 Mechanical Selector Valve
7. 2222 gt 2 ARE NOT POLARITY SENSITIVE za m TA 55 MAN VALVE GASKET 10171368 366 2 7 A HH ELE E REBEL RY IW E 2777 A eg we NIRS DITCH PLATE GASKET 2 el STEM 10181638 24 22424 A 4 27224 212 U RING MA379CP GASKET 1017334 TRANSMISSION GASKET D RING A2916FT SNAP RING A2915S vip ud PLUG 1017969 PORT nE BALL MI990H Ue D POSITION SCREW 1042 4 B SPRING 2702 9 TUER AME C D SHIM 1020005 5 REQ DO SPRING 1801 BALL 1990 SETSCREW A2870K E VALVE BODY ASSY 1018095 RING 2916 DITCHAREATE ESEE CHART aM S Md BODY 1018094 SPRING 2705 WASHER A2782AS SCREW SEE CHART SERT cu ERA BAL z waa X 2 BALL MI990H SECTION BALL 1990 52 a PICKUP PORT SPOOL 1017433 2 CDRYSEAL TH D NOTE INSTALL USING MA908 lt LOCTITE SWITCH MA866A 2 APPLY 895 THREAD SEALANT WITH TEFLON 9 THREADS MAIN PRESSUR E PORT A 242 TOP OF SCREW MUST BE TORQUE 30 0 lbf ft NUT M2027C PORT SCREW 1042 4 FLUSH WITH SURFACE HYDRAULIC DIAGRAM 7119 SHEET 1 DF e 407 N m SCREW M2000L 9 ATMOSPHERIC PRESSURE DBSULETE FOR PRODUCTION TRIC ATMOSPH
8. Cfimraract Figure 37 Removing Clutch Piston D Remove piston ring from ring groove in shaft seals of clutch piston and piston ring from ring groove in O D of clutch piston Note Do not separate clutch housing transfer gear from the secondary shaft unless the shaft or the clutch housing must be replaced and the mating part remains serviceable Use the following procedure to separate the housing transfer gear from the primary or secondary shaft 9 To remove clutch housing place shaft and clutch housing on a press front end of shaft down Place a sleeve over input front end of shaft with an I D only slightly larger than the O D of the shaft taper large end 95 25mm 3 75 in Rest one end of 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 shaft from clutch housing The shaft must be protected and restrained to prevent damage as the tapered joint separates Marine Transmission Service Manual 1020538 85 Disassembly Twin Disc Incorporated Selector Valve Disassembly Mechanical Valve 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 Remove the orifice plate cover orifice plate and check ball Figure 38 Removing Orifice Plate and Check Ball 2 Remove the check ball spring and shim s from the valv
9. XESCRIFLEN SIDE sur D JETAILS FOR PULLER ves pe m 7470 sere 5 0 20023 Te CTT 10 2 US 600c 1 1921 10 Sjlejoq 5100 19 4 25 0 UIML SESOZOL uoissiusueJ SUMEN 961 2510 10 US Z002 L 1921 10 S reieq i 25 1 722 994 9 94 p DP 8 16THD X DP lt 2 PLCS Xxx 4 MI Y 1 562 THRU 3 3 4 10THD L 319 THRU 3 8 16THD THRU 3 8 E 1 4157 be 11 4 10 50 7 OEE 3 8 16 X 25 1 I BY UNIFORM 4 PLCS 4 5750 348 sa 18 X 275 paz 32 36 X 24 38 centers Bp PET BOTH ENDS TE Ji 10 2 3 IN f 0 948 1 ws LEG SX 13 X 238 EMIN UNDER CU a 1 vs STRAP 5 X 113 X 10 03 X 45 2 amp 7 8 9 THD DET FA DIA PART 8 22 75 6 516 2 9 X 229 ZUGE n 7 8 8 14 27 25 MG 5202 a 8 THD TOP PLA amp HARD 11 59 X 2 13 NOTE ENERPAC INDER ME ROD 1
10. on L 2 CENTER 0 GRAVITY G f O S EYEBOLTS TD LIFT TRANSMISSIUN N BO L25 TAP THRU SUITABLE FOR MOUNTING BRACKETS 6 4 THRU PRIMARY SHAF CLUTCH ENGAGED NEUTRAL ED PICK UP PORT 6 X 1 5 THREAD RT CONFORMS 5149 BEF OF LL MICO CL 4 HREAD 318 EACH SIDE NG Ul DIL IN FROM HEAT EXCHANGER M33 X 2 THREAD M T INIT CAPSCRE WS CONNECT GAGE INI 1 X 15 TH METRIC PORT CONFORMS TU 150 6149 MOUNT GAGE NP T HDUSI AX 9 RESSURI RIC PORT CONFORMS 6149 HREAD PROTECTOR OPERATING UNIT ZTN pe1e10d402u 3510 HEA READ RT CONI FORMS D PROTECTOR RE OPERATING UNIT RATURE PICK UP PORT NPTF DRYSEAL OIL STRAINER DRAIN PLUG X 2 THREAD DRIVING THRU PRIMARY CLUTCH E DRIVING THRU SECONDARY CLUTCH pue 8c SESOZOL enuen uoissiusueJ IUEN jeuondo uoissiusueJj SUMEN 3aeecs 9W v MAIN PRESSURE CONNECT OIL PRESSURE GAGE LINE HERE 27 X 2 0 THREAD METRIC PORT CONFORMS ISO 6149 MOUNT GAGE IN PILOT HOUSE IN FROM x HREA PORT 49
11. 232 1018883 Electric Trolling Valve Kit Turned 909 233 1017555 Manual Trolling Valve Kit 234 A7119W Sheet 1 of 3 Control Valve Hydraulic Diagram OMithount trolling 235 A7119W Sheet 2 of 3 Control Valve Hydraulic Diagram With electrice Tolling mec 236 A7119W Sheet 3 of 3 Control Valve Hydraulic Diagram With manual troling 237 1016473 Pump Assembly Trailing 238 10 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc model MG 5222DC 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 f
12. 1018688 759 24 vod 2415 350 10171298 1017554 1 4 824518 BOTH SIDES MATING WIRING HARNESS 1017502 3 SCREEN 1020479 1 5 41256 1018688 2 xwe7ssrMe4 voc 7072 7072 703 1725 2509 10171294 1017554 1038 7 4 4 5 5 1 SERIES SPECIFY LENGTH e 7 72 27072 7 725 eso 10171298 417554 x eoem 4 MG seo iwe i misse 1017154 1017179 e eezserdea vnd aarozan hisas inrziese x 2201 2 5 4 Se 1018085 41304 1017179 5 24 voc ae7o7ap Aae7ossA eeo 270 10171294 1017554 0 x 20 6 4 24518 6 51415 10180854 41305 1017179 xwezsert e voc ae7o7ap 2703 4 1860 270 10171294 1017554 0 7 x 20 6 4 45 h 51415 Pu i ibai 1018085 41
13. 1 stk SHES 2 1 Ms HANDLE STAMP TOOL T 18050 116 oe es SCRIP PART NN XA 7292 Date 10 27 99 By AMZ BREAK ALL SHARP CORNERS SAVE TOLERANCE UNLESS OTHERWISE SPECIFIED BEARING CUP 001 ON THREE PLACE DECIMAL DIMENSION TAA 0 DN FRACTIONAL AND TWO PLAC FUR XA 29e DECIMAL DIMENSION CAD FILE T18050 116 MGS200 SER 1 4 ON ANGULAR DIMENSION CHANGE DESCRIPTION DATE BY TWIN DISC INC RACINE VIS osiq UIML 150 3 0 KNURL SESOZOL uoissiusueJ IUEN I 550 E 2510 UIML 021 09081 1 6 26 000 002 SS 8750 DRILL THRU DET 1 3 e ET 2 AND DET 2 FOR FOR SEAL MA440 3 1 STK SHCS 1 P 18 x 125 LG 1 5 HANDLE 15 DIA x 6125 STAMP TOOL T 18050 1920 1 1 FIRMEX DRIVER 75 DIA x 11375 PART NO ei 23 DET DESCRIPTION STUCK SIZE 7855 Date 10 28 99 JZ Scale FULL BREAK ALL SHARP CORNERS NAME Saban TOLERANCE UNLESS OTHERWI SEAL DRIVER 001 THREE PLACE I SR ES N 5 010 ON FRACTIONAL AND TWO PLACE UR 72925 SHEE oF 1 Mes 11 DECIMAL DIMENSION CAD F 118050 120 MGSe00 SER 18050 120 1 4 ON ANGULAR DIMENSION CHANGE DESCRIPTION DATE BY TWIN DISC INC RACINE WIS iride 5100 19 4
14. SCREW MA996F 45 PLUG MA1038E BALL MA1034C PIN 1035 22 PLUG M2051FL PLUG MA1040A SPRING A2706W FITTING MA927 SCREW MA996C 22 D RING A2916JT COVER 502 PLATE 212754 STRAINER Be130B NOTICE THIS PRINT CONTAINS TWIN DISC INCORPORATED RACINE VI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY DR LIMIT RIGHTS GRANTED TD THE US GOVERNENT DR OTHERS BY CONTRACT MOUNT INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION TOWARDS BREATHER PLATE 204098C GAUGE B3631X LINK A2007 BREATHER 1251 CHAIN M1072 CLIP M1763A EYEBOLT 41047 22 TAG 656 TUBE ASS Y 2301 L TUBE Be301 ADAPTER 2300 SCREW MA996B 3 SCREW MA996D 4 SCREW MA996F 9 METRIC MANUAL DVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL LEVER MAY BE LOCATED ANYWHERE DN ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 gt ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL SAE 1 HOUSING ELECTRIC CONTROL MODE SWITCH CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE WIRING DIAGRAM CONNECTOR PRIMARY CLUTCH SOLENOID E SECONDARY CLUTCH SOLENOID NEUTRAL SDLENDID MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH DETAIL OF OPTIONAL ELECTRIC VALVE EYEBOLTS 2 FOR LIFTING MARINE TRANSMISSION ONLY GRAVITY 177 775
15. Detent position Trolling mode orifice closed orifice opened Figure 22 Mechanical Trolling Valve 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 chamber 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 valve s 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 Marine Transmission Service Manual 1020538 55 Operation 56 Twin Disc Incorporated 1017554 Electric 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 The only difference between the electric trolling valve and the previously described mechanical trolling valve is that the electric trolling valve s orifice size is controlled by electrical current instead of a lever When the trolling valve is
16. Special Tools Twin Disc Incorporated Bearing Seat Driver T 18050 152 STAMP 18050 152 229945 VET 5715 f DE X 2 A co 2 20 KNURL ETG 74 2275 3249 Exo Se ay DLA 45 FUR BEARING MA 271 ONLY MATERIAL MS SEARING SEA JRIVER 10 05 99 TWIN DISC INCDRPRATED KJB 188 Marine Transmission Service Manual 1020538 SESOZOL uoissiusueJ SUMEN 681 TOOL NUMBER 18050 607 3 875 18050 608 4 900 STAMP TOOL ND PART NO BREAK SHARP CORNERS TOLERANCE UNLESS OTHERWISE SPECIFIED 01 ON THREE PLACE DECIMAL DIMENSION 1 010 ON FRACTIONAL AND TWO PLACE DECIMAL DIMENSION 1 4 ON ANGULAR DIMENSION CAD FILE C 84 131 T18050 607 BRE i OB Y AK ALL SHARP D CUP 184 8 84 MASS90AR 2 31 9 31 MASSOBK 1 DRIVER SEE TABLE MAT DESCRIPTIUN STUCK SIZE 11 04 99 AJZ Scale FULL NAME BEARING DRIVER FOR SHEET 1 1 0 SER 18050 607 CHANGE DESCRIPTION DA BY TWIN DISC INC RACINE WIS 18050 608 209 06081 1 2510 UIML 5100 061 86602014 enuen uoissiUsueJ STAMP TOOL BREAK
17. 1019698 COUPLING SAE 1 HOUSING MATERIAL MATIDI D IS U TO THE INTERESTS OF HEAT TREAT WI 53403 USA U S GOVERMENT B 116 39 6 139 98 9 0 02 1 1 DA Ay 5 20 0 SCREW MA996D 3 S yN N SS WASHER B1504BE RQ Y WS RING 810481 IN P d SS N HUB 1019735 SEE 1 amp 48 SHAFT ASS Y 1015231B 3 0 10152308 SHAFT MA1034B BALL 16 2 THRU 8 HOLES EQUALLY SPACED USE 10 9 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO S574 OR SERVICE MANUAL VALUES HUB E 2 SIMILAR THIRD ANGLE PROJECTION WEIGHT UNLESS DTHERWISE SPECIFIED DATE 1 ume wem 8 3 01 DISC 1046 X 0 75 SCALE INCORPORATED FIRST USE ASSY MODEL E MG S222DC MARINE TRANSMISSION FLEXIBLE COUPLING INPUTS 0 25 50 1 00 RACINE 53403 USA SHEET 4 DF 4 A xx ALL ANGULAR TOLERANCES ANG GEDMETRIC TOLERANCING PER ANSI 14 5 1982 0 13 LIE CHK ALC PRIMARY SECONDARY CLUTCH CLUTCH LUBE TUBE NW RELEASED I E m CLUTCHES __ eS X x gt m ZG 13 CLUTCH PRIMARY amp SECONDARY SHAFT LUBE Sa o SESS 222 7 1 87 2 EE za GH
18. 2 14 4 40482 2 nnna 208 Suelion 210 211 Transmission Hear 212 Transmission Section View 1 1 1 1 024 214 Electric Control Valve optional equipment 217 Trolling Valve optional equipment 219 Marine Transmission Service Manual 1020538 9 Table of Contents Twin Disc Incorporated Engineering Drawings 221 List of Engineering Drawings 221 1020391 Sheet 1 of 4 Cross Section 223 1020391 Sheet 2 of 4 End View 2 4 224 1020391 Sheet 3 of 4 Installation Dimensions 225 1020391 Sheet 4 of 4 Input 226 A7119R Transmission Hydraulic Diagram 227 1020412 Mechanical Control Valve Without trolling 228 1020413 Mechanical Control Valve With trolling 229 1018084 Control Valve Without Trolling 230 1018085 Control Valve With Electric Trolling 231 1018440 Control Valve With Manual Trolling
19. 9 270740 1585 lt 230 10171294 x 20 64 2451 141052 141052 RANGE z w 10523 2 _MG 5114 AES e ressona 1732 2 17 2 2 MG 540 6 6449 _ 6557 _ __ Ex ELECTRIC CONTROL MODE SWITCH CLOSED WHEN MANUAL VALVE STEM IS LDCKED IN ELECTRIC MODE MAX I 20 A USE AS REQUIRED MIN TROLLING Ji 709 41213 1017383 1018688 xme759FMe4 voc 4679 2415 lt 350 171294 7 x 20 6 24518 PRESSURE 2 1017583 1017569 1017613 1018688 759 24 voc 7072 27072 703 2000 2902 10171298 7 20 6 245 10184402 4169 1018584 1018594 7 _ 1018688 75 4 vnc xae7o7z 427072 27 1725 250 1017129 1038 27 20 6 824518 10184408 _____ 1017383 1017179 2 wessrMe voc 2 2655 365 1017129 7 x 24518 2 2 2 5 pre omar e L A e mig4soR ____ 1017383 1017179 759 24 2550 370 10171298 1036
20. 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 H 1 4 T Dowel Return spring 4 5 Figure 19 Neutral Solenoid Engaged Marine Transmission Service Manual 1020538 51 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 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 a
21. x 0 451 3 EA Esa PLATE 1018312 SCREW MA1052P 4 TORQUE 54 2 40 0 lbf Ft gt M8 X 125 6 TH D 1017363 1017179 mersa emet 2450 355 10171294 jutosecoe x 824513 CUTE CONNECT OQ 10184407 4164 1017134 1018688 5 4 vnc xae7o7Ap 270740 A2703AB 2000 lt 290 10171298 1038 427 x 24518 _ 6 52050 NOTE CONNECTOR SHROUD 1001825 NU RE Oliois44ou 4132 1017133 1017134 337 1018688 5 24 voc 27072 7072 703 1725 lt 250 10171298 7 x 0 6 824518 aa SECURE LEVER IN THE DEPRESSED TOP VIEW INSTALLATION NOTE 10018440v 4153 1018688 759 24 vnc 2415 lt 350 10171298 7 x 2451 5 ELECTRIC CONTROL POSITION 06 09 95 83 162 AT THE 460 1817 LOCATION DF THE 41178 118600 jwe7serM2a xaa7o7z aezwzz eor 725 250 10171298 eo em Beasia 45 eme waa BY PUDPING PLASTIC STRAP THRU zn EN MUST
22. 06 30 1 i 1 x 45 U CUT 4 1 DIA 1 00 4 n DIA Jac eed P re DIA FULI U A H EN 1 ae arn 5 MS DRIVER BASE lt HDN amp GRD IANDLE gt DESCRIPTIUN 5 SIZE Date 9 6 JPL FPN Scale FULL NAME DAG ETT BEARING DRIVER FOR ass y 1014841 SHT 2 amp DET 8 4 amp 5 6 22 96 JPL MG 5182 VARIDUS DESCRIPTION DATE BY TWIN DISC INC RACINE WIS 19 019 09081 1 pe1eJodjo2u 2510 UIML 5100 26 86602014 enuen uoissiUsueJ 5100 19 4 V 59 0 86661 1 4 437 DIA lt 6 REQ D LEGS TO PLATES u UNLESS SPECIFIE BREAK 41 SHARP CORNERS NOTE ALL GROUND DIA S amp SURFACES MUST BE SQUARE amp CONCENTRIC SERES OO D WITHIN 005 DF EACH OTHER PE SPRING RETAINER HOLD DOWN a RG VED 516 7470 Era osiq UIML CA 4 SESOZOL Jenuejy uoissiusueJ SUMEN
23. 1 Neutrol utch Solenoid Solenoid Section C C ELECTRIC CONTROL MODE SWITCH LEVER LOCKED FOR ELECTRIC OPERATION NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS TE mE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED MANUAL OVERRIDE NEUTRAL START SWITCH Section B B lt ia LIH d METRIC Q cj mum 1002456 UMESS m LENS BE 719 sae c peer PRS bee ee X WITHDUT TROLLING VALVE SHEET 3 OF 2 i Clutch Solenoid Neutrol Solenoid MANUAL OVERRIDE NEUTRAL START SWITCH VAL Section C C ELECTRIC CONTROL MODE SWITCH CLUTCH ENGAGED LAS Vl GE 2 ENGAGED ERE EIE EI ZZ SA LE MIL S Clutch Solenoid Clutch Solenoid MANUAL DVERRIDE MODE SHOWN IN NEUTRAL ll 2 LABIA Lete qm H 5 Section Vee 4 Section Trolling Valve xm ROR Orifice T NN NL LY m H H NEUTRAL REGULATOR p Se MANUAL MODE ELECTRIC MANUAL VALVE FOR MG 509 THRU MG 61842 REFERENCE VALVE ASSEMBLY 1018085 SHOWN WITH CLUTCH Clutch ENGAGED Solenoid SHOWN WITH CLUTCH ENGAGED Neutrol Solenold Solenoid Section C C ELECTRIC CONTROL MODE SWI
24. 19 20 21 Install cover capscrews and torque to 23 Nm 17 Ib ft 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 lb ft 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 of the large diameter ball at each switch location Install the pressure regulating piston into valve body with spring pocket out Marine Transmission Service Manual 1020538 Twin Disc Incorporated 22 2 24 Assembly 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 bogy Install neutral pressure regulating spring into the pocket of valve body Figure 105 Neutral Pressure Regulating Spring Location 25 26 27 28 29 Install orifice plate gasket onto valve body 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
25. Marine Transmission Service Manual 1020538 19 Description and Specifications Twin Disc Incorporated Lubrication Features The MG 5222DC transmission has a lubrication tube located inside the main housing The tube extends from the front to the rear of the inside of the housing The lubrication tube has drilled holes in the tube that spray oil on the transfer gears and the primary and secondary pinions Bearings and clutches on the primary and secondary shafts are lubricated through drilled passages in the shafts Output shaft bearings are gravity and splash lubricated Suction Strainer The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and the oil pump in the hydraulic circuit The strainer can be replaced if necessary Filter Assembly A spin on oil filter is located between the heat exchanger outlet and the selector valve in the hydraulic circuit The replacement element is Twin Disc part number XB3614 This should be replaced at 1000 hour or six month intervals whichever comes first 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 20 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Description and Specifications Flexible Torsional Input Coupling The purpose o
26. 29350 6 24 99 Prev ame wo awe zw ce pare D OR OTHERS BY CONTRACT ee SECTION WHITE WIRE VALVE BDDY ASSY 1018882 N BODY 1018881 BALL 1034 amp BOM No 41063 E TR THIRD ANGLE SIMILAR 1017554 PX 8671 UNLESS OTHERWISE SPECIFIED DATE ange Fes 58 INCORPORATED MACHINED DIMENSIONS RACINE WI 53403 USA em MG 5202DC ER ANSI 14 5 1982 iue 101888 VALVE ASS Y TROLLING Bie APPD MS SHEET 1 o rev ERE OMBRE PLATE IS NOT INCLUDED ASSEMBLY USE EXISTING PLATE FROM CONTROL VALVE A NOT SERVICEABLE SEPARATELY MATERIAL WEIGHT HEAT TREAT FIRST USE ALL ANGULAR TOLERANCES 31 ASSY 101 5207 TOLERANCING INSTALLATION NOTE 0 6 0 9N 5 5 8 3 Ib AT THE 46 0 1 81 LOCATION OF THE 6 4 1 4 DIA HOLE IS REQUIRED CAPSCREW 1042 2 TO OVERCOME DETENT REMOTE CONTROL ACTUATOR MUST PROVIDE 65 0 mm 2 56 TOTAL LINEAR TRAVEL AT THE 6 4 1 4 DIA HOLE LOCATION 9 STEM 1017901 SEAL 5591 ADAPTER 1017530 F d 22 SETSCREW MA1037D SCREW IN UNTIL POINT 5 THEN LOOSEN E 1 2 TURN BALL STOP IN NO TROLL POSITION PISTON P 10491 THE 90 LEVER ROTATION REQUIRED FOR CONTROL MAY FALL ANYWHERE WITHIN THE 360 IN WHICH THE LEVER MAY BE CLAMPED PROVIDED CL
27. necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly Disassembly The following procedure is for complete disassembly of the unit Prior to this procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility Note The MG 5222DC transmission requires the use of a SKF THAP 300 oil Injection Kit see Special Tools or similar device to remove the output gear from the output shaft Marine Transmission Service Manual 1020538 73 Disassembly Twin Disc Incorporated Prepare Transmission for Disassembly 74 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 don t forget the quantity size etc Drain the oil from the transmission sump by removing the M33x2 hex plug from the bottom of the rear side of the housing Drain the oil from the filter housing as well by removing the O ring plug located below the oil hose coming back from the heat exchanger 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
28. pliers Figure 55 Removing Roll Pin Retaining Shuttle Seat 21 Thread a M8x1 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 Marine Transmission Service Manual 1020538 95 Disassembly Twin Disc Incorporated 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 3 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 56 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them Remove the third Neutral solenoid units with hydraulic lock or plug units without hydraulic lock 96 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 6 Remove the filter screen from the valve body Figure 57 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 Remove the s
29. 18050 120 Remove excess sealant that is wiped off as seals are pressed into position A Install forward seal with spring loaded lip toward the inside of the transmission Install flush with inner face of seal carrier B Install rear seal with spring loaded lip of seal toward rear of the transmission Install flush with outer face of seal carrier 118 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly C Pack area between the seals with water pump grease Figure 71 Packing Cavity Between Output Seals With Grease D Install grease fitting if not previously installed 5 Install established shim pack aligning pusher screw clearance holes of shims with threaded pusher screw holes of seal carrier Figure 72 Installing Shim Pack left with Pusher Screw Holes Aligned right Marine Transmission Service Manual 1020538 119 Assembly Twin Disc Incorporated 6 Install assembled output seal carrier onto housing Install attaching screws and torque to 275 Nm 203 ft Ib Figure 73 Installing Seal Carrier 120 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Installation of Top Cover Assembly and Oil Gauge 1 Turn transmission over and block securely to rest in upright position 2 Install top cover assembly with its gasket Install attaching screws and torque to 112 Nm 83 ft Ib 3 Install breather filler cap 4 Install oil gauge tube assembly and oil
