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1. X 10 ASSY amp 98 PREHARD ROD Rc 32 36 FLANGE NUT EYE BOLT TECO LANGE NUT TOP CARB amp HARD 1 NERPAC CYLINDER ROD OLLAR RS rox GEAR amp SHAFT PUI Wi DISC INC RACINE WIS 7470 EX8566 5100 1eeus 62002 1 Ajquiessy 10 1e nd HEYS 1ndino osiq UIML 29902014 3914195 uoissiusueJ SUNEN 661 8 7 8 9 150 DEEP EQ SPACED Us EE DRILL CT BORE 500 3 8 16 TAP 2 PLACES 18 SPLI 177 CEN E 8 787 3 8 783 700 1 3 _ sl eS N LS HDN 45 49 Rc amp SPLIT EM A st 4 00 138 p 2 5 94 n 8 THREAD 7 8 9 THREAD DET 14 8 THRE e 15 2725 AUTOCAD FILE T 20023 DWG HDN x 49 45 50 Rc 94 HIS 416 1 00 DIA IRU 1 00 LENGTH REAM SL FIT Gps Scscoesent 5 4 1140 ROD 190 x 2750 13 4 spacer HIN 527 4 4140 SPACER 200 DIA x 2
2. 220 Marine Transmission Service Manual 1020667 29902014 enue y 3914195 uoissiusueJ SUNEN LZZ Qty 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 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 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 pe1eJodajoou 5510 UIML suonensnil Illustrations Twin Disc Incorporated Trolling Valve for Manual Control Valve o N ON f NX LOS OO SE 0 40 LEE Nom 7 222 N E LA Cs fe lt NA
3. Marine Transmission Service Manual 1020667 29902014 3914195 uoissiusueJ SUMEN 2744 Item Qty 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 O ring Plug optional oil inlet Plug Piston pressure regulating Screw short 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 pe1eJodajoou 5510 UIML suonensnyl Illustrations Twin Disc Incorporated Notes 224 Marine Transmission Service Manual 1020667 CONTROL VALVE GROUP 2 serne 2 __ ________ SPOOL 2 UNITS WITH HYD LOCK _______ ct 5 2 o ZY o o e PN gt serne 1 INNER PRESS REGULATNG 22 2742 2 e piston A 2 9 prame orree 41 24 2 2 1 sam ___ N cover INNS 1 FAIS H 12 caser 4 2 LIENS _13
4. 3510 UIML SSN i SRS 5 lt T S5 5 i N EEZ Q INSTALL INE HERE BE MOUNTED PRIMARY SHAFT FRONT amp REAR BEARING PINION amp CLUTCH LUBE SHOWN ENGAGED OPTIONAL TROLLNG VAL 73721 AND 73730 SM S 2222 SS XS S HE 2222 Sy BS uu dr amp CLUTCH LUBE SHOWN DISENGAGED STRAINER SUMP 4 Operation 36 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
5. 1017133 1017134 ISS7r weees wo 2 voci xae7o7z 427072 725 250 0171298 826918 MATUSEX 2 patosa 2 io1e0e R 40935 1017383 1017173 ves jwe7sorMaa a2707BD 7 2415 caso 10171298 x 0 BeasiB 8 557 am SCREW 1052 4 een 40954 1018584 1018594 3117 1018688 4 2 2 520 mene TORGUE 70 542 N m 40955 1017383 1017179 e ixwezserMe voc Doe 2655 395 10171298 0 x peasip NOTE G 1016084U 40956 1017383 1017179 2 xwe7serMes pu 2550 lt 370 10171298 7 x 24 6 24518 7 6 6557 SECURE LEVER IN THE DEPRESSED VIEW 40957 1017383 1017179 NO 2 xwe7serMa4 voc Sezony 2450 355 1017129 x 0 6 24518 5 85 pont PD E POSITION ED 6 sme soe manson DIEN eer aes BHL iSi 1 4 HOLE IN LEVER amp 8 THREADED 2
6. 119 Installation of Output Shaft Rear Bearing 121 Output Shaft Tapered Roller Bearing Adjustment 122 Assembly and Installation of Primary and Secondary Shafts 126 Installation of Bearing Carrier 137 Assembly and Installation of Manifold 139 Primary and Secondary Shaft Bearing Adjustment 140 Installation of Manifold Exterior Components 142 Installation of Top Cover Oil Gauge and Oil Pan 144 Installation of Output Flange 146 Assemble Control Valve 149 Installation of Transmission External Components 164 8 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Table of Contents mM 167 Prior niii 167 Alignment also reference SAE J 1033 and J 617 168 installation Meee 172 Centaflex R Assembly Instructions on Flange Mounted 179 HL 185 List f Special TOOlS 185 Bearing Driver T 18050 11 P 187 ioo Mm 188 Bearing Driver T 18050 183 L iiiiiiiiiiassassaaaaaaa
7. 11 Preventative 4 21 1 21 4 14 1 4 4 13 ij 13 Ordering Parts and Obtaining Services 14 Source of Service 15 E m S 16 Description and Specifications 17 tI Mee 17 o atii ipta ie RM MM MEAM AME 18 FOURS 19 Eie iai it o Mem 20 Hee 23 oda nnl 25 Torque Values for Fasteners 30 Operation Rm 33 c 33 Hydraulic System with Manual Control Valve 34 Hydraulic System with Optional Electric Control Valve 42 Trolling Yalye Optional 52 Power Take off 55 Trailing Pump CODIODBI 56 5 57 Preventative Maintenance 61 In boat Maintenance and Repai
8. 214 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Illustrations Qty Description 4 1 1 1 4 1 2 2 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 2 1 8 4 9 Screw hex head cap oil pump Tube assembly oil gauge Oil gauge Tag oil gauge Screw drive identification plate Plug ass y O ring secondary clutch press port Plug pipe lube pressure test port Screw socket head cap 12pt on some models Valve assembly Plate identification Plug pipe oil filter drain Screw socket head cap 12pt on some models Screw socket head cap 12pt on some models Plug ass y O ring Plug pipe Screw drive instruction plate Plate lubrication instruction Breather Eyebolt S link Chain Washer Clip Plate Plug ass y O ring Plug pipe Screw hex head cap manifold Screw hex head cap primary shaft end cover Screw hex head cap manifold Marine Transmission Service Manual 1020667 215 Twin Disc Incorporated Illustrations Transmission Section View 4 NE T N X N S5
9. j OIL STRAINER S emer i GREASE FITTING i preti e CENTER DF GRAVITY GRAVITY ENGINE ROTATION DRIVING THRU 4 10UNC 2B JO BOSSES CAN BE DRILL ND SECONDARY CLUTCH 118 DEEP E Um SS SUMP DIL FOR LUBRICATION HOLES 7 EACH SIDE DURING EXTENDED U WITH PROPELLER WINDMILLINC USE ALL FOURTEEN 14 HOLES AND OTHER USE DIRECTLY CONCERNED WITH FOR MOUNTING UNIT USE MG 5 gt HYDRAULIC C GRADE 8 QUALITY CAPSCREWS PER SAE J429 AND TORQUE TO 574 UR SERVICE MANUAL VALUES OIL DRAIN 1 S 16 12UN 2B TH D pue uonduosegq 1 UIML 29902014 enue y 3914195 uoissiusueJ SUNEN 6 2 uonejeisu 6 4 CONNECTOR I 771 PRIMARY CLUTCH SOLENOID m 9b SECONDARY CLUTCH SOLENOID UPTIDNA MATING WIRING SERIES SPECIFY MANUAI VERR SWITCH CLOSE JE ENC UNI WIRING DIAGRAM HARNESS 1017404 3TH NEUTRAL STAR Y WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION M8 X 1 25 6 THREAD 2 KOLES FOR REMOTE CONTRO ENGAGES PRIMARY SHAFT CLUTCH INC 1 4 DIA THRU ENGAGES CLUTCH IS IN SECONDARY NEUTRAL PRIMARY CLUTCH SOLENOID SOLENOID N E EO LEVER MAY BE ON ITS MOVEMENT WITHIN LOCA HA ED ANYWHERE PERMITS FREE THE 50 TOTAL
10. AI EU 5 TWIN DISC INCORPORATED RACINE VI 3403 USA HERE Russell 101746 51700 transmission SCREW M422B 4 PLATE 2415 PLUG M2051CD PLUG Se MOUNT LUBE INSTRUCTION PLATE REF B2415 WITH WORDS MARINE TRANSMISSION LUBRICANT TOWARDS RING A2916BT 2 BREATHER SCREW M1731CS SEE NOTE 11 SCREW M1731CT SEE NOTE 11 A PLUG M2702E PLUG 2051 MOUNT UNIT INSTRUCTION PLATE B2387 WITH TWIN DISC TRADEMARK TOWARD BREATHER PLATE 2387 VALVE ASSY 1020412 SCREW M1731BF SEE NOTE 11 PLUG 20510 PLUG 2782 RING A2916BV SCREW M422B 42 PLUG M2702E TEMP IND SWITCH B3424A TAG 656 GAUGE B3631E TUBE ASS Y XB2e301H TUBE B2301H ADAPTER B2300 CAPSCREW 2002 4 EYEBOLT M2071D 2 gt BREATHER 1251 S LINK 2007 CHAIN M1072 WASHER 1681 CLIP M1763 PLATE 212754 2 PLUG 2782 2 RING Ae916BV PLUG 20510 CAPSCREW 2002 8 CAPSCREW MA996D 45 CAPSCREW 2002 9 Qd VO OA TM gt L SUCTION TUBE 7 GAUGE B1703D SCREEN 2261 TUBE ASS Y XB6238A TUBE B6238A FLANGE MA818J RING A2916W 4 SPRING 201341JV RING A2916DN PLUG M2080J AND SCREEN MANIFOLD ASS Y 1019793 MANIFOLD 1017460 NIPPLE 1018720 BALL
11. zo 24 3 lt gt lal x 2 S EN zi A D a m gt CU 4 al lt T gt a CU Gye Lil D E a 7 e 5 2 ur 25 4 2 El pls x dis d 2 ES gd N cu ES 0 j 0 gt 59 A z cu 7 1 a s g gt Pe 2 T AN EA o o o Ne J 34 x F lt 0 Qd QJ s wi Q x p x 9 in a zz A a L Q Eee Marine Transmission Service Manual 1020667 203 Special Tools Twin Disc Incorporated Lifting Bracket for Clutch Removal in Boat 2 00 4 00 4 00 1 9 16 DIA 23 50 DRILL 50 DIA l O 13 32 Sea AP e 13 NC co 1 0 0 MI 15 ML 0 75 MAKE FROM 1 1 2 ANGLI SUN Use o Ml2 1 75 x 30 mm bolt to attach to shaft Use o 1 2 13 NC x 6 bolt to support shoft 204 Marine Transmission Service Manual 1020667 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 B FLAME HD N RADIUS PitHH923610 TDWMASS0EZ TR REAM PRESS T MAS90EZ BEARING A FIT BUSHING gt 18050 772 12500 005 150
12. em me m sm rer coer we me X SEE SHEET 1 F R MAXIMUM TRANSMISSION RPM ALL CDUPLINGS ABDVE HAVE TORSIDNAL STOP INCLUDED THE INNER PARTS INCLUDES HUB AND 1 4 4 FOR TRANSMISSION SHIPMENT SECURE COUPLING BY WIRE THROUGH COUPLING FLANGE HOLES AND SAE FLANGE HOLES DYNAMIC TORSIONAL STIFFNESS kN m rod NOT SERVICEABLE SEPARATELY FOR TRANSMISSION CDUPLING ASSEMBLY ENGINE INSTALL CDUPLING AND HUB TD 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 ENGAGE FLYWHEEL HOUSING PILOTS AND INSTALL ALL MOUNTING 574 OR SERVICE MANUAL VALUES CAPSCREWS USING 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 PROPRIETARY NE ORMATION AAD TS GRADE 5 QUALITY CAPSCREWS PER SAE J429 TORQUED CREE RE AT NAER TWIN DISC INCORPORATED RACINE WI 53403 USA 196 0 REF 139 98 9 0 02 Ww BANS 1019735 HUB 1017471A SHAFT ASS Y 1017470A SHAFT M1990E BALL 16 2 THRU 8 HOLES EQUALLY SPACED USE 10 9 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 574 OR SERMCE MANUAL VALUES NDT SERVICEABLE SEPARATELY FO
13. pure ggg pm fasa emm e 7339 i Darse sa persne wer jew Darse ws persnr ewe 2 jew E 060 73736 XA7371G 1397 624 M2089L 2089 B3576A XA7373H_ 516 xa74708_ xa7s7iu 397 88 1 meos 3 7539 1 P XA7373Y VALVE DEPT ASS Y GROUP CONSISTS B2452A 9160 MA778 82103 A2916DK 2700 8139 Me048N 6117 STEEL ALL B1398E URIFICE PLATE 1 CHART B1399G 1 M1927ED 1 CURRENT PRODUCTION PISTON NOW OBSOLETE PISTON DESIGN PISTON ASS Y TO BE WRAPPED IN_RUST_ INHIBITING PAPER THEN BAGGED SEPARATELY AND PLACED IN THE TROLLING VALVE BAG FOR SHIPPING GASKETS TO BE_BAGGED SEPARATELY AND PLACED IN THE TROLLING VALVE BAG FOR SHIPPING ASSEMBLED BY THE VALVE ASSEMBLY DEPT PER THIS DRAWING AND STOCKED AS AN ASSEMBLED UNIT OR PACKAGED AS AN ASSEMBLED UNIT AS DEFINED UN THE BILL OF MATERIALS FOR SHIPMENT TD CUSTDMER THESE PARTS ARE BE PACKAGED SEPARATELY AND PLACED IN THE TROLLING VALVE BAG FOR SHIPMENT SEE PACKAGING NOTES NOT SERVICEABLE SEPARATELY SPACER TU BE USED AS APPLICABLE PER CHART ASSEMBLY AND TEST NOTES REFER TO XA7372 SERIES ASS Y DRAWING FOR APPLICABLE ASS Y AND TEST NOTES Ls 23814 1171 91 es e381
14. 25 fe 0 Marine Transmission Service Manual 1020667 216 Twin Disc Incorporated Illustrations Qty Description 1 1 4 4 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 E 2 gt JJ Cover bottom Pan gear Screw hex head cap gear pan to cover Washer flat gear pan to cover Screw hex head cap cover Gasket Setscrew output gear to output shaft Housing Shield oil distribution Shaft output Bearing tapered roller output shaft front Seal input oil Shaft assembly primary close coupled units Plug seal protector Screw hex head cap front housing Housing front Gasket top cover plate Screw hex head cap top cover plate Plate top cover O ring breather Strainer oil filler Ring piston primary shaft O ring primary shaft end cover plate Plate primary shaft end cover Ring external retaining primary and secondary shaft rear bearing Gear transfer primary shaft RH helix O ring output seal carrier Fitting grease Screw hex head cap output flange Washer retaining output flange Flange companion Shim output flange 0 005 0 007 0 020 inch O ring output flange Flange output Seal output oil Screw hex head cap output seal carrier Carrier output seal Shim output bearing 0 005 0 007 0 020 inch Bearing tapered roller output shaft rear Plug oil drain O ring oil d
15. 1 1 ALUM BODY 2 00 x 362 7 00 o i ET REG MAT DESCRIPTION STUCK SIZE E Dote 3 14 96 By JPL FPN Scale FULL O NAME x E SLEEVE IR RUNOUT CHECK BREAK ALL SHARP CORNERS R SHEET 1 1 DLERANGE UNLESS OTHERWISE SPECI Rj ae 5 set ra amp str ve wwe 4 2 3008 9 Bae T C CAD FILE 21302 1 CHANGE DESCRIPTION DATE Bv TWIN DISC INC RACINE VIS BOVEM o o 202 5100 LVEL L 10199104d 295 OPTIONAL GRIND 16 FLATS UP TO 20 WID ON 2 561 2 559 DIAMETER TO ALLOW EASIER SEAL INSTALLATION 5 27 4 00 10 STEEL IR 4140 SEAL INSTALLING SLEEVE 8275 x 55 MAT DESCRIPTION STOCK SIZE Date 6 7 95 By JIM T Scale NONE NAM KA 1 N N N SEAI NSTA VG VI FOR P N 1015231 SER amp 1016127 SEAL FOR ENS SHEET 1 OF 1 CAD FILE T21347 DWG WAS 2 477 2 475 2 18 95 JIM eae de DC A CHANGE JESCRIPTION DATE BY TWIN DISC INC RACINE WIS a 29902014 enuen 2914199 uoissiUsUueJ osiq UIML Twin Disc Incorporated Special Tools Oil Seal Driver T 21347 1 uu t SPAM gt Oo A EET Y mai S 22 CU e x Zt T a lt
16. 407 N m T SCREW MA1042A 4 FLUSH WITH SURFACE HYDRAULIC DIAGRAM 47119W SHEET 1 DF 2 SCREW M2000L SPOOL 1017433 2 A ATMOSPHERIC PRESSURE Ae ATMOSPHERIC PRESSURE OBSOLETE FOR PRODUCTION M E T R I C LP INTERMEDIATE PRESSURE AND SERVICE e THIRD ANGLE RIES ELUTEE PRESSURE A NOT SERVICEABLE SEPARATELY THESE PARTS ARE BE PACKAGED SEPARATELY AND SHIPPED WITH UNIT NOTICE THIS PRINT CONTAINS UNLESS OTHERWISE SPECIFIED PROPRIETARY INFORMATION AND IS BE USED IN ANY MANNER x 30 75 CORPORATED STR D RING 1506149 WI DETRIMENTAL TO THE INTERESTS OF 20 25 ACIE VE 53803 USA MAIN PRESSURE DIL INLET WHEN TWIN DISC INCORPORATED 1013 acm ta sts a BSA re Se Bates 1018084 MODEL MG Se0eDC PER ANSI 145 1982 1 4 18 WHEN M2052AA d THIS NOTICE IS INTENDED ee REDUCER BUSHING IS SPECIFIED PP VALVE ASS Y CONTROL SERIES OR OTHERS BY CONTRACT WITHOUT TROLLING VALVE pas sur 1 nr 1 GASKET 1017555 PLATE GASKET 1017130 O T T E 829117 24 99 29015 12 17 98 0 1 2 28585 6 3 98 J e 30e89 8 30 00 aL 28500 4 20 98 CAPSCREW MA1042B 2 6 4 THRU ONE HOLE CRUISE MODE DETENT MAX TROLLING 70 75 TROLLING RANGE MIN TROLLING PRESSURE NO TROLLING PLATE IS NOT INCLUDED IN ASSEMBLY USE EXISTING P
17. e weoesav 5244 1 4 DRILL SEE NOTE 3 204087 1 Mi731aF 1 4 M20sik __ 1 7 16 2013410 1 M1990E ___ 83574 M2087K 2086 778 1867 POSITION B2297A 2 POSITION A2916AT 2nd CLUTCH ENGAGED FOR 3 POSITION CPRIMARY NEUTRAL SECONDARY USE F R 7512 amp XA7512A MGS16 0 PORT 1 IS ENGAGED AND NEUTRAL IS DISENGAGED S 55 7 4347J M1927B B1334A SEE CHART 131 2 1156 160 DRILL GASKET SURFACE 3 28 2 25 184 PORT FOR 69 R 2nd CLUTCH HOLE MUST 186 MIN 44 BE LOCATED IN THIS AREA IN MATING PART FOR CLUTCH DRAIN ib a j DATUM section C C SECTIUN 25 E XA7361B VALVE BODY AS USED FOR HOSE INLET THRU PORT X XA7361B CONSISTS OF A7361B VALVE BODY AND 1945 CORE PLUG A7361B VALVE BODY AS USED FOR FACE PORTED VALVE INLET HERE R 66 R nu 2 9 Ou 4 24 PURT F R 1st CLUTCH 7 16 DRILL 2 HOLES eal SSS 1 4 18 TH D PRESSURE GAUGE LINE LOCATION WHEN 2051 PLUG IS SPECIFIED AT X SHAS Y Nd YN SDN TT TEST VALVES PER TEST SPEC CONTAINED IN VALVE SPECIFICATION INSTALLATION DATA SEE CHART
18. CUSTOMER TO INSTALL PRESSURE GAUGE LINE HERE PRESSURE GAUGE TO BE MOUNTED IN PILOT HOUSE CSEE MARINE TRANSMISSION INSTALLATION DRAWING ro A A A M E XA7371W LUBE RELIEF VALVE MARINE 100 psi TRANSMISSION CONTROL VALVE SHOWN IN NEUTRAL Ss SSOa m ea aN RN rer A SSS N 2 OPTIONAL AUXILIARY LUBE SYSTEM USER TO SUPPLY COMPONENTS AND TO INSTALL OPTIONAL TROLLNG VALVE REF 7372 AND XA73730 2 2222222 2 A poop IRR OPTIONAL TROLLNG VALVE SS REF XA7372T AND XA7373Q LUBE HOSES TO MEET REQUIREMENTS OF SAE 517 FOR 10 HOSE SELF EXTINGUISHING AND FIRE RESISTANT UIREMENTS ALSO IDENTIFICATION REQUIRED BY THE U S COAST GUARD AS SPECIFIED IN CODE OF FEDERAL REGULATIONS 46 CFR 56 60 25 gt 250 psi MARINE TRANSMISSION 27 CONTROL VALVE G N ASS 1 1 1 1 Eu lt NE EY lt lt 5555 lt lt lt lt AWN ES NN foo MEME REMOVE 20510 1 2 14 NP TF SS PLUG FRDM MANIF LD PER INSTALL LUBE LINE TU DIRECT LUBE FLOW INTO TRANSMISSIUN HYDRAULIC CIRCUIT CUSTOMER SUPPLIED HEAT EXCHANGER AND LINES FILTER INSTALLATION BY PASS DRAWING 20 psi Ir LL P p LLN 5 8 DIA MIN I D HOSE lt lt 9 f SECONDARY SHAFT 55 M FRONT amp REAR BEARING PINION amp CLUTCH LUBE SHOWN DISENGAGED 25 MICRON FULL FLOW FILTER CUSTOMER SUPPLIED HEAT EXCHANGER AND CONNECTION LINES R
19. ma SEE CHART 314008 1 SEE CHART 1 a2703P__ 1 1 Meo 4 B1333D 813995 1 SEE NOTE 4 SEE CHART Ole SEE CHART 1 Al Bi398E 2 SEE CHART 1 SEE CHART 1 0 SEE CHART 1 79 DIA HOLE MUST BE LOCATED IN THIS AREA IN MATING PART TORQUE CONVERTER OR BEARING SOR og ms ox A 12 MIN LOCATED IN FOR LUBE EXCEED 80 P S I 1 VALVE SUITABLE FOR UP 25 GPM 2 CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 30 AND 90 P S I DEPENDING UPON SPRING ASS Y USED G P M THRU VALVE AND INTERMEDIATE PRESSURE 32 4 14 lbf AT THE 220R LOCATION OF THE 1 4 DIA HOLE IS REQUIRED TO OVERCOME DETENT EFFORT REMOTE CONTROL_VALVE ACTUATOR MUST PROVIDE tae LINEAR TRAVEL FROM NEUTRAL AT THE 1 4 DIA HOLE LOCATION WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT SPRINGS AND BALL MAY BE OMITTED THEN THE FORCE WILL BECOME 3 7 LBS THE DETENT FEATURE IS PROVIDED IN THE FULL 1st CLUTCH ENGAGED FULL CLUTCH ENGAGED AND NEUTRAL LEVER POSITIONS 4 TORQUE MOUNTING BOLTS 30 36 LB FT AS RECEIVED 5574 DR 25 29 LB FT LUBRICATED PER 55742 AFTER TORQUING MOUNTING BOLTS INSTALL 20260 PLUGS IN MOUNTING BOLT COUNTERBORES DIA SECTION D D GASKET HOLE MUST THIS AREA IN MATING PART F R VALVE DRAIN 13 32 DRILL THRU 4 HOLES FOR MOUNTING BOLTS
20. 15 00 15 00 MDUNTING PAD 6 51700 2224 7277 FOR PRODUCTION REPLACED BY 1017463A FOR SERVICE 251 00 RACINE 1017463 MARINE TRANSMISSION SEE SHEET 1 FOR MAXIMUM TRANSMISSION R P M THE WR OF INNER PARTS INCLUDES HUB AND 1 4 SHAFT C DYNAMIC TORQUE TORSIONAL kN m STIFFNESS kN m rad o 194 125 99 e 21 375 39 50 40 COUPLING A 1016215 ELEMENT MAIO41E HEX CAPSCREW 16 MA947D NUT 16 1016520 HUB SPLINED 1017471 SHAFT ASSY 01017470 SHAFT 1990 BALL SEE NOTE 7 SEE NOTE 1016217 ELEMENT sac i TORSIONAL gm kg ALL COUPLINGS ABOVE HAVE TORSIONAL STOP INCLUDED FOR TRANSMISSION SHIPMENT SECURE COUPLING BY WIRE THROUGH COUPLING FLANGE HOLES AND S A E FLANGE HOLES O NOT SERVICEABLE SEPARATELY COUPLING J 9 THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 574 OR SERVICE MANUAL VALUES 0 HOUSING 1019699 COUPLING FLYWHEEL OUTLINE MUST CONFORM TO J620 ND 460 M SS EEEE 1048 SNAP RING OS x 1019698 COUPLING K 9 THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER 150 898 1 AND TORQUE TO S574 OR SERVICE MANUAL VALUES COUPLING D COUPLING WR COUPLING TORSIONAL e wes peaa ewe
21. 7072 27072 427037 725 eso 10171294 0 BessiB 6 51700 42 d USE AS o is us m w w 69 z z A1062 THESE SOLENOID CONNECTIONS ARE NOT POLARITY SENSITIVE SETSCREW M2038W SPRING 270280 2 HYDRAULIC LOCK 3 eo PIN 2711 2 SPOOL 1017432 2 NITE HYDRAULIC LOCK ONLY D HYDRAULIC LOCK ONLY LEVER MAY BE LOCATED ANYWHERE PLUG MA1038E 2 ON ITS SHAFT THAT PERMITS FREE x MOVEMENT WITHIN THE 50 CTOTAL gt RADE PISTONE SEESCHART e E GASKET B1334C COVER ASSY 1017336 SPRING A2705AH 2 BALL 19906 2 TORQUE To 325 Ma CHART PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND CARRIER 1017335 PIN A2711R 2 BALL Mi990L 25 0 lbf Ft HYDRAULIC LOCK OPTIONAL CONDITION BUE OR WITHOUT WIRING DIAGRAM OPTIONAL HYDRAULIC LOCK BALL MI990M SCREEN 221336 MATING WIRING HARNESS 1017404 l M8 X 125 6 2 CONNECTOR SERIES SPECIFY LENGTH HOLES SPRING ASSY THY yF 172 PORT SOLENOID 9 MANUAL OVERRIDE NJ SS 5555 55 aah VALVE BODY ASSY 1017444 PORT Foren Mito EA 2 E 72 ELECTRIC CONTROL POSITION POSITION BODY 443 N lt 5 B
