Service Manual Marine
Contents
1. LJ Q ADAPTER 1017834 n zn nn E PLATE 1018480 i vi D RING 2916KD GASKET 1017569 T RING A2669FV Oc 0000 1 q z Odi z ADAPTER 1017836 i O SAE J744 No 38 4 O Inn O Selec el ars te re LO d pe i FE teen e 5 o8 Sacre ob _ o L AE i co PLUG DRAIN HOLE Zor EEOAE p A xx Erie e CO d D E d NAN A SAE J744 No 127 2 127 4 FLANGE AND poppe V E J744 No 32 4 PUMP DRIVE ADAPTER rr e ER QUT SHOWN BELOW CENTERLINE E us2. WASHER 1017522 SPRING ASSY A2707AD ond A2703AB GASKET B1334C B PLATE 1019786 COVER ASSY 1017336 lt SCREW MA1052J 45 SHIM B2451 AS REQ DD Seas eth se Em CLUTCH PRESSURE t SFr EN STEM 10181634 C i c90 PSI 2000 kPo f 7e 7 ENCA EL HIH 3 SNAP RING A2915W A Ed _ belt COVER 1017128 EIR IRE NC i tft Ch 1 3 bo EE A zn E LAL MM nS SECTION nis f ES LN p m SECTION B B ETa 2 CE C Lac il NN SS S i TRANSMISSION GASKET i dp touN _ sera e 1 Si M rs MUN quoc ee I SPRING 1801 1018884 We nt OUD ama M S CLE I A e Ya LL SETSCREW A2870K DITCH PLATE GASKET AZ ee e 72 Fn De L FA Scales te eil on VALVE BODY ASSY 1018095 INE GASKET 1017334 zy E GASKET 4017180 BALL M1990H NUTE eee in eren INSTALL USING M4908 LOCTITE z PISTON B1399H 5 242 TOP OF SCREW MUST BE D RING A2916AT SPRING A2702T l den n on an VE WASHER A2782AS SHIM 1020005 AS REQ D2 SE SPACER A 8854P DITCH PLATE 1018885 7 SCREW MA10528C SECTION R 9 BALL M1990E 0 RING A2916DK PIN M1927AX EAT 1017524 Y Refer to Bill of Materials for actual part number when ordering parts Figure 8 PTO Valve for MG516 MG5170DC MG52
3. Figure 39 Support Plate Configurations Not Recommended CAUTION Do not use any flexible mounting for PTO support 70 Marine Power Take off Service Manuall Twin Disc Incorporated Installation MG516 MG5170DC MG5202 with Mechanical Transmission Control Valve Refer to Figure 3 1 Hemove the cover from rear of marine transmission at the input shaft centerline Remove and discard the o ring Remove two o ring plugs from the transmission manifold tower Remove the pipe plug or o ring plug from the top of the manifold tower Temporarily remove the filter bypass valve components from inside the manifold tower located just below the plug at the top of the manifold tower Install the M1945AE expansion plug and press it into the manifold until seated against the shoulder in the bore Reinstall the filter bypass valve components and the plug that was removed from the top of the manifold tower Press the two M1035B dowel pins in the end of the primary shaft of the marine transmission until 9 mm of the pin protrudes from the end of the primary shaft Assemble the M1904L piston ring into the groove of the 1017834 adapter and install the adapter over the dowel pins in the shaft Fasten the adapter to the shaft with two MA1062C capscrews M12x70 Class 12 9 and torque the capscrews to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly
4. 11 DII DU asco QU earners CUR RERRMIM DUE VE RODA ep 12 Sources of Service Information ess 13 bib diii mm I T UE 14 Description and Specifications 15 RETIN al ME TED EI 15 Explanation of Model to Serial Number Compatibility 15 Explanation of Model Number Designation 16 Available Adapter Groups ccce eere eren 16 UU terc M P 17 SPEEA ONE osacthiionnoxieopoPpcndndob Fapdadbh nnper nb ood dnOE UON DUK 17 Torque Values for Fasteners Leere esee 18 Operation Leooeiconennibr pent TRUE DER ERE DAN EXRELAERRENK IARE ARA 33 GBHOPIOI ouosdbns iui sse GR CRIMEN eee E ee 33 Power Take off Clutch Engagement Procedure 33 C Tuer AGIS odi eia DR EFOON dra E QUAERIS SEBNPI DO DINI M DH PUOPMITS 33 Lubrication and Preventative Maintenance 35 DOW E A AA EE P EE A A E E 35 Marine Power Take off Service Manual 7 Table of Contents Twin Disc Incorporated Disassembly RR ETT DT 37 eir e E E E I 37 Disassembly of Clutched Power Take off 38 Disassembly of Valve ieee mnnn 39 Cleaning and Inspection 47 VS NIG sousresins pui ebeR nes eee RUDI EDD EENPI DIM
5. NG M2167 SHIM B2234 SAS REQ D CLUTCH PRESSURE 360 PSI 2482 kPa SA BI9994 AC916AT B1368b PLUG Metsik 1 4 18 NPTF CDRYSEAL TH Di PRING A227004 OIL PRESSURE CHECK POINT 3 4 14 P T F CDRYSEAL TH D HL INLET f s E BALL M1990H ING AZ 70SP 204087 DETENT B1139 BODY ASS Y XA7089 CAPSCREW M2001P 4 SPRING ASS Y XA2707BU m E SPRING 42707BU E UST ncn abu SPRING 427034J OP Be297A 2 POSITION CAPSCREW M1731AF Refer to Bill of Materials for actual part number when ordering parts Figure 6 PTO Valve for MG5301DC with Mechanical Transmission Control Valve poje1JodJoo2u OSig UIML suoneoiioedg pue uonduoseg 9c enuen 92lAJeS JJO aye 1 MOd euue u PLUG M1945 E SEE NOTE e P T D DISENGAGED p 7o E
6. 4 HOLES EQUALLY SPACE le x 1 75 TA 21 0 DEE 4 HOLES 8 EACH SIDE NOTE USE A 4 H S FUR UNTING A CUS ER SUPPLIED SUPPUR BRACKE 1 E P T U USE 88 PRUPERTY CLASS QUALITY CAPSCREWS PE ISO 898 1 AND RQUE SS IR SERVICE MANUAL VALUES Lg Saeco 5 25 116 00 Figure 2 Clutched Power Take off Installation Dimensions Ey Ew 180 APA DEEP RT poeje1JodJoo2u OSIA UIML suoneoiioedg pue uonduoseg CC enuen 2911S JJO aye 1 MOd JUEN PLUG M1945AE SEE NOTE 2 CATI F DRAIN HOLE IN MANIFOLD SEE NOTE CLUTCH ACTUATING PRESSURE M12 x 1 73 THREAD TAP THRU HOSE MA923Al ILES HOSE MA923AP GASKET B133 D PLATE B3576C SCREW MA996D 8 gt FITTING Me483BR FITTING MA1053L M8 x Les e H FITTING MA1053K 2 gt LOCATION OF PLUGS IN MANIFOLD TOWER SEE NOTE VALVE X 7540 e L DRAIN 2 X 1 75 THREAD ETRIC PORT CONFORMS TO ISO 6149 0 Refer to Bill of Materials for actual part number when ordering parts Figure 3 Installation MG516 MG5170 MG5
7. Refer to Bill of Materials for actual part number when ordering parts Figure 9 Installation MG5301DC MG6650 00 SC MG6848 00 SC with Electric Transmission Control Valve Jenue N VIIAIBS JJO aye 1 MOd UNEN poeje1JodJoo2u OSIA UIML Jenue N BDIAIVS JJO 9ye 1 MOd JUEN 6c WASHER 1017 5828 GASKET B1334C COVER ASSY 1017336 SEAL MA 8 STEM 10181634 SNAP RING A2915W ER 10173284 SCREW M2038W PISTON 1019791 NLITE NSTALL USING MA908 LOCTITE 242 THREAD DOG POINT INTO DETENT GROOVE UNTIL SNUG BACK DF 172 TURN SPRING ASSY A2 amp 707AD and A2 amp 03AB Va PLATE 1019786 lt SCREW MA1052J 4 p Ze n Pam BA PH Nir mt oy LOS Esso s E aa RNG Ye H pet a EES vL MG S ned A LE SPA SPA cM S ULAR RULLAA YT
8. Install the O ring into the counterbore in the cover assembly Apply grease to the stem O ring and oil seal lip Marine Power Take off Service Manual 63 Assembly 64 14 d LEN Il Twin Disc Incorporated 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 bogy Figure 36 Hole in Gasket and Hole in Cover Must Align 15 16 17 18 19 20 Install four M8 x 25 socket head capscrews and torque to 23 Nm 17 lb ft Install washer over stem and against oil seal Install spring over stem against washer Install lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew may be damaged Torque the lever s attaching screw to 9 5 Nm 7lb ft Install external retaining ring onto stem Install the steel balls and electrical switches into the bores in the sides of the valve body Note that the small diameter ball is inboard of the large diameter ball at each switch location Marine Power Take off Service Manual Twin Disc Incorporated 21 22 23 24 Assembly Install the pressure regulating piston into valve body with spring pocket out Install pressure regulating springs into valve body and into piston spring pocket Install the shims that were removed into the bore of the rate of rise piston
9. SAE J 44 No 1287 4 PLUG M1945T IULZS 3o SSOQE AZE NO Sess ADAPTER SAE J744 No 1le7 2 1e E J744 No 32 4 PUMP 4 FLANGE AND DRIVE ADAPTER SHOWN BELOW CENTERLINE SECTION A 742 46 DIMENSION TO SAE HUNTING F 00 HOUSING M16 X 2 0 TAP THRU 4 HDLES RING A2 amp 669DG CARRIER 10155328 O RING A2916KD CAPSCR EW MA1068R 2 Refer to Bill of Materials for actual part number when ordering parts Figure 11 Live Power Take off All MG516 MG5170DC MG5202DC MG5202DC and MG5301DC with Manual Transmission Control Valve Only Installation Dimensions for all Live Power Take offs suoneoiioedg pue uonduoseg poeje1JodJoo2u OSIA UIML Jenue N 291A13S JJO oye 1 MOd SULLY LE SCREW MA1062Q COD SCREW MA10628P C2 SCREW MA1068R 2 gt SAE J744 No 127 2 127 4 FLANGE AND GASKET B3404 SAE J744 No 38 4 PUMP DRIVE ADAPTER SHOWN ABOVE CENTERLINE PLATE 10184828 GASKET 1018481 PIN MA1035B 2 gt GASKET 1018886 RING M1904L PLATE 1018874