30. 9 _ M8 X 1 25 THRU e HOLES SUITABLE FOR CONTROL MOUNTING BRACKETS 6 4 THRU ENGAGES PRIMARY SHAFT CLUTCH ENGAGES SECONDARY SHAFT CLUTCH SPEED PICK UP PORT M16 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 0025 PILOT M20 X 2 5 THREAD 318 DEEP 18 HOLES 9 EACH SIDE USE ALL 18 HOLES FOR MOUNTING UNIT USE 8 8 PR PERTY CLASS QUALITY CAPSCREWS PER ISD 898 1 AND TORQUE TO 5574 SERVICE MANUAL VALUES DIL PRESSURE GAGE LINE HERE Mie X 15 THREAD METRIC PORT CONFORMS TD ISO 6149 MOUNT GAGE IN PILOT HOUSE DIL IN FROM HEAT EXCHANGER M33 X 2 THREAD METRIC PORT CONFORMS ISD 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT FILTER DRAIN PLUG MIO X 1 0 THREAD METRIC PORT CONFORMS 150 6149 LUBE PRESSURE X 15 THREAD METRIC PORT CONFORMS TO ISO 6149 AUXILIARY LUBE SUPPLY INLET SEE HYDRAULIC DIAGRAM SECONDARY CLUTCH ACTUATING PRESSURE X 15 THREAD nIL 007 TO HEAT EXCHANGER M33 X 2 THREAD METRIC PORT CONFDRMS TD 150 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT TEMPERATURE PICK UP PORT 1 4 18 NPTF DRYSEAL DIL STRAINER DIM X FROM PORT S FACE PINION O D Y REF H C SPEED PICK UP PORT M16 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 e PRIMARY CLUTCH ACTUATING PRESSURE X 15 THREAD METRIC PORT CONFORMS TD ISD 6149 Lupe PRESSURE MIB X 15 THREAD METRIC PORT CONFORMS TD 150 6149 AUX
31. Approximate Dry weight 1046 kg 2306 Ibs Oil pressure See Table 1 for oil pressure specifications Minimum oil pressure when cruising is 1620 kPa 235 psi _ E MARINE TRANSM BBRICANT SERVICE CLASS USE SERVICE 55 CD ENGINE DIL CERTIFIED BY VENDOR TO PASS 1 20 TEST ALSU APPROVED IS S AE A6PI SERVIC CLASS CC ENGIN IL MIL L 2104B VISCUSI EMP W START UP VISCUSITY ae M N NL v TF MIN AE NO50 J TEADY OPERA BOVE 200 F 5 UO P 22 Figure 2 Oil Specification Plate Marine Transmission Service Manual 1020538 Twin Disc Incorporated Description and Specifications Table 1 MG 5222DC Oil Pressure Specifications Oil pressure Limits 1725 kPa 250 psi rating 235psi minimum pressure when cruising Main Pressure at Valve Primary Clutch Min Secondary Clutch Min Shift Position Neutral 255 310 Primary 1586 1793 230 260 1558 600 Secondary 1586 1793 230 260 1558 226 14 55 ETE 1800 1725 1862 250 270 1696 97 234 Secondary 1725 1862 250 270 Note It is required that lube pressure with primary clutch engaged must equal lube pressure with secondary clutch engaged within 21 kPa 3 psi Note Oil temperature to be in normal operating range Mari
32. BODY DATE rm EDY PLATE seni CONSISTS DF E Jor FIRST AND NUMBER e e PART SIZE ASS Y CENTER INNER NOM ary APPR 20 41806 1020411 21527 104790 5 B1867 4270780 2704 2702 1725 82334 s Ape os 238 8 __ LL To o __ _____ LL LL LL L 1 L T 1 L 1 TT LL 1L LL ist CLUTCH ENGAGED FOR POSITION FWD NEU REV2 USE Ry _ LL bL bL bL bL Lb bL Lb Jj ENGAGED FOR 2 POSITION ENGAGED amp DISENGAGED USE 91 b p ub dp Eb HD F x 20 150 6149 TH D 5 Wunde a ee DIL INLET WHEN M2067R TH D Es 1038 O RING W PROTECTOR IS SPECIFIED NEUTRAL FOR 3 29 2 36 50 POSITION FWD NEU REV gt USE fgg A TEST VALVES PER TEST SPEC ND CONTAINED IN VALVE SPECIFICATION INSTALLATION DATA 1 v VALVE SUITABLE FOR UP 95 L min DISENGAGED FOR POSITION ENGAGED amp DISENGAGED USE CONTROL LEVER 1 4 DRILL SEE NDTE amp 3 55 4 2 CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 335 AND 296 kPa 32 44 89 N AT THE 55 9 R LOCATION OF THE 6 4 9 HOLE IS REQUIRED TO OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 35 8 LINEAR TRAVEL FROM NEUTRAL AT THE 6 4 HOLE 4 LOCATION
33. CLUTCH PRESSURE PX9975 7540 WEIGHT UNLESS OTHERWISE SPECIFIED DATE yenes em 8 2 01 TUJUN DIS MACHINED DIMENSIONS X 10 ME 1 NDT BE USED IN D SI DETRIMENTAL TO THE INTERESTS OF Ex 22 RER ee RACINE VI 53409 USA Eee ener assy ALL ANGULAR air PAR ceu RACINE 53403 USA Move MG 5222 DC He a te 1 0 e 0 4 1 2 TB 86 0472 11 15 01 THIS NOTICE 15 NOT INTENDED A A Be ECN00355 8 21 01 GRANTED TO THE US GOVERNMENT APP REV zone pare pare _ OTHERS BY CONTRACT VALVE ASSY CONTROL sweet 1 of 1 D B 1 A m VALVE VALVE VALVE ORIFICE VALVE SPRINGS sums First DATE ASSEMBLY a GASKET PLATE A X SPRING CONSISTS 9 PART ory use AND NO SIZE m n APPR E ee Tr E ERE re FE 274 5 01g LL 7201 6 __ ___ ___ _______ 11 LJ MA1038E O RING PLUG arae dare ursi 0 LL L Ll bL bL L LL fo WHEN SPECIFIED 9 PROTECTOR IS SPECIFIED 1 LI 111 1 ___ LI L bL L bL bL DL LL LJ L _____
34. EMT ER TRR RACE Me086DF PISTON SEE CHART 4537 SENI EIE MC e550 970 10171298 7 zz z wess KERE ROTATION amp 11 4mm AXIAL MOTION BEARING M2087AD Sri ENGIN CRNNEE TIONG 69 horsossar 41446 1017383 1017179 xve7ssrMe4 voci x 2 LII REQUIRED FOR CONTROL RACE M2086R ARE NOT POLARITY SENSITIVE bees ane el GASKET B1334C COVER 55 1017336 CARRIER 1017335 BALL 1990 SOLENOID SASS Y SEE CHART PARTS R UNITS WITHOUT NEUTRAL SOLENOID AND 25 0 tbf Ft HYDRAULIC LOCK OPTIONAL CONDITION SCREEN 221336 MIRING DIAGRAM Uc BALL 19906 2 BALL 1990 22 NEUTRAL SPRING 2705 2 SDLENDID A2711R 2 OR WITHOUT HYDRAULIC LOCK e BALL 1990 X 1 25 6 MATING WIRING HARNESS 1017404 2 HOLES SPRING ASSY gt CONNECTOR SERIES SPECIFY LENGTH MANUAL OVERRIDE 361 WEN SEE CHART 2 VALVE BODY ASS Y 1017444 ELECTRIC 247 NS SN N PISTUN B1399H VA 7 7 A BODY 1017443 PORT SDLENDID PORT che CONTROL 5 227 BALL 1 4 11 POSITION POSITION M BALL 19907 6 THESE SOLENOID CONNECTIONS SAS EEG Nix SN PLATE HAR SEAL MA778 SM 777 h 2 n ee he
35. FILTER DRAIN PLUG M10 X 10 THREAD HEAT EXCHANG D INFORMS THREAD PROTECTOR OPERATING UNIT METRIC PORT CONFORMS 614 TO ISO 6149 S pm e 18 X 15 THREAD METRIC PORT CONFORMS 50 614 TEMPERATURE PICK UP PORT 1 4 18 NPTF DRYSEAL SUCTION STRAINER 0 SUPPLY O5MM TO TEETH NDING ON RATIO S MAIN PRESSURE PICKUP PORTS ISU 6149 EYEBDLTS FOR LIFTING MARINE NSMISSIUN EQUALIZE LOAD ON BOT EYEBOL LIFT MARINE TRANSMISSION ONLY ENTER IRAVITY GREAS NC M20 X 2 5 THREAD 318 DEEP UNTING UNIT Y CAPSCREWS MANUAL VALUES DRIVING THRU PRIMARY CLUTCH DRIVING IRU SECONDARY CLUTCH DRAIN PLUG 2 THREAD pue uonduoseq 25 0 UIML SESOZOL Jenuejy uoissiusueJ IUEN 6c 5 041002 214129 3 nla WIRING DIAG CONNECTOR b 7 PRIMARY CLUTCH SOLENON 771 SECONDARY CLUTCH SOLENOID OPTIONAL MATING WIRING HARNESS 1017404 SERIES SPECIFY LENGTH MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL PRIMARY SECONDARY CLUTCH CLUTCH SOLENOID SOLENOID L85 6H THREAD N X OLES ENGAGES
36. IC Te 9 QN NN S95 AON Ae d V NL ee Nm ae M N gt AON SO Es ES os NE 129 Marine Transmission Service Manual 1020538 214 SESOZOL Jenuejy uoissiusueJ Sle Item Description Item Description Fitting grease output seal carrier Ring internal retaining inputhub O ring output flange Hub splined Screw sockethead output flange Screw hex head front housing Shim output flange retainer Gasket top cover Washer retainer output shaft Washer flat top cover Flange companion Screw hex head top cover Seal oil output flange Cover assembly top Carrier output seal Gear transfer primary shaft RH helix O ring output seal carrier Plug assembly M16x1 5 speed pick up ports Screw hex head output seal carrier Plug assembly M18x1 5 pressure test ports Plug assembly oil drain O ring primary shaftend cover Shim rear bearing output shaft Cover primary shaft end Bearing tapered roller output shaft rear bearing Shaft assem bly primary Gear output Shim bearing Bearing tapered roller output shaft front bearing primary and secondary shaft rear bearing Housing asse
37. INTO DETENT GROOVE UNTIL SNUG 1 2 TURN 101808540 ___ 018085 l1 THESE SULENUID 5 ARE NOT POLARITY SENSITIVE SETSCREV 018085 1 1018085 1 21 SPRING 270280 2 HYDRAULIC LOCK ON PIN A2711AC 2 SPOOL 1017432 2 NOTE HYDRAULIC LOCK ONLY HYDRAULIC LOCK ONLY RS MD er Pines ii TT RACE M2086DF PISTON SEE CHART MOVEMENT WITHIN THE 50 TOTAL gt SIS ntn uan RACE M2086R SPRING 2705 2 r AU VALVE BODY ASS Ya 4431017444 GASKET 1334 PIN A2711R 2 BODY 1017305 11 PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND COVER ASSY 1017336 NEUTRAL WITH OR WITHOUT HYDRAULIC LOCK 199 6 HYDRAULIC LOCK OPTIONAL CONDITION 4A CARRIER 1017335 SOLENDID SPRING ASSY SEE CHART WIRING DIAGRAM OPTIONAL VALVE GASKET 10171368 SCREEN 221336 BALL 1990 BALL M1990L 2 BALL 1990 MATING WIRING HARNESS 1017501 CONNECTOR SERIES SPECIFY LENGTH PORT SOLENOID PORT SOLENDID D PISTON B1399H M8 X 125 6 2 HOLES CONNECTOR SHROUD 1001826 MANUAL DVERRIDE POSITION WHITE WIRE WITH xx ELECTRIC PORT CONTROL CONNECTOR FEMA VALVE m POSITION THESE SOLENOID CONNECTIONS SEAL MA778 ARE NOT P
38. Manual 1020538 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 progressively 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 1020538 45 Operation 46 Twin Disc Incorporated Control Valve Assembly in Neutral Some of the main pressure oil from the oil inlet chamber flows through a passage
39. NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS DETRIMENTAL TO THE INTERESTS OF sc ow 19 EC ANGLE 9 TO PX10790 P 10481 A 2 B1400B 1 RACINE WI 53403 USA WEIGHT UNLESS OTHERWISE SPECIFIED 1 MENS ARE mm oH 01 TWIN 1203 NOT TO BE USED IN ANY MANNER MACHINED DIMUS INCORPORATED 0 TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT FIRST USE assy 1020413 MG 5222DC a mm 1020413 PETEN tor VALVE DITCH piston SOLENOID vi Tag ee F weep p ORIFICE X 4145 _ _HELNTING SCREWS FIRST CONSISTS OF p TEES ASS Y PLATE aep GASKET meg No parT 8 forr 5 ory 13372 1018688 ves 75 24 voc 7 72 42707 LAerosT qn e meme CONNECTOR MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN PORT A SOLENOID a pcnc KA V M menean aurei 1017179 wa e hereraa es voc nezoron weroenu eis cosmnmmeom peiesstmer x eem PORT SOLENOID TRANSMISSION 15 IN NEUTRAL er oaa 117134 pisar 1017179 nn e pmazsordaa voc _Ae707AD lises eao w
40. OUT 1 2 14 THREAD INSTALL PLUGS FOR SHIPPING FILTER REPLACEMENT ELEMENT FILTER PRODUCTS CORPORATION FPE 30 25N PARKER 925023 CROSS 4119025 n IN LAR 3 4 NPT QUICK DISCONNECT INSTALL PLUGS FOR SHPPING OIL IN 3 4 14 THREAD FEMALE SWIVEL PUMP FLOW RATE IS 110 l min 102 C 100 MESH INLET STRAINER REMOVABLE SCREEN M E T R I C ANGLE O C mas REMOVE THIS ENDCAP TO EXTRACT SCREEN FOR CLEANING UG REMOVE TO CLEAN 65 POWER COR D E S PRONG GROUNDING PLUG TWIN 1 DISC INCORPORATED 115 V WRAPI THIS NOTICE IS NOT INTENDED FOR SHIPMENTS PED LIMIT RIGHTS rev zoe DR DTHERS BY CONTRACT 1020538 01 02 AR TWIN DISC ld POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
41. Pump Set Bearing Driver Bearing Cup Driver Seal Driver Bearing Seat Driver Bearing Driver Driver Bearing Driver Spring Retainer Hold Down Output Gear and Shaft Puller Sh 1 of 4 Output Gear and Shaft Puller Sh 2 of 4 Output Gear and Shaft Puller Sh 3 of 4 Output Gear and Shaft Puller Sh 4 of 4 Sleeve for Runout Check Seal Protector Seal Driver 181 Special Tools Twin Disc Incorporated Lifting Bracket Clutch Removal in Boat 18050 772 Bearing Driver 19987 Output Gear Lifting Fixture 182 Marine Transmission Service Manual 1020538 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 2279574 Figure 129 THAP 300 Air driven Pump Set Marine Transmission Service Manual 1020538 183 Special Tools Twin Disc Incorporated Mounting Fluid LHMF 300 and Dismounting Fluid LHDF 900 SKF LHMF 300 and LHDF 900 are recommended when using SKF hydraulic equipment like hydra
42. Twin Disc Incorporated Description and Specifications Description and Specifications General 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 N MODE rom BUM SERIAI NU NU CAPACITY Aan mus kc ce cH CUM GAL MARINE RANSMISSIUN LUBRICATION MIN HIL PRESSURE WHEN CRUISING PSI EVERY 10 SERVICE HOURS UR DAILY CHECK DIL LEVEL WITH ENGINE RUNNING AND MARINE TRANSMISSION IN NEU RAL VERY 100 HOURS WHERE A GREASE FITTING IS PROVIDED UTPU SE ALS WITH WATER PUMP GREASE TO PREVENT BILGE WATER USING 00 SERVIC HOURS DR 6 MONTHS WHICHEVER COMES FIRST HI USING WITH CLEAN DIL REMOVE AND REPLACE F ER ELEMENT WHERE APPLICABLE JCTIUN SC 25 ARR UNLESS TRANSMISSION IS LUBRICATED AND MAINTAINED AS SPECIFIED IN THE SERV AVAILABLE UN REQUEST REFER ARINE RANSMISS IN LUBRICANT PLATE SHIPPED V 5 GILL OF NU uM BE C JEN WHEN ORDERING PARTS ry lt MADE IN USA n ud ES t Figure 1 Nameplate for MG 5222DC Marine Transmission Marine Transmission Service Manual 1020538 17 Description and Specifications Twin Disc Incorporated Power Ratings The MG 5222DC transmission can be operated through eit
43. Valve Secondary Sectional View SECONDARY CONTROL VALVE BODY TO PRIMARY CLUTCH TO SECONDARY CLUTCH CONTROL VALVE STEM g ATMOSPHERIC PRESSURE o ENGAGING PRESSURE Figure 12 Control Valve Secondary Cutaway View Marine Transmission Service Manual 1020538 43 Operation Twin Disc Incorporated Hydraulic System with Electric Control Valve 44 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 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 Marine Transmission Service
44. WHEN MANUAL VALVE MANUAL DVERRIDE IS IN USE amp STEM IS LOCKED IN ELECTRIC TRANSMISSION IS IN NEUTRAL MODE E PRIMARY SECONDARY CLUTCH CLUTCH SOLENOID SOLENOID M8 X 125 6 THREAD MANUAL OVERRIDE 3644 L H LES _ POSITION CFOR REMOTE CONTROL BRACKE N BS TE ELECTRIC 1 4 24 7 y PRIMARY SHAFT CONTROL CLUTCH POSITION En N 36 6 14 3 4 67 A ENGAGES SECONDARY SHAFT CLUTCH d gt 7 UA NOTE 4 LEVER MAY BE LOCATED ANYWHERE ON ITS THAT PERMITS FREE MOVEMENT WITHIN IE 50 TOTAL ROTATION amp 114mm AXIAL MOTION REQUIRED FOR CONTROL 2510 UIML Installation 180 Twin Disc Incorporated Mechanical Controls Movement of the operator s selector lever to the forward neutral or reverse position must result in the transmission control valve selector being positioned in the forward neutral or reverse detent location Cables and linkages must be supported properly and not have any excessive slack that will allow relative movement between the operators selector lever and the transmission control valve selector lever Power Controls Selector valve positioning devices must be installed so that full travel of the actuating cylinder places the transmission selector valve in the d
45. WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT SPRING AND PIN MAY BE OMITTED THEN THE FORCE WILL BECOME 13 31 THE DETENT FEATURE IS PROVIDED IN THE FULL FORWARD FULL REVERSE AND NEUTRAL LEVER POSITIONS 6 dg 2nd CLUTCH ENGAGED FOR 3 POSITION T FWD NEU REV USE 35 3 50 8 4 TORQUE MOUNTING BOLTS TO 57 68 N m AS RECIEVED PER 5574 OR 47 56 LUBRICATED S574 AFTER TORQUING MOUNTING BOLTS INSTALL M2067X PLUGS IN MOUNTING BOLT CDUNTERB RES 204087B PM 2306 D MA960A MA1038B 12 1 5 ISD 6149 PRESSURE GAUGE LINE LOCATION MA1038B 1400 2 ee i 3 SEE CHART CHART A R lt lt lt YK SX NRIZ MISSE eS SS E 3574 eu psi 9604 IN EE M2086AV MA778 1 3 POSITION B2297A 2 POSITION 2916 K FACOG SV UR ONU QN WUE ien SECTION D D SECTION EE 10 i GASKET ORIFICE PLATE 44347 1 GASKET SURFACE section e SECTION 1927 SEE CHART 1 4 1334 1 10481 _ 2 SEE CHART SEE CHART 1 GENERAL NOTES VW REMOVE BEFORE OPERATING UNIT THREAD PROTECTOR ATMOSPHERIC PRESSURE THIRD ANGLE ATMOSPHERIC PRESSURE PROJECTION I P INTERMEDIATE PRESSURE P
46. as Dow Corning 2008 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 Ib ft 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 8 Install the Weatherpak connector onto its retaining clip on the top of the valve body Marine Transmission Service Manual 1020538 147 Assembly Twin Disc Incorporated Assembly of Electrical Control Valve lower body half 1 2 Install the steel shuttle ball into its bore in the valve body Install the O ring onto the shuttle ball seat Apply lubricant such as Dow Corning 2006 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 M8x1 25 cover screws threaded into the seat can be used to adjust the seat location in the valve body 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 101 Installing Shuttle Ball Seat Roll Pin 148 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 align
47. cause of air leak Disassemble and repair as required Remove disassemble clean and repair the regulating valve Replace oil pump Replace heat exchanger Marine Transmission Service Manual 1020538 Twin Disc Incorporated Troubleshooting Table 8 Troubleshooting Chart continued Symptom High main oil pressure High temperature Excessive Noise Regulating valve stuck Improperly shimmed Lube relief valve malfunction 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 Im proper alignment Damaged propeller Misfiring engine Marine Transmission Service Manual 1020538 Remove and clean regulating valve Shim as required Inspect repair or replace parts as necessary Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch O verhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve O verhaul marine transmission Remove marine transmission Replace a worn or damaged coupling Select proper torsional coupling O verhaul marine tran
48. for information Set secondary transfer gear on fixture T 18050 609 with large diameter of tapered bore up Move fixture and transfer gear to a press with at least 445 kN 50 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 890 100 Ibs to 200 Ibs downward force on shaft Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Center fixture gear and shaft under ram of press and apply approximately 276 kN to 409 kN 31 tons to 46 tons of force on front end of secondary shaft Release pressure and turn fixture shaft and gear 180 Reapply pressure to complete advance 1 Figure 74 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 84 mm to 3 86 mm 0 112 in to 0 152 in If transfer gear has not been advanced as specified above contact the Product Service Department at Twin Disc Incorporated for information Marine Transmission Service Manual 1020538 123 Assembly Twin Disc Incorporated 2 Install piston seal ring into groove in secondary shaft Apply a coat of assembly grease or oil to seal ring 3 Install piston ring in gro
49. 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 Thetransmission output flange and companion flange bolts must be torqued to the proper value as identified in Description and Specifications Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation Torsional Input Coupling Alignment Free Standing Units Alignment of freestanding transmissions must begin by aligning the transmission output flange to the propeller shaft The engine must then be moved to properly align the engine flywheel to the transmission input hub Marine Transmission Service Manual 1020538 167 Installation Twin Disc Incorporated Engine and Marine Transmission Alignment A CAUTION When mounting the engine and transmission in the boat all of the mounting pads on both the engine and transmission must be used Failure to do so may result in damage to the transmission or the engine flywheel housing Recommended Figure 119 Transmission Mounting Configurations When mounting the engine and transmission in the boat all of the mounting pads o
50. 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 Make note of the oil level in the cold conditions for future reference as it corresponds to the correct oil level at operating temperature Marine Transmission Service Manual 1020538 65 Preventative Maintenance Twin Disc Incorporated 66 Torsional Coupling Do not obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling The ambient temperature of the air around the coupling should be between 6 C 22 F and 80 C 176 F Assure baffles are installed properly so hot air is ported out of the housing Visually inspect the element after the first 100 hours of operation and every 2000 hours thereafter or every six months whichever comes first Torsional vibration misalignment degradation by contaminants oil heat ultraviolet radiation and excessive system torque can cause cracks or other signs of distress to appear on the surface of the rubber The above described items affect the life of the coupling element When inspecting the flexible coupling look for evidence or conditions identified in the following steps Cracks in the surface of the rubber be caused torsional vibrations exc
51. is no gap between the shaft shoulder and the gear hub 11 Install the pinion front bearing cones for primary and secondary shafts onto bearing cups previously installed in transmission housing Marine Transmission Service Manual 1020538 115 Assembly Twin Disc Incorporated Installation of Output Shaft Rear Bearing 1 Install heated rear output shaft tapered roller bearing Install with small O D of bearing to the rear Press drive bearing to shaft shoulder using special tool T 18050 96 After bearing cools press drive bearing down again to assure that bearing is against shaft shoulder 2 Install chilled bearing cup into output seal carrier using tool T 18050 116 After bearing warms press drive bearing cup down to assure that bearing cup is bottomed in bore of seal carrier 116 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Output Shaft Tapered Roller Bearing Adjustment 1 To set output shaft bearing clearance proceed as follows A Install seal carrier without seals or O ring Secure seal carrier with capscrews using very little torque on capscrews Use a taper gauge or feeler gauge to measure gap between rear housing face and flange of output seal carrier Build a trial shim pack of thickness equal to gap plus 0 50 mm 0 020 in Install the shim pack To lift output shaft install eyebolts and strap to rear of output shaft Apply 1340 N to 4000 300 Ibs to 900 Ibs of downwar