22. Check the torque required to overcome the detent The torque should be 1 1 1 7 Nm 10 15 in Ib Adjust the detent setscrew 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 1020667 Twin Disc Incorporated Assembly 16 Install the steel ball onto the neutral pressure regulating spring Figure 133 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 134 Installing Orifice Plate left and Trolling Valve Onto Valve Body right Marine Transmission Service Manual 1020667 163 Assembly Twin Disc Incorporated Installation of Transmission External Components 1 Install control valve ditch plate and gasket units w
23. AUTDCAD 29 02 AZ nr Js 4 p ry X E 20 c3 Pas L gt 21 Y Y 2 RS 254 i sailed 6 38 5 75 pu 4 ji 1 amp x4 5 9 31070 0 9 STAMPI TOOL NAME TRANSFER GEAR DRIVER DATE 9 28 84 1000 T 18050 335 TWIN DISC INC AUTOCAD FILE T 18050 335 BY RS PART A7455 7473 193 Marine Transmission Service Manual 1020667 00 11 31 3 9 25 es 5 P 2 SES lt 2 P N is V 4 00 DIA im e o DIA 6 73 rd P 5 j L 931 Z DR THRU DET 2 amp TAP DET 3 FOR 172 13 SUC HD SCR D 3 o 3 o 0 5 o __ 3 1 CRS ANDLE 11 2 DIA X 9 1 2 L0 z 2 1 me DRIVER 7 DIA Ve uc e 1 1 STK SHCS 1 3 K 2 B 4 LG DET REG DESCRIPTION STOCK SIZE c DATE 19 BY R S FULL 2 BEARING DRIVER B 003728 SHEE 1 ool UU S ct T 180 5985 SUANGE MN DATE BY WIN DISC INCORPORATED RACINE WIS 18050 585 o o 5100 25 0 UIML 29902014 enue y 3914195 uoissiusueJ SUNEN 150 DIA REQ p 2 00 4 06 x 30 ON REF 400 DIA
24. 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 Ib 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 1020667 157 Assembly Twin Disc Incorporated 22 Install pressure regulating springs into valve body and into piston spring pocket 23 Installthe shims that were removed into the bore of the rate of rise piston Install the rate of rise piston over the springs and into valve body 24 Install neutral pressure regulating spring into the pocket of valve body Figure 127 Neutral Pressure Regulating Spring Location 25 Installthe orifice protection screen into the valve body Figure 128 Installing Screen 26 Install orifice plate gasket onto valve body 27 Install orifice plate and steel ball against spring onto valve body 158 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 28 Install orif
25. O RING 291600 RING 29168 SHIM 2057 5 PIN PM 3036 M INSERT SPRING A2701BN OVER ROLLPIN 3036 UNTIL FIRST SPRING COIL REMAINS LOCATED AGAINST STEM FACE SPRING A2701BM 9 SPRING A2701BN BOM NO 40588 M8 X 1 25 TH D 19 1 DEEP 2 HOLES GREASE APPLICATION PROCEEDURE BEFORE INSTALLING VALVE STEM INTO BODY APPLY GENERAL PURPOSE GREASE PER 5 564 6 NO 1 NLGI CONSISTENCY TO THE VALVE STEM FROM THE O RING GROOVE TO NECKED DOWN DIAMETER AT LEVER END MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm d MACHINED DIMENSIONS X 0 75 HEAT TREAT FIRST USE assy 1017546 VARIOUS SIMILAR TO NOTICE THIS PRINT CONTAINS NOT TO BE USED_IN ANY MANNER RACINE WI 53403 USA THIS NOTICE IS INTENDED TU NULLIFY DR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT GEOMETRIC TOLERANCING PER ANSI Y14 5M 1982 8671 ALL ANGULAR TOLERANCES 1 THIRD ANGLE PROJECTION 5530 97 TJIN 503 INCORPORATED 1017555 A SURFACE TREATMENT NAME BE ASSY TROLLING O uo 7 Oo CONNECTOR SHROUD 1001426 CLIP 1017322 I 40 00 _ 70 00 GASKET 1017334 PLATE GASKET 1017130 9 00 988 00 NOTICE THIS PRINT CONTAINS PROPRIETARY a ia ae AND IS NOT T USED IN ANY MANNER DETRIME
26. 1 ORFIEPRLAE 000000 TOP VIEW _ 3 NYI NS BALL Pe O N INN 15 SPRING 1 NEUTRALPRESS REGULATING _____ 77 Z 16 oRNG RING eee ae A 47 WASHER 5 a Pee 21 __ ANN 23 casser PORT B SOLENOID NS SSSA 9 24 THRUSTBEARING 1 THRUSTWASHERONEARLIERUNITS uer rem 26 __ 2 uwrswmHHYDiOCK ________ 27 switch 1 MANUALOVERRIDENEUTRALSTART pue 2 MAINPRESSURE PORTS 29 screw 4 SOCKETHEAD 30 CONNECTOR SHROUD 4 UNITS WITH HYD LOCK y ES X YYW 2 PLUG ASSEMBLY AL 22222 7 722 T IET ZA rte uk 222222 ALZA 7 27 EIS 8 2 switch 1 33 screw 4 __ SOCKETHEAD pare 35 2 1 __ o 1 1 40 sotENOD 2 S3REQD FORUNTSWITHHYD LOCK 4 sBuL 1 sum S S 42 one sa 1 45 sereen 00 0 0 0 0 0 0
27. 2089 3 CLOSURE 2067 3 5 2001 4 SPRING A2703P GASKET B1398E 2 BALL M1990H COVER B1333D PISTON B1399C SHIM B2334 AS REQ D PLATE B1397D SPRING A2707BD SPRING A2704BU SPRING A2702BC PISTON B1400B SCREEN 2261 TUBE ASS Y XB6238A TUBE B6238A FLANGE MA818J RING A2916W SPRING 201341JV RING A2916DN PLUG 2080 GASKET 2135 CAPSCREW M2001H 3 COVER Be133 SPRING 204368A POPPET 204367 FILTER B3614A LABEL MA950A SEE NOTE 12 TUBE 1017162 CAPSCREW 2001 22 WASHER 428886 2 BALL M1990Q SPRING A2706AC HOUSING 929 TWIN DIBE INCORPORATED RACE WE 1017463 meee MG 5170DC Pons ser Dev ii RATE OF RISE FUNCTIONS CONTROL TROLLING VALVE DETENT lt TROLLING FEATURE OPTIONAL MAX TROLLING PRESSURE 1 4 6 THRU TROLLING VALVE MIN TROLLING PRESSURE CONRTOL VALVE NO DETENT THE TROLLING LEVER ANGULAR LOCATION MAY BE ADJUSTED SO THAT THE 90 LEVER ROTATION REQUIRED FOR CONTROL FALLS ANYWHERE WITHIN THE 360 RANGE IN WHICH THE LEVER MAY BE LOCATED OPTIONAL TROLLING VALVE INSTALLATION AND OPERATING NOTES 1 REFER TO VALVE ASSEMBLY DRAWING FOR ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK TROLLING VALVE CONTROL LEVER IN DETENTED NO TROLL POSITION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT
28. N 017 2 lt 4 A BALL weer ey D PLATE SEE CHART A P lt BALL M1990Y 6 4 THESE SOLENOID CONNECTIONS j S SERIO Sii sedibus A ARE POLARITY SENSITIVE SY COVER 1017128 ac 2442 ior Mo Z VALVE GASKET 10171368 T ig SSS S cp WS SSS 6 NNI 2 d at M EL UNS 2228 02 SN N S SS P 5 Y 55 J CONNECTOR SHROUD 1001434 STEM 10181638 442777177 i 7777 88 7 8877 D RING MA379CP 2 A LH 1 D RING A2916FT hs bt GASKET 1017130 2 24 v SEE CHART X SNAP RING 29155 DAL S MISSUM PLUG 1017389 PORT BY POSITION SCREW 1042 4 x SPRING A2702T 5 B B sem C C 5 SPRING 1801 SHIM 1020005 5 REG DO HALL E SETSCREW A2870K 9 E VALVE BODY ASSY 1018095 DY RING 42916 DITCH FUATE SEE CHART 2 ch vd A BODY 1018094 SPRING 2705 WASHER A2782AS SCREW SEE CHART BALL 1034 E BALL MA1034D 2 n SEAT 1017584 BALL MI990H SECTION BALL 1990 52 MAIN PRESSURE PICKUP PORT SWITCH MA866A 2 M PORT 1 4 18 NP T F DRYSEAL TH D NOTE AG READ SEALANT arts INSTALL USING MA908 lt LOCTITE PORT A 242 TOP OF SCREW MUST BE TORQUE TO 30 0 lbf ft NUT 2027
29. Ru SECUNDARY SHAFT FRO amp REAR BEARING amp CLUTCH LUBE SHOWN DISENGAGED NIUN POR TION NCLOSED WITHIN THESE LIN 25 S REQ D us PTIDNA YD P T D A S d MARINE TRANSMISSION CONTROL VALVE Figure 21 Hydraulic Schematic electric control valve Marine Transmission Service Manual 1020667 pee Se e dedii oeil 51 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 52 Marine Transmission Service Manual 1020667 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 i
30. WITHIN 008R OF TRUE POSITION AT MMC IN RELATION TO DATUM OIL INLET A7361B VALVE BODY ONLY SEE SECTION C C p 4 28958 1 21 99 es ersse 8 8 97 _ lee 6 13 96 8 21 95 NOTICE 5 16 94 wo TU NUI GRANTED BE USED IN ANY MANNER DETRIMENTAL THE INTERESTS DF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT_INTENDED OR OTHERS BY CONTRACT ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE INTERMEDIATE PRESSURE CLUTCH PRESSURE MATERIAL WEIGHT vet 28 LBS LBS IN HEAT TREAT FIRST USE assy SEE CHART THIS PRINT CONTAINS SURFACE TREATMENT 1 THE U S GOVERNMENT VALVE ASS Y CONTROL SECTION E URIFICE PLATE e GENERAL NOTES V REMOVE BEFORE OPERATING UNIT ALUMINUM THREAD PROTECTOR XA73 1 SERIES APPD SHEET oF 1 Z flle nome XA7371 ORIFICE VALVE SPRINGS PLATE coar 7 spring CONSISTS DF ART NO SIZE DUTER CENTER INNER 15 CLUTCH ENGAGED FOR POSITION FWD NEU REV USE ENGAGED FOR 2 POSITION ENGAGED amp DISENGAGED USE MaxLe5 THD MC x 20 ISD 6149 THD OIL INLET WHEN M8067R TH D MA1038E O RING PLUG 55 9 WHEN SPECIFIED W PROTECTOR IS SPECIFIED NEUTRAL FOR 3 L POSITION FWD eee 36 50 NEU REV gt USE GASKET DISENGAGED FUR TEST VA
31. 1017510 SPRING ASS Y XA2703BD 32 THESE STANDARDS APPLY SPRING A2703BD S574 FASTENER TORQUE REQUIREMENTS 5 SPRING A2701BG S692 BEARING SHIMMING 4019017 B2501 SEE NOTE 5 1 2501 S765 TAPERED JOINT ASSEMBLY CAPSCREW 2004 122 RETAINER 616 2 RING M1904L 22 A RING Me693E 2 GEAR 47475 e BEARING MA217D 2 PLUG 2080 RING A2916KD RING M1904AQ 2 RING Ae916DP 2 PLUG 1945 PART NUMBERS F R 7772 4 lt 4 AVRO o SS ZZ PLATE 1015518 SHAFT ASS Y 1017474 SHAFT 1017473 RING 2915 25 BALL 1990 ASSEMBLE TAPERED EDGE lt gt SN SN SEE 8 SIDE AWAY FROM BEARING RING M2693F 2 yZ h PUMP XB6239A 5 RING B1048BC 2 N E e 2 ee CONE ASS Y MAS8SFUC2 gt CUP 590 1 22 e GEAR 47473 lt Nj Y NN SEAL 1016127 IS SEE NOTE 5 S M S lt RING A2916BD i GASKET B3617 FITTING 268 RETAINER 1017570 2 CAPSCREW 2007 4 PLATE 6231 BEARING M2321 2 RING 1904 2 RING 426694 lt 2 WASHER B1504KU PIN A2711A 2 fad LMM J SHIM 1017362 PISTON B6232 2 SHIM 1017365 AS_REQ D 113 SHIM 1017362B SEE NOTE 9 HOUSING 1015018 PLATE 206106 18 65 0 CONE ASS Y 585 PLATE 206107B 16 f CUP 59
32. 81337 1018688 7 1 vnc xee7ozz 2 we1oSeK 2 52025 Ss 018084 41171 a2703T 1725 250 1017129 1 8 x amp o ew Be4S1B MG 5170DC 14955 hoisosaa 41172 1018688 82703 1725 50 10171298 10 8 x 24 6 B2451B 5 7 0 82255 Az703T 725 5 10171294 MetessEoer x 0 MITICAH 2 7 wc 540 1018688 e vacl xA27072 no sen 24 Boigog4aN 4196 1017179 759 24 2707 2703 1860 eo 1017129 038 x 824518 5 5 45 01808448 41195 1017179 75 voc 270740 2703 860 270 10171294 x 4 24518 o we s141sc RGYATIDN AXIAL MOTION BEARING Me087AD ese SA IT UNEC Inecesan aga 7383 1017179 ves uersordes saret ezu 2450 255 10171290 x 5 45 REQUIRED FDR CONTROL RACE M2086R ARE PDLARITY SENSITIVE 101808445 41718 1018688 ves xwe7sorMe4 voc
33. F STATE MIN ALSO MAX L min gpm OF WATER FLOW H E HE INSTALLATION amp SERVICE REQUIREMENTS IIL LINES TRANSMISSION H E AND RETURN gt MAX VELOCITY IN FITTINGS PIPE HOSE AND TUBES 7 6m s 25ft s 2 BURST PRESSURE MIN 10 x PEAK OIL PRESSURE 3 HOS SAE J517 10081 MEETING USCG 46CFR 56 60 25 C 135 C 275 F TEMP RATING 4 PROTECT LINES FROM MECHANICAL DAMAGE ZINC ANDDES PROTEC LE RAW WATER PASSAGES FROM CORROSION CHECK amp REPLACI HEM FREQUENTLY MAY BE IMPUSSIBI R IMPRACTIC HEAT EXCHANGER SUITABLE FUR MAIN 183 F gt MAX UIL TEMPERATURE R CLOS NGINE JACKET WATER COOLING Figure 2 Heat Exchanger Requirements 22 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Description and Specifications Specifications Maximum operating speed 2500 rpm Maximum oil sump temperature 93 C 200 F Oil type and viscosity See data plate below Oil capacity 28 liters 7 5 gal plus hoses and heat exchanger Oil Pump 53 4 liters per minute 14 1 GPM at 1800 RPM Approximate Dry weight 849 kg 1870 Ibs Oil pressure See Table 1 for oil pressure specifications Minimum oil pressure when cruising is 1620 kPa 235 psi Z MARINE TRANSMISSION IBRICANT OIL SERVICE CLASS USE SERVICE 8 ASS CD ENGINE 01 CERTIFIED BY VENDOR
34. Suction niin 212 UB Fe 213 Transmission Rear 214 Transmission Section View eese 216 Torsronal 218 Manual Control Valve 221 111 1 nennen nennen nennen nnns 220 Trolling Valve for Manual Control Valve 222 Electric Control Valve me 225 Trolling Valve optional equipment 227 Engineering Drawings 229 List of Engineering Drawings eene 229 1017463 sheet 1 of 4 Marine transmission 231 1017463 sheet 2 of 4 Marine transmission 232 1017463 sheet 3 of 4 Marine transmission 233 1017463 sheet 4 of 4 Marine transmission 234 1017463A sheet 1 of 4 Marine transmission 235 1017463A sheet 2 of 4 Marine transmission 236 1017463A sheet 3 of 4 Marine transmission 237 1017463A sheet 4 of 4 Marine transmission 238 239 XA7371 Mechanical Control Valve 1017463 asse
35. Use a depth micrometer to measure from manifold gasket face to shim retainers Measured distance is shaft endplay 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 Install calculated shim pack at each shaft location with the thickest shim against bearing cup followed by the remaining shims and finally the spacer against the shims at each shaft Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly Assembly and Installation of Manifold 1 Install new O rings onto the 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 24 Nm 18 ft Ib Apply pipe thread sealant to the 1 2 NPTF plugs and install them into the manifold torquing them to 68 Nm 50 ft Ib Place new O rings onto the two O ring plugs and install them into the manifold side opposite the oil filter boss torquing them to 54 Nm 40 ft Ib Apply pipe thread sealant to the 1 4 NPTF plug and install it into the manifold below the oil filter torquing it to 34 Nm 25 ft Ib Apply pipe thread sealant to the 3 4 NPTF plug and install it into the manifold above the oil filter torquing it to 73 Nm 54 ft Ib Assemble and install filter bypass valve components Torque the screws to 20 Nm 15 ft lb Figure 102 Installing Filter Bypass Valve Components Apply a coat of assembly grea
36. 0 0 0 0 4 t1 0 0 0 0 5 az caser 1 vAVvEBOYHAF 48 1 SOME MODELS GASKET so 1 o 1 SCREW EE SOCKET HEAD PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND HYDRAULIC LOCK OPTIONAL CONDITION A A SECTION uz NG AT Y 2 N NUT 2 2 55 CONNECTOR SHROUD 1 UNITSWIHOUTHYD OCK SECTION D D 56 O RING UNITS WITHOUT HYD LOCK O RING UNITS WITHOUT HYD LOCK 1 UNTSWTHOUTHYD LOCK 2 UNTSWTHOUTHYD LOCK 1 RORORIFICEPROTECTION 1 COVER SIDE UNITS WITH THRUST BEARING 62 THRUSTRACE 1 STEMSIDE UNITSWITHTHRUSTBEARING Illustrations Twin Disc Incorporated Notes 226 Marine Transmission Service Manual 1020667 REMARKS SOCKET HEAD DOG POINT HEAD OME MODELS UTER INNER e 5 co 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 N LONS 27222 Y E Sol 221 7 2 QE SECTION SECTION
37. 1 4 18 34 25 22 3 8 18 37 27 23 17 1 2 14 68 50 41 30 3 4 14 73 54 46 34 09 114 1112 112 1112 Marine Transmission Service Manual 1020667 31 Description and Specifications Twin Disc Incorporated Table 7 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal Ib ft Ib ft Thread am or 5 Thread or im Or 596 Diameter Diameter wen w we w 9 _ ECC UK m 32 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Operation Operation General The control valve obtains primary neutral and secondary 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 1020667 33 Operation Twin Disc Incorporated Hydraulic System with Manual Control Valve 34 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 Lubricati
38. 3574 1 M1990H M2086AV 427021 MIN TROLLING M2087K 1 SEE CHART PRESSURE 222 158 68 NO TROLLING POSITION MIN TROLLING PRESSURE MA1038B 2013410 1 M1990E 1020005 e AIE ee I Wey RLY EH 2000 3036 1 EP Zi B n Li 10781 1 2305 51 2 IE 2041 A 2701 B 81883 LU n p TI i 4 A 2701 B 4 N SS SS S P 10504 1 i x 9 57699 gp SS ell DANYA 10491 A2916AT _ d 4 8992 lt GASKET SURFACE CETT SECTION SECTION Ai IN CU section B B SEE CHART MANUAL TROLLING VALVE CERES METRIC A ATMOSPHERIC PRESSURE 10481 2 THIRD ANGLE ATMOSPHERIC PRESSURE 814008 1 e PROJECTION I P INTERMEDIATE PRESSURE SIMILAR TO CLUTCH PRESSURE PX10790 pac _ GENERAL NOTES omaso aemm 83 01 TAI 238 REMOVE BEFORE OPERATING UNIT SECTION DETRIMENTAL THE INTERESTS OF fco 825 ue ee a THREAD PROTECTOR EX TWIN DISC INCORPORATED n hee 4020413 Nees ar PRN NOT SERVICEABLE SEPARATELY RACINE 53403 USA MG 5222Dc W Russel THESES PARTS ARE TO BE PACKAGED THIS NOTICE IS NOT INTENDED p e ec 1 0 2 0 4 1 5 SEPARATELY AND SHIPPED WITH UNI
39. 54 C 130 Marine Transmission Service Manual 1020667 25 Description and Specifications Twin Disc Incorporated Companion Flange Assembly The 1017494 companion flange assembly consists of the companion flange as well as the 8 bolts and nuts to secure it to the marine transmission s output flange Trolling Valve Several trolling valve kits are available for use with this transmission The XA7371 control valve uses the XA7373Q trolling valve which is mechanically actuated The 1020412 control valve uses K1331 which is mechanically actuated The 1018084 and 1017172 control valves use BOM 40588 which is mechanically actuated or BOM 41063 which is electrically actuated 26 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Description and Specifications Table 2 Gear Advance Transmission Primary and Secondary Transfer Gear Advance Minimum 1 96mm 077 in Transmission Out Maximum 2 97mm 117 in put Gear Advance Minimum 3 35mm 132 in Maximum 4 42mm 174 in Table 3 Bearing End Play Transmission Primary and Secondary Shaft Tapered Roller Bearing Endplay Minimum Maximum Transmission Output Shaft Bearing Endplay Minimum 0 05 mm 002 in Maximum 0 15 mm 006 in Marine Transmission Service Manual 1020667 27 8c Su BS mum x suoneoyioeds uonej eisu uoissiusueJ SULLY OZLS DIN p Z990ZO
40. 75 Disassembly Twin Disc Incorporated Remove Clutch Assemblies 1 Remove primary shaft end cover plate and O ring Figure 31 Removing Primary Shaft Cover left and O ring right 2 Remove manifold attaching screws Install two of the removed screws into the pusher screw holes near the dowel pins Tighten the screws alternately and evenly to push the manifold off of the bearing carrier and dowel pins Remove the manifold and gasket qun nrar una REP 41 Figure 32 Using Pusher Screws To Remove Manifold 76 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 3 Remove the bearing spacers and shims from the bearing bores of the bearing carrier Mark the shims and spacers for location identification F Figure 33 Removing Spacers and Shims 4 Remove the lubrication tube from the bearing carrier Figure 34 Lube Tube in Bearing Carrier left and Removing Tube right Marine Transmission Service Manual 1020667 77 Disassembly Twin Disc Incorporated 6 Install two of the removed screws into the threaded pusher screw holes of the bearing carrier near the dowel pins Tighten the screws alternately and evenly to push the bearing carrier off of the housing and dowel pins Remove the bearing carrier and prevent the bearing cups from falling out of the bores Figure 35 Using Pusher Screw To Remove Bearing Carrier 6 Remove the bearing cups from the bearing carrier Mark t
41. Add oil if necessary to bring the oil level up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the 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 1020667 63 Preventative Maintenance Twin Disc Incorporated 64 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 W
42. B B Illustrations Twin Disc Incorporated Notes 228 Marine Transmission Service Manual 1020667 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 1017463 sheet 1 of 4 Marine transmission 1017463 sheet 2 of 4 Marine transmission 1017463 sheet 3 of 4 Marine transmission 1017463 sheet 4 of 4 Marine transmission 1017463A sheet 1 of 4 Marine transmission 1017463 sheet 2 of 4 Marine transmission 1017463A sheet 3 of 4 Marine transmission 1017463 sheet 4 of 4 Marine transmission 7119 Hydraulic diagram XA7371 Mechanical Control Valve 1017463 assemblies 1020412 Mechanical Control Valve 107463A assemblies XA7373 Trolling Valve for XA7371 Control Valve 1020413 Trolling Valve for 1020412 Control Valve 1018084 Electric control valve 1017555 Valve assembly mechanical trolling 1017554 Valve assembly electric trolling 1016473 Electric trailing pump Marine Transmission Service Manual 102066