10. TWIN DISC INCORPORATED Service VE LLLUE 1 BB Marine Power Take off Document Number 1020075 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 1020075 March 2001 Marine Power Take off Service Manual 4 NE LS NS Note TheAbove constitutesthe basic Twin Disc Incorporated General Limited W arranty and may be supplemented by additional published warranty LIMITED TWIN DISC GENERAL WARRANTY WARRANTIES Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties are issued by the respective manufacturers thereof and are furnished to the original customer asto which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship For products and parts other than Rockford
11. Install the rate of rise piston over the springs and into valve body Install neutral pressure regulating spring into the pocket of valve body o Figure 37 Location for Neutral Pressure Regulating Spring 25 26 2f 28 29 Install orifice plate gasket onto valve bogy Install orifice plate and steel ball against spring onto valve body Install orifice plate cover and gasket onto valve body Install four of M8 x 25 socket head capscrews and torque to 23 Nm 17 lb ft Install gasket over lower valve body half Set upper valve body half over lower valve body half Insert the M10 x 150 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 Power Take off Service Manual 65 Assembly Twin Disc Incorporated 66 Marine Power Take off Service Manual Twin Disc Incorporated Installation Installation These PTO s are designed for use with Twin Disc marine transmissions They are available in clutchable and live configurations The marine transmission is available with the power take off installed at the factory or as a field installation kit There are several versions of the power take off installation groups however the only differences concern the mounting and engaging interface with the various models of marine transmission Refer to the section that pertai
12. TT th rr 7 HOSE MA923AP H SE A A OUT EW MA996D 8 l LUTCH CTUATING a ES 2 x 175 THREAD f IN A T Z gt OMN z is a m LOCATION OF DRAIN HOLE IN MANIFOLD scr NOTE 4 C READ ETRIC PORT CONFORMS Refer to Bill of Materials for actual part number when ordering parts Figure 5 Installation MG5301DC with Mechanical Transmission Control Valve suoneoiioedg pue uonduoseg poeje1JodJoo2u OSIA UIML enuen BDIAIVS jJO o xe 1 MOd SULLY Ge 3419A CAPSCREW Me001R D RING A2916BY PLUG M2052AA 4 PLUG Meyer GASKET B13344 Becol Le PIN MISSZB B3404 PISTUN Beess EM A4347H PLATE B3418B ORIFICE
13. This applies where a matched set of parts is not involved Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Marine Transmission Service Manual 49 Cleaning and Inspection Twin Disc Incorporated 50 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 Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the defect with a soft stone replace the gear Inspect g
14. Description and Specifications Table 5 Tapered Pipe Plugs with thread lubricant wm e ws s wa ow 5 wm ow 9 Table 6 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal Nm Ib ft Ib ft Ihnreac or 5 0r 596 Thread 0r 596 0r 5 96 Diameter Diameter Marine Power Take off Service Manual 19 Description and Specifications Twin Disc Incorporated RING M1904E lt 2 SHAR TL SOIRS ACE Me086CY gt Al J SUCCES E RING B1783N 72 PLATE A4480Q amp HDUSING 1017824 PLATE A4481A 7 PLATE amp 2018A BACKPLATE 1017822 CREW M422 25 BEARING M2898 RING 1017826 RING B1048E ADAPTER 10178214 SAE J744 No 38 45 BEARING M1989 RING A2SISCF CHVER 1017893 ADAPTER 1017821 SAE J744 No 32 4 PISTON 10178254 mua usce BEARING M2087P E eid RING M1904C TOV e PLUG MA1038B lt 2 B C4 NUT MA94 7 MAIUA9B 4 exp AD
15. VALVE Figure 10 PTO Valve for MG5301DC MG6650 00 SC MG6848 00 SC with Electric Transmission Control Valve poeje1JodJoo2u OSIA UIML suoneoiioedg pue uonduoseg 0 Jenue N 291A13S JJO aye 1 MOd UNEN 842 46 z DIMENSION TO SAE 0 HOUSING MOUNTING FACE CAPSCREW MA1062S lt 4 SAE J744 No 127 2 127 4 FLANGE AND pa a MOUNTING A SAE J744 No 38 4 PUMP DRIVE ADAPTER 4 BOLT PUMP REPLACE SHOWN ABOVE CENTERLINE 78 00 THESE SCREWS WITH STUDS IF ADEQUATE LENGTH TO ADAPTER 1017834 MOU I BOTH THE PUMP AND CARRIER SECURE PUMP AND e cx RING M1904L 85 00 CARRIER WITH NUTS PIN MA1035B 2 gt R x RING A2669FV 7 7 S is i ADAPTER 1017836 SAE J744 No 38 4 7 57 25 gt M 0 06 SAE J744 No 38 4 SPLINE 33 98 4 J TA 5 Y D PUMP DRIVE ADAPTER 197 06 2 Eg i HTS U l2 0 03 SPLINE 27 55 6 161 9 REFA LP 744 No 127 4 C SAE J SAE J744 No 32 4 PUMP DRIVE ADAPTER 81 0 CREE BERG
16. a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface in a film If the water puddles or forms beads use fresh solvent and reclean Marine Transmission Service Manual Twin Disc Incorporated Cleaning and Inspection Inspection Housings Cast Parts and Machined Surfaces Valve Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will change the designed fit of bearings races or seal rings 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 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
17. and the the next spring with the concave end first so that the two contact each other only at the outer diameter Alternately install the remaining springs such that the springs are not parallel to each other and the maximum overall spring length results See Figure 29 left 11 Install the 202265B race thick followed by the M2087P needle bearing and the M2086CY race thin coating each with a film of assembly lube See Figure 29 right Li ELE LETT rof vr cm s pu dass uma 5 t Aa gy el geno oct een lt n AS E r 7A Pes afte ted Ws am PLIN oW ow w wW gt Figure 29 Belleville Springs installed left and Installing Bearing and Races right Marine Power Take off Service Manual 57 Assembly Twin Disc Incorporated 12 Install the M1904C piston seal ring on the 10178254 piston and install the piston into the ring See Figure 30 left 13 Make sure the seal rings and o ring in cover are lubricated and install the 1017824 housing over the clutch assembly aligning the housing such that the drain hole of the housing is opposite the external hose ports on the rear cover The use of M12 alignment studs is recommended See Figure 30 right Figure 30 Install Piston Seal Ring left and Installing Housing right 14 Install the eight MA996D capscrews M12 x 30 class 10 9 and torque to 83 lb ft 112 Nm with the threads lubricated with a light oil film See Figure 31 Figure 31 Install
18. lubricated prior to assembly Install the four MA1049B studs M12x155 into the manifold The shorter length of threads must be installed into the manifold Install a new A2916KD o ring into the groove in the marine transmission manifold Install the power take off assembly onto the manifold so that the drain slot in the PTO housing aligns with the drain hole in the manifold Fasten with the four MA947B nuts and torque to 80 Nm 59 Ib ft Assemble the B1337D gasket B3576C ditch plate another B1337D gasket and the XA7540B control valve assembly onto the manifold tower with four MA1052L capscrews M10x45 class 12 9 and torque to a special reduced torque of 37 Nm 27 Ib ft with threads lubricated Install M2067Q protective caps into holes to prevent contamination Marine Power Take off Service Manual 71 Installation 72 10 Twin Disc Incorporated Remove the protective plugs and install two MA1053K fittings torque to 37 Nm or 27 Ib ft into the power take off housing Install the elbow MA1053L torque to 37 Nm or 27 lb ft at the top of the valve and fitting M2483BR into the end of the ditch plate torque to 16 Nm or 12 Ib ft Attach the MA923AL hose 15 in from the front transmission side of the power take off to the elbow at the top of the valve and the MA923AP hose 17 6 in from the rear of the power take off to the ditch plate fitting Torque the hose ends to 16 Nm 12 lb ft Attach and secure a customer suppli
19. mounting and engaging arrangements for the model of marine transmission that the power take off is being used on The bill of material of the live power take off assembly is only identified on the original paperwork and the differences are in the means to adapt to the applicable transmission model Clutch Plate Wear Limits 1 oteel separator plates must be flat within 0 010 inch Small areas of local heat are acceptable if the plate is within the flatness tolerance 2 Friction plates should be flat and the new thickness is 0 107 to 0 115 inch Any plate that is less than 0 100 inch total thickness should be replaced Marine Power Take off Service Manual 17 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 3 U S Standard Fine and Coarse Thread Capscrews Bolts and Nuts Thread SAE Grade 5 SAE Grade 8 Diameter ae nw 1 1 8 615 745 834 1010 1015 1185 1377 1606 1 1 4 850 1000 1163 1355 1375 1625 1865 2203 a Table 4 Metric Coarse Thread Capscrews Bolts and Nuts Thread Property Class 8 8 Property Class 10 9 Property Class 12 9 Sue wn nm wn m ben m ms 65 75 2 14 10 12 14 16 Ome 16 18 21 25 23 26 31 35 25 29 34 40 Mio 32 36 43 49 44 51 60 68 51 59 70 80 18 Marine Power Take off Service Manual Twin Disc Incorporated