52. level gauge Verify that the oil gauge tube assembly did not enter the output gear pan opening Marine Transmission Service Manual 1020538 121 Assembly Twin Disc Incorporated Assembly and Installation of Primary and Secondary Shafts 122 1 Assembly of 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 amp 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 C Install secondary transfer gear on secondary shaft taper small diameter of tapered bore up Seat gear on shaft taper with 445 N to 890 100 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 dimension B e Calculate expected advance Expected advance A B Calculated advance must be 2 84 mm to 3 86 mm 0 112 in to 0 152 in If calculated advance is 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
53. pressure regulation 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 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 1020538 Twin Disc Incorporated Operation E 1 7 22 CUSTOMER TD INSTALL PRESSURE GAUGE LINE HERE MOUNTED 2 2 r E 1 IN PILOT BEAR lt lt 44 SEE MARINI BEARING P f INSTALLAT PRIMARY SHAFT FRONT amp REAR BEARING PINION _ amp CLUTCH LUBE SHOWN ENGAGED MARINE TRANSMISSION 1 CONTROL VALVE LUBE RELIEF VALVE SE DAR 690 KPa Te FRONT amp REAR BEARING PINION 1 amp CLUTCH LUBE SHOWN DISENGAGED PORTION ENC THESE LINES IS L HYD
54. 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 30 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 3 Remove oil gauge and oil gauge tube assembly 78 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly Remove Output Shaft and Gear 1 Remove output shaft seal carrier Use two of the removed screws as pusher screws to separate seal carrier from housing Remove O ring and oil seals from seal carrier Figure 31 Removing Output Shaft Seal Carrier 2 Remove output shaft bearing adjustment shims from housing Marine Transmission Service Manual 1020538 79 Disassembly Twin Disc Incorporated 3 Use a hoist to lift output shaft and gear assembly until gear contacts housing Place blocks under gear to support the gear and shaft assembly in position Figure 32 Supported Shaft As
55. the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter Housing 7 Engine Engine Flywheel Engine Flywheel Engine MS Crankshaft ndicator 4 8 Figure 116 Checking the Flywheel Face Runout Marine Transmission Service Manual 1020538 163 Installation Twin Disc Incorporated 6 With the indicator mounted as in the paragraph above adjust the indicator tip so that it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot bore eccentricity of the engine flywheel should not exceed 0 13 mm 0 005 in maximum total indicator reading Thrust on the flywheel should be in one direction at all times to obtain a correct reading Engine Flywheel Engine J guess 4 L ft 52 1 Thousandths Indicator Paar Engine Crankshaft Engine j Flywheel n Figure 117 Checking the Flywheel Pilot Ring Bore Eccentricity Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation Installation Alignment Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boatto change its form with various loads and with age
56. the primary clutch Pressurized oil from port K travels through passage J and enters chamber L through an orifice in the orifice plate The orifice in this plate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against the springs until the piston is stopped by a shoulder in the valve body This causes the pressure in chamber B to rise to clutch engaging pressure When in primary passage E remains at atmospheric pressure because slot F remains open to sump When a shift is made from primary to neutral the valve stem is rotated to the position illustrated by Figures 7 and 8 Under these conditions passage D is connected to sump by slot F Passage J also is connected to sump by port H in the valve stem Because passage D is connected to slot F oil drains rapidly from the primary clutch to sump Because passage J is now at atmospheric pressure the oil pressure in chamber L unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The primary clutch is now disengaged and main system pressure reduced to neutral pressure Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation Oll Entry Passage B Oil Pressure Chamber G C Pressure Overflow Port D Oil Engaging Passage E Oil Engaging Passage F Oil
57. 01BN OVER ROLLPIN POR ER GASKET 1017553 UNTIL FIRST SPRING COIL E E POSITION B SCREW 1042 4 D PLATE SEE CHART REMAINS LOCATED AGAINST STEM FACE TRANSMISSION GASKET E GASKET 1017130 SEE CHART BALL M1990H SETSCREW A2870K 0 RING A2916DK DITCH PLATE GASKET iN D RING A2916AT SPRING A2702T PIN 927 SEE CHARTS ON PRING 2705 WASHER A2782A 222 b SPRING A8705 gt irs 0000S AS REG DAS SEAT 1017524 VALVE BODY ASSY 1018095 e B 22 A BODY 1018094 SECTIDN DITCH PLATE SEE CHART BALL 1034 gt SCREW SEE CHART BALL SPOOL 1017433 2 SWITCH MA866A 2 ALL 1990 5 PORT NDTE APPLY MARSS THREAD SEALANT MAIN PRESSURE PICKUP PORT INSTALL USING MA908 LOCTITE WITH TEFLUN THREADS NUT 2027 1 4 18 NP T F CDRYSEAL TH D 242 TOP OF SCREW MUST BE TROUE TO 300 lb Ft Ut FLUSH WITH SURFACE HYDRAULIC DIAGRAM A7119W SHEET 3 OF 3 9 SEU MNA did O OBSOLETE FOR PRODUCTION M R I AND SERVICE EJ TUIRD ANGLE PROJECTION ATMOSPHERIC PRESSURE A NOT SERVICEABLE SEPARATELY LEVER 2103 X STR TH D RING 1506149 MAIN PRESSURE DIL INLET WHEN NUT INTERNALLY SUPPLIED THREAD SIZE AT PORT o 1 4 18 WHEN M20S2AA
58. 09 X 23 0 HOLD DRILLED C BORED AND O COLLAR SEE 2 11 759 X 3 0 5 STE STE we e a es EF RS FULL L ermerwDICULARTY eF 11 13 99 DETAILS OUTPUT ON NOTE 1099 2 PEE om FILE 24 25 18 125 T FOR ya7470 sen TES RV DESCRIPTION aw 986 20025 5100 96 SESOZOL enuen 3914195 uoissiusueJ IUEN 5100 19 4 JO t uS 2002 1 Ajquiessy JJS 10 316 16 h 03 x 45 45 HT DIA p 01 R MAX 100 PET 16 1 MS SPACER C amp 575 DIA x 338 DET Real DESCRIPTIDN SIDCK SIZE 5 DATE 12 6 93 BY JIM SCALE FULL stamp TOOL 20023 DET 16 C n SPACER FOR SKF ASS Y PART B FOR MGS202 SHEET 4 nr 4 5 AS AUTOCAD 14 FILE 20023 8 20023 CHANGE DESCRIPTION DATE BY TWIN DISC INC RACINE WIS osiq UIML SESOZOL Jenuejy uoissiusueJ SUMEN 261 DRILL 21 15905 DIA i HRU TO HOLE 8 10 3
59. 1 2 GASKET 1001218 BEARING MA217D 22 SHAFT ASS Y 1015833 X SHAFT 1015232 BALL 1034 MANIFOLD 10026734 om WV SNNNNNNNNNNNNNS f 2222 RING M1904L RING 1048 2 RING M2693F 2 SN 72 PLUG 1945 7 2 RING A2916KD a ZN SS BEARING 1014856 22 oy 7 ASS Y MAS85HF 2 CUP 590 SHIM 1014883 m SHIM 1014884 5 REG D SHIM 1014885 SEE 5 GEAR 1001116 FITTING 1275 SEAL 440 CD SHIM 1020393 SHAFT ASS Y SEE SHEET 4 GR WILL KG COVER 1015518 S 24 RING 2915 Esos TAPERED EDGE SYS SY JRR YE E CRASS lt E QO M1904AQ 2 UN 1001349 SEE b 1014883 1014884 1014885 SEE NOTE 5 PLUG MA1038D 4 SEAL 1016127 SEN SSS lt lt BEARING M2795 2 CONE ASS Y 585 CUP MAS90AL SCREW MA996A 12 RING M1904DA 2 55 S PISTON 6232 PLATE 206106 22 PLATE 206107 205 PLATE B6231 22 RING A2669AU 2 SHIM 1020393B ZR gt 222 S pm T 1 YY 2 114 22 7 ka N 2122222 H SHIM 1880383 as REQ D SEE NOTE 6 SCREW 1135 7 GEAR 10011
60. 1020538 Twin Disc Incorporated Assembly 6 Use driver T 18050 152 and hydraulic press to press rear tapered roller bearing cone onto secondary shaft Install bearing with large O D toward transfer gear and press to seat against transfer gear mm OE Figure 78 Installing Clutch Shaft Rear Bearing Cone Marine Transmission Service Manual 1020538 127 Assembly Twin Disc Incorporated 7 Install external retaining ring with tapered edge side away from bearing 8 Beginning with a friction plate alternately install 11 friction plates and 10 steel plates into clutch housing transfer gear against clutch apply piston 9 Install clutch backplate and internal retaining ring Figure 79 Installing Clutch Backplate 11 Install tapered roller bearing cone onto secondary shaft Install with large diameter of bearing seating against shoulder of shaft inside the transfer gear opening Note This bearing is a slip fit and will not require special tools for installation 128 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 12 Assembly of pinion A Use special tool T 18050 607 to install chilled tapered roller bearing cup into rear of pinion for secondary shaft Bearing cup is installed with small 1 0 of taper toward the front and seated against shoulder of bore in clutch hub Figure 80 Installing Pinion Rear Bearing Cup Marine Transmission Service Manual 10
61. 171298 wat038E we7 x 20 24518 R 6505 PERT Ae SOLENOID l9 4400 _ wee i B THESE SOLENOID CONNECTIONS B PORT SOLENOID C 18440 ch ARE NOT POLARITY SENSITIVE SETSCREW M2038W NEUTRA 1 mes l ll ll ll F ped 1111 LL LL LL LL LL SPRING A27028Q 2 OPTIONAL pes lp 1 11114114111 1111 l HYDRAULIC LOCK Qs MATING WIRING HARNESS 1017403 4 4 4 pesce 1 l __ l 1 T 1 SS T PIN A2711AC 2 SPOOL 1017432 2 NOTE HYDRAULIC LOCK ONLY B HYDRAULIC LOCK a 4 LEVER MAY BE LOCATED ANYWHERE PLUG 2 NOTE ON ITS SHAFT THAT PERMITS FREE z MOVEMENT WITHIN THE 50 TOTAL RACE PISTON SEE CHART ADJUST SETSCREW SD THAT ROTATION amp 11 4mm AXIAL MOTION G BEARING M2087AD SPRING 2705 2 0 DETENT IS SOLENOID ASS Y SEE CHART REQUIRED FUR CONTROL RACE M2086R RIN RR AA 2 11 17 Nm 10 15 lbf in 339 N n VALVE BODY ASS Y 1017444 GASKET B1334C 2 HYDRAULIC LOCK INSTALL USING MA908 IEEE M BRL 11 PARTS FOR UNITS WITHOUT NEUTRAL AND port PORT COVER ASSY 1017336 NEUTRA SPRING ASSY BAL
62. 18 HOUSING 1015017 SEE NOTE 7 SAE 1 RING 203190B SPRING ASS Y XA2703BD 32 gt SPRING A2701BG SPRING A2703BD ASS Y 1002312 H FLANGE 1002276 SCREW 1046 12 STOPNUT 1048 12 UPTIDNAL EXTRA SUPPLIED ONLY WHEN SO SPECIFIED SHAFT 10007984 2 7 WASHER B3421D NS KZ 4 _ RING A2916LF FLANGE 1001048 BEARING 437 ASS Y 585 CUP 590 SHIELD 1001421 BEARING 1014858 CONE ASS Y MAS8SHD CUP MAS90EZ SCREW 1041 15 RING A2916HH SHIM 1020392 e SHIM 10203984 5 REQ D SEE NOTE 5 SHIM 1020392B CARRIER 1020347 HOUSING ASS Y 1020389 X HOUSING 1020388 TUBE 1002695 SS SS SHEET CROSS SECTIONS 1 OF 4 AND PART NUMBERS SHEET CROSS SECTIONS 2 DF 4 AND PART NUMBERS SHEET INSTALLATION 3 Dr 4 DRAVING SHEET FLEXIBLE GEAR 1015237 PLUG 1040 CDUPLING INPUTS MASS ELASTIC 6 961 RATIO 160T SYSTEM MAX INPUT SPEED 2500 RPM HEAT EXCHANGER GEAR CONSULT SALES DEPT APPLICATION B3649K REQUIREMENTS 6 5541 ENGINEERS F R DTHER LIMITING CONDITIONS ATIR HYDRAULIC GEAR DIAGRAM 6 101 GEAR 5 041 GEAR 4 591 GEAR 4 031 lt gt 7 CUSTDMER NDTES TIZZA o2 DIL CAPACITY 31 4L LESS HOSES AND HEAT EXCHANGER b THIS UNIT CAN NOT BE USED WITH LEFT HAND ENGINE c OPTIONAL EQUIPMENT COMPANION FLANGE ASSEMBL
63. 2 UNF RERED lt 1 TO o 1 12 x 305 TYP Lee Na i H 2 25 AT ds 45 bed Hs 1 1 1 012 DRILL 44 DIA TO SAW CUT CENT DRILL zu ES A 3 50 143 5 6 1 STK THREADED ROD 3 8 16 45 16 5 1 Mts WASHER 75 B 4 4 1 ms HANDLE o c M o STK SOC SET SCREW DOG DIA 2 DIA x 1 Yor DOWEL 5 i VY ind J 4 BODY 240 x 36e x 7 00 i V i DESCRIPTIUN STUCK SIZE N 4 96 By JPL Scale FULL C E 0234 3 8 16 MME SLEEVE FOR RUNDUT CHECK HM SET C3 8 ON FRACTIONAL AND TWD PLACE DET 2 REWORKED 4 22 96 JPL 3 4 X3 CAD FILE 21302 1 CHANGE DESCRIPTION DATE BY RACINE VIS pe1eJodjo2u 2510 UIML L Z0 LZ L 49949 1noung 10 5 5100 19 4 86 SESOZOL enuen 3914195 uoissiusueJ IUEN 5100 19 4 LVEL L 10 99 01d 1296 OPTIONAL GRIND 16 FLATS UP TD 20 WIDE ON 2561 2559 DIAMETER TO ALLOW FASIER SEAL INSTALLATION 527 4 00 TOOL 1 4140 SEAL INSTALLING SLEEVE 09 9 x 95 DET DESCRIPTION STUCK SIZE Date 6 7 95 JIM T FPN Scate NONI AME SEAL INSTALLING SLEEVE FOR P N 1015231 SER amp 1016127 SEAI X SHEI ir
64. 2040878 1 NC RANGE 23060 __ 1 57 6 4 DRILL 2nd CLUTCH ENGAGED 4 70 75 TROLLING PRESSURE i SEE NOTE 3 E MEI 15 i RATE OF RISE FUNCTIONS DETENT mon T N M2086AV 427020 __ 1 N TROLLING 2 7 1 SEE CHART 1 N 5 PRESSURE 15 1 9 7 MIN TROLLING PRESSURE S 9 5 1990 1020005 2 EE 5 5 2 z N T VES 8 2000 1 PM 3036 M 5 EL 2027 1 8291600 NAN IN SISH nA 372 No EOD 1 lt 2 EER cx ny 2 20518 PM 2305 S 2 SIE Fee TU Ka UAE Tt ni TI n m WG UI TIN 2701 E 1050 AYR m M SS SS S SS SS S Sq 10904 4347 1 gii von 2 CRESEN music SANAN KD MA1042K 3 mom Bo 2 1 GASKET SURFACE a amici B13344 1 B 1399 C 1 SEE CHART SECTION D D SECTION C C section B B MANUAL TROLLING VALVE GENERAL NOTES REMOVE BEFORE OPERATING UNIT THREAD PROTECTOR NOT SERVICEABLE SEPARATELY THESES PARTS ARE TO BE PACKAGED SEPARATELY AND SHIPPED WITH UNIT 8 _ 472 1 15 01 sc ae PAE 0 10399 18 21 01 DATE E SECTION En SEE CHART 1 ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE I P INTERMEDIATE PRESSURE C P CLUTCH PRESSURE
65. 20538 129 Assembly Twin Disc Incorporated B Install chilled needle roller bearing into bore at front of pinion C Install internal retaining ring into groove in pinion bore Figure 81 Installing Internal Retaining Ring Into Pinion D 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 130 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly E Install external retaining ring to retain pinion on shaft Figure 82 Installing External Retaining Ring Onto Clutch Shaft 13 Install two piston rings into grooves at rear end of shaft 14 Assemble primary shaft Assembly procedure for primary shaft is exactly the same as for the secondary shaft Repeat above procedure in steps 1 through 13 Marine Transmission Service Manual 1020538 131 Assembly Twin Disc Incorporated 15 Install clutch shaft assemblies into transmission housing Use caution to prevent damaging the shafts gears and bearings oat E Figure 83 Installing Clutch Shaft Assembly 132 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Installation of Bearing Carrier 1 Install bearing carrier gasket over dowels onto rear face of housing Install with silicone beaded side up 2 Assemble lube relief valve spring and lub
66. 308 1018688 xwe7s9rMe 7 7 2707 2703 2000 lt 290 10171298 1017554 103 8 7 x 20 6 4 2451 we sessc NUN 10180858 41310 1018688 xwezseri te vnc xaezo7ap ae7o7AD 270 2000 290 10171298 1017554 1038 20 60 4 45 gen we eesc ELECTRIC CONTROL MODE SWITCH njn SCREW 4 10180855 41709 1017134 1018688 no 759 24 707 a2707AD a2703AB 2000 290 10171298 1017554 7 x 20 60 4 824518 eeo CLOSED WHEN MANUAL VALVE RN aes 1017199 1017134 108689 fun 2 vod xaerorz ae7o7z ae7oar 725 2500 corem 2 nessie e TEE STEM IS LOCKED IN ELECTRIC a RS 2 SECURE LEVER IN THE DEPRESSED aue VIEW 21 CLIP CONNECTOR 1017322 2 ELECTRIC CONTROL MODE POSITION BY LOOPING PLASTIC STRAP THRU TROLLING VALVE 1018085 1 4 HOLE IN LEVER amp M8 THREADED CONNECTOR SHROUD 1001825 ASSEMBLY SEE CHART 1018085X HOLE BEHIND PULL TIGHT TRIM CASSEMBLY 1018883 SHOWN ___ END SHORT _______ INSTALL USING MA908 LOCTITE T 018085 242 THREAD DOG POINT
67. 38 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 Take off PTO for this marine transmission Live Power Take off The live PTO drives accessories using engine horsepower Since the live PTO connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven when the engine is running Hydraulic Clutched Power Take off The hydraulic clutched PTO also allows accessories to be driven using engine horsepower Since the PTO is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The PTO is engaged by the PTO control valve which is very similar to the valve used to control the transmission clutches The hydraulic clutched PTO operates with an engaged clutch pressure greater than that of the transmission s primary and secondary clutches For this reason the PTO control valve pressure increasing valve is in the transmission s hydraulic circuit before the control valve s inlet and pressure regulator Pressurized oil from the filter is directed to the PTO control valve with the overage oil flowing to the transmission s control valve Marine Transmission Service Manual 1020538 57 Operation Twin Disc Incorporated Trailing Pump Optional The trailing pump is used to su
68. 538 Twin Disc Incorporated Engineering Drawings Engineering Drawings List of Engineering Drawings The following pages include the engineering drawings that are specific to this model The engineering drawings included are listed below 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 1020391 1020391 1020391 1020391 A7119R 1020412 1020413 1018084 1018085 1018440 1018883 1017555 0 o0 O0 0 O0 0 0 0 0 A7119W A7119W Sheet 1 of 4 Cross Section Sheet 2 of 4 Cross Section con t Sheet 3 of 4 Installation Drawing Sheet 4 of 4 Input Couplings Transmission Hydraulic Diagram Mechanical Control Valve Without Trolling Mechanical Control Valve With Trolling Optional Electric Control Valve Without Trolling Optional Electric Control Valve With Electric Trolling Optional Electric Control Valve With Manual Trolling Electric Trolling Valve Kit Rotated 90 Manual Trolling Valve Kit for 1018084 Sheet 1 of 3 Optional Electric Control Valve Hydraulic Diagram Without trolling Sheet 2 of 3 Optional Electric Control Valve Hydraulic Diagram With electric trolling Marine Transmission Service Manual 1020538 221 Engineering Drawings Twin Disc Incorporated A7119W Sheet 3 of 3 Optional Electric Control Valve Hydraulic Diagram With man
69. ALI ND UN 001 010 1 4 THR SHARP CORNERS SS DTHERVISE PLACE DECIMAI ON FRACTIONAL AND TWO DECIMAL ON ANG DIMENSION ULAR DIMENSION SPECIFIED DIMENSION PLACE CAD FILE 6 00 2 5 m KNUR 300 1 25 00 CLEAN UP E EEEN ld 25 7 1 SACS 1 4 Sa 100 DRILL BOTH WALLS BREAK ALL SHARP CORNERS IPSI DRIVER 250 625 DET JREG DESCRIPTIUN STUCK SIZE Dote 11 04 99 AJZ Scale FULL NAME RIVER FOR p SHEE OF 1 7180502208 MGSe00 SER A JESCRIPTIUN DATE BY TWIN DISC INC RACINE WIS 18050 609 609 09081 1 19 5100 19 4 2510 SESOZOL Jenuejy uoissiusueJ IUEN 6 TOOL 1 18050 1 18050 PART ALL SHARP CORNERS TOLERANCE UNLESS OTHERWISE SPECIFIEI 001 ON THREE PLACE DECIMA 010 ON FRACTIONAL AND TWO PLACE DECIMAL DIMENSION 1 4 DN ANGULAR DIMENSION 610 611 18050 612 180 DIA 610 THRU REF 6 REQ D 4 00 DIA ES E DIM E CUP NB 1700 590 1641 590 2 8 75 590 UNLESS BREAK HERWISE SPECIFIED SHARP CDTNERS CHANGE 2 00
70. E td Ls 8 3 30566 2 06 01 omes moe Lus LR 30462 iieo X pesesedu 2e ar INCORPORATED RACINE WI 53403 USA ATMOSPHERIC PRESSURE ns LP INTERMEDIATE PRESSURE X THESE PARTS ARE TU BE PACKAGED CP CLUTCH PRESSURE SEPARATELY AND SHIPPED WITH UNIT B FIRST USE TWIN DISC INCORPORATED Q 130289 8 30 00 V Fe 4 6 20 01 RACINE VI 53403 USA 05207 1 0 1 8 4 4 0 RI ICER SHING IS SPECIFIED SURFACE TREATMENT NAME p EN esss s sa oo lecwioose 4 16 01 GR IMI RTS r pnm VALVE ASSY CONTROL SERIES B MODEL 52020 PER ANSI 14 5 1982 P cs 30015 4 12 00 V Bi 55 4 18 01 NOTICE 15 INTENDED Rev zme ame c pare _ OTHERS BY CONTRACT WITH TROLLING VALVE SHEET DF 1 CONNECTOR SHROUD 1001426 CLIP CONNECTOR 1017322 SCREW MA1042B 2 BLACK WIRE lt gt VALVE 1017170 TORQUE TO 33 9 GASKET 1017334 PLATE 6 GASKET 1017130 70 00 88 0 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS INTENDED uj T 32964110 8 99 L 129505 8 20 99
71. EARANCE EXISTS FOR FULL 90 OF TRAVEL NNN CA S A i 2 WN VALVE BODY 1017529 VA LLL 6 4 9 THRU ONE HOLE 2 INSTALL USING MA908 LOCTITE 242 CRUISE MODE AT DETENT MIN TROLLING PRESSURE SECTION MAX TROLLING _ CAPSCREW M2000H 70 75 NUT M2027C TROLLING RANGE LEVER B2103 MIN TROLLING PRESSURE NO TROLLING SETSCREW 2041 ADJUST SETSCREW SO THAT THE TORQUE REQUIRED ON STEM TO OVERCOME DETENT 15 1 1 1 7 10 15 Ibf in SPRING 10504 BALL M1990U e O RING A2916DD RING 29168 SHIM 2057 5 REQ DO PIN PM 3036 M INSERT SPRING A2701BN OVER ROLLPIN PM 3036 M UNTIL FIRST SPRING REMAINS LOCATED AGAINST STEM FACE pi K M p A ANS 4 in A T 67 1 S S ENN NST SPRING A2701BM 0 SPRING A2701BN 5 SECTION B B BOM NO 40588 M8 X 1 25 TH D 19 1 DEEP GASKET 1017553 2 HOLES METRIC PLATE 9 GREASE APPLICATION PROCEEDURE E THIRD ANGLE BEFORE INSTALLING VALVE STEM INTO BODY GASKET 1017130 PLATE IS NOT INCLUDED IN ASSEMBLY CONSISENG TO SIMILAR TD USE EXISTING PLATE FROM CONTROL VALVE THE VALVE STEM FROM THE O RING GROOVE PX 8671 TO NECKED DOWN DIAMETER AT LEVER END bo dE 29117 2 4 99 NOTICE
72. ED WITHIN 24 i HESE LINES IS REQ D FOR OPTIONAL HYD P T D ONLY FILTER dc BY PASS 138 kPa r anaes i d VES SS E Cm 1 E Figure 21 Hydraulic Schematic electric control valve Marine Transmission Service Manual 1020538 53 Operation Twin Disc Incorporated Trolling Valve Optional The trolling valve is used to reduce and control propeller speed below that normally attained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure to reduce the propeller speed 54 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation 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