43. Entry Passage B Oil Pressure Chamber C Oil Pressure Overflow Port D Engaging Passage E Oll Engaging Passage F Oil Interconnection Slot G Oil Directional Port H Connection Port J Oil Pressure Passage Directional Port L Oil Pressure Chamber F 8 HIGH PRESSURE REGULATOR PISTON RATE OF RISE PISTON CONTROL VALVE LEVER PISTON SPRINGS CONTROL VALVE STEM CONTROL VALVE BODY 2 ATMOSPHERIC PRESSURE I ENGAGING PRESSURE 6 Figure 11 Control Valve Secondary Sectional View SECONDARY CONTROL VALVE BODY TO PRIMARY CLUTCH TO SECONDARY CLUTCH CONTROL VALVE STEM 0 ATMOSPHERIC PRESSURE Im ENGAGING PRESSURE Figure 12 Control Valve Secondary Cutaway View Marine Transmission Service Manual 1020667 41 Operation Twin Disc Incorporated Hydraulic System with Optional Electric Control Valve 42 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
44. INDICATING SWITCH NOTE CUSTOMER INSTALL IN A 1 X 1 X 1 PIPE TEE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSION ALL PAINTS QVOILARLE FOR TES TING ARE PUMP THE HEAT EXCHANGER INLET WITH A 1 X 1 2 REDUCER BUSHING FOR THE TEMPERATURE SWITCH CONNECTION REFER TO HYDRAULIC DIAGRAM CONNECT DIL PRESSURE GAUGE HERE MOUNT GAUGE IN PILOT HOUSE 1 8 27 NP T F EXTERNAL TH DXODRYSEAL AT DIL GAUGE 15 THREAD PORT CONFORMS 150 6149 AT OIL SENDER LOCATION LUBE PRESSURE 9 16 18UN 2B TH D PER SAE J514 O RING CONNECTION EYEBDLTS FOR LIFTING MARINE TRANSMISSION 2BOLTS ONE au EACH SIDE EQUALIZE LDAD BOTH EYEBULTS LIFT MARINE TRANSMISSION ONLY PRIMARY CLUTCH ACTUATING PRESSURE 9 16 18UN 2B TH D PER SAE J514 D RING CONNECTOR 8 24 EYEBOLTS RH ENGINE ROTATION DRIVING THRU PRIMARY CLUTCH ALTERNATE DIL GAUGE POSITION GREASE FITTING RH ENGINE ROTATION DRIVING THRU SECONDARY CLUTCH 15 00 MOUNTING PAD NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 15 TO BE USED IN ANY WANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE VI LT ZZ 101 7463A 10 008 mm 7 Micon ser Sor 4 e COUPLING A COUPLING J THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 5574 SERVICE MANUAL VALUES SAE
45. Incorporated Assembly 3 Install O ring in groove in O D of output seal carrier Figure 85 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 18050 321 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 Marine Transmission Service Manual 1020667 123 Assembly Twin Disc Incorporated C Pack area between the seals with water pump grease Figure 86 Packing Cavity Between Output Seals With Grease D Install grease fitting if not previously installed 5 Install established shim pack aligning screw holes of shims with threaded screw holes of transmission housing Figure 87 Installing Shim Pack left with Holes Aligned right 124 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 6 Install assembled output seal carrier onto housing Install attaching screws and torque to 122 Nm 90 ft Ib Figure 88 Installing Seal Carrier Marine Transmission Service Manual 1020667 125 Assembly Twin Disc Incorporated Assembly and Installation of Primary and Secondary Shafts 1 Assembly of transfer
46. MA1034C PLUG MA1040E SPRING A2706W TN y 5 N ARLE AN AUN FILTER 3614 LABEL 950 SEE NOTE 12 TUBE 1017162 CAPSCREW 2001 WASHER A2888G 2 BALL M1990Q SPRING A2706AC HOUSING 929 FILTER BYPASS VALVE AND RELIEF VALVE NOTICE THIS PRINT CONTAINS MATERIAL PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA HEAT TREAT THIS NOTICE IS NUT INTENDED LLIFY DR LIMIT RIGHTS TU NUI GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT THIRD ANGLE PROJECTION SIMILAR WEIGHT wr UNLESS OTHERWISE SPECIFIED DATE mene meses 3 4 02 MISS SERS IN 0030 SCALE INCORPORATED FIRST USE XXXX 0005 50 1 00 RACINE 53403 USA ALL ANGULAR TOLERANCES i DRN ASSY WR GEDMETRIC TOLERANCING usse MODEL PER ANSI Y14 5M 1982 ISURFACE TREATMENT NAME M ARINE 1017463A MG 5170DC transmission HOUSING SAE 1 USE HARDENED FLAT STEEL WASHERS Raw 61 MIN UNDER SCREW HEADS Nis SEEN N ch N HOUSING SAE 0 CENTER OF GRAVITY 3 4 10UNC 2B TH D 112 DEEP 14 HOLES 7 EACH SIDE USE ALL FOURTEEN 14 HOLES FOR MOUNTING UNIT USE GRADE 8 QUALITY CAPSCREWS PER SAE J429 AND TORQUE 574 OR SERVICE MANUAL VALUES DIL IN FROM HEAT EXCHANGER 1 11 1 2 NP TF TH DXDRYSEAL REMOVE TH D PROTECTOR BEFORE
47. MOVEMENT WITHIN THE 50 lt TOTALD ROTATION amp 11 4mm AXIAL MOTION MANUAL DVERRID NEUTRAL STARI REQUIRED FOR CONTRI SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp 6 4 THRU TRANSMISSION IS IN NEUTRAL ENGAGES PRIMARY SHAFT CLUTCH MANUAL sites OVERRIDE 361 M8 X 125 6 IREAD POSITION z 22 HOLES FOR REMOTE CONTR ELECTRIC BRACKET CONTROL 247 POSITION h ass mL e g Y 5 ELECTRIC CONTROL MODE SWITCH S CLOSED WHEN MANUAL VALVE 5 STEM IS LOCKED IN ELECTRIC 5 Installation 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 detent 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 dev
48. MeoesaR 2 514 HOLE BEHIND PULL TIGHT TRIM 986 ENDE SERE 10160842 41045 1017134 1018688 2 759 24 vnc xae7o7a ae7074D 70 2000 eso 10171298 7 x 20 6 24518 Me seospc STRAP M2942B NOTE ______ 1017583 1017569 1017613 1018688 xwezssri 1e voc 7072 427072 42703T eooo lt 290 10171298 1038 0 245 0 2 2 marose 2 INSTALL USING MA908 LOCTITE 4093 1017133 1017134 813372 101866868 2 _ voc 7072 7072 7 725 eso 10171298 x 5 5 2 maisen 2 6 5 0 5677 42 THREAD DOG POINT INTO 40967 1017383 1017179 vES 3 fxwe7s9rM 24 vac aeren 2655 lt 385 1017129 x erent Beasts go Morenori 1 2 TURN horsogsan 4114 _ amesee wa 2 oo 2415 9010171298 x Bessie esee AeA 4115 1018688 xme759rM24 voc hee oigog4ar 4118 1017133 1017134
49. OPERATING UNIT FILTER DRAIN PLUG 1 4 18 NP T F TH IXDRYSEAL PRIDR TO INSTALLING NEW FILTER REMOVE THIS PLUG TO DRAIN OIL FROM USED FILTER THEN REINSTALL IG 5 16 180 2 TAP THRU 2 HOLES SUITABLE FOR CONTROL MOUNTING BRACKETS 67 FACE US PLUGS TO OBTAIN CONTROL MOUNTING 1 4 9 THRU ACCESS TD 4 BRACKET MOUNTING BOLTS ENGAGES CLUTCH ON SHAFT CALLED PRIMARY LUBE PRESSURE 172 14 THD lt DRYSEAL CAUXILIARY LUBE SUPPLY INLET REFER TO HYDRAULIC DIAGRAM LUBE PRESSURE 1 2 14 TH D DRYSEAL PRIMARY SHAFT ENGAGES CLUTCH ON SHAFT SECONDARY CLUTCH CALLED SECONDARY ACTUATING PRESSURE 9 16 18UN TH D SPEED PICK UP PORTS p 5 6 18 UNF 2B THD GT URING STOCK BORE SIZE GIL DUT TO HEAT EXCHANGER CUSTOMER TO FINISH BORE 1 11 1 2 TH IXDRYSEAL REMOVE TH D PROTECTOR BEFORE OPERATING INIT 750 10 998 9 002 DIL STRAINER DUTPUT FLANGE g OUTPUT FLANGE amp DUTPUT SHAFT 25 999 1001 CENTER DF GRAVITY ami COMPANION FLANGE QUTPUT FLANGE 245 DUTPUT FLANGE PILOT LENGTH 325 5 75 22 55 9 00 DIL DRAIN 1 5 16 12UN 2B TH D 15 00 MOUNTING PAD THESE TWO BOSSES CAN BE DRILLED AND TAPPED FOR ACCESS TO SUMP DIL FDR LUBRICATION DURING EXTENDED USE WITH PROPELLER WINDMILLING AND OTHER USE DIRECTLY CONCERNED WITH MG SI70DC HYDRAULIC CIRCUIT OPTIONAL TEMPERATURE
50. ORDERING PARTS GG TONS S DIK 3 042 165 PORATED hopes MADE n U S A 23405 U S A IW WE p Figure 1 Nameplate for MG 5170DC Marine Transmission Marine Transmission Service Manual 1020667 17 Description and Specifications Twin Disc Incorporated Power Ratings The MG 5170DC transmission can be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation 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 1020667 Twin Disc Incorporated Description and Specifications Construction Features Housings The MG 5170DC transmission has a one piece main housing Front housing sizes in SAE No 0 and SAE No 1 sizes are available A top cover oil pan 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
51. PASS 0 20 TEST ALSO APPREVED IS SERVICE CLASS CC ENGINI IL MIL L 2104B VISCOSITY BAS SUMP TEMP CLINDITI D BELUW START UP gt ATION VISCUSI S A EADY OPERATION BEL 65 BOVE 2007 93 C 15 y IN INCI IRPORATED RACINE WI 53403 USA 82415 Figure 3 Oil Specification Plate Marine Transmission Service Manual 1020667 23 Description and Specifications Twin Disc Incorporated Table 1 MG 5170DC Oil Pressure Specifications Oil pressure Limits 1725 kPa 250 psi rating 235psi minimum pressure when cruising 1018084 1017172 1020412 series control valve E Inlet Clutch Min kPa puo Lm _ mem ve o serus ema o ves sess mem o o Cw ew s mewn ae o Secondary 1725 1862 250 270 Oil pressure Limits 1725 kPa 250 psi rating 235psi minimum pressure when cruising XA7371 series control valve Main Pressure at Valve Primary Secondary Shift Inlet Clutch Min Clutch Min 345 517 50 75 may me v es uem 20200 o o 0 1800 1725 1862 250 270 0 0 1696 246 140 340 20 50 Note It is required that lube pressure
52. REQUIRE FULL POWER TO THE PROPELLER 2 MAXIMUM ENGINE SPEED WHILE TROLLING 1100 R P M OR 60 OF FULL LOAD ENGINE SPEED WHICHEVER IS SMALLER 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUNCTION BY MOVING TROLLING CONTROL LEVER OUT OF LOCKED DETENTED POSITION TO MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION OF TRAVEL BY MOVING CONTROL VALVE LEVER TO PRIMARY OR SECONDARY MOVE TROLLING CONTROL LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED CLOSE TO DETENTED NO TROLL POSITION THE TROLLING CLUTCH MAY ENGAGE FULLY HOUSING SAE 1 USE HARDENED FLAT STEEL WASHERS Rom 61 MIN UNDER SCREW HEADS HOUSING SAE 0 CENTER OF GRAVITY 3 4 10UNC 2B TH D 11e DEEP 14 HOLES 7 EACH SIDE USE ALL FOURTEEN 14 HOLES FOR MOUNTING UNIT USE GRADE 8 QUALITY CAPSCREWS PER SAE J429 AND TORQUE TO 574 OR SERVICE MANUAL VALUES 16 59 5 16 180 THRU 2 HOLES SUITABLE FOR MOUNTING BRACKETS 1 4 THRU ENGAGES CLUTCH DN SHAFT 6 CALLED PRIMARY PRIMARY SHAFT 6 ENGAGES CLUTCH DN SHAFT G CALLED SECDNDARY SPEED PICK UP PORTS 3 4 16UNF 8B TH D PER SAE 514 D RING CONNECTION STOCK BORE SIZE CUSTOMER TO FINISH BORE 7 50 10 998 008 COMPANION FLANGE DUTPUT FLANGE DUTPUT FLANGE 245 PILOT LENGTH 25 ES 575 9 00 DIL IN FROM HEAT EXCHANGER 1 11 1 2 NP T F TH DCDRYSEAL REMOVE TH D
53. 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 104 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 6 Remove the detent setscrew spring and detent ball Figure 74 Removing Detent Setscrew left and Detent Spring and Ball right 7 Remove the dog point setscrew from the valve body Figure 75 Removing Dog point Setscrew Marine Transmission Service Manual 1020667 105 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 spring will come out with the stem Figure 76 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 77 Removing O ring From Stem 106 Marine Transmission Service Manual 1020667 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 Remove the outer spring and piston from the bore of the valve body Note that there may be washe
54. THRU HOLES 7 i Vo TOOL ND DIM DIM DIM C DIM 0 DIM CUP D 6 240 7 38 125 2 75 17 00 MA S90 AL DIM 7 110 SS 1 84 2 34 16 41 MA 590 EZ 6 568 8 31 1 41 2 91 go MA S90 FA 2510 119 09081 1 NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP COTNERS 5 res MS DRIVER BASE HIN amp SEE CHAR 4 MS HANDLE SEE CHART DESCRIPTION STUCK SIZE Date 9 22 96 JP FPN Seale FULL NAM 961 oe SEE CHAR BEARING DRIVER BREAK ALL SHARP CORNERS TOLERANCE scri FOR ASS Y 1014841 DN LACE x GE A 6 22 96 JPL MG 5182 VARIDUS DECIMAL DIMENSION A D J es Y TENER 7 A UJL CHANGE DESCRIPTION DATE BY TWIN DISC INC RACINE WIS 1 4 UN ANGULAR DIMENSION 1001 12 4 Special Tools Twin Disc Incorporated Oil Injection Tool T 18614 5 REV DESCRIPTION DATE B aui Insel HRU en DRILL sss BEEF 74 4 Y 2 18 180 15 DEEP does HEX i i i Y Pd 4 50 P _ Sed EM Let 2 20 7 16 14 150 THREAD 1 Y _ 0 44 NAMI INJECTION TI DATE 23MAYO TOOL T 18614 5 NI
55. 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 atmospheric pressure at all times permitting the return to sump of any leakage oil past the pistons Marine Transmission Service Manual 1020667 Twin Disc Incorporated Operation A HIGH PRESSURE A Oil Ent ilg REGULATOR PISTON B Oil Pressure Chamber C Pressure Overflow Port D Engaging Passage E Oil Engaging Passage Interconnection Slot G Oil Directional Port Oil Connection Port J Oil Pressure Passage K Oil Directional Port L Oil Pressure Chamber lt NS Y CONTROL RATE CN RISE PISTON VALVE LEVER Lele 56 5 CONTROL 5 Ss SPRINGS VALVE STEM VALVE BODY LJ ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 7 Manual Control Valve Neutral Sectional View NEUTRAL CONTROL VALVE BODY TO FORWARD CLUTCH Q TO SUMP TO REVERSE CLUTCH CONTROL VALVE STEM ATMOSPHERIC PRESSURE ENGAGING pressure Figure 8 Manual C
56. bearing cups should not be attempted unless replacement of the bearing is necessary 4 Remove the oil pump suction tube and O ring LI NR A Figure 39 Removing Suction Tube 80 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly Remove Output Flange and Oil Pan 1 Remove the output flange retaining capscrews Remove the retaining washer shims and O ring Figure 40 Removing Washer and Shims left and O ring right 2 Use hydraulic ram to pull the output flange from the output shaft Figure 41 Removing Output Flange Marine Transmission Service Manual 1020667 81 Disassembly Twin Disc Incorporated 3 Remove the oil gauge tube assembly Figure 42 Removing Oil Gauge Tube Assembly 4 Remove the oil pan attaching screws Remove the oil pan and gasket Figure 43 Removing Oil Pan 82 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 5 Remove the gear pan from the oil pan Figure 44 Removing Gear Pan Marine Transmission Service Manual 1020667 83 Disassembly Twin Disc Incorporated Remove Output Shaft and Gear 1 Remove output shaft seal carrier attaching screws Use two of the removed screws as pusher screws to separate seal carrier from housing Figure 45 Removing Seal Carrier 2 Remove the seal carrier shim pack and O ring Figure 46 Removing Shim Pack left an
57. 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 to 4000 300 Ibs to 900 Ibs of downward 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 500 Ibs lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 300 16 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 Remove lifting fixture Remove capscrews and remove output seal carrier Marine Transmission Service Manual 1020667 Twin Disc
58. 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 B 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 890 100 165 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 B Calculated advance must be 1 96 mm to 2 97 mm 0 077 in to 0 117 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 for information C Set secondary transfer gear on fixture T 18050 335 with large diameter of tapered bore up Move fixture and transfer gear to a press with at least 445 kN 50 tons capacity D Install secondary shaft front end up into tapered bore of transfer gear Sea
59. 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 1020667 Twin Disc Incorporated Assembly Assembly of Electrical Control Valve lower body half 1 Install the steel shuttle ball into its bore in the valve body 2 Install the O ring onto the shuttle ball seat 3 Apply lubricant such as Dow Corning 2009 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 4 Install the roll pin to retain the shuttle ball seat Drive the roll pin in until it is flush with the gasket surface of the valve body Figure 123 Installing Shuttle Ball Seat Roll Pin 5 Install the stem into the valve body aligning the slot in the stem with the threaded hole in the valve body for the dog point setscrew Be sure the slot in the stem is aligned with the setscrew hole in the valve body to prevent damage to the stem and valve body Marine Transmission Servi
60. 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 subsequent
61. 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 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 40 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Operation A Oil
62. 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 48 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Operation The hydraulic lock is disabled when either the engine is stopped or the neutral solenoid is energized When the neutral solenoid is energized it sends pressurized oil to the dowel pins at the return spring end of each spool Since the dowel pin used at the return spring side of the spool is larger in diameter than the dowel pin inside the spool the hydraulic force acting on the larger pin forces the spool to connect the clutch passage to sump with assistance from the return spring Dowel pin Return spring Figure 19 Neutral Solenoid Engaged Marine Transmission Service Manual 1020667 49 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 pr
63. 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 24 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Description and Specifications Optional Equipment The following optional equipment for use with the model MG 5170DC 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 Mounting Brackets Steel fabricated mounting brackets for rigid mounting are available They are part number 1016428AD Torsional Input Coupling Several models of torsional input couplings are available including Vulkan VKE4911S in both 14 and 18 flywheel sizes as well as 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 filter kit available BOM K1296 Heat Exchanger The M1959AQ heat exchanger is suitable for raw or fresh water cooling with a maximum cooling water temperature of
64. 0 FLANGE ASS Y 1017494 aau E FLANGE 1017495 CAPSCREW 20097 8 STOPNUT M2026Z 8 A UPTIDNAL EXTRA SUPPLIED 9 ONLY WHEN SO SPECIFIED 5 1017472 SHIELD 83624 4 j X HOUSING 1017438 77 22 Yi LLM 4 SETSCREW M2042AT 4 46 2 f RING A2916BK f FLANGE 1017468 SEAL M2183 CARRIER B6237 2 CAPSCREW 2004 102 222 2 DBDSLETE PE a AND PART NUMBERS S N 2494 5 i B 777 SHIM B24944 S REG D lt 72222727 2742727272 SHIM B2494B SEE NOTE 5 Sees SHEET CROSS SECTIONS 4 BBR ERO DUE TION 2 OF 4 AND PART NUMBERS GEAR 1019680 e CONE ASS Y 585 10174634 F R SHEET INSTALLATION 3 4 DRAWING 6 951 RATIO 153T CUP MAS90AL SERVICE SHEET COUPLING GEAR 1002624 e 6 534 RATIO 124 PLUG 4 4 DRAVING GEAR 1017487 A7119V 5 951 RATIO 125 RING A2916CH MAX INPUT SPEED 2500 RPM B3504AS S GASKET 1002689 CAPSCREW 2004 285 WASHER A8888AV 4 CAPSCREW 2719 45 SEE 13 1002585 COVER 1002586 CUSTOMER NOTES o2 DIL CAPACITY 7 5 gal LESS HOSES AND HEAT EXCHANGER b gt THIS UNIT CAN BE USED WITH LEFT HAND ENGINE c2 OPTIONAL EQUIPMENT COMPANION FLANGE ASSEMBLY 1017494 GEAR 1017488 CONTROL TROLLING VALVE XA7372T 5 034 RATIO 146T CONSUL T SOLES ING FOR LIVE P T D 1017177 CAUXILIARY PUMP DRIVE GEAR 1017489 OTHER LIMI
65. 0 HOUSING 1016215 ELEMENT 1019699 COUPLING MAIO41E HEX CAPSCREW 16 MA947D NUT 16 FLYWHEEL OUTLINE MUST CONFORM TO J620 ND 460 N B 272 LS 2 S 1016520 HUB SPLINED SERVICE REFERENCE ROLLER MAT116C 8 lt cia T SEE NOTE HA 555 81048 SNAP RING 5 N en 1 i 7 01017470 SHAFT 1 1 196 0 9 REF 139 98 9 0 02 M1990E BALL SEE NOTE 7 FLYWHEEL DUTLINE MUST CONFORM TO SAE J620 NO 355 1019735 HUB 1017471A SHAFT ASS Y 1017470 SHAF M1990E BALL 16 2 THRU 8 HOLES EQUALLY SPACED 4 1019698 COUPLING CAPSCREWS BEMENT 5574 OR SERVICE MANUAL VALUES SAE f K AE 1 Sarat 9 THRU HOLES EQUALLY SPACED BUSING USE 8 9 PROPERTY CLASS QUALITY CAPSCREWS PER 150 898 1 AND TORQUE 574 DR SERVICE MANUAL VALUES COUPLING D E sum Dens e wee mud CF R Lm m eer RT mc n ELEM SEE SHEET 1 FOR MAXIMUM TRANSMISSION RPM ALL COUPLINGS ABOVE HAVE TORSIONAL STOP INCLUDED SEE SHEET 1 FOR MAXIMUM TRANSMISSION RPM ALL CDUPLINGS ABDVE HAVE TORSIDNAL STOP INCLUDED THE VR OF INNER PARTS INCLUDES HUB AND 1 4 xx THE WROF INNER PARTS INCLUDES HUB AND 1 4 SHAFT C SHAFT C FOR TRANSMISSION SHIPMENT SECURE COUPLING BY WIRE 4 FOR TRANSMISSION SHIPMENT SECURE COUPLING BY WIRE THROUGH COUPLING FLANGE HOLES AND S A E FLANGE HOLES THROUGH COUPLING F