20. o ring plug from the top of the manifold tower Hemove the filter bypass valve components Install the M1945AE expansion plug and press it into the manifold until seated against the shoulder in the bore Reinstall the filter bypass valve components and the plug that was removed from the top of the manifold tower Press the two M1035B dowel pins in the end of the primary shaft of the marine transmission until 9 mm of the pin protrudes from the end of the primary shaft Assemble the M1904L piston ring into the groove of the 1017834 adapter and install the adapter over the dowel pins in the shaft Fasten the adapter to the shaft with two MA1062C capscrews M12x70 Class 12 9 and torque the capscrews to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly lubricated prior to assembly Install the four MA1049B studs M12x155 into the manifold The shorter length of threads must be installed into the manifold Install a new A2916KD o ring into the groove in the marine transmission manifold Install the power take off assembly onto the manifold so that the drain slot in the PTO housing aligns with the drain hole in the manifold Fasten with the four MA947B nuts and torque to 80 Nm 59 Ib ft Assemble the 1018884 gasket and 1018885 ditch plate onto the manifold tower using four of MA1052C capscrews M10x40 class 12 9 and torque to 75 Nm 55 Ib ft Install the 1018594A gasket and the 1017172F valve assembly onto the d
21. so that the drain slot in the carrier bore aligns with the drain hole in the manifold Fasten with four MA1062S capscrews M12x90 Class 12 9 and torque to 130 Nm 96 Ib ft Assemble the internal snap ring into the splined adapter A2669DG snap ring with 1017835 adapter for SAE No 32 4 spline and A2669FV snap ring with 1017836 adapter for SAE No 38 4 spline and install it over the drive adapter The driven pump should now be installed using a gasket that will seal on the pump mount face Lube oil is supplied from the marine transmission to lubricate the pump spline and then flows to the sump through the power take off housing Consequently the pump face will be in contact with marine transmission oil but not pressurized Note that when using a 4 bolt pump the four MA1062S capscrews from step 5 above must be replaced with studs of adequate length to mount both the pump and the carrier The studs should be threaded into the manifold for a depth of 18mm on units with an iron manifold and 24 mm on units with an aluminum alloy manifold Secure the pump and carrier with nuts and torque to the appropriate value as shown in the bolt torque chart in the Description and Specification section Be sure that a gasket is installed between the pump face and its mounting surface Marine Power Take off Service Manual 83 Installation Twin Disc Incorporated 84 Marine Power Take off Service Manuall 1020075 03 01 TW Y 1 POWER TR
22. that identify these additional parts are referred to in the following paragraphs Note that the part numbers shown are for reference only and a current bill of material should be used to order the proper parts 68 Marine Power Take off Service Manuall Twin Disc Incorporated Installation EC LIMMENDE D XIENDED Z gt Pa ra 2 ECAHMMENDEL Figure 38 Recommended Support Plate Configurations Marine Power Take off Service Manual 69 Installation Twin Disc Incorporated PV TE CIE NCENEE 1D PIU BRACKE ke ky V esp HULL MOVEMENT WILL STRESS PTO HOUSING NOT RECUMMENDE D NDEPENDENT BRACKETS TO STRINGER HULL FLEXING WILL STRESS PTO H
23. the manual will result in consistent performance from the unit and help reduce downtime opecial Tools Engineering drawings are included for the fabrication of special tools that should be used during disassembly and assembly of a unit Repair of this equipment should not be attempted without special tools Twin Disc does not manufacture these tools for general use Marine Power Take off Service Manual 9 Introduction Twin Disc Incorporated Replacement Parts Parts Lists Engineering assembly drawings are provided in appropriate sections of this manual to facilitate ordering spare or replacement parts Current bill of materials are available from the nearest Authorized Twin Disc Distributor Ordering Parts A WARNING All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Renewal parts and service parts kits may be obtained from any authorized Twin Disc distributor or service dealer Parts Shipment Furnish the complete shipping information and postal address All parts shipments made from the factory will be FOB factory location USA State specifically whether the parts are to be shipped by freight express etc If shipping instruc
24. two halves of the transmission control valve assembly 6 Press the two M1035B dowel pins in the end of the primary shaft of the marine transmission until 9 mm of the pin protrudes from the end of the primary shaft 7 Assemble the M1904L piston ring into the groove of the 1017834 adapter and install the adapter over the dowel pins in the shaft Fasten the adapter to the shaft with two MA1062R capscrews M12x70 Class 12 9 and torque the capscrews to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly lubricated prior to assembly 8 Install the four MA1049B studs M12x155 into the manifold The shorter length of threads must be installed into the manifold 9 Install a new A2916KD o ring into the groove in the marine transmission manifold Marine Power Take off Service Manual 71 Installation Twin Disc Incorporated 10 Install the power take off assembly onto the manifold so that the drain slot in the PTO housing aligns with the drain hole in the manifold Fasten with the four MA947B nuts and torque to 80 Nm 59 Ib ft 11 Assemble the 1017974 gasket and 1018914 ditch plate onto the manifold tower using four MA1062Q capscrews M12x45 class 12 9 and torque to 130 Nm 96 Ib ft Install the 1018594A gasket and the 1017172K valve assembly onto the ditch plate with four MA1052J capscrews M10x120class 12 9 and torque to a special reduced torque of 54 Nm 40 Ib ft with the threads lubricated 12 Remove the
25. 02DC MG5205DC with Electric Transmission Control Valve with Mechanical Backup suoneoiioedg pue uonduoseg N M8 X 1 25 6H TH D 2 HOLES FITTING MA1053L P T D M 492 z A AS RENA SCREW MA1062Q lt 4 PLATE 1018914 VALVE 1017172K ae GASKET 1017974 25 i E 4 FITTING MA1053K f 36 6 FITTING MA1053K ml SE MA923AP fiteli o4 4 P T O HOSE MA923Al E e EN g FITTING MA1053L CLUTCH ACTUATI VIEW of e PRESSURE 12 x 1 75 THREAD PORT CONFORMS To ISO 6149 SCREW MA996D 8 SCREW MA1062P lt 2 GASKET B3404 SCREW MA1062Q lt 5 PLATE 1018482 SCREW MATUGSR 2 GASKET 1018481 GASKET 1018886 PLATE 1018874 PLATE 1018480 GASKET 1017569 suoneoiioedg pue uonduoseg La mTT e e i MEL l lki NEIN T E J d j 9 mx 1 READ INFORMS
26. 1018482 ditch plate onto the manifold using two MA1062P capscrews M12x130 class 12 9 and torque to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly lubricated prior to assembly Install the 1018481 gasket 1018874 ditch plate 1018886 gasket and 1018480 ditch plate using two of MA1062R capscrews M12x70 class 12 9 and five of MA1062Q capscrews M12x45 class 12 9 and torque to 130 Nm 96 Ib ft Heassemble the transmission control valve using gasket 1017569 and four existing MA1052P capscrews M10x150class 12 9 and torque to a special reduced torque of 54 Nm 40 Ib ft with threads lubricated Be sure to install a new 1017136B gasket between the two halves of the transmission control valve assembly Press the two M1035B dowel pins in the end of the primary shaft of the marine transmission until 9 mm of the pin protrudes from the end of the primary shaft Assemble the M1904L piston ring into the groove of the 1017834 adapter and install the adapter over the dowel pins in the shaft Fasten the adapter to the shaft with two MA1062R capscrews M12x70 Class 12 9 and torque the capscrews to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly lubricated prior to assembly Install a new A2916KD o ring into the groove in the marine transmission manifold Marine Power Take off Service Manuall Twin Disc Incorporated 10 11 12 Installation Install the 1015532 carrier onto the manifold