73. ERIC PRESSURE AND SERVICE LP INTERMEDIATE PRESSURE THIRD ANGLE CP CLUTCH PRESSURE PROJECTION A NOT SERVICEABLE SEPARATELY LEVER 2103 X STR TH D RING 1506149 MAIN PRESSURE DIL INLET WHEN NDT INTERNALLY SUPPLIED THESE PARTS ARE BE PACKAGED SEPARATELY AND SHIPPED WITH UNIT NOTICE THIS PRINT CONTAINS UNLESS OTHERWISE SPECIFIED PROPRIETARY INFORMATION AND IS DIMENSIONS ARE mn 3 23 98 MACHINED DIMENSIONS 3 23 28 UNTO Due 1 NOT TO BE USED IN MANNER SCALE DETRIMENTAL TD THE INTERESTS DF INCURPDRATED THREAD SIZE AT PDRT o HEAT TREAT 50 1 00 RACINE VI 53403 USA RACINE 53403 USA GEDMETRIC TOLERANCING 1 4 18 WHEN 2052 MODEL 5 52020 PER ANSI 14 5 1982 REDUCER BUSHING IS SPECIFIED TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT 7 SERIES BOTTOM VIEW d GRANTED TO THE U S GOVERNMENT VALVE ASS Y CONTROL UR OTHERS BY CONTRACT WITHOUT TROLLING VALVE SHEET 1 of 1 Rev AG B MANUAL DVERRIDE NEUTRAL START R AGRAM SWITCH CLOSED ONLY WHEN valve Bom DITCH BITCH piston SOLENOID Hs ORIFICE TROLLING erv 5 5 MOUNTING SCREWS FIRST AL BSS FN Ne PLATE GASKET GASKET NUM PLATE 1042 parT ary 454 996 vets mersorn
74. Engine and shaft alignment can also change on a boat due to varying loads and the boat s age The following steps may be taken to secure proper marine transmission alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure Install the mounting brackets on the side mounting pads of the marine gear Install the driving ring on the engine flywheel Bolt an indicator to the engine block and set the indicator stem on the engine flywheel housing INDICATOR INDICATOR STEM MARINE GEAR SUPPORT BRACKET ENGINE Figure 118 Marine Gear Alignment Marine Transmission Service Manual 1020538 165 Installation 166 Twin Disc Incorporated 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 moves from zero lift the marine
75. HESI OPTIONAL SAMA SEAS o P T O CONTROL VALVE REAR PTO CLUTCH Figure 6 A7119R Hydraulic Schematic manual control valve Marine Transmission Service Manual 1020538 37 Operation 38 Twin Disc Incorporated Manual Control Valve Neutral Refer to Figures 7 and 8 Oil enters the control valve body through passage A and fills chamber B The oil causes the pressure regulating piston to partially compress the piston outer and inner springs against the pressure rate control piston This pressurizes the oil in chamber B This pressure varies with engine speed The movement of the pressure regulation piston against the springs exposes port C in the valve body Port C directs overage oil to the lubrication oil circuit Passage D which is the engaging outlet to the primary clutch and Passage E which is the engaging outlet to the secondary clutch are interconnected by slot F in the control valve stem when in the neutral position The slot is aligned with a drilled hole and cored cavity in the face of the valve body The drilled hole and cored cavity are aligned and drilled holes that pass through the main housing to sump Therefore passages D and E are at atmospheric pressure at this time Also passage J is at atmospheric pressure because port H interconnects with slot F This area between pistons and around springs is vented to the sump of the transmission This area is at atmos
76. ILIARY LUBE SUPPLY INLET SEE HYDRAULIC DIAGRAM PRIMARY CLUTCH SH 4 DRIVING THRU PRIMARY CLUTCH i DRIVING THRU SECONDARY CLUTCH METRIC NOTICE THIS PRINT CONTAINS TARY ITION AND 15 NOT TO Be USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE VI 53403 USA THIRD ANGLE Inco RACIE 1020391 USE ooer THIS NOTICE IS NOT INTENDED pg ll SEE JO MALY OR LIMIT RIGHTS MG S222DC 5 DR OTHERS BY CONTRACT MARINE TRANSMISSION secr 3 0 4 J 9 THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES FLYWHEEL OUTLINE MUST CONFORM TO 12 7 COUPLINGS A amp B ONLY 64 DYNAMIC TORSIONAL kN m STIFFNESS 6 0 kN m rad ____ UE IT 0 HOUSING COUPLING A Lehre 7 4 1016215 ELEMENT MA1041E HEX CAPSCREW 16 EO 0620 N 460 DN VY MA947D HEX NUT 16 j E 2 x Etro 1016520 HUB SPLINED S CNN P ou SEE NOTES 1 amp 9 B1048X SNAP RING SX 2 10152314 SHAFT ASS Y SAE J620 COUPLING 460 C o 355 ee 3000 50 PER chart 0206 SAE J620 NI MARINE FLYWHEEL COUPLING COUPLING 014 R 308 014 0013 HR FLYWHEEL OUTLINE MUST CONFORM TO S A E 9620 NO 355 K 9 TH
77. Interconnection Slot RATE OF G Oil Directional Port RISE PISTON H Oil Connection Port J Oil Pressure Passage K Directional Port L Pressure Chamber D A HIGH PRESSURE REGULATOR PISTON CONTROL VALVE LEVER SPRINGS CONTROL VALVE STEM CONTROL 2 VALVE BODY LJ ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 9 Control Valve Primary Sectional View PRIMARY TO PRIMARY CLUTCH TO SUMP TO SECONDARY CLUTCH CONTROL VALVE STEM B ATMOSPHERIC PRESSURE LJ ENGAGING PRESSURE Figure 10 Control Valve Primary Cutaway View Marine Transmission Service Manual 1020538 41 Operation Twin Disc Incorporated Manual Control Valve Secondary When a shift to the secondary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 11 and 12 The pressurized oil in chamber B is directed through ports G and K to passages E and J Passage E is aligned with a passage directing main pressure to the secondary clutch Pressurized oil from port G travels through passage J and enters chamber L through an orifice in the orifice plate The orifice in the plate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against springs until the piston is stopped by a shoulder in the valve body The causes the pressure
78. L M1990Y 6 HYDRAULIC LOCK DPTIUNAL CONDITION SEE CHART SOLENOID SOLENOID CARRIER 1017335 SOLENOID BALL Mi990G 2 WIRING DIAGRAM OPTIONAL BALL MI990Y PISTON 81399 BALL MI990L VAVE GASKET SH 10 1 1968 MATING VIRING HARNESS 1017404 SHIM SEE CHART BALL 1990 SCREEN 221336 PUN CONNECTOR SERIES SPECIFY LENGTH M8 X 125 6H TH D NUT M2027C PORT SOLENDID 2 HOLES POSITION S SIEN 1017901 PORT SOLENOID ELECTRIC 247 SEAL 5591 CONTROL ADAPTER 1017530 POSITION POST UON BALL MI990U SPRING P 10504 SETSCREW 2041 D RING 291600 D RING A2916B SEAL 778 Lo m NINE 592 WAS SH THESE SOLENOID CONNECTIONS ARE NOT POLARITY SENSITIVE i 3 G YD nN SHIM 2057 as REQ D2 us T Ji HH PIN PM 3036 M A N WY CONNECTOR SHROUD 1001434 gt LAE Se SAS SI SPRING 42701 N SANSS S Ky ZZ SPRING A2701BN Sit gt SN N U RING 79 _ 4 ANSA D EE ISR INN N 25 STEM 1018163B j VALVE BODY 1017529 ALALLA HAM D RING 2916 PISTON P1049 AA 1017309 ba 4 4 ps SNAP RING 29155 Q n 7 e INSERT SPRING A27
79. NES REFER TO TEMPERATURE INDICATING 10 HOSE i INSTALLATION DRAWING SWITCH USING PIPE TEE WITH E STRAINER CLUTCH APPLY GR e REDUCER BUSHING 5 REDUCER BUSHING 27 TP INSTALLATION OF OPTIONAL MA1040B DRAIN PLUG LOCATION 1725 KPa NO oe M33 X 2 THREAD REDUCER BUSHING PER MARINE TRANSMISSION i CONTROL Las INSTALLATIDN AND ASSEMBLY EUNT UIL PUMP 5 SIMILAR E HYDRAULIC DIAGRAM HYDRAULIC DIAGRAM METRIC ADDED WHEN INFORMATION PICTORIAL GRAPHICAL J LC SYMBOLS E I 7 WEIGHT WR INCORPORATE 0 U R DETRIMENTAL TO THE INTERESTS OF 6 RACINE WI 53403 USA HEAT TREAT FIRST USE PE ubi T DSE INCORPORATED hssr MG S202DC RACINE WI 53403 USA GEDMETRIC TOLERANCING MODEL PER ANSI Y14 5M 1982 RE we perf CAN OTHERS bY CONTRACT pul pe zone rev zone pare DR OTHERS BY CONTRACT TBC 1 of 1 B F B A STRAINER NOTICE THIS PRINT CONTAINS MATERIAL UNLESS DTHERWISE SPECIFIED C MATER AD s 12 7 9 208 NOT TO BE X 10 75 D VALVE x ORIFICE VALVE SPRINGS SHIMS 7 VALVE
80. OLARITY SENSITIVE BLACK WIRE WITH SOCKET 36 6 ead VALVE CONNECTOR SHROUD 1001434 7 ASSEMBLY SEE CHART lt 1017554 SHOWN STEM 1018163B 4 22 44 1 LA tco Se RING 79 RING 2916 SNAP RING 429155 PLUG 1017389 s SHIM SEE CHART SECUS L D D POSITION SCREW 1042 4 D TRANSMISSION GASKET C PLATE SEE CHART SPRING 1801 SALE SEE CHART BALL M1990H SPRING A2702T SETSCREW 2870 0 RING A2916DK PIN 1927 DITCH PEATE GASKET D RING A2916AT SEE CHAR SPRING 2705 WASHER A2782AS iim 00005 AS REGS SEAT IET 7 LY pare see oer Wa oe ik SCREW SEE CHART BALL MA10344 BALL MAI034D ce MAIN PRESSURE PICKUP PORT ALL 1990 5 SWITCH MA866A 2 1 4 18 CDRYSEAL NDTE BALL MI990Y 5 SPOOL 1017433 2 APPLY MA895 S THREAD SEALANT INSTALL USING MA908 LOCTITE WITH TEFLON 95 TD THREADS 242 TOP DF SCREW MUST BE TORQUE TO 30 0 lbf ft NUT M2027C SCREW MA1042A FLUSH WITH SURFACE HYDRAULIC DIAGRAM A7119W SHEET 1 DF e 40 7 N m SCREW M2000L SEE CHART FOR a QUANTITY OTHE 1018883 TROLLING VALVE IS REQUIRED TO PROVIDE CLEARANCE ETRIC FROM THE HYDRAULIC PTO THIRD ANGLE PROJECTION ATMOSPHERIC PRESSURE A NOT SERVICEABLE SEPARATELY Ay z ATMO
81. PRIMARY CLUTCH 9 WM INCH 1 4 DIA THRU REMOTE CONTROL BRACKET N CONNECTOR PRIMARY CLUTCH SOLENOID 71 SECONDARY gt C m CH SOLENOI NEUTRAL SOLENOID PTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH ECTRIC CONTROL MODE SWITCH CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MANUAL OVERRIDE 361 4 LJ POSITION ELECTRIC 24 7 CONTROL POSITION gt 649 ENGAGES SECONDARY SHAFT f CLUTCH J4 v v nore LEVER MAY BE LOCATED ANY WHERE ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTAL ROTATION amp 11 4mm REQUIRED FOR CONTROL MOTION Van M NS ues D D E gt 3510 UIML pue uondiuoseg Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Note All threads and bearing face to be lubricated with light oil film prior to assembly Table 4 U S Standard Fine and Coarse Thread Capscrews Bolts and Nuts 30 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Description and Specifications Table 5 Metric Coarse Thread Capscrews Bolts and Nuts Thread Property Class 8 8 Pro
82. PROVIDE A 41177 010688 we759FM24 0 7 7 0 7 2000 ceso 10171298 x 5 6 HOLE BEHIND PULL TIGHT TRIM TOTAL LINEAR TRAVEL AT THE 6 4mm 40 49 DIA HOLE 4 41253 1018688 Na 759 24 1 xae707z 427072 703 1725 lt 250 10171294 1 x 0 24518 0 END SHORT mE 10184407 41252 1018688 xwe7ssri 1e xae707z 27072 7037 1725 lt 250 1017129 x 20 61 B2451B wG 5eo 1MP Mies STRAP M2942B INSTALL USING MA908 LOCTITE WIRING DIAGRAM 018440 41302 1017179 759 24 voc 707 1 703 1860 270 1017129 0 27 x 20 6 24518 MG siaisc 242 THREAD DOG POINT INTO 101844088 41303 1017179 no xme7soruf1e voc 270740 2703 4 1860 270 10171294 038 eo em B2451B 58 6 51415 CUNT SNUG CONNECTOR 18440 41309 1018688 2759 12 70740 42707AD 70 2000 lt 290 10
83. RU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES MAX NO FLYWHEEL NOMINAL TORQUE kN m __ 4 460 2750 50 CHART O06 04 ND 355 2750 500 PER CHART 2800 500 PER CHART 0 290 0166 1015230 SHAFT MA1034B BALL NJ OPTIONAL INERTIA N 2 N __ 3 49802 RING E i EERE COUPLING B gt T 1016217 ELEMENT S A E 1 HOUSING DYNAMIC TORSIONAL STIFFNESS COUPLING WR g m 2 OUTER PARTS INNER PARTS J 9 THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO S574 OR SERVICE H MANUAL VALUES PS 2 4 Pe RRR 641 12 7 0 HOUSING COUPLING C 4 1019699 COUPLING 05950 040 950 0061 FLYWHEEL OUTLINE OX OX MUST CONFORM TO 9000600 SAE J620 NO 460 DYNAMIC T 460 TORSIONAL NER ET QS TA e uw j m I 2 N N so g N SERVICE REFERENCE NN Y N loc WS 5 ud LL SS N A SN SEE NOTES 1 amp 4 S 1015231A SHAFT ASS Y WN 1 1015230A SHAFT SERVICE REFERENCE MA1034B BALL ROLLER 1116 8 FLYWHEEL OUTLINE MUS
84. S pant fore 57 x ary APPR LOCTITE 242 1018440 1 1713 1017134 1337 1018688 ves 3 xwe7serM24 voc xa2707z ae7o7z 7 1725 eso 10171298 10 7 x 51 _ marosea 2 52 2 wc seoenc emmy 309 9 MANUAL DVERRIDE NEUTRAL START 1 SWITCH CLOSED ONLY WHEN MANUAL DVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL 20 i44 ____ 1017383 1017179 e 759 24 voc ae7o7BD ae7o4pu 2415 lt 350 10171298 jaoserwe7 x 6 2451 amp we sesev PLUG M2051K 2 CAPSCREW M2000H 101844081 1017133 1017134 pi37r 1017179 59 4 __ 2707 1585 lt 230 gt 10171294 0230 3 2 Meossac 2 SCREEN 1020479 018440 1017133 1017134 37 1017179 xwe7ssrMe vDC xa2707BzZ A2707BW A2703BA 1380 200 1017129 451 i 3 p stev MAX TROLLING H 10184400 1017133 1017134 37 1017179 no 75 voc __ 27 7 585 230 EOT 530 B24518 2 Meoesec 2 16 of Ta PRESSURE p LEVER 203 jhore44or ___
85. SPHERIC PRESSURE prance LP INTERMEDIATE PRESSURE X THESE PARTS ARE TU BE PACKAGED CP CLUTCH PRESSURE SEPARATELY AND SHIPPED WITH UNIT C D D ee mnes Deum Wess ren wr TIN DISS s 3 30568 2 06 01 Nor TB BE USED IN NER 0 000000 7 77070707079 ke mes Rs INCORPORATED X 302 5 LEVER 2103 p Es STR TH D 0 RING 1506149 MAIN PRESSURE DIL INLET WHEN 30462 11 16 0 CINEHSPDRATED HEAT TREAT FIRST USE AM RACINE VI 53403 USA DEC d os ees rre ee 777 crm 1018085 J 3 i 30 V 10 26 01 MODEL 52020 PER ANSI 14 5 1982 REDUCER BUSHING IS SPECIFIED 30277 8 30 00 V _ 026 0 TO OR LIMIT RIGHTS SURFACE TREATMENT Nae RM BJE SERIES VIEV 30015 4 12 00 U 3 6 20 01 GRANTED THE Us GOVERNMENT pue EA VALVE ASS Y CONTROL MEE rev zone pere Rev zone nare DR OTHERS BY CONTRACT WITH TROLLING VALVE DAS 1 oF 1 REV F E D B A SETSCREW MA1037D FEN LOWSEN 172 TURN 5 valve DITCH DITCH rransmssion Hvo SOLENOID VALVE SPRINGS CLUTCH ORIFICE sums MOUNTING SCREWS FIRST DATE ASS Y N N PLATE No PLATE PISTON VOLTAGE SPRING CONSISTS OF kPa PSD PLATE rm CU USE AND INSTALL USING MA908 Ne GASKET GASKET uxe arY Wo WM
86. T CONFORM TO 1 S A E 9620 5 NO 355 air HOLES EQUALLY SPACED 0 ene oe USE 88 PROPERTY CLASS QUALITY CAPSCREWS PER 555656606056 7 COUPLING D ISO 898 1 AND TORQUE PORK RK 2 MATING U TO S574 OR SERVICE MANUAL VALUES TRANSMISSIDN CDUPLING ASSEMBLY ENGINE INSTALL CDUPLING AND ENGINE FLYWHEEL ADVANCE MARINE TRANSMISSION INTO POSITION WITH ENGINE FLYWHEEL HOUSING MOUNTING FLANGE LINE UP INPUT SHAFT EXTERNAL SPLINE WITH INTERNAL SPLINE IN COUPLING HUB AND MOVE ENGINE AND MARINE TRANSMISSION TOGETHER MAINTAINING ENGINE FLYWHEEL HOUSING AND MARINE TRANSMISSION FLYWHEEL HOUSING MOUNTING FACES IN PARALLEL RELATIONSHIP SEE SHEET 1 FOR MAXIMUM TRANSMISSION R P M THE WR OF INNER PARTS INCLUDES HUB AND 1 4 SHAFT 0 NOT SERVICEABLE SEPARATELY F ALL COUPLINGS ABOVE HAVE TORSIONAL STOP INCLUDED FOR TRANSMISSION SHIPMENT SECURE FLEXIBLE COUPLING TO HOUSING FLANGE HOLES USING STANDARD METHOD BEFORE SHIPMENT OF UNIT E ENGAGE FLYWHEEL HOUSING PILOTS AND INSTALL ALL MOUNTING CAPSCREWS USING 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 GRADE 5 QUALITY CAPSCREWS PER S A E J429 TORQUED TO 574 OR SERVICE MANUAL VALUES NOTICE NOT TO BE DETRIMENTAL TWIN DISC INCORPORATED RACINE THIS NOTICE IS INTENDED NULLIFY OR LIMIT RIGHTS GRANTED TD THE DR DTHERS BY CDNTRACT THIS PRINT 5 IN AN
87. TCH LEVER LOCKED FOR ELECTRIC OPERATION oO 1 Clutch Solenoid Clutch Solenoid MANUAL DVERRIDE NEUTRAL START SWITCH Es E NEUTRAL REGULATOR a METRIC ELECTRIC MODE c uas Electric Manual valve for MG 509 thru MG 61242 REFERENCE VALVE ASSEMBLY 1018085 esos NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 15 TE mE INTERES TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED CLUTCH APPLY INTERMEDIATE PRESS LUBE JAIN PRESS M S UMP rur gen HS A7119W pas sect a or a Solenoid ASCO MANUAL OVERRIDE NEUTRAL START SWITCH Section ELECTRIC CONTROL MODE SWITCH CLUTCH ENGAGED lt n Z4 CLUTCH ENGAGED MANUAL MODE Clutch Solenoid Neutrol Solenoid Clutch Solenoid 22 4 2 E SX MANUAL DVERRIDE MODE SHOWN IN NEUTRAL Lead Section B 5 FUNCTIONS DETENT TROLLING Section Gn MIN TROLLING PRESSURE Trolling Valve i SN 5 LJ ELECTRIC MANUAL VALVE FOR MG 509 THRU MG 61242 REFERENCE VALVE ASSEMBLY 1018440 1 Clutch SHOWN WI
88. TE Oi INSTALL USING MA908 LOCTITE DETENT GROOVE UNTIL SNUG 1018084 40967 1017383 1017179 5 3 759 24 voc 27028 2704 5 BACK OFF 1 2 TURN ee eee ae ae o 2415 lt 3507 10171298 0 7 x 2 6 B2451B w eeeesc anis iness e eossrHee vid cosi paisates x bees THESE SULENUID CONNECTIONS 69 4118 1017133 1017134 B1337F 1018688 2 xwezssri 1e 7 72 27072 427037 1725 lt 250 gt 10171298 10 8 7 x 2451 455 105 2 105 2 52025 ARE NOT POLARITY SENSITIVE SETSCREW M2038W 6 e hoisos4ac 4163 4171 cci O horeogaas HYDRAULIC LOCK ONES 9600 1 41250 PIN A2711AC 2 SPOOL 1017432 2 41251 x 1 xA27072 NOTE HYDRAULIC LOCK ONLY HYDRAULIC LOCK ONLY 9 va en aene ef eS 4 LEVER MAY BE LOCATED ANYWHERE PLUG 1038 2 p 41195 ne eo EXDCEARUEGDEMEMC T oez x eo erd Ba4SIR EMEN AU
89. TH ENGAGED Solenoid SHOWN WITH CLUTCH ENGAGED 1 Clutch Solenoid Section ELECTRIC CONTROL MODE SWITCH LEVER LOCKED FOR ELECTRIC OPERATION CLUTCH Neutral Solenoid Solenoid 5 MANUAL DVERRIDE NEUTRAL START SWITCH 2222 IET 4 D m Trolling Valve mel VUA SN E nC rt NEUTRAL REGULATOR Ly IN SS ELECTRIC MODE Electric Manual valve for MG 509 thru MG 61242 REFERENCE VALVE ASSEMBLY 1018440 C CLUTCH APPLY INTERMEDIATE PRESS LUBE M MAIN PRESS S SUMP TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS INTENDED TO NULLIFY DR LIMIT RIGHTS GRANTED TD THE US GOVERNMENT OR OTHERS BY CONTRACT DIAGRAM HYDRAULIC WITH TROLLING VALVE CENTER LABEL 1018729 HERE MAX TEMP 100 C REDUCE SHAFT SPEED IF EXCEEDED 100 C SINGLE PHASE CAPACITOR TYPE C THERMALLY PROTECTED DUAL VOLTAGE DUAL ROTATION 8 LEAD T Zu Te E DR REDUCE PROPELLER SHAFT RPM 222222222222222222222222222222222222224222222222222222222222222222222222222224 Zz HEAT EXCH FAN MAXIMUM TEMP SSSSSSSSSSSSSSSSSSSSS PART 1016473 ON RED PILOT LIGHT MOTOR NAMEPLATE LIT WHEN MOTOR IS OPERATING GAUGE REMOVE PLUG TO INSTALL 9379 Wee USTOMER SUPPLED PRESSURE ALARM SWITCI 13 8 41 4 kPa SETTING SEE TOP VIEW FOR LOCATION OL TO AIR HEAT EXCHANGER OIL
90. THIS PRINT CONTAINS MATERIAL WEIGHT wee UNLESS OTHERWISE SPECIFIED TV b DISE __ _____ 4129015 12 17 98 NOT TD USED IN ANY MANNER went MACHINED DIMENSIONS Pt ae te ara edi 2 28585 6 3 98 TO Y RENT TREAT FIRST USE 35 RACINE VI 53403 USA 2455255 sre cipes VIN DISC 4 menn P 29863 1 31 o0 B a 4 28315 1 21 98 NOTICE 15 NOT INTENDED VARIOUS PER ANS 1982 1 1 5 E E e7 293s0 s 2 se A ALL 28208 11 26 97 LIMIT SIGS y pe VALVE ASS Y TROLLING ess cw no ame wo pore OR OTHERS CONTRACT Clutch Solenoid Neutrol oet Solenoid Solenoid ASCO Solenoid ASCO MANUAL OVERRIDE MODE SHOWN IN NEUTRAL MANUAL OVERRIDE NEUTRAL START SWITCH gt lt 2 2 dac 1 Section C C Section B B ELECTRIC CONTROL MODE SWITCH Section CLUTCH ENGAGED EIN bu Me el T NEUTRAL REGULATOR WW ae MANUAL MODE ELECTRIC MANUAL VALVE FOR MG 509 THRU MG 61842 REFERENCE VALVE ASSEMBLY 10180845 CLUTCH ENGAGED MAIN PRESS SUMP SHOWN WITH CLUTCH ENGAGED Clutch Solenoid 5 SHOWN WITH CLUTCH ENGAGED
91. TION Z ay 1 VA EXE HANS AS SPECIFIED IN CODE OF FEDERAL RE Sees sean 4 REGULATIONS 46 CFR 56 60 25 lt 1 L f ZZ lt lt P T D LUBE CA B REPLACES IT 3 2 ro EM amp COOLING CLUTCH REMOVE MA1038D MI8 X 15 SECONDARY T PLUG FROM MANIFOLD PER FRONT amp REAR BEARING PINION SS tee E MARINE TRANSMISSION amp CLUTCH LUBE pL m SHOWN DISENGAGED INSTALL LUBE LINE DIRECT LUBE FLOW INTO i REFER INSTALLATION HYDRAULIC 1 ENG DIS DRAWING SH WND P N 7540 EM p UTER TR 225082 PORTION ENCLOSED WITHIN Lug occ 38 K j THESE LINES IS REQ D FOR EET ud SHECK OPTIONAL HYD P T D ONLY VN 15 8 MIN PETERS rra d TEMP I D HOSE xen eee 138 KPa mE 25 MICRUN im or Hide 1 i lt SS pos SST Le ELECTRIC MOTOR e FG Pe on cmd a DRIVE PUMP TAT TTT OTT LLU n 19 38 L ON 14 INSTALLATION OF OPTIONAL 19 0 DIA MIN CLUTCH AND CONNECTION LI
92. TWIN DISC INCORPORATED __ Service WELL ual Marine Transmission Components MG 5222DC Document Number 1020538 NOTICE Twin Disc Incorporated makes no warranty or guaranty of any kind expressed implied or otherwise with regard to the information contained within this manual Twin Disc Incorporated has developed this manual through research and testing of the information contained therein Twin Disc Incorporated assumes no responsibility for any errors that may appear in this manual and shall not be liable under any circumstances for incidental consequential or punitive damages in connection with or arising out of the use of this manual The information contained within this manual is subject to change without notice Document Number 1020538 January 2002 Marine Transmission Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE TRANSMISSION Twin Disc Incorporated warrants all assembled products and parts except component products or partson 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 isthe or
93. Y 1002312 MECHANICAL TROLL K1331 USE DN 1020412 VALVE ONLY MECHANICAL TROLL 1017555 USE ON 1018084 VALVE ONLY ELECTRICAL TROLL 1017554 USE DN 1018084 VALVE ONLY LIVE P T O 1017177 AUXILIARY PUMP DRIVE HYDRAULIC CLUTCHED P T O 1017820 TRAILING PUMP 1016473 FLEXIBLE CDUPLING INPUTS SEE SHEET 4 4 METRIC ADAPTER KIT K1090 DIL TEMPERATURE INDICATING SWITCH 83424 FOR INSTALLATION LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 3 REMOTE FILTER KIT 1019824 1296 1015240 RATID 131T 1015841 RATID 128 1015242 RATID 126 1015243 RATID 124 GEAR 5 4031 6 091 4 591 6 554 1015244 5 041 6 9611 RATIO 121T 3 pee D ________ 1ESECNIS7 72 15 31 _ ECNI03548 27 01 sro 20 NOT SERVICEABLE SEPARATELY BEFORE OPERATING 2 PLACES PLUGS Exi Lo JR 1020391 MG SeeeDc 5 MARINE TRANSMISSION sect Lo 4 ev FILTER ASS Y XB3614 FILTER B3614 LABEL 950 MOUNT LUBE INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION LUBRICANT AWAY FROM BREATHER PLATE B2415 SCREW M422B 8 SCREW 996 242 WASHER M 1039B 24 GAUGE B1703D PLUG MA1038G 2 PLUG 1038 SCREW 1124 SCREW MA1184D 3 VALVE 557 1020412 APLUG M2702F