66. 1 YATAIN TOTAL RUNOUT DATUM AUTOCAD FILE 18050 32 OHG DEREDRAWN ON CAD 3OMAYO2 BAZ 470 651 POSITION DIAMETER REV DESCRIPTION DATE BY TWIN DISC INC RACINE WIS osiq UIML Twin Disc Incorporated Special Tools Bearing Driver T 18050 323 REV DESCRIPTION DATI BY A REDRAWN IN AUTOCAD 29MAY02 AZ 512 DIA gt ud x4 D CRS i I WELD i i c 2 5 6 25 REF X 1 e ch 4 500 CEN UBING STAMP 18050 93293 4 0 MGoale TOOL NAME BEARING CONE DRIVER DATE 4 26 84 18050 323 WIN DISC INC AUTOCAD FI 18050 323 Y RS PART MASSSAN Marine Transmission Service Manual 1020667 191 Special Tools Twin Disc Incorporated Bearing Driver T 18050 327 REN DESCRIPTION DATE BY US A REDRAWN ON AUTOCAD 29MAY02 AZ CrS y m ges En 4 i S D i i gt Y STAMP 18050 32 4 0 MG316 TUUL NAME BEARING DRIVER DATE 4 30 84 1000 T 18050 327 TWIN DISC INC AUTOCAD FILE T 18050 327 BY RS PART MAG27 192 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Bearing Driver T 18050 335 Special Tools DESCRIPTION DATE BY REDRAWN
67. 16 Pilot Spool Passages 46 Marine Transmission Service Manual 1020667 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 spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Marine Transmission Service Manual 1020667 47 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 HYDRAULIC LOCK UNITS Figure 18 Hydraulic Lock Units The resulting reaction is a force on the spool that overcomes the spool s return spring force Should the
68. 2B THRU HOLES SUITABLE FOR CONTR MOUNTING BRACKETS PRIMARY CLUTCH aT H H r3 NEUTRAL us i zl ENGAGES SECONDARY SHAFT CLUTCH 041002 4 29902014 enuen uoissiUsueJJ CONNECT OIL PRESSURE GAUGE HERE MOUNT GAUGE IN PILOT HOUSE 1 8 87 NPTF EXT lt DRYSEAL AT GAUGE 1 4 18 NPTF INT TH D DRYSEAL XA7371 SER VALVE OR 12 1 5 THREAD ISO 6149 PORT 1020418 SER VALVE AT VALVE PRESSURE TEST PORT uonejeisu 1 UIML 29902014 enue y 3914195 uoissiusueJ SUNEN est 2 WIRING DIAGRAM 5 o N P AAAS e 71 SECONDARY CLUTCH SOLENOID as SECONDARY CLUTCH SOLENOID 8 EL ce o PRIMARY CLUTCH SOLENO n d PRIMARY CLUTCH SOLENOID E 5 771 NEUTRAL SOLENOID 5 OPTIONAL 2 MATING WIRING HARNESS 1017404 OPTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH NOTE LEVER MAY BE LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREI
69. 3 z ee TROLLING VALVE INSTALLATION 7373714 ene pce m XA7371 SERIES VALVE XA 373 2 e NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS BE USED IN ANY MANNER DETRIMENTAL THE INTERESTS DF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT_INTENDED TU NUI 1 GRANTED THE U S G VERNMENT OTHERS BY CONTRACT TROLLING VALVE ADDITION KIT COMPONENT PARTS MATERIAL EIGHT vet LBS LBS HEAT TREAT FIRST USE assy SEE CHART SURFACE TREATMENT B INSTR Y amp spring _ EQUIVALENT PLATE TROLLING amp org JASS Y ss B2384 XA2707CB 73720 2464 2707 7372 2464 xa2707AV 7372 82384 2707 XA7372G Be464 XA2707CA 7372 Be384 PX10241 7372 1 4 DRILL SEE 1 EC SHE SECTION E PLATE TO BE WRAPPED IN RUST INHIBITING PAPER VALVE BAG F R SHIPPING THIRD ANGLE e PRDJECTIUN 0 7 SIMILAR see T UJ 009 9086 SCALE INCORPORATED EH APPD SHEET _ OF 1 VALVE ORIFICE ASSEMBLY GASKET PATE 47 9 gt 72 1 M27 x 2 0 150 6149 MA1038E O RING PLUG 38 8 WHEN SPECIFIED OIL INLET WHEN M2067R TH D PROTECTOR IS SPECIFIED 6 4 TEST VALVES PER TEST SPEC NO 2408 CONTAINED IN VALV
70. 301H ADAPTER 2300 CAPSCREW 2002 42 MOUNT LUBE INSTRUCTION PLATE CREF B2415 WITH WORDS MARINE TRANSMISSION LUBRICANT TOWARDS BREATHER nS th ENANS SCREW Me089Y CLOSURE 2067 CAPSCREW 2001 4 COLLAR 1867 SCREW MI73IAF BALL M1990E PLUG 2782 2 RING A2916DK 22 COVER B3574A SPRING 2013410 LEVER 804087 GASKET 1334 SEAL MA778 PIN 1927 BEARING 2087 RING A2916AT WASHER M2086AV 22 GASKET B1337D STEM 44347 BODY A7361B EYEBOLT M8071D 2 BREATHER 1251 S LINK 42007 CHAIN M1072 WASHER 1681 CLIP M1763 PLATE 212754 22 PLUG M2782A 2 RING 2916 22 PLUG 20510 CAPSCREW 2002 85 CAPSCREW MA996D 4 CAPSCREW 2002 9 P1213 yan LOCATION OF PILOT HDUSE MOUNTED PRESSURE GAGE CONNECTION XA7371W CONTROL VALVE 557 2 ANN 3199 SUCTION TUBE AND SCREEN MANIFOLD ASS Y 1019793 MANIFOLD 1017460 NIPPLE 1018720 i one gt 3 1 22 AWS 4 2277777777777774 OBOSLETE FOR PRODUCTION REPLACED BY 1017463A FOR SERVICE CETETER BYPASS VALVE RELIEF VALVE NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 15 TO BE USED IN ANY WANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI GAUGE B1703D PLUG M2051CD PLUG 2051 SCREW
71. 4140 00 180 DIA x 2300 COLLAR T175 DIA x 300 suc 45 95 sv SCALE FULL D Nue DEMENS DETAILS FDR PULLER B Sues ees 7470 A nene 457 95 unt m DAC T 20023 owe av rum msc mco RACINE WIS 19945 600c 1 19 40 Sjrejoq 2510 UIML 1001 12 4 005 29902014 enuen T zs T e ON gt 0 40 125 Gy TNI C 90 40 415 1 9 94 9 94 318 X 8 DP 3 8 16THD X DP CQ PLES 0 50 569 THRU 3 4 10THD EN THRU L 4157 TYP e Ue ence 97 540 PLCS 1050 Rc 45 50 15 LENG ORAE 1 BY UNIFORM 40 PLCS 72 1 2 8 7 T 7 5 19 X 2438 CENTERS 1314 94 ID X 2 OD 1 1 z e 1 WEZ 12 4 DX 2 0D 1 1 NDS 1 4 3 8 16 X 1 0 Y 1012 3 8 16 X 5 0 948 N 5 X L13 X 238 03 X Su 01 01 a 1 a 5 X mE 3 5 fat N 9 2 WELDMENT ASSY 9 7 8 9 DET FA DIA PART 7 8 9 THD 8 22 75 16 625 MG 516 8 4 PREHARD ROD Rc 32 36 X 228 gt 5 T 12 Tar 8 9 14 27 25 MG 5202 Mrs 5 4 1 8 THD 4 1 RB amp HARD 11 59 X 2 13 NOTE gia SYLIN
72. 43 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1020667 175 Installation 176 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 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 lea
73. 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 1518050775 ______ BY misc wc RACING VIS SHIELD 1001421 HOUSING ASS Y 101523 HOUSING 1015235 TUBE Special Tools Twin Disc Incorporated Notes 206 Marine Transmission Service Manual 1020667 47 7 7 7 7 AAAI a rx YYXYWY Y YYYwY 474747487474 445767445747 02 PLCS IN DET 1A 97 8 THRU DETS 1B amp 1C 1 1 2 SQ TUBING EXXXXXXXXXXXXXXALL 4 T XXXXXXXXXXXXXX gt STK SHCS 5 8 11 X 1 25 PUR BALL L CL 10 BLPB 2 STK SHCS 5 8 11 X 1 5 LG GRIPPER 1 R H amp 1 L H 1 5 X 1 8 X 4 1 STK DOWEL 5 8 DIA X 2 HANGER CROSS PLATE 5 8 X 7 X 11 8 5 8 STK A qo EN cc WE 2 2 HANGER ARM 1 5 SQ X 41 5 TUBING BOTTOM GUSSET TOP ARMB 8X 4 X 7 VERTICAL 1 5 SQ X 13 5 TUBING GUSSET TOP ARM 3 8 X 2X7 EYE BOLT ARM 1 5 SQ X 24 5 TUBING SHOULDER FORGED EYE BOLT 3 4 10 EYE BOLT PAD 5 8X3 X4 CLAMP PLATE 5 8 X 5 0 X 15 40 T SSS
74. 7 229 Engineering Drawings Twin Disc Incorporated 230 Marine Transmission Service Manual 1020667 PINION ASS Y 1019682 22 GEAR 1019681 6 95 1 RATIO 22T PINION ASS Y 1017486 2 GEAR 1017485 6 53 4 RATIO 19T PINION ASS Y 1017484 2 GEAR 1017483 HUB 1017469 x 101 eo PLATE A4342A 5 95 4 RATIO 21T CAPSCREW 2002 102 PINION ASS Y 1017482 2 GEAR 1017481 5 03 1 RATIO 29T PINION ASS Y 1017480 2 GEAR 1017479 4 50 11 RATIO 2 PINION ASS Y 1017478 2 GEAR 1017477 1017469 4 06 11 RATIO 35 RING A2916W SCREEN MA993 CONE ASS Y MAS85AY 2 CUP MAS90 2 gt GASKET 1017511 GASKET 1017509 ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 55700 NOTES 1 THRU 10 ARE IN 55700 11 CONTROL VALVE BOLTS ONLY ARE TD TORQUED DRY 30 36 lbf ft OR WELL OILED TO 25 29 lbf ft AFTER TORQUING MOUNTING BOLTS INSTALL M2067Q PLUGS IN MOUNTING BOLT CDUNTERB RES AFTER PAINTING TRANSMISSION AND FILTER ELEMENT TWIN DISC GRAY PLACE TWIN DISC FILTER LABEL 950 OVER EXISTING VENDOR LABEL WITH TWIN DISC LOGO TOWARD CLOSED END OF FILTER OIL PAN BOLTS ONLY ARE BE TORQUED DRY 19 25 lbf ft OR WELL OILED TD 16 20 lbf ft INPUT HUB COUPLING JOINT ASSEMBLY APPLY MA908 TO THE AS RECEIVED BOLTS JUST BEFORE ASSEMBLY AND TORQUE PER 574 GASKET B1338A RING 203190B 25 CARRIER
75. 9 7 70782 427078 7 1380 eo 1017129 991 RA10536 B ee a 703 1725 2502 10171294 Meosor 51 MATING WIRING HARNESS 1017403 2 2 we sem 2 2 e wee 2 2 2 2 2 e 2 BOTH SIS ro ro io ojo mx xjr A1062 106 1052 1052 1052 10180842 40761 1017583 1017569 1017613 1018688 75 12 vnc xeeozz 427072 a2703T 2000 290 10171298 1038 2 x 20 6 40762 10171334 1017134 37 1017179 e 75 4 vnc 4870740 1585 230 10171294 7 x 22 6 CONNECTOR SHROUD 101825 076 1017179 e _ ae7074D 585 exo 10171298 x 20 RACER TT dad EN 40775 1017563 1017569 107613 1018688 7072 27472 270 2000 250 071298 x 2 4 w semm E PA SWIT 006 40817 1015688 e 5 vnc xserozen AZ7O7AD A270RAD 2000 es 1171258 x SiS p STEM 18 LOCKED IN ELECTRIC
76. 92 BEARING SHIMMING JS SN SHIM B2501B SEE NOTE 5 ERR S765 TAPERED JDINT ASSEMBLY 1t Li N b 7 JON RING M1904L 2 EEA J GEAR 47475 CAPSCREW 2004 122 BEARING MA217D 2 LOW RING B1048BC 2 h 22 1 KLAD SEAL 1016127 022 0 RING A2916KD 9 SEE NOTE 14 RING M1904AQ 22 PLUG 1945 6 9 N PLATE 1015518 SHAFT ASS Y 1017474 INPUT OPTIONS lt lt RING M2693F 2 SSS PUMP BERSOA Y SS 3 2 WG 7 CONE ASS Y MAS8SFUCe zii Z CUP 9 22 Y 54 4 WV rm Ny 55 7 x d SHAFT 1017473 RSS 1 Ds S MSS AN SES gt NY 55 Q J gt GEAR A7473 SEE NOTE 5 RING A2916BD GASKET B3617 FITTING M268 RETAINER 1017570 2 gt BEARING M2321 2 CAPSCREW 2007 4 PLATE 6231 RING M1904DA 2 777 Z RING A2669AU 2 Pz WASHER BISO4KU 7 NS KR E SHIM 1017362 PISTON B6232 2 1 SHIM 10173624 AS REQ D PLATE 206106 18 en SHIM 1017362 598 CZ SNY N X ASS Y MASSSCX 4 OXY PLATE 206107B 16 CUP MAS90CB 23 WSN H FLANGE ASS Y 1017494 1017472 ZAN HERE gt CAT CAU AM G _ UPTIDNAL EXTRA SUPPLIED SHIELD 83624 D XY 227 HOUSING 1017438 p ZZ 2 2 224 UN
77. DER 214 1 04 X 23 0 D DRILLED RED AND OR 1 COLLAR SEE SHTf 2 11 750 X 50 VODIFER PED HOLES 005 E DESCRIPTION STOCK SIZE ana Bj RS FPN FUL OUTPUT PULLER AUTOCAD FILE 22 n 0 8566 5 4 OF DIAMETER TATE Bv TWN DSC NC RACINE WS 19945 600c 1 19 40 Sjrejoq 5100 osiq UIML 29902014 enuen 3914195 uoissiusueJ IUEN 375 REAM SL FIT THRU lt 2510 UIML u 2 00 a 4 VV d DR ps DR 21 1590 DIA i DN THRU TO HOLE N 10 32 UNF 2 REQ D cf 0 471 DIA pe el Lc 7 9 E 1 e 30 lL NA yey 08 066 20612 1 10942 1noung 20 eAee s T N x o DRILL 24 DIA SAW CUT CENT LOZ JRILL 5 16 631952 gt E DIA 3 38 DEEP E I EE 3 50 6 STK IREADED RUD 3 8 16 4 5 G 5 1 Se WASHER 75 DIAx38 Dx1e THK 4 1 MS HANDLE G o 3 5 STK SDC SET SCREW DOG DIA 1 stk power
78. 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 Sealed 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 clean surfaces by applying 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 1020667 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
79. E p 2 0 SST X 8 E PT X 16865 X6575056 ______1_ 1 1 32 45 4 220 de 6510 amp BOO 750 Bo894C GEAR TOOL NAME WIN DISC INC 188 GEAR DRIV AUTOCAD FILE 0 3 8 RS 1 18050 25 XBS893D ER 18050 25 DATE BY TOOL PARI Marine Transmission Service Manual 1020667 Twin Disc Incorporated Special Tools Bearing Driver T 18050 183 REV DESCRIPTION A REDRAWN AUTOCAD 4 25 DIA TOOL NAME BEARING DRIVER DATE 11 11 81 L 18050 183 TWIN DISC INC AUTOCAD E T 18050 183 BY RS X227694A Marine Transmission Service Manual 1020667 189 061 8x45 BORE DET 1 TAP DET 3 FOR DE 5100 1 6 04081 1 6 6 50 1 50 H 95 25 mI i E x 4 KNURL 7 6 5 5 5 5 3 o 0 5 o t 5 c 5 1 ANDLE 1 5 x amp 5 D 2 SHCS 1 2 13 x 1 SYMB TIC SYMBOL MODIFIER 1 1 30DY 6 5 x 1 5 I D MAX MATERIA Date By RS e Sa woo Ne PARALLELISM CONDITION a y R S m PERPENDICULARITY REGAROLE JRIVER co CONCENTRICITY A NAME FOR CIRCULAR RUNOU DATUM FEATUR A AP AD T 18050 39
80. E SPECIFICATION INSTALLATION DATA 8 1 25 TAP THRU 2 HOLES 1 VALVE SUITABLE FOR UP TO 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 MUST PROVIDE 35 8 LINEAR TRAVEL FROM NEUTRAL AT THE 6 4 2 HOLE LOCATION WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT SPRING AND PIN MAY BE OMITTED THEN THE FORCE WILL BECOME 13 31_N THE DETENT FEATURE IS PROVIDED IN THE FULL FORWARD F LL REVERSE AND NEUTRAL LEVER POSITIONS CONTROL TORQUE MOUNTING BOLTS 57 68 N m AS RECEIVED PER S574 OR i gt LEVER 47 56 LUBRICATED PER S574 AFTER TORQUING MOUNTING BOLTS INSTALL M2067X PLUGS IN MOUNTING BOLT COUNTERBORES i 7 NEUTRAL POSITION 1st CLUTCH ENGAGED o MA960K a M12x1 8 150 6149 TH D masek CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK MA960P 2 TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION FL PRESSURE LINE GAUGE LOCATION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS J r1 M2067X THAT REQUIRE FULL POWER TO THE PROPELLER SEE NOTE 4 6 4 DRILL SEE NOTE 5 48 UNI 2040878 1 RANGE ML Wb 23060 1 sales 1 6 4 DRILL 2nd CLUTCH ENGAGED MA960A ae NOTES 10388 N MA10388 ___ 1 RATE RISE FUNCTIONS DETENT
81. EDUCE SHAFT SPEED IF EXCEEDED 2 Y d V4 SN LL SINGLE PHASE CAPACITOR TYPE C THERMALLY PROTECTED DUAL VOLTAGE DUAL ROTATION 8 LEAD REMOVE PLUG TO INSTALL CUSTOMER SUPPLIED PRESSURE ALARM SWITCH 8 41 4 kPa 13 8 SEE INSTALL PLUGS FOR SHIPPING OIL IN 3 4 14 N P T THREAD FEMALE PIPE SWIVEL 100 MESH INLET STRAINER REMOVABLE SCREEN LARGE HEX PLUG REMOVE THIS ENDCAP TO SMALL PIPE PLUG SCREEN FOR CLEANING REMOVE TO CLEAN LIT I _ 3 65M POWER CORD 2 2 5 29860 1 26 00 3 PRONG GROUNDING PLUG c 9 29423 7 6 99 B_ 4 1 29078 1 19 99 COILED AND TIE WRAPPED FOR SHIPMENT 29003 te 4 5e rev zoe pw SETTING FOR NS HEAT EXCH FAN 00 OIL TO AIR HEAT EXCHANGER 3 4 NPT QUICK DISCONNECT PUMP FLOW RATE IS 11 0 l min AT 102 C METRIC Ee Is sil E cow T d A H me 1016473 PUMP ASSEMBLY TRALING __ 5 sur iori Engineering Drawings Twin Disc Incorporated Notes 248 Marine Transmission Service Manual 1020667 1020667 07 02 TWIN DIS POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
82. EFER TO INSTALLATION DRAWING ELECTRIC MOTOR DRIVE PUMP 5 10 GPM 3 4 DIA MIN HOSE STRAINER 5 ANGLE KO c nma TWIN DISE d E E ERE INSTALLATION OF OPTIONAL TEMPERATURE INDICATING REDUCER BUSHING INSTALLATION OF OPTIONAL TEMPERATURE INDICATING SWITCH USING PIPE TEE WITH REDUCER BUSHING OIL PUMP Me080B DRAIN PLUG LOCATION 1 5 16 12UN 2B THREAD INSTALLATION AND ASSEMBLY MG 5170DC DRAVING HYDRAULIC DIAGRAM GRAPHICAL J LC SYMBOLS NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS TU BE USED IN ANY MANNER STRAINER DETRIMENTAL THE INTERESTS DF HEAT TREAT FIRST USE qoae 141290901125 NN NN NNNM me __ TWIN DISC INCORPORATED RACINE VI 53403 USA THIS NOTICE IS INTENDED TO NU OR OTHERS BY CONTRACT assy 1017463 MG 5170DC MATERIAL WEIGHT LBS LBS PRIMARY NEUTRAL 15 CLUTCH ENGAGED FOR 3 POSITION SECONDARY ENGAGED FOR POSITION ENGAGED amp DISENGAGED USE USE FARI 5 16 18UNC 2B TH D 2 HOLES 9 NEUTRAL FOR 3 POSITION PRIMARY NEUTRAL SECDNDARY USE t R DISENGAGED F R 2 POSITION CENGAGED amp DISENGAGED USE CONTROL 4 LEVER USE_M2702D THREAD PROTECTOR WHEN IT IS SPECIFIED eo e e 9 9 Qo 9 N
83. GLE ATMOSPHERIC PRESSURE INTERMEDIATE PRESSURE CLUTCH PRESSURE PX9975 7540 PRINT contains CESS OTERVISE SPECIFIED 1 m 8 2 01 TWIN DISE ee ee 3 ER E R bebe te 1 055 INCORPORATED fed uu RACINE 53403 USA Ram MG Seeepc W Russell 1 0 z 0 4 1 0472 11 15 01 THIS NOTICE IS INTENDED TREATMENT Wr ee Eee 10355 8 21 01 15 me VALVE ASSY CONTROL ser loge 1 D z SECTION A SE A GASKET SECTIUN B B ORIFICE PLATE Parr nafsiz 90 Jary Q2 QTYINO 2 ASSY 9 VALVE ass sso ores paren mese pene e ves maosor ER pans pner e reser e PF Deren sores rester neas param e PF serre Drersroa fan 1017463 ava 1 emer 3 section C C GASKET CHECK BALL SEAT CHAMFER ON OPPOSITE INTERNAL SIDE OF PLATE AS ASSEMBLED Z BOLT SYMBOL FOR XA7373H amp CONTROL LEVER XA7373Q ONLY 2 84 1 4 DRILL UE NW Ss NOW OBSOLETE PISTON DESIGN gaa Z2 0 07 IN LCS INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO CONTROL LEVER IN DETENTE POSITION DURING MANEUVER AND O
84. L enuen 2 DIL PRESSURE GAUGE HERE MOUNT GAUGE IN PILOT HOUSE RES 1 8 27 NPTF EXTERNAL TH D DRYSEAL UIL IN FROM HEAT EXCHANGER DIL GAUGE 14 1 2 NP TF TH DCDRYSEAL REMOVE TH D PROTEC BEFORE OPERATING UNIT 1 4 18 NPTF DRYSEAL OR 5 THREAD PORT CONFORMS TD ISO 6149 DIL SENDER LOCATION 7 PRIMARY SHAFT FILTER DRAIN PLUG OR TH 9 16 18UNC 8B THRU 1 4 18 TH DXDRYSEAL PER SAE J514 D RING 2 HOLES SUITABLE FOR CONTRO PRIOR TO INSTALLING NEW ER CONNECTION MOUNTING BRACKETS REMOVE THIS PL DRA FROM USED FILTER THEN REINSTALL PLL E EYEBOLTS FOR LIFTING MARINE TRAN SSIUN BOLTS ONE EACH SIDE EQUALIZE LOAD ON BOTH EYEBDLTS TL FT MARINE TRANSMISSION ONLY 74 THRU PRIMARY SHAFT CLUTCH ENGAGED AUXILIARY LUBE SUPPLY IN REFER HYDRAULIC DIAGRA 1 14 TH D CDRYSEAL gt CONNECTOR NEUTRAL LUBE PRESSURE 1 2 14 THD lt DRYSEALD INDARY CLUTCH UATING PRESSURE SECONDARY SHAFT 6 18UN TH D CLUTCH ENGAGED PER SAE J514 D RING CONNECTION RH ENGINE ROTATION DRIVING THRU OIL QUT TO HEAT EXCHANGER PRIMARY CLUTCH 1 M 1 2 NP T F TH DCDRYSEAL TERNATE OIL GAUGE POSITION 4 16UNI PER SAE J514 O RING CONNECTION
85. LANGE HOLES AND SAE FLANGE HOLES DYNAMIC DYNAMIC TORSIONAL TORQUE TORSIONAL STIFFNESS kN n STIFFNESS kN m rad O NOT SERVICEABLE SEPARATELY kN m rad O NOT SERVICEABLE SEPARATELY os D NOT SERVICEABLE SEPARATELY os 1255 a eso 6 375 n3 50 1 5 FOR TRANSMISSION CDUPLING ASSEMBLY ENGINE M E T R I C INSTALL COUPLING AND HUB TO 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 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 AE J429 TORQUED 574 OR SERVICE MANUAL VALUES poe 0174654 MARINE Tato PRIMARY SECONDARY ea SPRING RELEASED CLUTCHES LUBE TUBE gt GEAR LUBE PRIMARY amp SECDNDARY SHAFT LUBE E c LIE cer 2 NS c 5 lt 1 E FRONT amp REAR BEARING PINION amp CLUTCH LUBE SHOWN ENGAGED N N PINION Eg SSS I FRONT TAPERED FRONT PINION BEARING BEARING BEARING REAR REAR CUSTOMER TO INSTALL G PRESSURE GAUGE AND LINE HERE
86. LATE FROM CONTROL VALVE H 29863 1731 00 B 4 28315 1 21 98 29350 6 24 99 ALL 28208 11 26 97 mv ane c D PROPRIETARY INFORMATION AND IS DETRIMENTAL TU THE INTERESTS OF TWIN DISC INCORPORATED INSTALLATION NOTE 0 6 0 9N 5 5 8 3 Ib AT THE 46 0 1 81 R LOCATION OF THE 6 4 1 4 DIA HOLE IS REQUIRED 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 4 THE 90 LEVER ROTATION REQUIRED FOR CONTROL MAY FALL ANYWHERE WITHIN THE 360 IN WHICH THE LEVER MAY BE CLAMPED PROVIDED CLEARANCE EXISTS FOR FULL 90 OF TRAVEL 55 50 INSTALL USING MA908 LOCTITE 242 MIN TROLLING PRESSURE SECTION S 9 Pos 4 4 P m PH 22222 22 SZ ie 39 00 4 40 LS ZN ANS NS ONS ISSUES Ch SES SECTION 9 STEM 1017901 SEAL 5591 ADAPTER 1017530 SETSCREW MA1037D SCREW IN UNTIL POINT BOTTOMS THEN LOOSEN 1 2 TURN BALL STOP IN NO TROLL POSITION PISTON 10491 VALVE BODY 1017529 CAPSCREW M2000H NUT M2027C LEVER B2103 SETSCREW M2041AB ADJUST SETSCREW SO THAT THE TORQUE REQUIRED ON STEM TO OVERCOME DETENT IS 1 1 1 7 10 15 Ibf in SPRING 10504 BALL M1990U
87. LVES PER TEST SPEC NL 2 POSITION ENGAGED CONTAINED IN VALVE SPECIFICATION amp DISENGAGED USE INSTALLATION DATA 1 VALVE SUITABLE FOR UP 95 L min 2 CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 335 AND 296 3 44 89 AT THE 55 9 LOCATION OF THE 6 4 9 HOLE IS REQUIRED OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 35 8 LINEAR TRAVEL FROM NEUTRAL AT THE 6 4 HOLE LOCATION 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 TORQUE MOUNTING BOLTS TD 57 68 Nom AS RECIEVED PER 5574 OR TIMES 2 47 56 LUBRICATED PER 5574 AFTER TORQUING MOUNTING BOLTS INSTALL M2067X PLUGS IN MOUNTING BOLT COUNTERBORES 2nd CLUTCH ENGAGED FOR 3 POSITION Emm FWD NEU REV USE 12 1 5 150 6149 PRESSURE GAUGE LINE LOCATION M2067X es xv SWS NIN NR WES E SS SENS S lt gt 1399 ISG ON D m EI 2 2 2208 42 Wis RU eee section 0 0 section ORIFICE PLATE dl 1 ste CHART O A GASKET SURFACE SECTION Kl SECTIUN 1 o SEE CHART 1 1 P 10481 A e GENERAL NOTES W REMOVE BEFORE OPERATING UNIT THREAD PROTECTOR ATMOSPHERIC PRESSURE THIRD AN