27. 17834 adapter and install the adapter over the dowel pins in the shaft Fasten the adapter to the shaft with two MA1062C capscrews M12x70 Class 12 9 and torque the capscrews to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly lubricated prior to assembly 4 Install the four MA1049B studs M12x155 into the manifold The shorter length of threads must be installed into the manifold 5 Install a new A2916KD o ring into the groove in the marine transmission manifold 6 Install the power take off assembly onto the manifold so that the drain slot in the PTO housing aligns with the drain hole in the manifold Fasten with the four MA947B nuts and torque to 80 Nm 59 Ib ft ra Assemble the 1017974 gasket 1017973 ditch plate B3404 gasket and the XA7108B control valve assembly onto the manifold tower with three MA996X M12x120 class 10 9 and one MA996L M12x70 class 10 9 capscrews and torque to 112 Nm 83 Ib ft with threads lubricated 8 Remove the protective plugs and install four MA1053K fittings torque to 37 Nm or 27 lb ft two into the PTO housing and two into the 1017973 ditch plate Attach the MA923AL hose hose A 15 in from the front of the power take off to the starboard side fitting on the 1017973 ditch plate and the MA923AP hose hose B 17 6 in from the rear of the power take off near the pump mounting surface to the other ditch plate fitting Torque the hose ends to 16 Nm 12 lb ft Marine P
28. 202 with Mechanical Transmission Control suoneoiioedg pue uonduoseg poeje1JodJoo2u OSIA UIML Jenue N 291A13S jJO O xe 1 MOd JUEN c MA10 38 2013418 MISSE Be eh EDS M208 K M2086AV MA 78 BeeS A 2 PUSITIUN AC916Al 4347 J M1927B B1334A B133 Refer to Bill of Materials for actual part number when ordering parts B2334 S CLUTCH PRE 1 85 kPa B1400 B A2 03P M1990H MA9604 ina es 94 B1399C TDI HIMS AS RED SSURE i es tee Bl39SE AQ 707BD MUTER 1 D Ac 02BU CE N 1 R Figure 4 PTO Valve for MG516 MG5170 MG5202 with mechanical transmission control A2 02BC INNE R poeje1JodJoo2u OSIA UIML suoneoiioedg pue uonduoseg vc enuen 92lAJeS JJO aye 1 MOd euue u P T O DISENGAGE VALVE XA 108B CREW MA996X G3 2 SCREW MASSSL PLATE 1017973 HUSE MA9234AL C GASKET 1017974 FITTING MA1053K lt 2 FITTING MA1053K 42
29. 7 E 9 CAPSCREW MA1062S lt 4 Nx Q Q WHE UNTING A 4 BOLT PUMP REPLACE THESE SCREWS WITH STUDS ADEQUATE LENGTH TO A PLUG MI945T UNT BOTH THE PUMP AND CARRIER SECURE PUMP AND ADAPTER 1017835 CARRIER WIT TS SAE J744 No 38 40 RING A2669DG CARRIER 1015332 CAPSCREW MA10628R 2 Refer to Bill of Materials for actual part number when ordering parts Figure 12 Live Power Take off MG5301DC MG6650 00 SC MG6848 00 SC with Electric Transmission Control Valve poeje1JodJoo2u OSIA UIML suoneoiioedg pue uonduoseg Description and Specifications 32 Twin Disc Incorporated Figure 13 Clutch Cross Section Expanded Marine Power Take off Service Manual Twin Disc Incorporated Operation Operation General The following information is intended for use by the operator Instructions apply to the power take off only See the operators manual for information on the operation of the marine transmission Power Take off Clutch Engagement Procedure The clutchable power take off can be engaged at engine speeds up to one half of the rated match point speed The control valve has a built in rate of pressure rise making it unnecessary to try and feather or slip the power take off into engagement Clutch Adjustment There are no clutch adjustments necessary for the power take off Make sure
30. ANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
31. APTER 1017 834 CREW MAl062C 2 RING M1904L PIN MALOSDB C2 Figure 1 Clutched Power Take off Parts for reference only Refer to Bill of Materials for actual part number when ordering parts Marine Power Take off Service Manual 20 Jenue N BDIAIBS 4JO O xe 1 MOd SULLY ANIFOLD FACE l C 127 06 0 03 al LOCATION IN MANIFO OF DRAIN HOLE LD CSAE J744 No 38 42 SAE J744 No que yeu ATING URE 1 7 5 THREAD CONFORMS 6149 AN mr eq SEEN i ee e RA III C ELE Te MA TUULT S von Jri a sis n P ni ge ee gt a ES tb Se up us P m na fo 438 A z 9546 mue 181 0 a2 REF HC a4 2 TE N 53 coca mg x uu 161 9 d d 945 SREB HE A TONY SAE J744 No 127 44 a 0n om Uwa TE 2 a ADAPTER 1017821 ax Ne Mile A qoo TAP 2R0 IEE
32. INUER EEUU MIN eee 47 NU PR E TTE ESSI RIOT 49 Assembly F 53 Erg M 53 Assembly of Clutched Power Take off 54 PRS SEI TON ru 59 Valve for MG516 MG5170 MG5202 MG5301DC with Mechanical Transmission Control Valve cereus 60 Valve for MG516 MG5170DC MG5202DC MG5205DC MG5301DC MG6650 00 SC MG6848 00 SC with Electric Transmission Con trol Valve with Mechanical Backup 61 Installation eee eee eren 67 Clutchable Power Take off eere nn nnn nnne en 68 Live Power Take Off 1 ec eeer erre nne 80 8 Marine Power Take off Service Manual Twin Disc Incorporated Introduction Introduction General Information This publication provides the information necessary for the operation and maintenance of the Twin Disc Incorporated equipment specified on the cover of this manual 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 have this manual at their disposal and be familiar with its contents Applying the information in
33. NGAGED i ES rN Y z M ect ius L VALV l Lesen aL Saam d SCR E 1017178F aaue elle LOCATION OF DRAIN HOLE IN MANIFOLD SEE NOTE 6 HOSE MA9234P CLUTCH HOSE MA9234P ACTUATING FITTING M24 PRESSURE M12 x 1 75 THREAD PORT CONFORMS TD ISO 6149 FITTING MAIO LOCATION OF PLUGS IN MANIFOLD TOWER SEE NOTE 1 mw EW MA996D 85 Refer to Bill of Materials for actual part number when ordering parts Figure 7 Installation MG516 MG5170DC MG5202DC MG5205DC with Electric Transmission Control Valve with Mechanical Backup suoneoiioedg pue uonduoseg poej
34. SPAC SECTIDN A no A RING 289164T i j ps i LL j i WASHER A2 82AS ER A amp 88sAP GASKET 1017334 GASKET 1017 BALL M1990H PISTON B1399H SPRING Ae70eT SHIM 1020005 AS R DITCH PLATE 1018914 SCREW M 1068Q 45 EQD SHIM B2451 AS R CLUTCH PRESSURE 3o0 PSI 2415 kPa COVER 1017128 130 EQ D gt GASKET 1017136B BALL BALL M1990E BALL M1990M M1990G APPLY SWITCH M 8664 895 THREAD SEALANT WITH EFLON gt TO THREADS Ep 2i SECTIUN 9 m E SECTION H E SPRING 1801 SEISCREW A28 0K 0 RING A2916 PIN M1927AX SEAT 1017524 BALL M1990E DK Refer to Bill of Materials for actual part number when ordering parts SECTION TRANSMISS 1017974 DITCH PLAT 10185944 UN GASKE E GASKET VALVE BUDY ASSY 1018095 NOTE NSTALL USING MA908 CLUCTITE 242 TUR UF SCREW MUST BE FLUSH WITH BR SLIGHTLY BELOW BOTTOM FACE
35. ake off Service Manual Twin Disc Incorporated Disassembly 15 Remove the detent setscrew spring and steel ball from the valve body Figure 21 Detent Setscrew and Spring 16 Remove the dog point setscrew Note that the setscrew is retained with MA908 threadlocker Figure 22 Dog point Setscrew Marine Power Take off Service Manual 45 Disassembly Twin Disc Incorporated 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 23 Thrustwasher 19 Remove the stem from the valve body 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 24 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 46 Marine Power Take off Service Manual Twin Disc Incorporated Cleaning and Inspection Cleaning Cleaning and Inspection Note Replace all oil seals gaskets O rings piston rings seal rings snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents or by steam cleaning Parts must he dried and oiled immediately Examine all parts carefully for grit dirt and abrasives and reclean them if necessary Clean all oil passages by working a piece of wire back and fo
36. dvancing technology and improvements in state of the art Individual product service bulletins are issued to provide the field with immediate notice of new service information For the latest service information on Twin Disc products contact any Twin Disc distributor or contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA or by e mail at service twindisc com Marine Power Take off Service Manual 13 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 14 Marine Power Take off Service Manual Twin Disc Incorporated Description and Specifications Description and Specifications General The Twin Disc high torque capacity power take off unit is designed to mount directly to a Twin Disc marine transmission and is available in two output shaft sizes Size 32 4 is rated at 592 N m 437 Ft Ibs of torque and size 38 4 is rated at 1187 N m 875 Ft lbs of torque These are available as live or clutchable power take offs and are designed for driving SAE J 744 configured hydraulic pumps Twin Disc assembly drawings provide dimensional information They are designed to fit various models of marine transmissions as described below Note that they are not compatible with marine transmissions that were built before the noted beginning serial number without si