94. YYYYYYYYYYYY E ed gt HOLD DRILLED C BORED AND OR TAPPED HOLES 005 7 4 stk SHCS 5 8 11 X 1 25 SHCS 5 8 11 X 1 5 LG 4 2 GRIPPER 1 RH amp 1 LH 1 5 X 1 8 X 4 13 2 1 ms HANGER CROSS PLATE 5 8 X 7 X 11 8 1H t ws HANGER ARM 1 5 SQ X 41 5 TUBING 16 ms BOTTOM GUSSET TOP X 4 X 7 1F 1 ms VERTICAL 1 5 SQ x 15 5 TUBING LiE 1 GUSSET TOP AR 3 8Xx2x7 1 1 EYE BOLT ARM 1 5 SQ X 24 5 TUBING 1C stk SHOULDER FORGED EYE BOLT 3 4 10 1B 1 ms EYE BOLT PAD 5 8X53 4 ms CLAMP PLATE 5 8 X 5 0 X 15 40 1 WELDMENT DETS 1A 1H amp 1J DESCRIPTION STOCK SIZE Date 10 2 84 SPATH Scale HALF NAME QUT PUT GEAR LIFTING FIXTURE FOR ASSEMBLY DEPT 344 FOR XA7470 A7496A A7491A p REDRAWN TO AuTOCAD14 7 1223 99 7486 1002580 A7501A 12193987 Special Tools Twin Disc Incorporated Notes 204 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Illustrations Illustrations List of Illustrations The following pages include illustrations that are specific to this model The illustrations included are listed below Note Any part numbers listed in th
95. __ 1017133 1017134 7 1017179 7 9 7 2 7078 A2703BA 1380 200 gt 1017129 PPK 036 2451 5 1 3 6 RATE OF Rise 1018440F 10171334 1017134 7 1018688 75 4 voc 7072 427072 7 1725 lt 250 10171294 7 x 6 24518 4 2 2 _ 5 5 DETENT 10184406 10171334 1017134 1337 1018688 75 12 7072 7037 1725 lt 250 10171294 ec ew Be4SiB _ weoesr 2 2 we sui 1018440 4175 1017583 1017569 1017613 1018688 xwe75orMe4 vnc 7072 427072 703 2000 lt 290 10171298 x 0 6 824518 626 2 560 109275 1018440J 4176 1017583 1017569 1017613 1018688 xwe7sorue voc 7072 7072 703 2000 eso 10171298 7 0 6 824518 2 560 M B 1018440k 1017133 1017134 7 1017179 75 4 vnc 48270740 1585 eao or71e9a 7 x ecce 824518 e 1018440 _____ 10171334 1017134 37 1017179 no
96. all 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 1020538 47 Operation Twin Disc Incorporated 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 opposite end causing the spool to stroke over and connect the clutch passage with main pressure passage Figure 16 Pilot Spool Passages 48 Marine Transmission Service Manual 1020538 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 on a pin on the return spring side of the opposite spool to ensure the opposite spoo
97. ar using only the weight of the shaft 8 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 52 mm to 11 05 mm 0 375 in to 0 435 in Figure 68 Measuring Output Gear Advance Marine Transmission Service Manual 1020538 113 Assembly Twin Disc Incorporated 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 4 Connect the oil injector to the output shaft 5 Install T 20023 onto the output shaft and gear Figure 69 Output Gear Advancing Tools Installed 6 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 7 Advance gear to shaft shoulder stop with the portable press 8 Release injection oil pressure between the mating surfaces and wait five minutes before lowering the press force and removing the assembly tool 114 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 9 Remove the assembly tools from the output shaft and gear 10 Confirm that the output gear has been advanced completely such that there
98. arine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Preliminary Assembly 1 Lay the transmission on blocking with the rear side up 2 Install the seal protector into input shaft front bearing area using a soft hammer Figure 65 Seal Protector Installation 3 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 610 to press drive cups to the bottom of the bore Itis important to maintain downward force as temperatures equalize to ensure that cup is at bottom of bore Figure 66 Front Pinion Bearing Cup Installation Marine Transmission Service Manual 1020538 111 Assembly Twin Disc Incorporated 4 Measure and record the distance from the machined surface of the housing to the bottom of the bearing cup bore where the oil shield contacts dimension A Measure and record the thickness of the oil distribution shield at the outer edge dimension Measure and record the width of the bearing cup dimension 5 Install oil distribution shield into output shaft front bearing bore Be sure shield is properly centered 6 Install chilled front output tapered roller bearing cup into housing bore Use driver T 18050 611 to press drive cup to bottom of its bore Note Care must be taken to ensure that the shield remains centered 7 Use 18050 772 to ensure the b
99. arine Transmission Service Manual 1020538 81 Disassembly Twin Disc Incorporated Disassembly of Primary Shaft or Secondary Shaft Disassembly of Secondary Shaft is Described 1 Remove two piston rings from rear end of shaft 2 If rear bearing must be removed remove bearing retaining ring from rear end of shaft Remove the bearing as follows Note Do not remove rear bearing unless bearing must be replaced Bearing is an interference fit with shaft and will be destroyed during removal A With a hammer and chisel cut cage off bearing to remove bearing cage and rollers B Use a split type bearing puller cheese cutter to grip flange at small end of tapered inner race C With a hydraulic jack pull on bearing inner race while pushing on rear end of shaft to remove bearing inner race from shaft 3 Set shaft upright with input end up 82 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 4 Remove and disassemble pinion s A Note Remove round retaining ring from input end of shaft and remove pinion from shaft Remove internal retaining ring from input end of pinion and remove straight roller bearing The straight roller bearing in the bore of the input end of the pinion is a tight fit and will likely be destroyed during removal Remove the straight roller bearing with the use of a puller behind the roller ends GJ Figure 35 Removing Round Retaining Ring From In
100. condary 2 2 Bearing tapered roller primary amp secondary shaft rear bearing 24 2 Spacer bearing 6 1 Manifold Bearing tapered roller primary amp secondary shaft rear bearing Retainer spring primary amp secondary shaft 2 Ring piston primary shaft 9 2 31 1 Backplate clutch 32 1 Gasket oil pump 33 AR Shim bearing 005 007 020 Ring external retaining Spring Assembly primary amp secondary clutch consists of 1 spring inner amp 1 spring outer Carrier bearing primary amp secondary shaft rear bearing Gasket manifold Gear transfer secondary shaft LH helix Gasket bearing carrier Piston clutch Ring external retaining primary and secondary shaft rear bearing 17 2 Ring piston clutch piston outer 41 22 Plate clutch friction 18 1 Housing lube relief valve 43 2 Ring internal retaining clutch backplate 19 1 Spring lube relief valve 03 OSIA UIML suoneusnyll Illustrations Twin Disc Incorporated Mechanical Selector Valve 75 N 54 55 NL SN 53 yf X PS 4 ES 77 M 76 JUS D N 2 N V J 1 Ed SS d m Me ay 208 Marine T
101. considerations This requires that the transmission assembly be adequately supported and properly positioned as identified in the following paragraphs Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly Remove Transmission External Components and Sub Assemblies 1 Remove the oil filter element 2 Remove the control valve and gasket Set it aside for later disassembly 3 Remove torsional coupling from spline on primary shaft if not previously removed 4 Remove front housing from main housing 5 Remove top cover assembly and gasket 6 Remove the oil pump and gasket ps Remove hex head capscrew securing clamp plate for suction strainer cover Remove clamp plate suction strainer cover with O ring and suction strainer Figure 26 Removing Suction Strainer Cover Marine Transmission Service Manual 1020538 75 Disassembly Twin Disc Incorporated Remove Output Flange Note It is necessary to block and support the transmission with the output side facing up Use caution to avoid damaging the spline on the primary shaft 1 Remove the output flange retaining capscrews Use one of the removed Screws as a pusher screw in the center of the washer if necessary Remove the retaining washer shims and O ring Figure 27 Removing Shims left and O ring right 2 Use hydraulic ram to pull the output flange from the output shaft Figure 28 Removing Output Flange 76 Mar
102. couplings in the market today that solve a variety of problems Couplings to reduce noise and vibration Couplings to allow a permanent angular misalignment Couplings that allow engines to be flexibly mounted and take out the momentary misalignment In some cases the proper alignment of these couplings requires an accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation Torsional Input Couplings Installation For Models Provided by Twin Disc CAUTION Be sure the internal retaining ring is properly installed inside the torsional input coupling hub See Engineering Drawings section of this manual for correct ring location Assembly Instructions for CENTAFLEX R on Flange Mounted Gears Information Taken Directly from CENTA Drawing 26 60062 91 3 1 Bolt flywheel flange onto flywheel and tighten bolts as follows a ci T Figure 123 Assemble Flywheel Flange to Flywheel 123 Assemble Flywheel Flange to Flywheel Marine Transmission Service Manual 1020538 173 Installation Twin Disc Incorporated Table 10 Centa Torque Chart odi htening Torque bs ns 98 ERN RE EM RENE MN Tightening torque is for slightly oiled bolts tolerance is or 5 Securing of the bolts by adhesives e g Loctite is possible Assemb
103. d force on rear end of output shaft Seat front bearing rollers by rotating shaft several revolutions with weight applied 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 Using a hoist exert 2225 to 4000 500 Ibs to 900 Ibs of lifting force onto the shaft Minimum of 2224 N 500 Ibs lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 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 Make a shim pack to decrease endplay to 0 05 mm to 0 15 mm 0 002 in to 0 006 in Arrange the shims so the clearance holes for the pusher screws are aligned Install shim pack between seal carrier and housing Repeat steps B through D until endplay is between 0 05 mm to 0 15 mm 0 002 in to 0 006 in 2 Remove lifting fixture Remove capscrews and remove output seal carrier Marine Transmission Service Manual 1020538 117 Assembly Twin Disc Incorporated 3 Install O ring in groove in O D of output seal carrier Figure 70 Installing O ring onto Output Seal Carrier 4 Coat O D of seals with M2828 anaerobic sealant and install oil seals into output seal carrier using driver T
104. d Repair 63 General 64 Marine Transmission Service Manual 1020538 7 Table of Contents Twin Disc Incorporated Troubleshooting sisina 69 Troubleshooting Chart 69 a 73 Prepare Transmission for Disassembly 74 Remove Transmission External Components and cuanto gn e 75 Remove Output 76 Remove and Disassemble Manifold and Bearing Carrier 77 Remove Primary and Secondary 78 Remove Output Shaft and Gear 79 Disassembly of Primary Shaft or Secondary Shaft Disassembly of Secondary Shaft is Described 82 Disassembly of Upper Valve Body Half electric section 96 1017555 Trolling Valve Optional Equipment 98 Cleaning and Inspection 103 jj 103 5 PEWT 105 til qe 109 Prior to 946 nM EP TR n mien 110 Preliminary 45 111 Installation of Output Shaf
105. de the stem out of the cover 10 Remove the oil seal from the cover Marine Transmission Service Manual 1020538 89 Disassembly Twin Disc Incorporated 11 Remove the O ring from the stem Figure 46 Removing O ring from Stem 12 Remove the thrust bearing and races from the stem Figure 47 Removing Thrust Bearing and Races from Stem 13 Remove the remaining plugs from the valve body 90 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly Selector Valve Disassembly Electric Valve A CAUTION 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 48 Removing Orifice Plate Cover Gasket 2 Remove orifice plate 3 Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket Marine Transmission Service Manual 1020538 91 Disassembly Twin Disc Incorporated 5 Remove rate of rise piston Note that shims are located between the piston and springs Figure 49 Rate of Rise Piston left and Regulator Springs right 6 Remove pressure regulating springs ra Remove pressure regulating piston with an external retaining ring pliers Figure 50 Removing Regulating Piston with Pliers 8 Remove external retaining ring from the lever end of the
106. e Maintenance nennen 13 Er 13 Ordering Parts and Obtaining Services 14 Source of Service 22 2 1 1 4 15 Rs 16 Description and Specifications 17 topo M tt ce X 17 Power Ratings 18 Constr ction MI 19 Lubrication Features A 20 Haee 22 Optional ge 24 Torque Values for Fasteners mnnn nnnnnn 30 EUNIS ene P 33 UE MCN UNDE 35 35 Hydraulic System with Manual Control Valve 36 Hydraulic System with Electric Control Valve 44 Trolling Valve Optional ener 54 Power Take Off lt 2 lt 57 Trailing Pump lt 58 la AM Pte e 59 Preventative Maintenance 63 In boat Maintenance an
107. e and gasket Torque the valve attaching capscrews to 54 Nm 40 ft Ib Figure 112 Optional Electric Control Valve Installed 156 Turn transmission over supporting it by the output side input side up Coat input seal bore of housing and outside diameter of input seal with athin film of M2828 anaerobic sealant do not apply excessive sealant as seal and or bearings may be damaged Verify that there is no M2828 sealant on primary shaft Apply a film of oil or assembly grease to the seal surface of the primary shaft Install input shaft oil seal into housing using seal protector T 21347 and driver T 21347 1 Press oil seal into bore with the spring loaded lip of seal toward the inside of the housing Press seal into bore until outer face is flush with bottom of counterbore in housing Install front housing onto transmission housing Install attaching screws and torque to 112 Nm 83 ft lb Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Attach a dial indicator to the input shaft spline using fixture T 21302 1 with the probe on the front housing machined face Rotate input shaft and note total indicator runout The runout must not exceed 0 42 mm 0 016 in for both a SAE 0 and SAE 1 housing Figure 113 Measuring Front Housing Face Runout Attach a dial indicator to the input shaft spline using fixture T 21302 1 with the probe on the O D of the front housing pilot Rotate input shaft and not
108. e body Figure 39 Removing Check Ball Spring 86 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 3 Remove the rate of rise piston and remove the pressure regulator adjustment shims from the rate of rise piston Figure 40 Removing Shims from Rate of Rise Piston 4 Remove the pressure regulating springs and pressure regulator piston Figure 41 Removing Regulator Springs and Regulator Piston Marine Transmission Service Manual 1020538 87 Disassembly Twin Disc Incorporated 5 Remove the O ring plug detent spring and detent ball Figure 42 Removing O ring Plug Detent Spring and Ball 6 Mark the lever and the stem to indicate the position the lever was installed on the stem Loosen the screw clamping the lever to the stem and remove the lever 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 lever or bearing might get damaged Figure 43 Removing Lever 88 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 7 Remove the cover and stem together as a unit Figure 44 Removing Stem and Cover Together 8 Mark the stop collar and the stem to indicate the position the collar was installed on the stem While supporting the collar drive the roll pin out of the collar with a drift punch and remove the collar Figure 45 Removing Roll Pin and Stop Collar 9 Sli
109. e following illustrations are for reference only Please refer to your bill of material for part numbers specific to your model Clutch Group Mechanical Selector Valve Suction Strainer Oil Filter Transmission Rear View Transmission Section View Electric Control Valve optional equipment E HB B B8 O B B5 Trolling Valve optional equipment Marine Transmission Service Manual 1020538 205 Illustrations Clutch Group AY Twin Disc Incorporated NNNNNNNNNNNNNNNNSNNNSSNI N N ex p pes bs AUN 4 NS Ka 206 fe Ww Marine Transmission Service Manual 1020538 SESOZOL UOISSIUISUEJ 202 Description Bearing tapered roller primary amp secondary shaft front bearing Bearing needle roller Item Qty 1 Description Ball steel lube relief valve 20 21 2 Screw hex head lube relief valve Shaft assembly secondary 2 Washer lube relief valve Ring external retaining primary amp secondary shaft at needle bearing Ring internal retaining pinion at needle bearing Pinion assembly primary amp se
110. e relief valve steel ball into lube relief valve housing Attach assembled lube relief valve to inner face of bearing carrier with the screws and washers Torque the screws to 33 Nm 24 ft Ib 3 Install two alignment studs into face of transmission housing Install bearing carrier over studs and onto dowels in housing face Use a soft hammer near the dowels to seat carrier against gasket and over dowels Figure 84 Bearing Carrier Installed Marine Transmission Service Manual 1020538 133 Assembly Twin Disc Incorporated 4 Install lube tube through keyed hole in bearing carrier and into machined pocket in front inner face of housing Rotate tube so elongated key of tube fits into corresponding key in bearing carrier Properly installed lube tube will be flush with rear face of bearing carrier m Figure 85 Key Orientation of Installed Lube Tube 5 Install cups for rear tapered roller bearings on primary and secondary shafts into bores in bearing carrier Tap cups down gently with soft hammer or brass drift to seat against bearing cones on shafts 6 Install manifold gasket over alignment studs and against bearing carrier Install with silicone beaded side up 7 Push tapered roller bearing cups with shim retainers firmly against roller bearing cones on rear of primary and secondary shafts Use a depth micrometer to measure from manifold gasket face to shim retainers Measured distance is shaft endpla
111. e shaft of the valve stem the oil seal and the O ring Install the stem into the valve cover 142 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 4 Install the stop collar onto the stem so that the roll pin holes are aligned as well as the marks made at disassembly Drive the roll pin into the collar and stem while supporting the stem to prevent damage to the parts Figure 93 Installing Stop Collar left and Roll Pin right 4 Place the cover gasket over the stem assembly against the cover Install the assembly into the valve body and torque the attaching screws to 33 Nm 24 ft Ib Figure 94 Installing Stem Assembly into Valve Body Marine Transmission Service Manual 1020538 143 Assembly Twin Disc Incorporated 5 Install the detent ball spring and O ring plug Torque the plug to 37 Nm 27 ft lb Figure 95 Installing Detent Ball Spring and O ring Plug 6 Install the valve lever aligning the marks made at disassembly Torque the screw to 15 Nm 11 ft lb 7 Install the pressure regulator piston and springs into the valve body Figure 96 Installing Regulator Piston left and Springs right 144 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 8 Install the pressure regulator adjustment shims into the rate of rise piston Figure 97 Pressure Regulator Adjustment Shims 9 Install the rate of rise piston with shims into the val
112. e total indicator runout The runout must not exceed 0 30 mm 0 012 in for both a SAE 0 and SAE 1 housing Note Should total indicator runout exceed stated limits contact the Product Service Department of Twin Disc Incorporated for information and recommendations Slide input coupling onto splines of input shaft If the unit is to be shipped with the coupling on the shaft it must be attached to prevent it from sliding off and causing damage Marine Transmission Service Manual 1020538 157 Assembly Twin Disc Incorporated 158 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation Installation Prior to Installation CAUTION Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be made before the driven component is installed After installation of the driven component the crankshaft endplay should be measured again The endplay at the second measurement should be the same as the first A difference in these two endplay measurements could be an indication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage cau