88. LY WHEN 50 SPECIFIED SETSCREW M2042AT 45 X QS gt 3 S N 9 i AK RING A2916BK 7 2 FLANGE 1017468 SEAL M2183 2 i GASKET 1002689 CAPSCREW 2004 285 WASHER A8888AV 4 CARRIER 6237 CAPSCREW M2719A 4 SEE NOTE 13 CAPSCREW M2004DE 10 SHIM 85294 SHEET CROSS SECTIONS a SHIM B2494A AS REQ D 1 DF 4 AND PART NUMBERS SHIM 2494 SEE 5 SHEET CROSS SECTIONS COVER 1002586 2 OF 4 AND PART NUMBERS GEAR 1019680 CONE ASS Y MAS8SAN SEL INSTALLATION 6 9511 RATIO 153T CUP MAS90AL SHEET COUPLING GEAR 1002624 PLUG M2080B 4 OF 4 DRAWING 6 531 RATIO 1247 HYDRAULIC 3951 Ravi nas MAX INPUT SPEED 2500 HASS ELASTIC CUSTOMER NOTES eat RAIN der CONSULT SALES DEPT sasosas MASS SS ee 4 APPLICATIUN ENGINEERING FOR B3649N HEAT EXCHANGER a DIL CAPACITY 7 5 gal LESS HOSES AND HEAT EXCHANGER GEAR 1017489 OTHER LIMITING CONDITIONS REQUIREMENTS 4 501 RATIO 144T b gt THIS UNIT CAN BE USED WITH LEFT HAND ENGINE GEAR 1017490 OPTIONAL EQUIPMENT 4 061 RATID 142 GEAR RATIDS SEE BILL DF MATERIAL PRUDUCT LIST 4064 5954 4504 6531 5 03 1 6 95 1 PAN 1002585 SSSA NOT SERVICEABLE SEPARATELY NOTICE THIS PRINT CONTAINS REMOVE BEFORE OPERATING 2 PLACES PLUGS PROPRIETARY INFORMATION AND 15 4 0
89. 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 all pinion bearing cups and both pinion inner needle roller bearings 116 Marine Transmission Service Manual 1020667 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 80 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 585 to press drive cups to the bottom of the bore It is important to maintain downward force as temperatures equalize to ensure that cup is at bottom of bore Figure 81 Front Pinion Bearing Cup Installation Marine Transmission Service Manual 1020667 117 Assembly Twin Disc Incorporated 4 Measure and record the distance from the machined surface
90. NTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED ij dl Too TTT T LE a4 Ec 10580 12 20 01 1 D M 3 29641 10 8 99 29503 8 20 99 29350 6 24 99 l 28585 6 3 98 Th THE Us GOVERNMENT mem lom evi etre NP D WIRING DIAGRAM CONNECTOR WHITE FEMA VALVE 1017170 TORQUE TO 33 9 WHITE WIRE C 67 1 SECTION VALVE CDVER ASSY 1017185 COVER 1017184 BALL MA1034A BOM NO 40537 O c mma ANGLE PLATE IS NOT INCLUDED O c mma ASSEMBLY USE PLATE FROM CONTROL VALVE PX 8671 NOT SERVICEABLE SEPARATELY MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED DATE DIMENSIONS ARE mm d MACHINED DIMENSIONS X 0 75 m TJIN Disc NCORPORATED RACINE WI 53403 USA GEDMETRIC TOLERANCING MODEL MG 5202DC PER ANSI 14 5 198 eer HEAT TREAT FIRST USE assy 1015207 ALL ANGULAR TOLERANCES 1 APPD A A CENTER LABEL 1018729 HERE D ls B ERATURE 100 C DR REDUCE PROPELLER SHAFT RPM MAXIMUM TEMP PART 1016473 RED PILOT LIGHT MOTOR NAMEPLATE UT WHEN MOTOR IS OPERATING OIL OUT 1 2 14 N P T THREAD INSTALL PLUGS FOR SHIPPING FILTER REPLACEMENT ELEMENT FILTER PRODUCTS CORPORATION FPE 30 25N PARKER 4925025 CROSS 119023 gt CAUTION MAX TEMP 100 C R
91. P TF TH D CDRYSEAL UIL INLET THREAD SIZE AT PORT 1 4 18 WHEN 2052 REDUCER BUSHING IS SPECIFIED BOLT SYMBOL FOR XA7371J amp XA7371W_ONLY D G VALVE BODY VALVE VALVE Bay ASSEMBLY BL Xx NUMBER QTY SECT C C xara 93577 Biaon 228 nz7ozx nezuenu 230 nn xararic 895 7 B48 ne7ozax nezuemu 250 wn PSP 7 228 ne7uSBa 150 wn 88 38 i wem7z emer wn xa7371J 7361 813370 13970 248 3 4 14 xeezozan 2707 703 ves B2334 eran arase Pen maoro 222 2224 eso ves XA7371L 7361 51387 813970 248 5 E vl 7 7 2707 a2704Bu 230 N Be334 xara P 226 v EB EWES MEH 250 ves XA7371P 473618 7 13970 548 KZN 7 2707 2704 0 230 ves B2334 5871 Sete e7o7an 7 200 mo raras PSP miaon 38 2 were ne7ozax azroenu 230 ves xa7371w REP B1970 255 ei MEE
92. PING DEVICES SO CAPACITY OF THE VALVE ROTATIONAL STOPS IS NOT EXCEEDED EXCEEDING THE CAPACITY OF THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS OF CONTROL CONNECT OIL PRESSURE GAUGE HERE MOUNT GAUGE IN PILOT HOUSE 1 8 27 NP T F EXTERNAL TH DCDRYSEAL AT DIL GAUGE 1 4 18 INTERNAL TH DXDRYSEAL AT DIL SENDER LOCATION LUBE PRESSURE 9 16 18UN 2B TH D PER SAE J514 D RING CONNECTION EYEBOLTS FOR LIFTING MARINE TRANSMISSION 2BOLTS ONE EACH SIDE EQUALIZE LOAD UN BOTH EYEBOLTS TO LIFT MARINE TRANSMISSION ONLY PRIMARY CLUTCH ACTUATING PRESSURE 9 16 18UN 2B PER SAE J514 O RING CONNECTOR PRIMARY CLUTCH SHAFT 6 824 EYEBOLTS RH ENGINE ROTATION DRIVING THRU PRIMARY CLUTCH ALTERNATE DIL GAUGE POSITION GREASE FITTING RH ENGINE ROTATION 1 1 32 9 THRU DRIVING THRU 8 HOLES EQUALLY SPACED OIL DRAIN 1 5 16 12UN 2B TWD 15 00 MOUNTING PAD THESE TWO BOSSES CAN BE DRILLED AND TAPPED FOR ACCESS TO SUMP OIL FOR LUBRICATION DURING EXTENDED USE WITH PROPELLER WINDMILLING AND OTHER USE DIRECTLY CONCERNED WITH MG S170DC HYDRAULIC CIRCUIT OPTIONAL TEMPERATURE INDICATING SWITCH CUSTOMER TO INSTALL IN A 1 X 1 X 1 PIPE TEE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSION PUMP TO THE HEAT EXCHANGER INLET WITH A 1 X 1 2 REDUCER BUSHING FOR THE TEMPERATURE SWITCH CONNECTION REFER TO HYDRAULIC DIAGRAM NOTE ALL POINTS AVAILABLE FOR TESTING ARE SECONDARY CLUTCH
93. PROTECTOR BEFORE OPERATING UNIT FILTER DRAIN PLUG 1 4 18 TH KDRYSEAL PRIOR INSTALLING NEW FILTER REMOVE THIS PLUG TO DRAIN OIL USED FILTER THEN REINSTALL REMOVE 4 PLASTIC 67 5 PLUGS OBTAIN CONTROL MOUNTING ACCESS TO 4 BRACKET MOUNTING BOLTS LUBE PRESSURE 1 2 14 NP TF TH D KDRYSEAL CAUXILIARY LUBE SUPPLY INLET REFER TO HYDRAULIC DIAGRAM LUBE PRESSURE 1 2 14 NP T F TH D gt SECUNDARY CLUTCH ACTUATING PRESSURE 9 16 18UN TH D PER SAE 514 D RING CONNECTION OIL QUT TO HEAT EXCHANGER 1 11 1 2 NP T F TH DCDRYSEAL REMOVE TH D PROTECTOR BEFORE OPERATING INIT CENTER OF GRAVITY CONTROL VALVE 18 62 4 14 lbs AT THE 560 2 20 R LOCATION OF THE 1 4 HOLE IS REQUIRED TO OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE FULL PRIMARY CLUTCH FULL SECONDARY CLUTCH AND NEUTRAL LEVER POSITIONS THE DETENT SPRING AND PIN MAY BE OMITTED WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY SECONDARY AND NEUTRAL DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS FORCE AT THE LEVER HOLE TD OPERATE THE VALVE THEN REDUCES TD 3 7 LBS THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE i141 LINEAR TRAVEL FROM NEUTRAL AT THE 1 4 9 HOLE LOCATION ROTATIONAL STOPS AT THE STATED VALVE TRAVEL LIMITS HAVE A MAXIMUM CAPACITY OF 100 LBS AT THE 1 4 9 HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING THIS LIMIT MUST HAVE SEPARATE STOP
94. R PRODUCTION REPLACED BY 1017463A FOR METRIC SERVICE O clum m etian os ser d o PINION 55 1019682 e PINION 355 2017482 gt ASSEMBLY _ INSTRUCTIONS x 4 x 7 x HUB 1017469 1017469 ASSEMBLE AND TEST PER 55700 6 95 1 RATIO 22T 5 03 1 RATIO 29T NOTES 1 THRU 10 ARE IN 55700 PINION ASS Y 1017486 2 PINION ASS Y 1017480 2 gt ENTRE AVES BUE TSON YS ARE T0 DE TUROUED RG TU X GEAR 1017485 X GEAR 1017479 RING A2916W x HUB 1017469 x HUB 1017469 d 12 AFTER PAINTING TRANSMISSION AND FILTER ELEMENT 653 4 RATIO 191 450 d RATIO 32T TWIN DISC GRAY PLACE TWIN DISC FILTER LABEL MA950A d SCREEN MA993 OVER EXISTING VENDOR LABEL WITH TWIN DISC LOGO PINION ASS Y 1017484 2 PINION ASS Y 1017478 2 X GEAR 1017483 X GEAR 1017477 4 OIL PAN BOLTS ONLY ARE BE TORQUED DRY 19 25 of ft x 1017469 x HUB 1017469 rH DR WELL OILED 16 20 Ibf ft PLATE 4342 5 95 11 RATID 21T 406 11 RATIO 35T INPUT HUB CDUPLING JOINT ASS Y AND SPEED PICK UP PLUG GASKET 1017511 APPLY 908 TO THE AS RECEIVED BOLTS PLUGS JUST CAPSCREW 2002 102 BEFORE ASSEMBLY AND TORQUE PER 5574 GASKET 1017509 GASKET B1338A RING 2031908 2 CARRIER 1017510 SPRING ASS Y XA2703BD 32 THESE STANDARDS APPLY SPRING A2703BD S574 FASTENER TORQUE REQUIREMENTS HOUSING 1015017 AE SHIM B2501 SHIM 501 5 REG D SPRING 4270186 6
95. ROTATION amp 114mm AXIAL MOTION REQUIRED FOR CONTROL CONNECTOR EE 77 NEU OPTIONAL MATING WIRING HARNESS 1017403 SERIES CSPECIFY r ELECTRIC CONTROL MODE CCLUSED WHEN MANUAL STEM IS LUCKED IN ELEC MODE MANUAL OVERRIDE T 361 POSITION ELECTRIC 24 7 CONTRO POSITION SECONDARY SULENUID CH PRIMARY CLUTCH SOLENOID SOLENOID N pe1e10d402u 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 SAE Grade 5 SAE Grade 8 30 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Description and Specifications Table 5 Metric Coarse Thread Capscrews Bolts and Nuts Thread Property Class 8 8 Property Class 10 9 Property Class 12 9 o m we 65 75 10 12 14 16 16 18 21 25 23 26 31 35 25 29 34 40 M10 32 36 43 49 44 51 60 68 51 59 70 80 Table 6 Tapered Pipe Plugs with thread lubricant InSteelorCastiron In Aluminum NPTF Size in 5 Ib ft 5 or 596 or 596 1 16 27 11 5 8 5 7 5 5 5 1 8 27 14 10 5 9 6 5
96. SC INC AUTOCAD FILE T 18614 5 BY AZ PART MGS16 5170B6 196 Marine Transmission Service Manual 1020667 29902014 enue y 3914195 uoissiusueJ SUMEN 261 290 06 ZZ ZZ CAD FILE 19998 4 4 a 1 BREAK JS M T Al NOTE UNLESS OTHERWISE SPECIFIED SHARP CORNERS NOTE ALL GROUND DIA S amp SURFACES SQUARE amp CONCENTRIC WITHIN 005 DF EACH OTHER 86661 1 5 Hd re 0 13 347 4 75 DIA DIA 4 437 DIA 6 REQ D P F LEGS PLATES SENA 68 TK 16 TEK Da By FPN FULL WE SPRING RETAINER HOLD DOWN SET RED CAD amp REVISED MG 516 XA 7470 C 1 Bic CHANGE DESCRIPTION BY TWIN DISC INC RACINE VIS 1 19998 pe1e10dijoou 926101 UIML 1001 12 4 861 29902014 enuen RR INSQ DOWN INSQ UP DAMETER AUTOCAD 1 20023 WAS 5 amp ADD HON NOTE REDRAWN TO CAD NOT CHG WAS 12 2 95 DET 11227 3 JM T Date BY
97. T D TO THE U S GOVERNME APPD OR OERS BY CONTACT sect rev DITCH SOLENOID VALVE SPRINGS CLUTCH sums MOUNTING SCREWS VALVE BOM DITCH TRANSMISSION SOLENOID ORIFICE FIRST CONSISTS PS MIRING DIAGRAM 5l BSS Ne GASKET GASKET pns B Moss PLATE N x lar R x Srs CONNECTOR MANUAL OVERRIDE NEUTRAL START 40750 1017133 1017134 1337F 1018688 ves 75 24 voc xae7o7z 7072 7 725 50 10171298 x exer 82418 FE PORT SOLENOID BAUR OVERRIDE IS N UE a TRANSMISSION IS NEUTRAL H 07 337 1017179 2759 24 vnc 4e7ozeD 1565 230 10171294 A 2 PORT SOLENOID zi x PLUG M2051K 2 1018084 40753 1017133 1017134 pis37r 1017179 kwe7serMa vc xae7o7sz ae7o75v A2703BA 1380 eo 1017129 A 1 Meoesr 3 00 56 NEUTRAL SOLENOID 10180840 40754 1017133 1017134 7 1017179 no xwezssri ie voc 7070 585 230 10171294 REPS os gS 2 Meossac 2 H deri SCREEN 1020479 1018084 40755 1017133 1017134 813377 101717
98. THER OPER T REQUIRE FULL POWER TO THE PROPELLER X 7373Y PARTS ARE BE COMPLETELY ASSEMBLY NOTES 1 80 35 LBS AT THE 1 818 LOCATION OF THE 1 4 DIA HOLE IS REQUIRED OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 2 56 LINEAR TRAVEL FROM DETENT AT THE 1 4 DIA HOLE LOCATION THE DETENT FEATURE IS PROVIDED IN THE RATE OF RISE POSITION ONLY TROLLING LEVER MIN TROLLING PRESSURE NO DETENT MER SSN OI 2 NCGS 4 LE ECCE 2202 HH INET RMS AIRES SS MAX TROLLING PRESSURE NO DETENT 2464 2707 XA7372T ADJUSTS CONTROL TROLLING PRESSURE o o c PS a E z o o lt o 2 3 a lt ADJUSTS TROLLING PRESURE PLATE SEE CHART INSTRUCTIONS Q 4 lt FIELD INSTALLATION INSTR 4 2465 Be465B e B2451 2451 Be451B SPRING 455 BE BAGGED SEPARATELY AND PLACED IN THE TRDLLING VALVE BAG F R SHIPPING SHIMS TO BE WRAPPED IN RUST INHIBITING PAPER THEN BAGGED SEPARATELY AND PLACED IN THE TROLLING VALVE BAG FOR SHIPPING TROLLING VALVE ASS Y ND DESEE dE 12 PT SCREWS SPACER Part 512 C9 Jary 62 GT Y parsrss SIRE avaran 2 pem e 846 azae peser pem e T
99. TING CONDITIONS HYDRAULIC CLUTCHED P T O 1017820 GEAR pue e TRAILING PUMP 1016473 FLEXIBLE COUPLING INPUTS SEE SHEET 4 OF 4 4 061 RATID 142 GEAR RATIOS ELECTRIC CONTROL VALVE WITH MECHANICAL BACKUP 24 VDC 1018084AH ADE d 15981 ELECTRIC CONTROL VALVE WITH MECHANICAL BACKUP 12 VDC 1018084AJ 4S0 4 65531 ELECTRIC TROLLING VALVE KIT 1018883 5034 695 1 MANUAL TROLLING VALVE KIT 1017555 8 e REMOTE FILTER KIT 1019824 1296 DIL TEMPERATURE INDICATING SWITCH B3424A FOR INSTALLATION LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 3 NOT SERVICEABLE SEPARATELY REMOVE BEFORE OPERATING 2 PLACES PLUGS BALANCING REQUIRED FOR 5 29923 4 10 00 SURVEY SOCIETY APPLICATIONS ______ Ere SEE PARTS DRAWINGS LL van 297981 1 7 0 P 2963610 18 99 LIII l 1 U 069413 02 1 1 29465 7 22 99 sro rev me foran 1017463 wc nd MG 5170DC ransmission P pas ser toa ev SCREW M422B 4 PLATE 82415 PLUG M2051CD PLUG 2080 2 RING 2916 2 A PLUG 2702 PLUG 2051 MOUNT UNIT INSTRUCTION PLATE CREF B2387 WITH TWIN DISC TRADEMARK TOWARD BREATHER PLATE B2387 PLUG M2051U 2 PLUG M2782A RING A2916BV SCREW M422B 42 A PLUG M2702E TEMP IND SWITCH B3424A TAG 656 GAUGE B3631E TUBE ASS Y XB2301H x TUBE B2
100. TWIN DISC INCORPORATED Service Manual Marine Transmission Components MG 5170DC Document Number 1020667 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 1020667 July 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 inte
101. There is a lubrication oil pressure relief valve to limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation Marine Transmission Service Manual 1020667 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 engagin
102. WOOFER HOLD DRILLED C BORED AND OR SAS g FLATNESS MMC MAX MATER TAPPED HOLES 005 Date 10 2 84 By SPATH Scole HALF jee Geen E NAME QUT PUT GEAR LIFTING FIXTURE FOR ASSEMBLY CONCENTRICITY FEATURE SIZI DEPT 344 Er E GIRCULAR runout MEL MME T FOR XA7470 7496 A7491A Recien AA agat Ried AUTOCAD FILE 1 1998 D REpRAww AuTocaD14 12 3 99 TMV A7486A 1002580 7501 PEL POSITION DIAMETER REV DESCRIPTION DATE Bv TWIN DISC RACINE WS 15 3 8 AN STK NOTE z gt A x Ner BEER HEEE ul Special Tools Twin Disc Incorporated Notes 208 Marine Transmission Service Manual 1020667 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 the following illustrations are for reference only Please refer to your bill of material for part numbers specific to your model Clutch Group Suction Strainer Oil Filter Transmission Rear View Transmission Section View Torsional Input Coupling Manual Control Valve Trolling Valve for Manual Control Valve Electric Control Valve optional equ
103. aaaaa aaa a aaa aa aaa aaa a aaa aaa anna nada 189 seal Driver 190 Bearing Driver T 18050 323 191 Bearing Driver T 18050 327 eene 192 Bearing Driver T 18050 335 193 Bearing Driver 18050 585 eese 194 Bearing Driver 18050 611 1 44 195 Oil Injection Tool 18614 5 115 196 Spring Retainer Hold Down 7 19998 197 Output Gear amp Shaft Puller for Assembly 20023 Sheet 1 198 Details for Puller T 20023 Sheet 2 199 Details for Puller T 20023 Sheet 3 200 Sleeve for Runout Check 21302 1 201 Oil Seal Protector T 21347 202 Oil seal Driver T 21347 1 203 Lifting Bracket for Clutch Removal in Boat 204 Bearing Driver T 18050 772 oou FARA ARRA AA RR RR EXER ERE EE EXE XXX XX RR DA 205 Output Gear Lifting Fixture 19987 207 Marine Transmission Service Manual 1020667 9 Table of Contents Twin Disc Incorporated n 209 List 0f 209 ilis E t prs 2 210
104. 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 1020667 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 1020667 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 1020667 Twin Disc Incorporate
105. acy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Torsional Input Couplings Installation For Models Provided by Twin Disc A 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 The following pages include the Assembly Instructions for CENTAFLEX R on Flange Mounted Gears taken directly from CENTA document 26 01 02 Marine Transmission Service Manual 1020667 CENTA CENTAFLEX R Assembly instructions on flange mounted gears CAUTION Before you start the coupling assembly Check there is axial play in each direction of the engine crankshaft to ensure the engine thrust bearings are not loaded Record the result Assembly Method Mount the gear half of the coupling to the gearbox input shaft as the design dictates Insert the rubber rollers into each of the sockets of the gearbox hub Usually the rubber rollers of the smaller sizes are held by an adhesive pad but on the large sizes a plastic assembly strap is used if these are not available or the coupling is being reassembled temporarily hold the rollers in place using string or tape secured with a slip knot ensuring the end is placed to the gearbox side Trial fit the assembly by offering up the coupling flange outer part or flywheel half to the gear half and push the
106. aft spline using fixture T 21302 1 with the probe on the O D of the front housing pilot Rotate input shaft and note 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 1020667 165 Assembly Twin Disc Incorporated 166 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Installation Installation Prior to Installation A CAUTION Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be 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 r
107. ailure 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 1020667 Twin Disc Incorporated Introduction Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Operators 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 9 One or more engines on a multiple transmission vessel are shut down while under way Sailboat under sail with auxiliary engine shut down Vessel tied up or docked in a heavy current The following solutions are applicabl
108. ainst transfer gear T Figure 93 Installing Clutch Shaft Rear Bearing Cone Marine Transmission Service Manual 1020667 131 Assembly Twin Disc Incorporated 7 Install external retaining ring with tapered edge side away from bearing 8 Beginning with a friction plate alternately install 9 friction plates and 8 steel plates into clutch housing transfer gear against clutch apply piston 9 Install clutch backplate and internal retaining ring Figure 94 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 132 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 12 Assembly of pinion A Use special tool T 18050 11 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 95 Installing Pinion Rear Bearing Cup Marine Transmission Service Manual 1020667 133 Assembly Twin Disc Incorporated B Install chilled needle roller bearing into bore at front of pinion with T 18050 25 C Install internal retaining ring into groove in pinion bore Figure 96 Installing Internal Retaining Ring Into Pini
109. ate 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 ball unseats from the orifice plate allowing main oil pressure to return to the neutral pressure level rapidly and again be regulated by the ball and spring regulator The ball returns to the pressure regulating position once the spring force is equal to force induced by the pressure at the rate of rise piston Marine Transmission Service Manual 1020667 45 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
110. cations 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 effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist itis evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush Overhaul Interval A complete overhaul and thorough inspection of the unit should be made at the scheduled engine overhaul Refer to Cleaning and Inspection for more detailed inspection instructions 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 9 Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required 66 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting Chart The following chart is intended as a guide for determining the cause of problems that could be enco