37. e reconditioned or renewed with the use of a Speedi Sleeve Marine Transmission Service Manual 51 Cleaning and Inspection Twin Disc Incorporated 52 Marine Transmission Service Manual Twin Disc Incorporated Assembly Assembly General A cross sectional drawing is shown in the Description and Specifications section of this manual Part numbers that are listed on those drawings and on the following assembly notes are for reference only and should not be used for ordering repair parts Refer to these part numbers as a guide during assembly of the power take off Identify correct replacement repair parts by referring to the Bill of Material that is identified on the nameplate If this is not available it may be obtained from your Twin Disc Authorized Distributor Marine Power Take off Service Manual 53 Assembly Twin Disc Incorporated Assembly of Clutched Power Take off 1 Press the M1989 tapered roller bearing cone assembly on the 1017826 ring and install theA2915CF external retaining snap ring See Figure 25 left 2 Press the M2898 ball bearing onto the 1017827 shaft See Figure 25 right Figure 25 Bearing with Snap Ring left and Ball Bearing On Shaft right d Press the M1989 tapered roller bearing cup into the 1017823 cover See Figure 26 left 4 Install the A2916FW o ring in the groove of the 1017823 cover See Figure 26 right Figure 26 Install Bearing Cup left and Install O ring right 54 Mar
38. e1JodJoo2u OSIA UIML Jenue N BDIAIVS JJO 9ye 1 MOd JUEN le NSTALL USING MA908 LDCTITE 242 THREAD DUG POINT INI DETENT GROOVE UNTIL SNUG Hu BACK HFF 1 2 TURN GASKET 1017136B BALL M1990G SWITCH MA amp 866A ER 1017324 B APPLY MA895 THREAD SEALANT BALL M1990E WITH TEFLON gt TO THREADS ETSCREW M2 8038W BALL MI990M PISTON 1019791 poeje1JodJoo2u OSIA UIML
39. ear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear Inspect thrust faces of gears for scores scratches and burrs If you cannot remove these defects with a soft stone replace the gear Marine Transmission Service Manual Twin Disc Incorporated Cleaning and Inspection oplined 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 Seal Ring Bores Inspect the seal ring bores for evidence of the seal ring spinning within the bore If any groove exists that is deep enough to feel with a fingernail replace the parts as necessary to restore a correct fit of the seal ring Lip Seal Surfaces Inspect the seal surfaces for grooving scratches or burrs Remove any damage by polishing being careful to not introduce any lead that could result in oil being pumped out past the seal In some instances seal surfaces can b
40. ed fabricated support plate to the marine transmission support bracket or other acceptable area before securing to the power take off The PTO housing must not be strained by the support plate when it is anchored Any gap that remains between the surface of the support bracket and the PTO housing must be shimmed to reduce the gap to zero without straining the PTO housing 11 12 Install and tighten four M12 class 8 8 capscrews through the support bracket into the power take off and torque to 80 Nm 59 Ib ft Following this procedure will prevent damaging deflection or strain when attaching the support plate The driven pump should now be installed using a gasket that will seal on the pump mount face Lube oil is supplied from the marine transmission to lubricate the pump spline and then flows to the sump through the power take off housing Consequently the pump face will be in contact with marine transmission oil but not pressurized Marine Power Take off Service Manuall Twin Disc Incorporated Installation MG5301DC with Mechanical Transmission Control Valve Refer to Figure 5 1 Hemove the cover from the rear of the marine transmission at the input shaft centerline Remove and discard the o ring e Press the two M1035B dowel pins in the end of the primary shaft of the marine transmission until 9 mm of the pin protrudes from the end of the primary shaft 3 Assemble the M1904L piston ring into the groove of the 10
41. esult in damage or personal injury Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Power Take off Service Manual 11 Introduction Safety Twin Disc Incorporated General oafe practices must be employed by all personnel operating and servicing this unit Twin Disc Incorporated will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unaccepted maintenance operating practices Important Safety Notice Because of the possible danger to person s or property from accidents which may result from the use of manufactured products it is important that correct procedures be followed Products must be used in accordance with the engineering information specified Proper installation maintenance and operation procedures must be observed Inspection should be made as necessary to assure safe operations under prevailing conditions Proper guards and other suitable safety codes should be provided These devices are neither provided by Twin Disc Incorporated nor are they the responsibility of Twin Disc Incorporated Marine Power Take off Service Manual Twin Disc Incorporated Sources of Service Information Each series of manuals issued by Twin Disc Incorporated is current at the time of printing When required changes are made to reflect a
42. gnificant modification to the marine transmission Explanation of Model to Serial Number Compatibility These power take offs are compatible with the model transmissions with serial numbers equal to or greater than those shown in Table 1 Consult the factory for other applicable transmission models Table 1 PTO Compatability Beginning Serial Numbers Marine Power Take off Service Manual 15 Description and Specifications Twin Disc Incorporated Explanation of Model Number Designation The power take off is designed to drive hydraulic pumps meeting SAE J 744 with flange size 127 and shaft size 32 4 or 38 4 Adapter kits are available to drive smaller sized pumps The following is an explanation of the number designation for pumps meeting the SAE J 744 criteria The flange size designation is comprised of two numbers such as 127 4 The first number is the approximate pilot diameter in millimeters The second number is the quantity of bolt holes for attaching the pump The power take off is capable of fitting either the two bolt or four bolt designed pumps The shaft size is also comprised of two numbers such as 32 4 The first number is the approximate major diameter of the shaft in millimeters The second number is an arbitrary designation for the shaft design The 4 means a 30 degree involute spline Available Adapter Groups The following adapter groups are available for use with smaller pumps Table 2 Available Adapters for Smaller P
43. ied on the nameplate for the correct part numbers of the power take off assembly If this is unknown it may be obtained from your Twin Disc Authorized Distributor A cross sectional drawing is shown in the Description and Specification section of this manual Refer to this as a guide during disassembly of the power take off Marine Power Take off Service Manual 37 Disassembly Twin Disc Incorporated Disassembly of Clutched Power Take off 1 2 10 11 12 38 Hemove the pump assembly from the power take off Disconnect the supporting plate from the power take off housing Disconnect two hoses from power take off housing Remove the four MA947B nuts from the studs and remove the power take off housing from the marine transmission Place the power take off assembly face down using appropriate blocks to support the power take off on the front housing face and not the shaft Hemove the eight 8 MA996D capscrews M12x30 from the rear cover The bearing outer race should remain in the cover Slide the pump spline adapter out and set aside Lift the 1717826 ring out of the housing The inner race of the tapered roller bearing will provide a lifting means Remove the A2915CF snap ring from the ring to remove the tapered roller bearing This should be a slip fit Lift the shaft and ball bearing out of the bore using care to not damage the seal rings on the spring inner diameter Remove the clutch plates and backing