113. e vc xnerorz 37 res 2 sees OPTIONAL CONNECTOR PORT SOLENOID 1018085 re rre ec eM EE E m me E m 3 eres 40760 1017179 wa e peersere4 vod leeran pets 017294 nosse ussstoer erso ees t Be eu 5 L 10180858 _____ 1018584 1016594 B3117 1018688 75 24 voc 7072 427072 we7osr 725 250 10171 1017554 0 20 60 4 4 48 ion arent NEUTRAL SOLENOID E 1018085 41079 1017383 1017179 no 7 4 voc 2655 365 1017129 1017554 7 x 20 69 4 Bessies 6 6449 jx cles s pere vic amem BUE CONNECTOR 1018085 _____ 1017383 1017179 0 2 759 24 vnc 2450 355 10171298 017554 MAto38Ewe7 x ao e 4 24518 8 ses FEMA VALVE 7 9 04 9000 osoesr p torrie _ no 2 puezsores vocxaeroran ae7o7An 2000 eoo 10171298 eosin 2 sss _ _ we seospe aa B 8 g 10160856 41152 _
114. earing cup is properly seated Tighten puller rod to standard torque limit for thread size of puller rod or 275 Nm 200 ft Ib whichever is less Maintain this torque until bearing cup and housing temperatures equalize approx 10 minutes Figure 67 Installing Output Shaft Bearing Cup 8 Remove puller and steel plate 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 minus dimension B minus dimension C within 0 025 mm 0 001 in 112 Marine Transmission Service Manual 1020538 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 amp 7070 cleaner is recommended CAUTION Tapered surface of shaft and matching tapered bore of gear must be completely free of grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance measurement of gear on shaft and adversely effect torque carrying capacity of the assembled joint 2 Install front output bearing cone and output gear Use special tool T 19987 to position gear into correct location Install the output shaft into the output gear and bearing cone in the transmission housing Seat shaft onto the taper of the ge
115. econdary shaft assemblies See special tools section for lifting bracket to aid in shaft removal or installation Changing primary and secondary clutch plates Further disassembly reassembly of the primary or secondary shafts will require use of tools and equipment normally not available on board the vessel Marine Transmission Service Manual 1020538 63 Preventative Maintenance Twin Disc Incorporated General Maintenance 64 Lubrication Grease the oil seals on the output end of the output shaft through the grease fitting with water pump lithium soap based NLGI No 2 grease Apply grease every 100 hours or when the boat is docked No other lubrication is required beyond the daily oil check 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 With a new transmission change the oil and filter element within the first 50 hours of operation Change oil and filter element after each 1000 hours thereafter or more often if conditions warrant For a rebuilt transmission chec
116. ed with the setscrew hole in the valve body to prevent damage to the stem and valve body Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 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 102 Installing Dogpoint Setscrew 7 Install the steel detent ball into the valve body 8 Install the detent spring over the detent ball 9 Apply 908 threadlocker to the threads of the hollow setscrew install into the threaded hole A stepped Allen wrench 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 103 Installing Detent Ball Setscrew Marine Transmission Service Manual 1020538 149 Assembly 150 10 11 12 13 14 Twin Disc Incorporated 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 104 Holes in Gasket and Cover Must be Aligned 15 16 17 18
117. en bolting the gear flange to the flywheel housing make sure that no axial thrust is exerted to the coupling by tightening of the bolts Before the engine is started the first time check that the crankshaft has endplay otherwise serious damage may occur to the engine 176 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation Propeller Shaft Before any attempt to align the engine and gearbox to the propeller shaft proper alignment of the propeller shaft must be determined This includes alignment of the propeller shaft through all struts and intermediate bearings Failure to properly align the propeller shaft may result in premature wear on bearings vibrations or possible damage to other components If the length of the shaft from the last support bearing to the gearbox is excessive or a flexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Transmission Controls CAUTION Transmission controls must be checked for proper function and alignment after any transmission selector valve is properly indexed in relation to the operator s control lever Failure to do so could cause control system malfunction resulting in personal injury and or damage to equipment and property See specific marine transmission installation drawings for detail and dimensional information needed for the proper installation of control linkages power engaging de
118. essive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate or deterioration of the rubber to metal bond See above Deterioration of the rubber element as evidenced by sponginess or by black carbon like dust on rubber surface May be caused by contaminants or excessive heat either external or internal to the coupling Cracked bent or otherwise damaged flex plate or coupling plate Bolt holes in flex plate or coupling plate elongated oval shaped not round This could be caused by improperly assembled parts loose parts vibration or improperly torqued parts Bolts nuts bent worn or stripped threads Marine Transmission Service Manual 1020538 Twin Disc Incorporated Preventative Maintenance Inspect the hub looking for the following Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found Marine Transmission Service Manual 1020538 67 Preventative Maintenance Twin Disc Incorporated Heat Exchanger Check 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 5096 of the rod is disintegrated it should be replaced to provide effect
119. etent position for forward or reverse as selected without exerting pressure on the rotational stop on the selector valve stem Selecting neutral must place the selector valve in the neutral detent position Improper installation of power engaging devices could cause failure of the selector valve stop permitting improper positioning of the selector valve and resulting in control malfunction Electrical Controls All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connections must be tight and free from any corrosion Final Checks Be sure the transmission is filled with oil before starting See Description and Specifications and Preventative Maintenance for proper oil and filling procedure Marine Transmission Service Manual 1020538 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 continue on the following page Recommended Pump Set and Fluids THAP 300 18050 96 18050 116 18050 120 T 18050 152 18050 607 18050 609 18050 610 612 T 19998 T 20023 T 20023 T 20023 T 20023 T 21302 1 21347 0D o0 O0 0 0 O0 0 O0 0 0 O0 O0 0 O0 O0 T 21347 1 Marine Transmission Service Manual 1020538 SKF Air Driven
120. f 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 when servicing that replacement couplings are matched to this criteria Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh water through the heat exchanger The heat exchanger should be installed in alocation convenient to both coolant and marine transmission oil Marine Transmission Service Manual 1020538 21 Description and Specifications Twin Disc Incorporated Specifications Maximum operating speed 2500 rpm Maximum oil sump temperature 93 C 200 F Oil type and viscosity See data plate below Oil capacity 31 4 liters 8 3 gal plus hoses and heat exchanger Pump 88 liters per minute 23 2 GPM at 2300 RPM
121. flange can usually be corrected by repositioning the coupling on its spline or taper Excessive shaft coupling runout is usually due to inaccuracy of the taper fit or key to keyway interference The optimum relative mating location will be where the measured runout dimensions of the transmission flange and the shaft coupling flange compliment each other to result in the least relative out of true parallel measurement Figure 121 Checking Output Flange Face Runout Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation Figure 122 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 Marine Transmission Service Manual 1020538 171 Installation Twin Disc Incorporated There are many types of flexible
122. ge 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 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 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 250 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 Since the pressure in the rate of rise chamber is much greater than the pressure itis to be regulated at the b
123. has been attained 136 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 7 Check endplay for primary shaft Repeat steps 1 through 6 on the previous page to adjust endplay for primary shaft Figure 87 Checking Primary Shaft Bearing Adjustment Marine Transmission Service Manual 1020538 137 Assembly Twin Disc Incorporated Installation of Manifold Exterior Components 1 2 Install pump suction strainer into bore in manifold Install O ring into groove in suction screen cover Apply assembly grease or oil to the O ring Install suction screen cover and secure with clamp plate and screw Torque attaching screw to 112 Nm 83 ft Ib Install O ring into groove in face of manifold at primary shaft location Install cover onto manifold at primary shaft bore Install attaching screws and torque to 112 Nm 83 ft lb Figure 88 Primary Shaft Cover O ring Installed left and Primary Shaft Cover Installed right 5 6 138 Install oil pump gasket and oil pump at mounting location at end of secondary shaft Mesh drive tang on pump shaft with drive slot in secondary shaft Install attaching screws and torque to 112 Nm 83 ft Ib Install oil filter Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Installation of Output Flange 1 Heat output flange in 300 F 150 C maximum oven for a half hour to an hour 2 Install heated output flange Ass
124. hat the entire power package be considered when problems are encountered Tables begin on the next page Marine Transmission Service Manual 1020538 69 Troubleshooting Table 8 Troubleshooting Chart Twin Disc Incorporated Symptom Cause Remely 2 70 Low main oil pressure No oil pressure or erratic low pressure at control valve tap Partially clogged oil strainer Stuck pressure regulation piston 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 suction 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 over board Remove and clean oil strainer Disassemble the valve and clean the piston Remove the collector and inspect piston rings Replace damaged or worn oil pump assembly pump is not serviceable Adjust linkage so that control valve stem is indexed properly by detent Remove orifice plate cover Clean parts Shim as required Raise engine speed Remove and clean strainer Check oil le vel and correct Correct
125. her 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 series of marine transmissions 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 18 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Description and Specifications Construction Features Housings The MG 5222DC transmission has a one piece main housing Front housing sizes in SAE No 0 and SAE No 1 sizes 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 Tapered roller bearings also support the output shaft and have bearing clearance adjusted by use of shims at the bearing carrier Oil Pump and Drive The oil pump is driven by the secondary clutch shaft
126. in chamber B to rise to clutch engaging pressure When in secondary passage D remains at atmospheric pressure because slot F remains open to sump When a shift is made from secondary to neutral the valve stem is rotated to the position illustrated by Figures 7 and 8 Under these conditions passage E is connected to the sump by slot F Passage J is also connected to sump by port H in the valve stem Because passage E is connected to slot F oil drains rapidly from the secondary clutch to sump Because passage J is now at atmospheric pressure the oil pressure in chamber L unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The secondary clutch is now disengaged and main system pressure reduced to neutral pressure 42 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation Entry Passage B Oil Pressure Chamber C Pressure Overflow Port D Engaging Passage E Oil Engaging Passage Oil Interconnection Slot Oll Directional Port Connection Port J Oil Pressure Passage K Directional Port L Oil Pressure Chamber A HIGH PRESSURE REGULATOR PISTON RATE OF RISE PISTON CONTROL VALVE LEVER PISTON SPRINGS CONTROL VALVE STEM CONTROL VALVE BODY ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 11 Control
127. 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 valve body bore and main oil pressure is not reduced The trolling valve is actuated by sending a controlled amount of current through the valve s 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 valve s 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 valve s 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 10205
128. inaon deem WE TT 5 D PLUG M2051K 2 1 t 1 3 mex E S EA LU ee 2 Meoesac 2 nn stav a D i xa2707Bz a2707Bw 703 1380 eoo 1017129 EOST 10530 45 lt 1 3 n sev 6 OPTIONAL 18 e 1 27 x 1725 ces 1 8 wenesr Mosor 2 ae MUN Dess r persori ves eso besesr a nosu g 1 7 2000 lt 290 10171298 7 x 2 B2451B 0 1062 2 10626 2 we seo bor i Bio wise cas mr ms eoo o 2 T resen T 20762 ros zia mos woe Werbe vi eaw x 2 meer sau somes wer es ense foes coo uere ec nen Pese cu 40764 ioraa wo puezssrHe vod mei gp LER 255 imme ur ces orses vae e nes v pev 0089
129. ine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly Remove and Disassemble Manifold and Bearing Carrier 1 Remove the four primary shaft end cover attaching screws Remove cover and O ring 2 Remove capscrews securing manifold and bearing carrier to housing 3 Use two of the removed screws as pusher screws to separate manifold from bearing carrier and dowel pins Remove manifold and gasket 4 Remove bearing shims and spacers from bearing bores in bearing carrier for primary and secondary shafts 5 Remove lubrication tube from bearing carrier 9 das Figure 29 Lube Tube Located in Bearing Carrier 6 Use two of the removed screws as pusher screws again to separate bearing carrier from housing Remove bearing carrier and gasket T Remove tapered roller bearing cups from bearing carrier for rear bearings for primary and secondary shafts 8 Remove lube relief valve housing relief valve spring and steel ball from bearing carrier 9 Remove hex head O ring plug compression spring and steel ball from manifold located on opposite side of filter 10 Remove the remaining O ring plugs from manifold and housing Marine Transmission Service Manual 1020538 77 Disassembly Twin Disc Incorporated Remove Primary and Secondary Shafts 1 Lift out primary and secondary shafts Disassembly of the primary and secondary shafts are covered later in this section Use caution with
130. 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 The exclusive rem Incorporated be either the repair or replacement of any T win Disc Incorporated part or Disc Incorporated to be defective and the labor to rm that work and to remove and reinstall or equivalent credit In this context labor is defined asthe flat rate labor hours established Twin Disc Incor i Incorporated be liable for economic loss incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part w
131. ith installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment Only a Twin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subseque
132. ive protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist itis evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush Overhaul Interval A complete overhaul of the unit should be made at the same time that the engine is overhauled Periodic Visual Inspection Check the mountings for tightness or damage such as cracks Tighten loose mountings and replace damaged parts Check pressure and temperature gauge where applicable Inspect the oil lines and heat exchanger for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required 68 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting Chart The following chart is intended as a guide for determining the cause of problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important t
133. k the filter element after eight hours of operation If the filter 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 1020538 Twin Disc Incorporated Preventative Maintenance Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located in the manifold below the pump See Engineering Drawings for suction strainer location Type Oil Recommended See Description and Specifications Filling 1 2 Remove the filler breather in the top cover of the transmission Fill the transmission s sump with 31 4 liters 8 3 U S gal of the proper weight and type oil See Description and Specifications for oil recommendations Start the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low
134. l is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Marine Transmission Service Manual 1020538 49 Operation Twin Disc Incorporated Hydraulic Lock Feature some models Some control valve models have a hydraulic lock feature and are identifiable by a third 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 Figure 18 Hydraulic Lock Units The resulting reaction is a force on the spool that overcomes the spool s 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 is running 50 Marine Transmission Service Manual 1020538 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
135. led Joints For previously sealed joints scrape surfaces to remove old gasket material or silicone Clean surfaces with solvent to remove oil and grease residue Test for clean surfaces by applying a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface in a film If the water puddles or forms beads use fresh solvent and reclean Marine Transmission Service Manual 1020538 Twin Disc Incorporated Inspection Cleaning and 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 or nicks If you cannot remove the defect with a soft stone replace the part Inspect ground tapers for scratches galling or scoring damage If any of these the defects replace the part Inspect threaded openings for damaged
136. ling of output hub This procedure is for gears with splined shaft where the output hub of the coupling is axially free 174 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation 2 Place rubber rollers in the deepest section of the cam in the output hub Normally they stick there by friction View X Figure 124 Insert Rollers and Note Alignment 3 In case that they should not stick place a tape or a cord with a slipknot around all rollers close to the gear side Let the end of the tape or cord long enough that itis hanging outside the flange Turn the two couplings halves in a position that the arrows of both halves are just opposite See Figure 124 View X tape or cord 5 plined shaft Figure 125 Coupling into Flywheel Flange Marine Transmission Service Manual 1020538 175 Installation Twin Disc Incorporated 4 Then push the output side of the coupling with the gear into the outer flange If necessary apply some lubricant on the outer flange Suitable lubricants are soap water detergents etc but no oil or grease In case atape or cord had to be used push the coupling only half way together and then take the long end of the tape or cord and pull it away Then grease or oil the gear shaft and plug it into the coupling spline remove tape or cord Figure 126 Final Assembly 5 Bolt the gear flange to the flywheel housing Note Wh