111. ce Manual 1020667 155 Assembly 156 Twin Disc Incorporated 6 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn Figure 124 Installing Dogpoint Setscrew 7 Install the steel detent ball into the valve body 8 Install the detent spring over the detent ball 9 Apply MA908 threadlocker to the threads of the hollow setscrew and 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 itis flush with the gasket surface of the valve body Check the stem rotation and detent action Figure 125 Installing Detent Ball Setscrew Marine Transmission Service Manual 1020667 Twin Disc Incorporated 10 11 12 13 14 Assembly Install the thrust bearing and races thrust washer on earlier units 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 126 Holes in Gasket and Cover Must be Aligned 15 16 17 18 19 20 21 Install cover capscrews and torque to 23 Nm 17 lb ft
112. 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 Marine Transmission Service Manual 1020667 19 Description and Specifications Twin Disc Incorporated Lubrication Features The MG 5170DC 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 XB36144A This should be replaced at 1000 hour or six month intervals whichever comes first Gears All gears are h
113. d Description and Specifications Description and Specifications General The suffix on the assembly drawing number designates the revision level of the transmission Assembly 1017463 uses the XA7371 series control valve as the standard mechanical valve Assembly 10174634 uses the 1020412 series control valve as the standard mechanical valve Service information is provided for both variations within this manual and the assembly drawing number is identified on the bill of material BOM 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 mu C EE RATIU V 30M NO cds CUSTDMER NUMBER MARINE TRANSMISSION CAPACITY GAL S MIN GIL PRESSURE WHEN CRUISING 1 UBRICATION EVERY 10 HOURS DAILY CHECK OIL LEVEL EVERY 100 HOURS DR WHEN IS DOCKED UBRICATE COUNTERSHAFT SEALS WI WATER PUMP GREAS PREVENT BILC WATER ENTERINC JUSINC EV ERY 1000 HOURS DRAIN AND REFILL HOUSING WITH CLEAN OIL REMOVE AND REPLACE FILTER ELEMENT TROLLING OPERATE ACCORDING TO INSTRUCTIONS IN SERVICE MANUAL MPLIR TANT WARRANTY IS VOID UNLESS TRANSMISSION IS LUBRICATED AND MAINTAINED AS SPEC ne IN THE ag MA NUAL AVAILABLE REQUEST REFER MARINE TRANSMISSION B UBRICANT PLZ SHIPPED WITH UNIT y BILL OF MATERIAL NO MUST BE GIVEN WHEN
114. d O ring right 84 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 3 Install three flat washers 1 2 ID or larger between the seal carrier and housing at each of the ten screw locations Reinstall the six hexhead capscrews and torque to 60 Nm 45 ft lb The gap between the seal carrier and the housing should be approximately 4 5mm 0 17 in Figure 47 Washers Installed 4 Remove the four setscrews from the two threaded holes in the output gear hub Figure 48 Output Gear Setscrews 5 Fill one hole in the output gear with oil until it flows out of the other hole Be sure all air bubbles are removed Marine Transmission Service Manual 1020667 85 Disassembly 86 Twin Disc Incorporated Wrap the threads of T 18614 5 with teflon tape and install the tool into one of the threaded output gear holes Wrap the threads of a 7 16 14 x 2 00 inch screw with teflon tape and install into the other output gear hole Fill tool with oil wrap screw with teflon tape and tighten screw into T 18614 5 Note If the gear does not come loose rewrap the threads on the screw with teflon tape refill the cavity with oil and try again Figure 49 Removing Output Gear from Output Shaft When the output gear comes loose remove T 18614 5 from the output gear Remove the output seal carrier Install wo eyebolts into the output shaft and hoist out the shaft Press the rear bearing cone off of t
115. d be installed in location convenient to both coolant and marine transmission oil HEAT EXCHANGER REQUIREMENTS PERMISSIB EMPERATURE INTO XCHANGER RATIO OIL VISCOSITY MAX MIN ALL RATIUS SAE 40 85 CU85 F gt 65 lt 150 gt A RATIOS SAE 50 93 CC200 F gt 8092 175 2 MIN HEAT TRANSFER CAPACITY kWCBtu min PER ENGINE RID gt APPLY APPROPRIATE SERVICE FACTUR CONTINUOUS DUTY C amp INT DUTY FOR FRESH AND RAW WATER 035 1 484 030 1 272 APPROX IW HI 2 96 L min C0 78 gpm gt PER 100 ENGINE rpm DIL PRESSURE H E PROOF TEST AT 15 X kPatpsi gt 2241 psp MAX A WABI PRESSURE DROP ACROSS HE WI 207 kPa 66mm s 300 SUS OIL AT RATED ENGINE rpm 30 psi Try WABLE WATER PRESSURE DROP ACROSS H E s oe WATER F W HE USE 15 TO 3 0 TIMES OIL L min Cgpm gt WATER PRESSURE RATING MIN 15 X T WATER kPalpsi BATA PURCHASER MUST LE VENDUR STATE IF RAW OPEN CHANNEL amp SEA OR FRESH CLOSED ENGINI E JACKET AND OR KEE COOLER WATER WI COOL H STATE MAX WATER TEMP INTO TYPICAL RAW WATER 29 C 32 C 85 F 90 F KEEL COOLER WATER 46 C 60 C 115 F 140 F ENGINE JACKET WATER x 74 C 85 C 165 F 185
116. 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 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 1020667 111 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratche
117. e for all MG 5170DC transmissions if any of the above conditions are present Lock the propeller shaft to prevent rotation Add 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 1020667 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services 14 All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you Note Do not order parts 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 the unit s nameplate
118. e transmission s control valve Marine Transmission Service Manual 1020667 55 Operation Twin Disc Incorporated Trailing Pump Optional The trailing pump is used to supply oil flow to the transmission lubrication circuit when the transmission is in a backdriving condition Backdriving sometimes referred to windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller 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 acheck 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 56 Marine Transmission Service Manual 1020667 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 re
119. e wires of all but one solenoid from the Weatherpak connector using the extraction tool Tool is Packard Electric P N 12014012 Figure 71 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them 5 Remove the third Neutral solenoid units with hydraulic lock or plug units without hydraulic lock 102 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 6 Remove the filter screen from the valve body Figure 72 Removing Filter Screen 7 Remove the two socket head O ring plugs from the bores in the end of the valve bogy 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 spool return spring and dowel pin from the bottom of each of the spool bores in the valve body Marine Transmission Service Manual 1020667 103 Disassembly Twin Disc Incorporated 1017555 Trolling Valve Optional Equipment 1 Remove the trolling valve attaching screws Figure 73 Removing Trolling Valve Attaching Screws A CAUTION 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
120. ed 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 1020667 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 th
121. elical 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 1020667 Twin Disc Incorporated Description and Specifications Flexible Torsional Input Coupling The purpose of the torsional coupling is to transmit power from the engine to the marine transmission through a rubber or silicone element that will Dampen torsional vibrations Change the natural frequencies of a system to move critical frequencies out of the operating speed range 9 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 Marine Transmission Service Manual 1020667 21 Description and Specifications Twin Disc Incorporated Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh water through the heat exchanger The heat exchanger shoul
122. emoved and the source of interference found and corrected Twin Disc will not be responsible for system damage caused by engine to Twin Disc component interference regardless of the cause of interference This engine crankshaft endplay check is considered mandatory The transmission housing flange and pilot the engine flywheel and the flywheel housing must be checked for trueness Clean the engine flywheel and flywheel housing mounting surfaces thoroughly before any measurements are made Note To isolate engine vibration and prevent transferring it to the hull through the propeller shaft the distance from the marine gear output flange to a fixed stuffing box or the first fixed bearing must be a minimum of 20 times the shaft diameter If the distance is less than this a flexible coupling may be necessary to isolate the engine vibration Marine Transmission Service Manual 1020667 167 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 woe Engine Enos ANE Flywheel Crankshaft Ji Engine j 4 Flywheel Housing Figure 137 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keepi
123. epth micrometer measure distance from rear face of output flange to end of output shaft Record this distance as dimension A Measure distance from rear face of output flange to inner shoulder of flange against which retainer washer is installed Record this distance as dimension B Determine gap between retainer washer and end of shaft by subtracting dimension from dimension A Figure 111 Measuring Output Flange Gap Use shims to develop a shim pack to reduce gap between retainer washer and end of shaft to 0 127 mm to 0 254 mm 0 005 in to 0 010 in 146 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 4 Install O ring to seal output shaft splines and output flange Figure 112 Installing Output Flange O ring 5 Install shim pack developed step 3 and retainer washer Install the hexhead capscrews and torque to 434 Nm 320 ft Ib Figure 113 Installing Output Flange Shims and Retainer Washer Marine Transmission Service Manual 1020667 147 Assembly 148 Twin Disc Incorporated 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 housing with probe resting on O D of output flange pilot Check pilot runout by rotating output flange Total indicated r
124. equate lifting devices and procedures are necessary for safety considerations This requires that the transmission assembly be adequately supported and properly positioned as identified in the following paragraphs 72 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly Remove Transmission External Components and Sub Assemblies 1 Remove coupling from spline on primary shaft if not previously removed 2 Remove front housing from main housing 3 Support the unit on an assembly stand or blocks with the output side facing up Use caution to prevent damaging the primary shaft splines 4 Remove the oil filter element Figure 26 Removing Filter Element 5 Remove filter bypass valve components from manifold Figure 27 Removing Filter Bypass Valve Components Marine Transmission Service Manual 1020667 73 Disassembly Twin Disc Incorporated 6 Remove the control valve and gasket Set it aside for later disassembly 7 Remove breather and oil filler screen from top cover plate Figure 28 Removing Breather and Screen 8 Remove top cover plate and gasket 9 Remove oil pump and gasket Figure 29 Removing Oil Pump 74 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 10 Remove suction strainer cover hex head O ring plug Remove spring and suction strainer Figure 30 Removing Suction Strainer Marine Transmission Service Manual 1020667
125. er stop with the portable press 6 Remove T 20023 from the output shaft and gear 7 Confirm that the output gear has been advanced completely such that there is no gap between the shaft shoulder and the gear hub 8 Install the two setscrews into each hole in the output gear hub torquing each setscrew to 20 Nm 15 ft lb 9 Install the pinion front bearing cones for primary and secondary shafts onto bearing cups previously installed in transmission housing 120 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 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 323 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 After bearing warms press drive bearing cup down to assure that bearing cup is bottomed in bore of seal carrier Marine Transmission Service Manual 1020667 121 Assembly Twin Disc Incorporated Output Shaft Tapered Roller Bearing Adjustment 122 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
126. ert additional shims Continue this procedure until the marine gear is completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of the engine flywheel housing secure the mounting brackets to the engine bed rails Before securing the mounting brackets to the engine bed rails the propeller shaft should be checked for alignment Note The transmission output flange and companion flange bolts must be torqued to the proper value as identified in Description and Specifications Marine Transmission Service Manual 1020667 173 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 142 Transmission Mounting Configurations When mounting the engine and transmission in the boat all of the mounting pads on both the engine and the transmission must be used Failure to do so may result in damage to the transmission It is important to align the engine and transmission only when the boat is afloat and NOT in dry dock During this alignment period it is also advisable to fill the fuel tanks and load the boat in the typical manner that it is to be used Some boats are built wit
127. eso ves VALVE SPRINGS SPRING CONSISTS OF ASS Y OUTER INNER ORIFICE PLATE PART SIZE A270 Rl INN TY gum Y SHIMS lt OY 6 WS 270 Bessa 4 e 2 16038 12 PT SCREVS 2 wcsi4 wenesr 2 maosna weogsac 2 226 2 wenesec 88 22 2 2 2 e e 8 meosor e TE 5 K 2089 E ZIIR 6 2089 1 mosis E E maono maosa 84 mus 2 weossr 2 SERES Meog9P 2 2 MEHL SENS P e weossak mestaa 32 e wcsie 1 amp 2 weoesr 5090 22 INeosor e maosa 2 SHR 5 2 weossas 2 ES mex 2 2 5645 JS DAS 1 meves 5 pese 52 USE AS REQUIRED 1704 7 71 8127 B1397D 952 270 YES
128. essure 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 a V Sa p gt m E 2 Figure 20 Stem Pocket or Passage Main pressure oil can flow through the hole in the end of the stem to a narrow slot between the two pockets This slot does not connect to any other passages when the stem is in the Neutral position When the lever and stem are rotated to engage either the primary or secondary clutch main pressure oil flows through the slot in the stem to the appropriate clutch pressure port The opposite clutch port passage remains connected to sump by the same pocket in the stem as when the stem was in the Neutral position When the stem is rotated back to the Neutral position the main pressure oil slot in the stem is no longer aligned with either clutch port Both clutches are again vented to sump by the two pockets in the stem 50 Marine Transmission Service Manual 1020667 Twin Disc Incorporated mu 7B 222720 ARY MESE ING PINIDN amp Cl UT CH SHOWN UED Operation
129. f hand tools lifting equipment power tools or unaccepted maintenance working practices Marine Transmission Service Manual 1020667 11 Introduction 12 Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure safe operations under prevailing conditions Proper guards and other safety devices that may be specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Inc Selecting NEUTRAL disengages transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a shaft brake or other shaft locking device must be used To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove ignition key from the switch Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these points could cause f
130. face to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter o IL JT 1f Engine Flywheel c Engine Thousandths Crankshaft Indicator Figure 139 Checking the Flywheel Face Runout 170 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Installation 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 Housing ce 4 gt I Thousandths P L Indicator Engine Crankshaft Flywheel Figure 140 Checking the Flywheel Pilot Ring Bore Eccentricity Marine Transmission Service Manual 1020667 171 Installation Twin Disc Incorporated Installation Alignment Y Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boat to change its form with various loads and with age Eng
131. ft 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 1020667 91 Disassembly Twin Disc Incorporated Selector Valve Disassembly Mechanical Valve 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 Remove the orifice plate cover orifice plate and check ball Figure 53 Removing Orifice Plate and Check Ball 2 Remove the check ball spring and shim s from the valve body Figure 54 Removing Check Ball Spring 92 Marine Transmission Service Manual 1020667 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 55 Removing Shims from Rate of Rise Piston 4 Remove the pressure regulating springs and pressure regulator piston Figure 56 Removing Regulator Springs and Regulator Piston Marine Transmission Service Manual 1020667 93 Disassembly Twin Disc Incorporated 5 Remove the O ring plug detent spring and detent ball Figure 57 Removing O ring Plug Detent Spring and Ball 6 Mark the leve
132. g and remove clutch backing plate 7 Remove clutch plates 8 steel 9 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 51 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 from pockets in face of piston 90 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly C Carefully apply compressed air to hydraulic pressure port to force piston from piston bore Remove clutch piston Figure 52 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 of the sha
133. g 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 1020667 43 Operation 44 Twin Disc Incorporated Control Valve Assembly in Neutral Some of the main pressure oil from the oil inlet chamber flows through a passage to the orifice in the orifice plate The small flow of oil through this orifice fills and begins to pressurize the rate of rise chamber Both clutches are connected to sump when the control valve is in Neutral Since there is no pressure acting on the shuttle ball from either clutch the passage behind the ball and spring regulator is also connected to sump This allows the oil pressure in the rate of rise chamber to be regulated by the ball and spring since the overage oil can flow to sump The oil pressure in the rate of rise chamber acting on the rate of rise piston causes it to stroke over partially which compresses the pressure regulating springs additionally This additional spring compression further resists the movement of the pressure regulating piston resulting in a force balance between the area at the pressure regulator the springs and the area behind the rate of rise piston Neutral main pressure