44. ine Power Take off Service Manual Twin Disc Incorporated Assembly 5 Install the B1048AK internal snap ring into the splined bore of the 1017826 ring See Figure 27 left 6 Place the rear cover with the rear face down and apply a coat of oil to the bearing cone and place the 1017826 ring assembly into the rear cover See Figure 27 right am Figure 27 Installing Snap Ring left and Installing Ring With Bearing right Marine Power Take off Service Manual 55 Assembly Twin Disc Incorporated 7 Install the two M1904E sealing rings into the grooves of the shaft and carefully hook the ends Lubricate the seal rings and insert the shaft and bearing into the bore of the 1017826 ring See Figure 28 left 8 Soak the friction plates in oil for at least one hour prior to installing them into the power take off Insert the 1017822 backplate followed by an A4480Q friction plate and an A4481A steel plate Install an additional seven friction plates and six steel plates alternating such that there is a steel plate between each friction plate A friction plate will be the last plate installed See Figure 28 right Figure 28 Installing Seal Rings left and Install Clutch Plates right 56 Marine Power Take off Service Manual Twin Disc Incorporated Assembly 10 Install the seven B1783N belleville spring washers as shown in Figure 13 The first spring must be installed with the convex end against the shoulder of the shaft
45. ing Housing Capscrews 58 Marine Power Take off Service Manual Twin Disc Incorporated Assembly Assembly of Valve Note that all of the valves for the power take off clutches are similar in construction but part numbers vary Refer to the appropriate valve drawing in the Description and Specifications section for specifics and refer to Figure 4 and the illustration below as a guide 23 a4 oe pt m L Eget Pp LESE EN J Plug Rate of Rise Piston Lever Bushing Shim Fin Valve Body Outer Spring Valve Stem Spring Inner Spring Fistan Check Ball Bearing Detent Lrapscrew O Ring 3pring Driface Cover Cover D Ring Gasket Capso rey Plug Orifase Plate callar Gasket Capsorew 1 2g 3 4 5 B T d B l Figure 32 Mechanical Selector Valve Exploded View Marine Power Take off Service Manual 59 Assembly Twin Disc Incorporated Valve for MG516 MG5170 MG5202 MG5301DC with Mechanical Transmission Control Valve 1 gs 60 Install the bearing onto the valve stem Install the O ring into the counterbore in the valve cover Coat the O ring and the stem with light assembly grease Install the valve stem into the valve cover Use caution to prevent damage to the O ring and bearing Install the cover gasket and valve stem and cover assembly onto the valve body Install the four of 5 16 18 x 1 25 capscrews and torque to 20 Nm 15 lb ft Install the stop and ro
46. itch plate with four MA1052J capscrews M10x120class 12 9 and torque to a special reduced torque of 54 Nm 40 Ib ft with threads lubricated Marine Power Take off Service Manual 75 Installation 76 10 Twin Disc Incorporated Remove the protective plugs and install two MA1053K fittings torque to 37 Nm or 27 Ib ft into the power take off housing Install the elbow MA1053L torque to 37 Nm or 27 lb ft at the top of the valve and fitting M2483BR into the end of the ditch plate torque to 16 Nm or 12 lb ft Attach one MA923AP hose hose A 17 6 in from front of the power take off to the elbow at the top of the valve and the other MA923AP hose hose B 17 6 in from the rear of the power take off to the ditch plate fitting Torque the hose ends to 16 Nm 12 lb ft Attach and secure a customer supplied fabricated support plate to the marine transmission support bracket or other acceptable area before securing to the power take off The PTO housing must not be strained by the support plate when it is anchored Any gap that remains between the surface of the support bracket and the PTO housing must be shimmed to reduce the gap to zero without straining the PTO housing 11 12 Install and tighten four M12 class 8 8 capscrews through the support bracket into the power take off and torque to 80 Nm 59 Ib ft Following this procedure will prevent damaging deflection or strain when attaching the support plate The driven p
47. llpin lining up the marks made at disassembly Use small punch to line up the rollpin hole in the stop with the corresponding hole in the stem Continue to hold the holes in alignment as the rollpin is driven into place Support the stop while driving in the roll pin to prevent damage to the stem and valve Install the shift lever onto the stem lining up the marks made at disassembly Torque the screw to 15 Nm 11 Ib ft Install the pressure regulator piston regulating springs shims and rate of rise piston into the bore in the valve body Install the spring and check ball orifice plate gasket Install the orifice plate with the chamfered side of the hole check ball seat toward the check ball Install the cover gasket cover and four of 5 16 18 x 1 00 inch capscrews and torque to 20 Nm 15 Ib ft Marine Power Take off Service Manual Twin Disc Incorporated Assembly Valve for MG516 MG5170DC MG5202DC MG5205DC MG5301DC MG6650 00 SC MG6848 00 SC with Electric Transmission Control Valve with Mechanical Backup 1 Install the steel shuttle ball into its bore in the valve body Figure 33 Shuttle Ball Shuttle Seat and Roll Pin 2 Install the O ring onto the shuttle ball seat 3 Apply lubricant such as Dow Corning 2008 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 A M8x1 25 screw threaded into the seat can be
48. mpletion of the in warranty repair 2 The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 The warranty is void unlessthe product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated 6 The warranty is void unless all required replacement parts or products are of Twin Disc origin or are Twin Disc authorized replacement parts 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 omissio
49. ng with 1017836 adapter for SAE No 38 4 spline and install it over the drive adapter The driven pump should now be installed using a gasket that will seal on the pump mount face Lube oil is supplied from the marine transmission to lubricate the pump spline and then flows to the sump through the power take off housing Consequently the pump face will be in contact with marine transmission oil but not pressurized Note that when using a 4 bolt pump the four MA1062S capscrews from step 5 above must be replaced with studs of adequate length to mount both the pump and the carrier The studs should be screwed into the manifold a minimum of 18 mm Secure the pump and carrier with nuts and torque to the appropriate value as shown in the bolt torque chart in the Description and Specification section Be sure that a gasket is installed between the pump face and its mounting surface Marine Power Take off Service Manual 81 Installation Twin Disc Incorporated MG5301DC MG6650 00 SC MG6848 00 SC with Electric Control Valve 82 Refer to Figure 12 Note The installation of a live power take off on these transmissions requires the relocation of the control valve Hemove the cover from the rear of the marine transmission at the input shaft centerline Remove and discard the o ring Hemove the existing control valve ditch plate and gasket from the manifold Discard the ditch plate and gasket Assemble the the B3404 gasket and
50. ns 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 reservesthe right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit terms dependent upon the product involved Supplementary warranty terms are available upon request June 1 1999 TDW P0001 S Twin Disc Incorporated Table of Contents Table of Contents Introduction p PNE TTE 9 General Information e eere esee eene nennen nnne nnn nnn nnne 9 HODIACBIDSDE Fal So Goss rinde rod I i anm een 10 Preventative Maintenance Troubleshooting
51. ns to the appropriate model of marine transmission Preparation ie The installation of the power take off requires exposure of internal passages to the possibility of contamination Prior to beginning with the installation clean the marine transmission and surrounding area 2 A support plate is required on all clutchable power take off installations The support plate must prevent any relative movement of the power take off in relation to the marine transmission The ideal installation would support the power take off from the marine transmission mounting plate that is attached to the side of the marine transmission Provisions should be made for the support plate mounting at this time See Figure 14 Installation to Marine Transmission The installation procedures depend on the model of the marine transmission and whether it is equipped with a mechanical or electrical control valve Be sure and follow the appropriate instructions that are listed later in this section of this manual Marine Power Take off Service Manual 67 Installation Twin Disc Incorporated Clutchable Power Take off The parts for this clutchable power take off are the same for all marine transmission models and is shown in Figure 1 The installation dimensions for the clutchable power take off are also the same for all transmission models and are shown in Figure 2 Additional installation parts are necessary depending on the transmission model The figures