137. mbly Flange output Shaft output Plug protection behind input oil seal Housing front Screen strainer oil filler Coupling flexible Shield oil distribution Seal oil input D D 1 1 1 1 1 1 7 A 1 1 2 1 1 15 1 A 1 1 1 1 1 1 1 1 pe1e10djo2u 26101 UIML suonensn ll Illustrations Twin Disc Incorporated Notes 216 Marine Transmission Service Manual 1020538 Illustrations Twin Disc Incorporated Notes 218 Marine Transmission Service Manual 1020538 REMARKS SOCKET HEAD DOG POINT HEAD OME MODELS UTER INNER e 5 Q2 SOME MODELS HEX TROLLING VALVE GROUP SF S N PLATE ORIFICE SEAL VALVE BODY SCREW NUT PIN LEVER BALL O RING O RING WASHER SPRING SPRING SETSCREW BS lt LONS NN N 27222 Y E 221 7 2 7 SECTION SECTION B B Illustrations Twin Disc Incorporated Notes 220 Marine Transmission Service Manual 1020
138. mission Service Manual 1020538 61 Operation Twin Disc Incorporated Secondary In secondary the same parts are turning that were turning in neutral When the secondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates together The secondary 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 Secandary Clutch Engaged Figure 25 MG 5222DC Power Flow with Secondary Clutch Engaged 62 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance In boat Maintenance and Repair Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures are D D DO Note Note Removing and installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Removing and installing the control valve Removing and installing the manifold or top cover bearing carrier and lube tube Removing and installing the primary and s
139. mp manifold suction strainer cover 81 1 Strainer suction 210 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Illustrations Oil Filter d Tum Po ra 82 83 89 90A NS No e Item Qty Description 82 1 Filter assembly 83 1 Fitting threaded filter to manifold 88A 1 Ball 89 1 Spring filter bypass valve 90A 1 Plug Marine Transmission Service Manual 1020538 211 Illustrations Twin Disc Incorporated Transmission Rear View NA 212 Marine Transmission Service Manual 1020538 SESOZOL Jenuejy uoissiusueJ IUEN Ele aty Description tem Qy Description 91 t instruction ube 108 92 8 ube amp identiicaton 104 85 1 _ Piate instruction identification 105 106 4 Screw hex head pump memwe ____________ 3 OSIA UIML suoneusnyl Twin Disc Incorporated Illustrations Transmission Section View RB CX ds N q e 2 D Oy q sy 4 oO 2 Wu e D AN ite NEY
140. n and note the face deviation of the engine flywheel housing flange The face deviation must not exceed the figures given in Table 9 160 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation Table 9 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face e Eccentricity 0 48 0 019 0 41 0 016 0 36 0 014 0 30 0 012 0 28 0 011 0 25 0 010 0 23 0 009 0 20 0 008 0 18 0 007 Marine Transmission Service Manual 1020538 161 Installation Twin Disc Incorporated 3 With the indicator mounted as in the above paragraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing Thousandths Engine s Y m T Flywheel Engine 21 Crankshaft Engine Flywheel Housing Figure 115 Checking Flywheel Housing Bore Eccentricity 162 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the above Table for allowable tolerances 5 Bolt a thousanaths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face ofthe flywheel Rotate the flywheel The variation of the face runout of the surface to which
141. n both the engine and the transmission must be used Failure to do so may result in damage to the transmission Itis important to align the engine and transmission only when the boat is afloat and NOT in dry dock During this alignment period it is also advisable to fill the fuel tanks and load the boat in the typical manner that it is to be used Some boats are built with flexibility and may change shape as the loading varies 168 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Installation When a heavy boat is dry docked it naturally undergoes some bending Therefore it is always good practice to unbolt the marine transmission coupling to prevent bending of the shaft With the engine and transmission in position on the engine bed arrangements must be made to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine can be raised by screwing down or lowered by backing off on the jacking screws to obtain the desired adjustment Steel plates must be inserted under the jacking screws so that the bolts will not damage the engine bed Lifting can also be accomplished by the use of chain hoists or properly placed jacks Adjustable shims also are available and can simplify the alignment process particularly for future realignment It may also be necessary to move the engine and transmission t
142. ndary positions When these positions are selected the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate control piston within the control valve assembly provides a rapid smooth oil pressure increase in the hydraulic system during clutch engagement Marine Transmission Service Manual 1020538 35 Operation Twin Disc Incorporated Hydraulic System with Manual Control Valve 36 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 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
143. ne Transmission Service Manual 1020538 23 Description and Specifications Twin Disc Incorporated Optional Equipment The following optional equipment for use with the model MG 5222DC is available through the nearest authorized Twin Disc distributor Optional Trailing Pump A 115 vac electric powered trailing pump system is available It is identified as part number 1016473 A drawing is included in the Engineering Drawings Power Take off A live power take off pump mount is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 A hydraulically clutchable PTO is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 Metric to NPTF Adapter Kit An adapter kit K1090 is available to convert the oil drain plug opening the transmission oil ports to and from the heat exchanger and the pressure test ports from metric to NPTF threads Mounting Brackets Steel fabricated mounting brackets for rigid mounting are available They are part number 1016428Y 24 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Description and Specifications Torsional Input Coupling Several models of torsional input couplings are available including Vulkan 49115 in both 14 and 18 flywheel sizes as well as Centa CF R in both 14 and 18 flywheel sizes There is also an optional inertia ring available for use with the Vulkan VKE type couplings Remote Oil Filter There is a remote oil filte
144. nt 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 September 4 2001 TDW P2003 TWIN DISC INCORPORATED FLAT RATE HOUR ALLOWANCE Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated COMMERCIAL MARINE TRANSMISSIONS ALL RATIOS MODEL SERIES R amp R UNIT REBUILD CLUTCH REPAIR BOTH PACKS MG 502 MG 5010 MG5011 MG5005A MG5015A 10 0 8 0 MG 506 MG5061 MG 5050 MG5055A MG 507 MG 5081 MG5085 MG5090 MG 5091 MG5112 MG5113 MG 509 MG 5111 MG5114 MG5114A MG5114RV MG 514C MG514M MG5141 MG514CHP MG 516 MG 5161 MG 518 1 MG520 1 MG 5202 MG5203 MG5204 MG5205 MG 530 MG530M MG5301 MG 540 MG5600 MG6000 MGN 80 MGN 232 MGN 233 MGN272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN 472 MGN 493 MGN 650 MGN 800 MGN 1000 MGN 1400 MGN 1600 PUMP ALL MODELS VALVE ALL MODELS September 4 2001 TDW P2003A Twin Disc Incorporated Table of Contents Table of Contents emo 11 General m 11 Safety and General Precautions 11 Preventativ
145. nts could cause failure at the lift point or points and result in damage or personal injury A CAUTION Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Transmission Service Manual 1020538 Twin Disc Incorporated Introduction Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Operator s Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment Under the 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 the lack of component lubrication Backdriving also called windmilling occurs when an engine is shut down and the propeller shaft is being driven by the flow of water across the propeller which in turn rotates the components in the marine transmission During backdriving conditions the transmission does not receive proper lubrication Conditions where backdriving may occur Vessel is being towed One or more engines on multiple transmission vessel are shut down while under way Sailboat under sail with auxiliary engine shut down Vessel tied up docked in a heavy current The following
146. ny 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 52 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation Cost 4 7 0 PRIMARY SHAFT TROLLI FRONT amp REAR BEARING PINION 1 amp CLUTCH LUBI ND sen es SH WN ENGAGED E 22 2 Kal SNS NY KX SSS LEAL AN _ CSS ro a cp lt YA N 4 i VaL VE PSX 7 AMIE 4 t qii E SECUNDARY SHAFT I 650 tee p Ee a RE FRONT amp REAR BEARING PINION amp CLUTCH LUBE SHOWN E i 2 AM 2 ENCLDS
147. o 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 Atthe same time a straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE MALE FEMALE STRAIGHT EDGE Figure 120 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1020538 169 Installation 170 Twin Disc Incorporated 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
148. ove in O D of clutch apply piston Apply a coat of assembly grease or oil to seal ring 4 Install clutch apply piston into piston bore in transfer gear Figure 75 Installing Clutch Piston 124 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 5 Installation of clutch return springs A Install 16 clutch return spring assemblies into pockets in face of clutch apply piston Each assembly consists of one inner and one outer spring B 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 Figure 76 Return Springs and Spring Retainer Ready for Installation Marine Transmission Service Manual 1020538 125 Assembly Twin Disc Incorporated C Install external retaining ring over shaft to rest against spring retainer Move shaft assembly to press and install tool T 19998 Press down tool T 19998 to compress springs and expose retaining ring groove of shaft Keep force on springs and install retaining ring into exposed groove of shaft Figure 77 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 T 19998 126 Marine Transmission Service Manual
149. perty Class 10 9 Property Class 12 9 Size wn nm wh m on m 16 18 21 25 23 26 31 35 25 29 34 40 M10 32 36 48 49 44 51 60 68 51 59 70 80 Table 6 Tapered Pipe Plugs with thread lubricant InSteelorCastiron InAluminum NPTF Size in Nm or 5 Ib ft 5 Nm 0 596 596 1 16 27 11 5 8 5 7 5 5 5 1 8 27 14 10 5 9 6 5 x 1 4 18 1 2 14 68 50 41 30 3 4 14 73 54 46 34 wm ww 9 Marine Transmission Service Manual 1020538 31 32 Description and Specifications Twin Disc Incorporated Table 7 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal Nm lb ft lb ft Thread 5 5 Thread 5 5 Diameter Diameter M27X2 0 IN M27X2 0 IN 85 326 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Description and Specifications Wear Limits MG 5222DC Clutch Plates Steel separator plates cone Minimum 0 33mm 0 013 in Maximum 0 58mm 0 023 in Friction clutch plates cone Maximum 0 25mm 0 010 in Friction plates minimum thickness 2 90mm 0 114 inch Marine Transmission Service Manual 1020538 33 Description and Specifications Twin Disc Incorporated 34 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation Operation General The control valve obtains primary neutral and seco
150. pheric pressure at all times permitting the return to sump of any leakage oil past the pistons Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation A HIGH PRESSURE A Oil Entry Passag y REGULATOR PISTON B Oil Pressure Chamber C Oil Pressure Overflow Port D Oi Engaging Passage E Oil Engaging Passage Oil Interconnection Slot G Oil Directional Port H Oil Connection Port J Oil Pressure Passage Directional Port L Oil Pressure Chamber RATE OF RISE PISTON CONTROL VALVE LEVER SPRINGS CONTROL VALVE STEM CONTROL VALVE BODY ATMOSPHERIC PRESSURE B ENGAGING PRESSURE Figure 7 Manual Control Valve Neutral Sectional View NEUTRAL CONTROL VALVE BODY TO FORWARD CLUTCH p em TO SUMP TO REVERSE CLUTCH CONTROL VALVE STEM ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 8 Manual Control Valve Neutral Cutaway View Marine Transmission Service Manual 1020538 39 Operation 40 Twin Disc Incorporated Manual Control Valve Primary When a shift to the primary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 9 and 10 The pressurized oil in chamber B is directed through ports G and K to passages D and J Passage D is aligned with a passage directing main pressure oil to
151. pool return spring and dowel pin from the bottom of each of the spool bores in the valve body Marine Transmission Service Manual 1020538 97 Disassembly Twin Disc Incorporated 1017555 Trolling Valve Optional Equipment 1 Remove the trolling valve attaching screws Figure 58 Removing Trolling Valve Attaching Screws Steel 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 5 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 98 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 6 Remove the detent setscrew spring and detent ball Figure 59 Removing Detent Setscrew left and Detent Spring and Ball right ra Remove the dog point setscrew from the valve bogy Figure 60 Removing Dog point Setscrew Marine Transmission Service Manual 1020538 99 Disassembly Twin Disc Incorporated 8 Slide the stem and adapter out of the valve body together as one piece Push the stem out of the adapter such that the spring end of the stem exits the adapter first Note that the inner
152. pply 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 The remote trailing pump option is driven by an electric motor This trailing pump pulls oil through its suction strainer and discharges it through a filter to a check valve The oil then flows through an oil to air heat exchanger and into the transmission s lubrication circuit via one of the lubrication oil pressure test ports 58 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation Power Flow Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is splined to the forward end of the primary forward clutch shaft causing the primary shaft to rotate in engine direction during engine operation Power is transmitted to the secondary shaft by means of the transfer gear teeth on the outer diameter of the primary clutch housing These teeth are in constant mesh with gear teeth on the of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the
153. 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 Marine Transmission Service Manual 1020538 59 Operation Twin Disc Incorporated Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Driving Gear Primary Shaft _ secondary Shaft Gear Output Gear Figure 23 MG 5222DC Power Flow in Neutral 60 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation 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 Primary Clutch Engaged Figure 24 MG 5222DC Power Flow with Primary Clutch Engaged Marine Trans
154. put End Of Shaft Remove tapered roller bearing outer race from bore at rear of pinion if bearing requires replacement This bearing race is an interference fit in the pinion bore To remove use an electric welder to weld a light bead around the I D of the bearing race This will shrink the bearing cup to facilitate removal Bearings removed with this method must be replaced Marine Transmission Service Manual 1020538 83 Disassembly Twin Disc Incorporated 5 Remove tapered roller bearing inner race from shaft Bearing supports rear of pinion This bearing is a slip fit and should remove easily 6 Remove internal retaining ring at front of clutch housing and remove clutch backing plate 7 Remove clutch plates 10 steel 11 friction maintaining the respective order for inspection purposes 8 Remove clutch apply piston A Place clutch in a press input side up Use special tool T 19998 to compress clutch release springs and expose round retaining ring Figure 36 Removing Retaining Ring From Spring Retainer B Remove retaining ring Slowly release pressure on press and remove shaft from press Remove special tool T 19998 and spring retainer Remove clutch release springs form pockets in face of piston 84 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly C Carefully apply compressed air to hydraulic pressure port to force piston from piston bore Remove clutch piston J
155. r kit available BOM K1296 Heat Exchanger There are two different remote heat exchangers available M1959AN for use with raw water and M1959AM for use with fresh engine jacket water Companion Flange Assembly The 1002312 companion flange assembly consists of the companion flange as well as the 12 bolts and nuts to secure it to the marine transmission s output flange Trolling Valve The mechanical trolling valve kit for the standard mechanical control valve is K1331 Two trolling valve kits are available for use with this transmission when equipped with the optional electric control valve BOM 40588 which is mechanically actuated and 41063 which is electrically actuated Marine Transmission Service Manual 1020538 25 Description and Specifications Twin Disc Incorporated Table 2 Gear Advance Transmission Primary and Secondary Transfer Gear Advance 2 84mm 112 in 3 86mm 152 in Transmission Output Gear Advance 9 52mm 375 in 11 05mm 435 in Table 3 Bearing End Play Transmission Primary and Secondary Shaft Tapered Roller Bearing Endplay 0 05 mm 002 in 0 15 mm 006 in Transmission Output Shaft Bearing Endplay 0 05 mm 002 in 0 15 mm 006 in 26 Marine Transmission Service Manual 1020538 SESOZOL Jenuejy uoissiusueJ IUEN 1 SIUEN OGZZZS DIN MARINI ONLY
156. r the dowels to seat manifold against gasket and over dowels Install manifold attaching screws and torque to 112 Nm 83 ft lb Marine Transmission Service Manual 1020538 135 Assembly Twin Disc Incorporated Primary and Secondary Shaft Bearing Adjustment Note Procedure for setting and checking endplay for primary and secondary shafts is the same Procedure described and illustrated is for the secondary shaft Repeat same procedure for the primary shaft 1 With a felt tip pen make a mark across the rear end of the secondary shaft 2 Install a dial indicator on a machined surface on the manifold with the probe resting on the mark made on the secondary shaft Figure 86 Checking Secondary Shaft Bearing Adjustment 3 Install an eyebolt into the end of the shaft and exert 890 200 Ibs downward force while rotating the shaft several revolutions in each direction Stop so that the dial indicator probe is resting on the mark 4 Zero the dial indicator 5 Remove downward pressure and exert 1334 to 1557 300 Ibs to 350 Ibs lifting force on the shaft Rotate the shaft several revolutions in each direction stopping with the dial indicator probe resting on the mark 6 Dial indicator reading is secondary shaft endplay Endplay should be between 0 05 mm to 0 15 mm 0 002 in to 0 006 in Add or remove shims as necessary to achieve correct endplay Use dial indicator and above procedure to confirm that desired endplay
157. ransmission Service Manual 1020538 SESOZOL Jenuejy uoissiusueJ SUMEN 605 Item Qty 44 45 46 47 48 49 50 51 52 53 54 55 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 2 gt 4 Description Race thrust O ring valve cover Collar stop Pin roll Screw Socket head Lever shift Screw hex head Seal oil Cover valve Gasket valve cover Spring detent O ring Plug optional oil inlet Plug Piston pressure regulating Screw short 12pt head or socket head depending on model Screw long 12pt head or socket head depending on model Spring outer pressure regulating Closure plastic valve to manifold screw holes Shim neutral pressure adjustment Spring inner pressure regulating Body valve Spring check ball Ball steel check Gasket orifice plate and orifice plate cover use same gasket Cover orifice plate Screw hex head Plate orifice Piston rate of rise Shim pressure adjustment Gasket valve Stem valve Ball detent Bearing needle thrust pe1e10dj02u UIML suonesnil Illustrations Twin Disc Incorporated Suction Strainer 2 he Item Qty Description 78 1 O ring suction strainer cover 79 1 Cover suction strainer 80 1 Plate cla
158. rew if necessary to achieve the proper torque to rotate the lever out of the detent position 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 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 and nut to clamp the lever to the stem Tighten the screw and nut to 9 5 Nm 7 ft lb Install the neutral pressure regulating spring into the bore of the control valve if removed Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 16 Install the steel ball onto the neutral pressure regulating spring Figure 110 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 17ft Ib Figure 111 Installing Orifice Plate left and Trolling Valve Onto Valve Body right Marine Transmission Service Manual 1020538 155 Assembly Twin Disc Incorporated Installation of Transmission External Components 1 Install control valve ditch plate and gasket units with optional electric control valve Torque the ditchplate attaching capscrews to 75 Nm 55 ft lb Install control valv