134. grease oil etc Do not touch cleaned surfaces Loctite amp 7070 cleaner is recommended A 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 gear using only the weight of the shaft 3 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 3 35 mm to 4 42 mm 0 132 in to 0 174 in Figure 83 Measuring Output Gear Advance Marine Transmission Service Manual 1020667 119 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 Install T 20023 onto the output shaft and gear Figure 84 Output Gear Advancing Tools Installed B Advance gear to shaft should
135. h flexibility and may change shape as the loading varies 174 Marine Transmission Service Manual 1020667 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 to one side or the other on the engine bed to obtain horizontal alignment This can be done with a jack placed horizontally between the engine and the foundation At the same time a straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE MALE FEMALE STRAIGHT EDGE Figure 1
136. he bearing cups for location identification 7 Remove the lubrication oil pressure relief valve from the bearing carrier Figure 36 Lubrication Oil Pressure Relief Valve 78 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly Remove Primary and Secondary Clutch Shaft Assemblies 1 Lift out primary shaft Disassembly of the primary and secondary shafts are covered later in this section Use caution with the front pinion bearing cones They are loose on the pinion diameter and should remain in the housing On some ratios the diameter of the output gear will allow the bearing to come out with the shaft and it could easily fall off causing damage Set the shaft aside for further disassembly UT W 4 Figure 37 Removing Primary Clutch Shaft Assembly 2 Lift and push aside the suction tube to allow the secondary shaft assembly to pass by Lift out secondary shaft assembly Again use caution with the front pinion bearing cone s at uli Figure 38 Lifting Secondary Clutch Shaft Assembly Past Suction Tube Marine Transmission Service Manual 1020667 79 Disassembly Twin Disc Incorporated 3 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
137. he output shaft Slide the output gear out of the housing on wood boards far enough to install lifting eyebolts Using a hoist remove the output gear Remove the front output bearing cone Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 13 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 I D of the bearing cup with an electric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced 14 Remove input oil seal Remove input oil seal protector plug if replacement is necessary Marine Transmission Service Manual 1020667 87 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 s
138. hen inspecting the flexible coupling look for evidence or conditions identified in the following steps Cracks in the surface of the rubber May be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate 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 1020667 Twin Disc Incorporated Preventative Maintenance Inspect the hub looking for the following 9 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 1020667 65 Preventative Maintenance Twin Disc Incorporated Heat Exchanger Check Heat exchangers furnished by Twin Disc to be used for salt water appli
139. ice Manual 1020667 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 91 Return Springs and Spring Retainer Ready for Installation Marine Transmission Service Manual 1020667 129 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 92 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 130 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 6 Use driver T 18050 327 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 ag
140. ice plate cover and gasket onto valve body Install cover capscrews and torque to 23 Nm 17 lb ft 29 Install gasket over lower valve body half 30 Setupper 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 1020667 159 Assembly Twin Disc Incorporated 160 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 129 Installing O ring onto Adapter 2 Install a new O ring into the groove of the stem 3 Install the roll pin into the end of the stem if removed 4 Install the inner spring onto the roll pin in the stem end with a counterclockwise twisting motion The spring is to be installed onto the roll pin such that the first coil contacts the end of the stem 5 Apply assembly grease to the stem from the O ring to the reduced diameter end Install the stem into the adapter with the reduced diameter end entering the adapter first Adjust the position of the stem if necessary to bring the helical slot into alignment with the dog point setscrew hole 6 Install the large diameter washer used on some models inside the bore of the adapter and over the i
141. ices 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 1020667 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 T 18050 11 T 18050 25 18050 183 18050 321 18050 323 18050 327 18050 335 18050 585 18050 611 T 18614 5 T 19998 T 20023 T 20023 T 20023 T 21302 1 T 21347 0 0 0 D0 0 O0 0 0 yu O0 0 Jg LB T 21347 1 Marine Transmission Service Manual 1020667 Bearing Driver Driver Bearing Driver Seal Driver Bearing Seat Driver Bearing Driver Driver Bearing Driver Bearing Driver Oil Injection Tool Spring Retainer Hold Down Output Gear and Shaft Puller Sheet 1 Output Gear and Shaft Puller Sheet 2 Output Gear and Shaft Puller Sheet 3 Sleeve for Run
142. il 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 check 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 1020667 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 28 liters 7 5 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
143. 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 1020667 Twin Disc Incorporated Operation d Oil Pressure Chamber C Oil Pressure Overflow Port 0 c REGULATOR FIERIN D Oil Engaging Passage E Oil Engaging Passage F Oil Interconnection Slot G Directional Port H Oil Connection Port J Oil Pressure Passage K Oil Directional Port L Pressure Chamber RATE OF RISE PISTON CONTROL VALVE LEVER SPRINGS CONTROL VALVE STEM CONTROL Q VALVE BODY 0 ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 9 Control Valve Primary Sectional View PRIMARY CONTROL VALVE BODY TO PRIMARY CLUTCH TO SUMP TO SECONDARY CLUTCH CONTROL VALVE STEM EJ ATMOSPHERIC PRESSURE LJ ENGAGING PRESSURE Figure 10 Control Valve Primary Cutaway View Marine Transmission Service Manual 1020667 39 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
144. ine and shaft alignment can also change on a boat due to varying loads and the boats 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 FLYWHEEL HOUSING Figure 141 Marine Gear Alignment Marine Transmission Service Manual 1020667 Twin Disc Incorporated Installation 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 gear and ins
145. iously 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 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 engag
146. ipment D D D D DO OD Trolling Valve optional equipment Marine Transmission Service Manual 1020667 209 Illustrations Clutch Group AO NU LAL NU gt a 5 ate H ERN 2 gt AN T TT Twin Disc Incorporated 607 210 Marine Transmission Service Manual 1020667 29902014 3914195 uoissiusueJ SUMEN LLZ Qty Description 2 Bearing tapered roller primary and secondary shaft front bearing Ring internal retaining Ring external retaining primary and secondary shaft needle bearing Shaft assembly secondary Bearing needle roller Pinion assembly O ring speed pick up port plug Plug 5 8 18 speed pick up port Bearing tapered roller primary and secondary pinion rear bearing Backplate clutch Ring internal retaining clutch backplate Retainer spring primary and secondary shaft Ring external retaining primary and secondary shaft 9 spring retainer Spring assembly compression clutch release Ring piston clutch piston inner Piston clutch Ring piston clutch piston outer Gear transfer secondary shaft LH helix Bearing tapered rol
147. ith optional electric control valve Torque the ditchplate attaching capscrews to 52 Nm 38 ft Ib Install control valve and gasket Torque the valve attaching capscrews to 54 Nm 40 ft lb Figure 135 Optional Electric Control Valve Installed 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 88 Nm 65 ft Ib Marine Transmission Service Manual 1020667 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 136 Measuring Front Housing Face Runout Attach a dial indicator to the input sh
148. lace the gear Inspect thrust faces of gears for scores scratches and burrs 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 Transmission Service Manual 1020667 113 Cleaning and Inspection Twin Disc Incorporated 114 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly Assembly 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 1020667 115 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
149. ler primary and secondary shaft rear bearing Gasket bearing carrier Gasket manifold Manifold Gasket oil pump Pump oil Ring piston secondary shaft Shim bearing 0 005 0 007 0 020 inch Spacer bearing Pin dowel Carrier bearing Plate clutch friction Plate clutch steel PNA 2 5510 UIML suonensnil Illustrations Twin Disc Incorporated Suction Strainer pA JA xt lt _ js Strainer suction Spring compression O ring suction tube Tube assembly suction O ring suction strainer plug Plug suction strainer 212 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Cil Filter Tube lubrication Filter oil Gasket filter bypass valve Screw hex head cap filter bypass valve Cover filter bypass valve Spring compression filter bypass valve Poppet filter bypass Ball steel lube relief valve Washer flat Screw hex head cap Housing lube relief valve Spring compression lube relief valve Marine Transmission Service Manual 1020667 Illustrations 213 Illustrations Twin Disc Incorporated Transmission Rear View
150. ling Check Ball Spring Shim s and Spring 152 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 11 Place one orifice plate gasket the check ball and the orifice plate onto the valve bogy Figure 121 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 lb 13 Install valve onto the transmission and torque the attaching screws to 20 Nm 27 ft Ib 14 Install the remaining O ring plugs Torque the M12 plugs to 16 Nm 12 ft Ib and the M27 O ring plug to 75 Nm 55 ft Ib Marine Transmission Service Manual 1020667 153 Assembly Twin Disc Incorporated 154 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 122 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 75 Nm 55 Ib ft 6 Apply lubricant such as Dow Corning 2006 30 000cSt fluid to the O rings of the solenoids and plug plug used on units without
151. mall 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 88 Marine Transmission Service Manual 1020667 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 Figure 50 Removing Round Retaining Ring From Input 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 1020667 89 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 housin
152. mblies 240 1020412 Mechanical Control Valve 107463A assemblies 241 XA7373 Trolling Valve for XA7371 Control Valve 242 1020413 Trolling Valve for 1020412 Control Valve 243 1018084 Electric control valve 244 1017555 Valve assembly mechanical trolling 245 1017554 Valve assembly electric trolling 246 1016473 Electric Trailing PU vcscssccssccscsscscsccccssssssscccccccccccccccccsssas 247 10 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc model MG 5170DC marine transmission Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wisconsin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and application of the material in this manual will result in consistent performance from the unit and help reduce downtime Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Inc will not be responsible for personal injury resulting from careless use o
153. nded 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 with
154. 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 necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil Marine Transmission Service Manual 1020667 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 Marine Transmission Service Manual 1020667 71 Disassembly Twin Disc Incorporated Prepare Transmission for Disassembly Note During service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the old O rings gaskets and seals with the appropriate components being disassembled for future reference during the inspection and assembly process to make sure you don t forget the quantity size etc Drain the oil from the transmission sump by removing the hex drain plug from the bottom of the oil pan Drain the oil from the filter housing as well by removing the pipe 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 ad
155. ng a thrust in the same direction and note the face deviation of the engine flywheel housing flange The face deviation must not exceed the figures given in Table 9 168 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Installation Table 9 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations and Bore Eccentricity mm in 0 48 0 019 0 41 0 016 0 36 0 014 0 25 0 010 0 23 0 009 0 20 0 008 0 18 0 007 _____ _____ ____ 0 28 0 011 _____ ____ With the indicator mounted as in the previous paragraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing p Thousandths Engine M A Hh 27 Flywheel Engine y Crankshaft E Engine Flywheel Housing Figure 138 Checking Flywheel Housing Bore Eccentricity Marine Transmission Service Manual 1020667 169 Installation Twin Disc Incorporated 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the previous Table for allowable tolerances 5 Bolt a 5 dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the sur
156. ng 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 has been attained 140 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly Check for primary shaft Repeat steps 1 through 6 on the previous page to adjust endplay for primary shaft Figure 104 Checking Primary Shaft Bearing Adjustment Marine Transmission Service Manual 1020667 141 Assembly Twin Disc Incorporated Installation of Manifold Exterior Components 1 Install pump suction strainer into bore in manifold followed by the spring Figure 105 Installing Suction Strainer into Manifold 2 Install new O ring onto suction strainer O ring plug Apply assembly grease or oil to the O ring and install the plug torquing it to 108 Nm 80 ft lb 3 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 106 Installing Primary Shaft Cover O ring left and Primary Shaft Cover Installed right 142 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 4 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
157. ng 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 secondary 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 1020667 61 Preventative Maintenance Twin Disc Incorporated General Maintenance 62 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 o
158. nner spring until it lays flat on the end of the stem 7 Install the small washer used on some models inside the piston The washer must lie flat at the bottom of the bore in the piston Marine Transmission Service Manual 1020667 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 130 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 0 12 in from the valve body when the dog point of the setscrew is fully engaged in the helical slot Figure 131 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 1020667 161 Assembly Twin Disc Incorporated 11 Install the detent ball and spring into the remaining hole in the valve body Apply MA908 threadlocker to the threads of the detent setscrew and install until flush with the valve body gu Figure 132 Installing Detent Ball Spring and Setscrew 12 13 14 15
159. of approximately 40 psi is maintained by relieving excess oil behind the rate of rise piston through the ball and spring regulator Ball and Spring Regulator Figure 14 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1020667 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 passage to the opposite clutch The pressurized oil also forces the ball of the ball and spring regulator against its seat on the orifice plate stopping the flow of oil from the rate of rise chamber to sump Since oil continues to flow into the rate of rise chamber through the orifice the oil pressure in the rate of rise chamber increases This increased oil pressure forces the rate of rise piston to stroke over to its stop in the valve body compressing the pressure regulating springs even further yet Rate of rise piston Figure 15 Rate of Rise Piston in Neutral left and Rate of Rise Piston with Clutch Engaged right The travel rate of the rate of rise piston and resulting pressure rate of rise is controlled by the orifice size regulator spring stiffness and the final main pressure after completion of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the r
160. of the housing to the bottom of the bearing cup bore where the oil shield contacts dimension Measure and record the thickness of the oil distribution shield at the outer edge dimension B Measure and record the width of the bearing cup dimension 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 T 18050 772 to ensure the bearing 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 82 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 minus dimension C within 0 025 mm 0 001 in 118 Marine Transmission Service Manual 1020667 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
161. on 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 134 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly E Install external retaining ring to retain pinion on shaft d Figure 97 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 1020667 135 Assembly Twin Disc Incorporated 15 Install oil suction tube into transmission housing with flange end lifted out of position to allow the secondary shaft assembly to pass by Figure 98 Installing Suction Tube left with Flange Positioned right 16 Install clutch shaft assemblies into transmission housing Use caution to prevent damaging the shafts gears and bearings UIT jl Figure 99 Installing Clutch Shaft Assembly 17 Move the oil suction tube into the installed position so its flange is seated within the housing counterbore 136 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly Installation of Bearing Carrier 1 Install a new O ring into
162. on 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 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 1020667 29902014 enue y 2914199 uoissiusueJ SUNEN oneuieuos A6LLZV 79 S
163. ontrol Valve Neutral Cutaway View Marine Transmission Service Manual 1020667 37 Operation 38 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 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
164. ot ser viceable 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 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 1020667 Twin Disc Incorporated 3 4 5 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 Improper alignment Damaged propeller Misfiring engine Marine Transmission Service Manual 1020667 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 Overhaul marine