52. ntified in figures that are referred to in the following paragraphs Note that the part numbers shown are for reference only and a current bill of material should be used to order the proper parts Marine Power Take off Service Manuall Twin Disc Incorporated Installation All MG516 MG5170DC MG5202DC MG5205DC and MG5301DC with Manual Control Valve Only Refer to Figure 11 1 Remove the cover from the rear of the marine transmission at the input shaft centerline Remove and discard the o ring Press the two M1035B dowel pins in the end of the primary shaft of the marine transmission until 9 mm of the pin protrudes from the end of the primary shaft Assemble the M1904L piston ring into the groove of the 1017834 adapter and install the adapter over the dowel pins in the shaft Fasten the adapter to the shaft with two MA1062R capscrews M12x70 Class 12 9 and torque the capscrews to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly lubricated prior to assembly Install a new A2916KD o ring into the groove in the marine transmission manifold Install the 1015532 carrier onto the manifold so that the drain slot in the carrier bore aligns with the drain hole in the manifold Fasten with four MA1062S capscrews M12x90 Class 12 9 and torque to 130 Nm 96 Ib ft Assemble the internal snap ring into the splined adapter A2669DG snap ring with 1017835 adapter for SAE No 32 4 spline and A2669FV snap ri
53. ower Take off Service Manual 73 Installation Twin Disc Incorporated 9 Attach and secure a customer supplied fabricated support plate to the marine transmission support bracket or other acceptable area before securing to the power take off The PTO housing must not be strained by the support plate when it is anchored Any gap that remains between the surface of the support bracket and the PTO housing must be shimmed to reduce the gap to zero without straining the PTO housing 10 Install and tighten four M12 class 8 8 capscrews through the support bracket into the power take off and torque to 80 Nm 59 Ib ft Following this procedure will prevent damaging deflection or strain when attaching the support plate 11 The driven pump should now be installed using a gasket that will seal on the pump mount face Lube oil is supplied from the marine transmission to lubricate the pump spline and then flows to the sump through the power take off housing Consequently the pump face will be in contact with marine transmission oil but not pressurized 74 Marine Power Take off Service Manuall Twin Disc Incorporated Installation MG516 MG5170DC MG5202DC MG5205DC with Electric Control Valve with Mechanical Backup Refer to Figure 7 1 Hemove the cover from rear of marine transmission at the input shaft centerline Remove and discard the o ring Remove two o ring plugs from the transmission manifold tower Remove the pipe plug or
54. plate Hemove seven 7 release spring washers and needle thrust bearing and races Remove the piston from the bore of the housing Remove the piston seal rings Marine Power Take off Service Manual Twin Disc Incorporated Disassembly Disassembly of Valve Note All of the valves for the power take off clutches are similar in construction but part numbers vary Refer to the appropriate valve drawing for specifics and Figure 4 as a guide in Description and Specifications Valve for MG516 MG5170 MG5202 MG5301DC with Mechanical Transmission Control Valve 2B8 27 67 SE 3 25 29 23 24 LF ae igh B I E m j F H IA a D Plug Rate of Rise Piston Lever Bushing Shim Fin Valve Body Outer Spring Valve Stem Spring Inner Spring Piston Check Ball Bearing Detent Capscrew O Ring 3pring Driface Cover Cover D Ring Gasket Capsorewy Plug Orifase Plate callar Gasket Capsorew 1 2g 3 4 5 B T d B p s Figure 14 Mechanical Selector Valve Exploded View Marine Power Take off Service Manual 39 Disassembly Twin Disc Incorporated 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 Hemove the four 5 16 18 x 1 25 inch capscrews and remove the orifice cover orifice plate gaskets check ball and spring Figure 15 Cover Gaskets Orifice Plate Check Ball and Spring 2 Hemove
55. pline and then flows to the sump through the power take off housing Consequently the pump face will be in contact with marine transmission oil but not pressurized 78 Marine Power Take off Service Manuall Twin Disc Incorporated Installation Adjustments Prior to Operation The only mechanical adjustment necessary is to confirm that the linkage of the engaging mechanism allows correct travel of the power take off valve lever as shown in the respective installation figures The valve lever should be in its detent position at full travel of the control lever The power take off clutch actuation pressure can be adjusted by adding or removing shims from the power take off control valve as shown on the illustrations of the appropriate control valve If the transmission control valve was disturbed confirm that the linkage of the engaging mechanism allows correct travel of the marine transmissioin control valve lever Marine Power Take off Service Manual 79 Installation Twin Disc Incorporated Live Power Take off 80 The installation dimensions for the live power take off are the same for all transmission models and are shown in Figure 11 The parts for the live power take off assembly are also the same for all transmission models and are also shown in Figure 11 Mounting arrangements do vary depending on the marine transmission model Additional installation parts may be necessary depending on the transmission model and are ide
56. power take offs such warranty shall extend for a period of twenty four 24 months from the date of original shipment by Twin Disc Incorporated to theoriginal customer but not to exceed twelve 12 months of service or two thousand 2 000 LIMITATIONS OF REMEDIES AND LIMITATION OF OTHER Ko J hours of service whichever occurs first For Rockford power take offs products and parts such warranty shall extend for a period of fifteen 15 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twelve 12 month of service or one thousand five hundred 1 500 hours of service whichever occurs first T his is the only warranty made by T win Disc Incorporated and is in lieu of and all other warranti or implied including the warranties 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 repair or replacement of any T win Disc Incorporated part or uct found by Twin Disc Incorporated to be defective or equivalent credit Under no circumstances including a failure of the exclusive rem 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 co
57. protective plugs and install two MA1053K fittings torque to 37 Nm or 27 lb ft one into power take off housing at the rear location and one into ditch plate at the rear location Install two MA1053L elbows torque to 37 Nm or 27 lb ft one into power take off housing at the front location and one into the ditch plate at the starboard side location Attach the MA923AL hose 15 in from the elbow at the front of the power take off to the elbow at the right of the ditch plate and the MA923AP hose 17 6 in from the rear of the power take off to the fitting at the rear of the ditch plate Torque the hose ends to 16 Nm 12 lb ft 13 Attach and secure a customer supplied fabricated support plate to the marine transmission support bracket or other acceptable area before securing to the power take off The PTO housing must not be strained by the support plate when it is anchored Any gap that remains between the surface of the support bracket and the PTO housing must be shimmed to reduce the gap to zero without straining the PTO housing 14 Install and tighten four M12 class 8 8 capscrews through the support bracket into the power take off and torque to 80 Nm 59 Ib ft Following this procedure will prevent damaging deflection or strain when attaching the support plate 15 The driven pump should now be installed using a gasket that will seal on the pump mount face Lube oil is supplied from the marine transmission to lubricate the pump s
58. rth 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 cover with a stone or file if necessary in the vicinity of all pusher screw locations Marine Transmission Service Manual 47 Cleaning and Inspection Twin Disc Incorporated 48 Cleaning Bearings Do not remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease Never dry bearings with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently 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 sealant Clean surfaces with solvent to remove oil and grease residue Test for clean surfaces by applying