159. rom careless use of hand tools lifting equipment power tools or unaccepted maintenance working practices Marine Transmission Service Manual 1020538 11 Introduction 12 Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure safe operations under prevailing conditions Proper guards and other safety devices that may be specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Inc Selecting NEUTRAL disengages transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a shaft brake or other shaft locking device must be used To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove ignition key from the switch Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these poi
160. rp 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 106 Marine Transmission Service Manual 1020538 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 Tran
161. s inside the piston The washer must lie flat at the bottom of the bore in the piston Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 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 107 Installing Trolling Valve Parts Into Trolling Valve Body 9 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 The end of the setscrew should protrude approximately 3mm from the valve body when the dog point of the setscrew is fully engaged in the helical slot Figure 108 Installing Dog point 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 Marine Transmission Service Manual 1020538 153 Assembly 11 Twin Disc Incorporated 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 Figure 109 Installing Detent Ball Spring and Setscrew 12 13 14 15 Check the torque required to overcome the detent The torque should be 1 1 1 7 Nm 10 15 in Ib Adjust the detent setsc
162. sed 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 1020538 159 Installation Twin Disc Incorporated Alignment also reference SAE J 1033 and J 617 1 Bolt a thousandths increment dial indicator or gauge to the engine flywheel so that the indicator is perpendicular to the face of the engine flywheel housing and the indicator stem is riding on the face of the flange Thousandths Indicator Engine p arg 1 2 gt A Az Flywheel Engine 77 Crankshaft LJ J Engine TENE Flywheel Housing Figure 114 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keeping a thrust in the same directio
163. sembly 4 Connect oil injection equipment to the 1 4 19 BSP threaded port on the rear end of the output shaft Figure 33 Oil Injection Equipment Connected 80 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly Install eyebolts into the end of the output shaft and into the main housing mounting pads Thread a heavy strap through the eyebolts in the output shaft and the strap to the eyebolts in the main housing The strap will restrain the output shaft during disassembly Figure 34 Safety Strap Installed Always use a safety strap to hold parts being separated with oil pressure Parts may separate with extreme force 7 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature dismounting fluid into the output shaft until the shaft and gear separate Remove the output shaft gear and front output bearing cone Use special tool T 19987 to remove gear from housing Tapered roller bearing cups for front bearings on primary pinion secondary pinion and output shaft are an interference fit in their respective bearing bores Remove these bearing cups only if replacement is required To remove these bearing cups weld a light bead around the 1 0 of the bearing cup with an electric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced Remove input oil seal Remove input oil seal protector plug if replacement is necessary M
164. smission Check alignment of engine and transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine 71 Troubleshooting 6 7 8 9 72 Twin Disc Incorporated Table 8 Troubleshooting Chart continued Symptom No neutral Harsh engagement Low lube oil pressure Oil spilling out of breather 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 and hydraulic lock 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 Remove clutch plates O verhaul unit Check and adjust control linkage Replace defective solenoid Inspect repair or replace hydraulic lock spool 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 the suction screen Inspect and correct cause of suction leaks Remove and clean or replace parts as
165. smission Service Manual 1020538 107 Cleaning and Inspection Twin Disc Incorporated 108 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Assembly The MG 5222DC 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 1020538 109 Assembly Twin Disc Incorporated Prior to Assembly 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 the output side of the transmission from the rear Identify and place the following bearing components in an oven at 120 C 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 in a deep freeze 51 C 60 F for at least two hours prior to assembly both output bearing cups all pinion bearing cups and both pinion inner needle roller bearings 110 M
166. solutions are applicable for all MG 5222DC transmissions if any of the above conditions are present Lock the propeller shaft to prevent rotation Add an electric driven auxiliary oil pump into the lubrication circuit Refer to the hydraulic system prints for more details on auxiliary pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Marine Transmission Service Manual 1020538 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services 14 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 from 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
167. spring will come out with the stem Figure 61 Removing Stem and Adapter from Valve Body left and Removing Stem from Adapter right 9 Remove the O ring from the groove in the end of the stem Figure 62 Removing O ring From Stem 100 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 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 Removethe outer spring and piston from the bore of the valve body Note that there be washer s the bore of the piston some models Figure 63 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 ir n Figure 64 Removing O ring From Adapter Marine Transmission Service Manual 1020538 101 Disassembly Twin Disc Incorporated 102 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Cleaning and Inspection Cleaning and Inspection Cleaning Note Replace all oil seals gaskets O rings piston rings seal rings snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents by steam cleaning Parts must be dried and oiled immediately to preven
168. stem 9 Loosen the clamping nut and remove the control 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 10 Remove the washer and spring from the stem 92 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 11 Remove four of x 25 socket head capscrews 12 Remove the cover assembly with gasket from the valve body 13 Remove the O ring and oil seal from the cover assembly Figure 51 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 bogy Figure 52 Removing Detent Setscrew and Spring Marine Transmission Service Manual 1020538 93 Disassembly Twin Disc Incorporated 16 Remove the dog point setscrew Note that the setscrew is retained with 908 threadlocker Figure 53 Removing Dogpoint Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 54 Removing Thrustwasher 19 Remove the stem from the valve body 94 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Disassembly 20 Remove the roll pin retains the shuttle ball seat with a needle nose
169. t corrosion Examine all parts carefully for grit dirt and abrasives and them if necessary Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent to flush pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher screw locations Marine Transmission Service Manual 1020538 103 Cleaning and Inspection Twin Disc Incorporated Cleaning Bearings Do not remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease A CAUTION Never dry bearings with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently it is 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 Sea
170. t Econ CAD FILE T21347 DwG WAS 2477 2478 DIA 9 18 95 JIM T MGSe0eDC ere CHANGE DESCRIPTION DA TWIN DISC INC RACINE WIS 2134 2510 Twin Disc Incorporated Oil Seal Driver T 21347 1 DRILI HRU E 03 7 2 2 dr N 21 Ol S deo ok e j 2 gt W joja gt Ps lt L Et gt 0 25 j 2 a gt za 5 a C lt es d gt le l RI lt e gt 2 lg 5 9 A Alz m ta E e 1 E 40 0 c lt ui e X o5 12 c x a L x 2 zT tX Marine Transmission Service Manual 1020538 Special Tools 199 Special Tools Lifting Bracket for Clutch Removal in Boat 12 00 4 00 4 00 1 N DRI 9 16 23 50 MAKE ROM 1 1 2 ANGLE IRON Use a Mle 1 75 x 30 mm bolt to attach Use o 1 2 13 NC bolt to support 200 to Twin Disc Incorporated 1 00 Cp lt 075 shaft shaft Marine Transmission Service Manual 1020538 DRILL 5 16 THRU TAP 3 8 16 X 100 THD HOLES FOR LIFTING GRIND amp PDLISH TD FIT X D SNC N INDUCTION DR J
171. t and Gear 113 Installation of Output Shaft Rear Bearing 116 Output Shaft Tapered Roller Bearing Adjustment 117 Installation of Top Cover Assembly Oil Gauge 121 Assembly and Installation of Primary and Secondary Shafts 122 Installation of Bearing Carrier 133 Assembly and Installation of Manifold 135 Primary and Secondary Shaft Bearing Adjustment 136 Installation of Manifold Exterior Components 138 Installation of Output Flange cereus 139 Assemble Control Valve 142 Installation of Transmission External Components 156 8 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Table of Contents Merana 159 Prior to Installati n 159 Alignment also reference SAE J 1033 and 617 160 7977 165 MUT 181 ErLdqolb Moo 181 Recommended Pump Set and Fluids 183 Driver 1T 18050 96 185 Bearing Cup Driver T 18050 116
172. the unit s nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty Marine Transmission Service Manual 1020538 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 Marine Transmission Service Manual 1020538 15 Introduction Twin Disc Incorporated 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 16 Marine Transmission Service Manual 1020538
173. threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels 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 1020538 105 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Bearings Inspect bearings for roughness of rotation Replace the bearing if the rotation is rough Inspect bearings for corrosion and for indication of wear of balls or rollers Inspect for scored scratched cracked pitted or chipped races If you find one of these defects replace the bearing Inspect bearing bores and shafts for grooved burred or galled conditions that would indicate the bearing has been turning in its housing or on its shaft If you cannot repair the damage with a crocus cloth replace the part Bushings and Sleeves Inspect bushings for size and out of roundness Inspect for scores burrs sha
174. to 23 Nm 17 Ib ft 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 Ib ft Marine Transmission Service Manual 1020538 151 Assembly Twin Disc Incorporated 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 Figure 106 Installing O ring onto Adapter Install a new O ring into the groove of the stem Install the roll pin into the end of the stem if removed 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 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 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 Install the small washer used on some model
175. 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 spring regulator T Ball and Spring Regulator Figure 14 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1020538 Twin Disc Incorporated Operation Control Valve Assembly in Primary or Secondary Pressurized oil is directed to one of the transmission s clutches to engage it The pressurized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the passa
176. ual trolling 1016473 Pump Assembly Trailing 222 Marine Transmission Service Manual 1020538 PINION ASS Y 1015213 1015212 xHUB 1015225 6961 RATIO e3T PINION ASS Y 1015215 2 1015214 xHUB 1015225 6551 RATIO PINION ASS Y 1015217 GEAR 1015216 xHUB 1015225 6 10 1 RATIO 21T PINION ASS Y 1015219 2 GEAR 1015218 HUB 1015225 5 041 RATIO 25 PINION ASS Y 1015221 2 gt XGEAR 1015220 1015225 4 591 RATID 27T PINION ASS Y 1015223 2 XGEAR 1015222 xHUB 1015225 4 031 RATID 30T SCREEN 9 93 ASS Y 1000974 COVER 1000 ADAPTER 976 1966 GASKET 1000874 ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 570 NOTES 1 THRU 6 ARE IN 5570 NOTE 7 TORQUE PER 5574 M20 PROPERTY CLASS 10 9 THESE STANDARDS APPLY S574 FASTENER TORQUE REQUIREMENTS 692 BEARING SHIMMING 765 TAPERED JOINT ASSEMBLY PLUG MA1038C 22 BEARING 1014857 22 ASS Y 585 CUP MAS90AR HOUSING 929 BALL 1034 SPACER 1015108 2 THIS SPACER USED WITH 6 961 6 551 AND 6101 RATIOS ONLY TUBE 1001380 RETAINER 3616 22 RING 269 2 SPRING 2706 HOUSING 1015018 AE 0 SCREW 960 2 WASHER 1039 2 Q N N N gt PART NUMBERS FDR GASKET 1001096 INPUT OPTIONS SEE SHEET 4 CARRIER 1000063 GASKET 1001109 RETAINER 100209
177. ulic pumps HMV nuts oil injection equipment etc The fluids contain anticorrosives and are non aggressive to seal material like nitrile rubber Buna N 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 130 SKF LHMF 300 and LHDF 900 Note Order Through Your Local Authorized SKF Distributor 184 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Driver T 18050 96 Special Tools STAMP 18050 96 255 352 0 V UO A 7 45 f 5 630 5 620 DIA 2 50 KNUR 6 89 5 4 5 76 5 058 Iz 06 Q gt DEQ p DIA X NS 434 FOR BEARIN MA 437 7278 MATERIAL MS BEARING SEAT DRIVER 10 05 99 D T 18050 96 WIN DISC INCORPRATED KJB Marine Transmission Service Manual 1020538 185 981 86602014 enuen uoissiUsUueJ 5100 19 4 911 09081 1 dno 50 1 60 x 8 25 REF Boetius s T 5 7 2b 25 4 1 1 i 1 N in EE i K ca NEC Pa 175 150 25 3 1 4 1 1 1 S 06 75 DRILL THRU DET 7 180 0028 _ AND TAP DET 2 FOR 1 2 1X SEES 88 960 005 BEARING 2 CUP 5
178. ure that flange seats solidly against rear tapered roller bearing on output shaft 2 With a depth micrometer measure distance from rear face of output flange to end of output shaft Record this distance as dimension Measure distance from rear face of output flange to inner shoulder of flange against which retainer washer is installed Record this distance as dimension Determine gap between retainer washer and end of shaft by subtracting dimension B from dimension A Figure 89 Measuring Output Flange Gap Use shims to develop a shim pack to reduce gap between retainer washer and end of shaft to 0 076 mm to 0 152 mm 0 003 in to 0 006 in Marine Transmission Service Manual 1020538 139 Assembly Twin Disc Incorporated 4 Install O ring to seal output shaft splines and output flange Figure 90 Measuring Output Flange Gap 5 Install shim pack developed in step 3 and retainer washer Install the seven retainer washer sockethead capscrews and torque to 530 Nm 391 ft lb Figure 91 Output Flange Shims left and Screws Installed right 140 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly 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 Attach dial indicator to ho
179. using 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 proceed as follows With a felt tip pen draw a line across the end of the output shaft and face of output shaft counterbore to mark original installed position of the output flange versus the output shaft Remove the output flange as described in Section 6 and reinstall 90 from original position Recheck runout of flange face and flange pilot using procedures in steps 6 and 7 above If runout is within specification do nothing more If runout continues to exceed tolerance repeat procedure in B above at positions 180 and 270 from originally installed output flange position Stop at whatever position output flange runout is no more than 0 10 mm 0 004 in If output flange runout cannot be reduced to acceptable tolerances contact the Product Service Department at Twin Disc Incorporated for information recommendations Marine Transmission Service Manual 1020538 141 Assembly Twin Disc Incorporated Assemble Control Valve Assembly of Mechanical Control Valve 1 Install the thrust race thrust bearing and remaining thrust race onto the stem Figure 92 Installing Thrust Bearing and Races 2 Install a new oil seal and O ring into the valve cover 3 Apply assembly grease or oil to th
180. ve body 10 Install the check ball spring shim s and spring into the valve body Figure 98 Installing Check Ball Spring Shim s and Spring Marine Transmission Service Manual 1020538 145 Assembly Twin Disc Incorporated 11 Place one orifice plate gasket the check ball and the orifice plate onto the valve body Figure 99 Installing Gasket Check Ball and Orifice Plate 12 Install the remaining gasket and orifice plate cover onto the valve body Install the attaching screws and tighten them alternating and evenly to 33 Nm 24 ft Ib 13 Install valve onto the transmission and torque the attaching screws to 52 Nm 50 ft Ib 14 Install the remaining O ring plugs Torque the M12 plugs to 37 Nm 27 ft Ib and the M27 O ring plug to 171Nm 131 ft Ib 146 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Assembly of Electrical Control Valve upperbody 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 body Figure 100 Dowel Return Spring Spool and Plug 3 Install one spool into each of the two bores of the valve body 4 On units equipped with the hydraulic lock feature install one spring followed by one pin small diameter into each of the spools 5 Install the two O ring plugs into the valve body and tighten to 85 Nm 63 Ib ft 6 Apply lubricant such
181. vices or electrical connections Marine Transmission Service Manual 1020538 177 Installation Twin Disc Incorporated FOURN PRESSUR EAD IN 6149 1 5 GAG N TRIC ISU UN HOUSE A Mie CH o CLUTC AFT AFT C 245 Y Vs gt Y5 Tu gt ET lt equ gt 8 4 lt ma Co D MOUNT NEU S AGES Les N MF ES SUITAB 4 2 THRU X gt lt RACK J Figure 127 Mechanical Control Valve Installation Specifications 178 Marine Transmission Service Manual 1020538 SESOZOL Jenuejy uoissiusueJ SUMEN 5 041002 921 aniy 621 WIRING DIAGRAM CONNECTOR 1 PRIMARY CLUTCH SOLENOID d 7 PRIMARY CLUTCH SOLENOID m E 771 SECONDARY CLUTCH SOLENOID m 7 SECONDARY CLUTCH SOLENOID gt EP 77 NEUTRAL SOLENOID OPTIONAL E MATING WIRING HARNESS 1017404 OPTIONAL EBIES ROSE EN LENG JEMES MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH MANUAL DVERRIDE NEUTRAL START ELECTRIC CONTROL MODE SWITCH SWITCH CLOSED ONLY WHEN CLOSED
182. y Use necessary shims to develop a shim pack for each shaft to reduce shaft endplay to 0 05 mm to 0 15 mm 0 002 in to 0 006 in 8 Install calculated shim pack at each shaft location with the thickest shim against bearing cup followed by the remaining shims and finally the retainer against shims at each shaft 134 Marine Transmission Service Manual 1020538 Twin Disc Incorporated Assembly Assembly and Installation of Manifold 1 Install new O rings onto the M18 O ring plugs used for the clutch and lube pressure test ports Lubricate the O ring and threads and install the plugs torquing them to 74 Nm 55 ft Ib Place new O rings onto the M22 O ring plugs and install them into the manifold side opposite the oil filter boss torquing them to 100 Nm 74 ft Ib Place a new O ring onto the M10 O ring plug and install it into the manifold below the oil filter torquing it to 25 Nm 18 ft Ib Place a new O ring onto the M27 O ring plug and install it into the manifold above the oil filter torquing it to 81 Nm 63 ft lb 2 Assemble and install filter bypass valve Assemble parts in manifold oil inlet port in the following order A Check ball B Spring C Plug 3 Apply a coat of assembly grease or oil to the seal rings of both clutch shafts Center the seal rings in the shaft grooves to prevent seal ring damage during manifold installation 4 Install assembled manifold over alignment studs and dowels Use a soft hammer nea

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