165. out Check Seal Protector Seal Driver 185 Special Tools Twin Disc Incorporated Lifting Bracket for Clutch Removal in Boat 18050 772 Bearing Driver T 19987 Output Gear Lifting Fixture 186 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Special Tools Bearing Driver T 18050 11 BEARING 247 REV DESCRIPTION DATE BY CUP MA 590 D A REDRAWN ON AUTOCAD o 7 97 s Ew ZLA aX 1 16 x 45 TYP 150 DIA 3 00 KNURL aet A IRILL THRU DET 1 ee amp TAP DET 2 FOR 51 Pp SCREW DET 3 NS 1 Ne 20 z M R13 A d N Gee N J eo REF N 4 N Y N J N 1 40 FN 90 052 0 90 NM RE me n 75 DIA 3614 N R 06 407 3 SHLDR HEAD CAP SCREW 1 2 13 x 12510 CEA 0 11 2 MS DRIVER HANDLE 1 75 DIA x 5 25 2 n n 2 X 229945 4140 DRIVER BASE 4 50 DIA x 175 SCALE FULL DET REQ DESCRIPTI SIZE NAME MA 247 BEARING DRIV DATE 9 2 80 DBL 7 18 WIN DISC INC AUTOCAD FILE R S 229945 Marine Transmission Service Manual 1020667 187 Special Tools Driver T 18050 25 Twin Disc Incorporated MP 2893 SHAI tets e DIA y DESCRIPTION REDRAWN ON AUTOCAD ES AZ EV DATE 29MAYO 4
166. 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 MG 502 MG 5010 MG5011 MG5005A MG5015A 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 MG516 MG5161 MG5170DC MG 518 1 MG520 1 MG 5202 MG5203 MG5204 MG5205 MG 530 MG530M MG5301 MG 540 MG5600 MG6000 80 MGN232 MGN233 MGN272 MGN273 MGN332 MGN334 MGN335 MGN432 MGN433 MGN472 MGN493 MGN650 MGN800 MGN1000 MGN 1400 MGN1600 PUMP ALL MODELS VALVE ALL MODELS September 4 2001 UNIT REBUILD CLUTCH REPAIR BOTH PACKS TDWP2003A Twin Disc Incorporated Table of Contents Table of Contents 19 enterica 11 General Information 11 Safety and General Precautions
167. r 61 General 4 4 4 0 1111111 62 Marine Transmission Service Manual 1020667 7 Table of Contents Twin Disc Incorporated 67 Troubleshooting 67 pj get T1 Prepare Transmission for Disassembly 72 Remove Transmission External Components and ctc pu 73 Remove Clutch Assemblies 2 1 2 76 Remove Primary and Secondary Clutch Shaft Assemblies 79 Remove Output Flange and Oil 81 Remove Output Shaft and 84 Disassembly of Primary Shaft or Secondary Shaft Disassembly of Secondary Shaft is Described 88 Disassembly of Upper Valve Body Half electric section 102 1017555 Trolling Valve Optional Equipment 104 Cleaning and Inspection 109 Clea ea a 109 P 111 i Y 115 Prior ASSEIDIV vatican ean 116 Preliminary 117 Installation of Output Shaft and Gear
168. r 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 58 Removing Lever 94 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 7 Remove the cover and stem together as a unit Figure 59 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 60 Removing Roll Pin and Stop Collar 9 Slide the stem out of the cover 10 Remove the oil seal from the cover Marine Transmission Service Manual 1020667 95 Disassembly Twin Disc Incorporated 11 Remove the O ring from the stem Figure 61 Removing O ring from Stem 12 Remove the thrust bearing and races from the stem Figure 62 Removing Thrust Bearing and Races from Stem 13 Remove the remaining plugs from the valve body 96 Marine Transmission Service Manual 1020667 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 lo
169. r s in the bore of the piston some models Figure 78 Removing Spring and Piston from Valve Body 13 Remove the O ring from the groove and the oil seal from the end of the adapter Figure 79 Removing O ring From Adapter Marine Transmission Service Manual 1020667 107 Disassembly Twin Disc Incorporated 108 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Cleaning and Inspection Cleaning and Inspection Cleaning Note Replace all oil seals gaskets O rings piston rings seal rings snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents by steam cleaning Parts must be dried and oiled immediately to prevent corrosion Examine all parts carefully for grit dirt 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 oil pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher screw locations Marine Transmission Service Manual 1020667 109 Cleaning and Inspection Twin Disc Incorporated 110 Cleaning Bearings
170. rain plug Gear output Marine Transmission Service Manual 1020667 217 Illustrations Twin Disc Incorporated Torsional Input Coupling d gt gt cu 0j LLL N rai N _ RU Sa UU N prd z a 2 N ay N NN 21 D gt m at 5 CD a a gt 5 C2 218 Marine Transmission Service Manual 1020667 29902014 enue y 3914195 uoissiusueJ SUNEN 61 Item Qty Description 6 6 1 1 1 1 1 1 1 1 1 8 1 1 1 1 3 Coupling assembly SAE 1 Screw hex head cap input coupling hub Nut hex input coupling hub Hub splined coupling close coupled units Ring internal retaining Coupling assembly SAE 0 Coupling assembly SAE 1 Ring internal retaining Coupling assembly SAE 0 Element to service item 127 or 129 Hub splined coupling free standing units Ring internal retaining Washer retaining Shaft assembly primary free standing units Screw hex head cap input coupling hub pe1eJodajoou 5510 UIML suoneusnill Illustrations Twin Disc Incorporated Manual Control Valve
171. remains the responsibility of the assembler to ensure the CENTAFLEX coupling offered is dimensionally suitable for the application CENTA cannot accept 55 any liability for incompatibility of fit or SG consequence thereof Remove the coupling flange outer part and bolt it to the engine flywheel Torque tighten using the engine manufacturers recommendation but in the absence of it the table below gives gene ral guidelines Coupling Flange to Engine Flywheel Bolts These bolts are not supplied with the CENTAFLEX R Coupling but where no instructions are available from the engine supplier the following can be used as a guide SAE J620c May93 290 11 M10 DIN 8 8 SAE 3 8 16 SAE 8 B M12 DIN 8 8 SAE 15 13 SAE 8 18 M16 DIN 8 8 SAE 5 8 11 SAE 8 530 21 M16 DIN 8 8 SAE 5 8 11 SAE 8 Best Commercial Based on lightly oiled bolts Tolerance 5 Anaerobic adhesives eg Loctite can be used As necessary refit the rubber rollers to the coupling hub using advice as given above Complete the engine gearbox connection by engaging both halves of the coupling again ensu ring the arrows cast into both flange and hub are aligned see sketch 2 CORRECT INCORRECT SKETCH 2 ENSURE CORRECT ASSEMBLY ALIGNMENT WITH THE ARROWS Bolt the gearbox mounting flange to the engine flywheel housing using the gearbox manufac turers engine manufacturers instruction MANDATORY Caution Before you
172. s 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 sharp edges and evidence of overheating Remove scores with a crocus cloth If the bushing is out of round deeply scored or excessively worn replace it Thrust Washers and Spacers Inspect thrust washers for distortion scores burrs and wear Rework or replace any defective thrust washers or spacers 112 Marine Transmission Service Manual 1020667 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 rep
173. s blocked when either clutch is engaged This full pressure causes the rate of rise piston to remain against its stop in the valve body bore and main oil pressure is not reduced Detent position Trolling mode orifice closed orifice opened Figure 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 1020667 53 Operation 54 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 prev
174. se 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 Install assembled manifold over alignment studs and dowels Use a soft hammer near the dowels to seat manifold against gasket and over dowels Install manifold attaching screws and torque to 37 Nm 27 ft Ib Marine Transmission Service Manual 1020667 139 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 103 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 N 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 readi
175. secondary shaft Install attaching screws and torque to 37 Nm 27 ft Ib 5 Install oil filter Marine Transmission Service Manual 1020667 143 Assembly Twin Disc Incorporated Installation of Top Cover Oil Gauge and Oil Pan 1 Install top cover assembly with its gasket Install attaching screws and torque to 37 Nm 27 ft Ib 2 Install strainer and breather filler cap Figure 107 Installing Strainer and Breather 3 Install oil gauge tube assembly and oil level gauge Figure 108 Installing Oil Gauge Tube 144 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 4 Install the gear pan onto the oil pan and torque the screws to 24 Nm 18 ft Ib Figure 109 Installing Gear Pan 5 Install two alignment studs into the transmission housing to help guide and align the oil pan Install a new gasket over the alignment studs Install the oil pan aligning the oil gauge and suction tube with the appropriate holes in the gear pan flange Install the attaching screws and torque to 88 Nm 65 ft Ib Figure 110 Suction Tube Engaged into Gear Pan Flange Marine Transmission Service Manual 1020667 145 Assembly Twin Disc Incorporated 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 Assure that flange seats solidly against rear tapered roller bearing on output shaft 3 With a d
176. spective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in anti engine direction Application of the secondary clutch locks the secondary pinion to the secondary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in engine direction Marine Transmission Service Manual 1020667 57 Operation Twin Disc Incorporated Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Pi nimi Driving Gear Primary Shaft _ secondary Shaft a 7 Driven Gear NEUTRAL Output Gear Figure 23 MG 5170DC Power Flow in Neutral 58 Marine Transmission Service Manual 1020667 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 inpu
177. ss of steel ball 1 Loosen and remove four of M8 x 25 socket head capscrews and remove orifice plate cover and gasket Figure 63 Removing Orifice Plate Cover Gasket 2 Remove orifice plate Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket Marine Transmission Service Manual 1020667 97 Disassembly Twin Disc Incorporated 5 Remove rate of rise piston Note that shims are located between the piston and springs Figure 64 Rate of Rise Piston left and Regulator Springs right 6 Remove pressure regulating springs T Remove pressure regulating piston with an external retaining ring pliers Figure 65 Removing Regulating Piston with Pliers 8 Remove external retaining ring from the lever end of the stem 9 Loosen the clamping nut and remove the control lever from the stem may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 10 Remove the washer and spring from the stem 98 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 11 Remove four of M8 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 66 Removing O ring from Cover 14 Remove the two electrical switches from the sides of the valve body and the
178. ssion Service Manual 1020667 149 Assembly Twin Disc Incorporated 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 115 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 116 Installing Stem Assembly into Valve Body 150 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly 5 Install the detent ball spring and O ring plug Torque the plug to 37 Nm 27 ft lb Figure 117 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 118 Installing Regulator Piston left and Springs right Marine Transmission Service Manual 1020667 151 Assembly Twin Disc Incorporated 8 Install the pressure regulator adjustment shims into the rate of rise piston Figure 119 Pressure Regulator Adjustment Shims 9 Install the rate of rise piston with shims into the valve body 10 Install the check ball spring shim s and spring into the valve body Figure 120 Instal
179. st relative out of true parallel measurement Figure 144 Checking Output Flange Face Runout Marine Transmission Service Manual 1020667 Twin Disc Incorporated Installation M DIAL INDICATOR 9J Figure 145 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 1020667 177 Installation Twin Disc Incorporated 178 There are many types of flexible couplings in the market today that solve a variety of problems Couplings to reduce noise and vibration Couplings to allow a permanent angular misalignment Couplings that allow engines to be flexibly mounted and take out the momentary misalignment In some cases the proper alignment of these couplings requires an accur
180. start the engine Check there is axial play in each direction of the engine crankshaft to ensure the engine thrust bearings are not loaded Check it is the same as before the coupling was fitted Doc 26 01 02 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 A 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 devices or electrical connections Marine Transmission Service Manual 1020667 181 28 1 18UNC
181. t pinion will be backdriven engine direction when the unit is in the primary position Primary Glutch Engaged Figure 24 MG 5170DC Power Flow with Primary Clutch Engaged Marine Transmission Service Manual 1020667 59 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 Secondary Clutch Engaged Figure 25 MG 5170DC Power Flow with Secondary Clutch Engaged 60 Marine Transmission Service Manual 1020667 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 0D O0 0 Note Note Removing and installing the oil pump Changing the filter Removing cleaning and installi
182. t shaft in tapered bore of gear by applying 445 N to 890 100 165 to 200 165 downward force on shaft 126 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Assembly Center fixture gear and shaft under ram of press and apply approximately 200 kN to 338 kN 22 tons to 38 tons of force on front end of secondary shaft Release pressure and turn fixture shaft and gear 180 Reapply pressure to complete advance mta Figure 89 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 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 1 96 mm to 2 97 mm 0 077 in to 0 117 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 1020667 127 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 groove 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 gt _ E cu Figure 90 Installing Clutch Piston 128 Marine Transmission Serv
183. the flange of the suction tube 2 Install bearing carrier gasket over dowels onto rear face of housing 3 Assemble lube relief valve spring and lube 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 20 Nm 15 ft lb 4 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 100 Bearing Carrier Installed Marine Transmission Service Manual 1020667 137 Assembly Twin Disc Incorporated 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 Figure 101 Installing Lube Tube left and Lube Tube Installed right 138 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 Install manifold gasket over alignment studs and against bearing carrier Push tapered roller bearing cups with shim retainers firmly against roller bearing cones on rear of primary and secondary shafts
184. transmission Inspect and correct cause of suction leak Inspect repair or replace control valve Overhaul marine transmission Remove marine transmission Replace a worn or damaged coupling Select proper torsional coupling Overhaul marine transmission Check alignment of engine and transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine 69 Troubleshooting 6 7 8 9 70 Twin Disc Incorporated Table 8 Troubleshooting Chart continued Symptom No neutral Harsh engagement Low lube oil pressure Cil 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 Overhaul unit Check and adjust control linkage Replace defective solenoid Inspect repair or replace hydraulic lock spool Disassemble control valve Clean parts Replace parts if
185. two halves together Should the resistance be too high use a lubricant such as soft soap silicone grease or similar mineral oil can be used sparingly as a non preferred lubricant Should the rollers be held with tape or string once the outer part is started remove it Push the coupling flange outer part fully home to the aligned position Rotate the com plete assembly a few times to ensure that there is no interference If there is the source must be identified and eliminated before you proceed Check the axial length dimension G1 in sketch 1 between the gearbox mounting flange and coupling flange do this in several places and take the average result Measure engine flywheel flywheel housing mounting dimension Dimension G2 in sketch 1 G1 should be less than or equal to G2 G1 G2 The CENTAFLEX CF R has a generous 2 mm to compensate for this difference SKETCH 1 ENSURE CORRECT AXIAL ALIGNMENT J620c in mm in mm in mm in mm in mm in mm 8 00 203 2 1 56 39 6 8 75 222 25 1 00 25 4 0 0 0 62 15 7 0 0 0 0 The CENTAFLEX Series R coupling series is designed according to the dimension tables in SAE J620c Flywheels and SAE J617a Housings There are several engi nes on the market which do not conform fully with the SAE specifications CAT MWM VOLVO YANMAR etc Engineers at CENTA will assist in the correct selection from both torque rating and dimensional requirements based on information they have but it
186. two steel balls from each of the switch bores in the valve body some models 15 Remove the detent setscrew spring and steel ball from the valve body Figure 67 Removing Detent Setscrew and Spring Marine Transmission Service Manual 1020667 99 Disassembly Twin Disc Incorporated 16 Remove the dog point setscrew Note that the setscrew is retained with 908 threadlocker Figure 68 Removing Dogpoint Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 69 Removing Thrustwasher 19 Remove the stem from the valve body 100 Marine Transmission Service Manual 1020667 Twin Disc Incorporated Disassembly 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 70 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 1020667 101 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 th
187. unout 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 A 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 B 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 C 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 D 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 1020667 Twin Disc Incorporated Assembly Assemble Control Valve Assembly of Mechanical Control Valve 1 Install the thrust race thrust bearing and remaining thrust race onto the stem Figure 114 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 the shaft of the valve stem the oil seal and the O ring Install the stem into the valve cover Marine Transmi
188. untered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Tables begin on the next page Marine Transmission Service Manual 1020667 67 Troubleshooting Table 8 Troubleshooting Chart Twin Disc Incorporated Symptom 2 68 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 li nkage 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 dri ve on reverse dutch 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 n

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