59. t head capscrews and remove orifice plate cover and gasket Figue 17 Orifice Plate and Gasket 2 Hemove orifice plate 3 Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket 42 Marine Power Take off Service Manual Twin Disc Incorporated Disassembly 5 Remove rate of rise piston Note that shims are located between the piston and springs Figure 18 Rate of rise piston left and Regulator Springs right 6 Hemove pressure regulating springs f Hemove pressure regulating piston with an external retaining ring pliers Figure 19 Removing Regulating Piston with Pliers Marine Power Take off Service Manual 43 Disassembly 10 11 12 13 Twin Disc Incorporated Remove external retaining ring from the lever end of the stem Loosen the clamping screw and nut and remove the control lever from the stem It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged Hemove the washer and spring from the stem Remove the four M8 x 25 socket head capscrews Remove the cover assembly with gasket from the valve body Remove the O ring and oil seal from the cover assembly Figure 20 O ring in Cover 14 44 Remove the two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body Marine Power T
60. that the engagement linkage is adjusted such that full travel of the engaging lever results in the valve being in the detent position See the Installation section Marine Power Take off Service Manual 33 Operation Twin Disc Incorporated 34 Marine Power Take off Service Manual Twin Disc Incorporated Preventative Maintenance General Lubrication and Preventative Maintenance Lubrication of the marine power take off is accomplished internally with the marine transmission s oil No external lubrication is required oee the Installation section for proper adjustment of the shift lever of the clutchable power take off control valve There are no adjustments on the live power take off A plug M1945T is supplied for sealing if the marine transmission is to be operated without a driven pump installed This plug should have a thin coat of M2828 anaerobic sealant applied to the outer diameter prior to installation into the power take off pilot bore It should be pressed until flush with the rear face of the housing lt is important that the alignment of the support plate be rechecked whenever it has been disconnected to insure that no side load is transmitted to the power take off clutch housing Marine Power Take off Service Manual 35 Preventative Maintenance Twin Disc Incorporated 36 Marine Power Take off Service Manual Twin Disc Incorporated Disassembly Disassembly General Refer to the Bill of Material that is identif
61. the rate of rise piston pressure regulating springs and pressure regulator piston The pressure regulator adjustment shims are in the spring pocket of the rate of rise piston 3 Hemove the O ring plug O ring detent spring and detent 4 Mark the lever and the stem to indicate the position the lever was installed on the stem Loosen the screw clamping the shift 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 40 Marine Power Take off Service Manual Twin Disc Incorporated Disassembly D Mark the stop and the stem to indicate the position the stop was installed on the stem Drive the rollpin out of the stop with a drift punch and remove the stop Figure 16 Drive Roll Pin Out of Stop 6 Remove the valve cover and valve stem 7 Slide the valve stem out of the valve cover 8 Remove the gasket and O ring from the valve cover 9 Remove the bearing from the valve stem Marine Power Take off Service Manual 41 Disassembly Twin Disc Incorporated Valve for MG516 MG5170DC MG5202DC MG5205DC MG5301DC MG6650 00 SC MG6848 00 SC with Electric Transmission Control Valve with Mechanical Backup Steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Loosen and remove the four M8 x 25 socke
62. tions are not specified the equipment will be shipped the best way considering time and expense Twin Disc Incorporated will not be responsible for any charges incurred by this procedure Twin Disc Incorporated having stipulated the bill of material number on the units nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating from any of the above stated changes will notbe accepted for credit Furthermore any equipment which has been subjected to such changes will notbe covered by a Twin Disc warranty Marine Power Take off Service Manual Twin Disc Incorporated Introduction Preventative Maintenance Troubleshooting Frequent reference to the information provided in this manual regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for the recommended maintenance of the equipment and if observed minimum repairs aside from normal wear will result Lifting Bolt Holes Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these points could cause failure at the lift point or points and r
63. ump should now be installed using a gasket that will seal on the pump mount face Lube oil is supplied from the marine transmission to lubricate the pump spline and then flows to the sump through the power take off housing Consequently the pump face will be in contact with marine transmission oil but not pressurized Marine Power Take off Service Manuall Twin Disc Incorporated Installation MG5301DC MG6650 00 SC MG6848 00 SC with Electric Control Valve Refer to figure 9 1 Hemove the cover from the rear of the marine transmission at the input shaft centerline Remove and discard the o ring 2 Remove the existing transmission control valve ditch plate and gasket from the manifold Discard the ditch plate and gasket 3 Assemble the B3404 gasket and the 1018482 ditch plate onto the manifold using two MA1062P capscrews M12x130 class 12 9 and torque to 130 Nm 96 Ib ft Note that all threaded fasteners should be lightly lubricated prior to assembly 4 Install the 1018481 gasket 10189874 ditch plate 1018886 gasket and 1018480 ditch plate using two MA1062R capscrews M12x70 class 12 9 and five MA1062Q capscrews M12x45 class 12 9 and torque to 130 Nm 96 Ib ft 5 Reassemble the transmission control valve using gasket 1017569 and four existing MA1052P capscrews M10x150class 12 9 and torque to a special reduced torque of 54 Nm 40 Ib ft with threads lubricated Be sure to install a new 1017136B gasket between the
64. umps Adapter Clutched XB2403D 127 4 127 4 flange 32 4 shaft 32 4 shaft 101 2 101 2 flange 22 4 shaft 22 4 shaft Clutched XB2403E 127 4 flange 32 4 shaft 82 2 flange 16 4 shaft XB2403F 127 4 flange 32 4 shaft 101 2 flange 22 4 shaft XB2403G 127 4 flange 32 4 shaft 82 2 flange 16 4 shaft 16 Marine Power Take off Service Manual Twin Disc Incorporated Description and Specifications Description The Live power take off consists of appropriate adapters to drive a pump in the direction of engine rotation at a speed equal to engine rpm The pto and attached pump rotate whenever the engine is running The Clutched power take off assembly consists of an input adapter a hydraulically applied spring released clutch assembly with a control valve and a splined output adapter The power take off drives a pump in the direction of engine rotation at a speed equal to engine rpm when the pto control valve is in the engaged position The rotating components are supported by a combination of ball tapered roller and needle thrust bearings Lubrication is provided from the marine transmission fluid Threaded holes are provided for use with a customer supplied support bracket Specifications The clutched power take off assembly has a metal tag with the bill of material number stamped identifying the configuration as built and shipped by Twin Disc The differences between the various available versions are only in the
65. 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 Marine Power Take off Service Manual 61 Assembly Twin Disc Incorporated 9 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 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 34 Dogpoint Setscrew with Threadlocker 62 Marine Power Take off Service Manual Twin Disc Incorporated Assembly Install the steel detent ball into the valve body Install the detent spring over the detent ball 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 it is flush with the gasket surface of the valve body Check the stem rotation and detent action Figure 35 Detent Ball Spring Hollow Setscrew 10 11 12 13 Install the thrust washer over the end of the stem Press the oil seal into the cover assembly until flush with the adjacent cover surface
Download Pdf Manuals
Related Search