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2. 2 i 1521 m 43 Figure 11 Hydraulic Schematic electric control valve Marine Transmission Service Manual 1020825 Operation Twin Disc Incorporated Trolling Valve Optional 44 The trolling valve is used to reduce and control propeller soeed below that normally attained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure to reduce the propeller speed The trolling valve for this transmission does not control the pressure in the rate of rise chamber When in the trolling mode it controls the flow of oil to the engaged clutch Trolling is achieved by restricting the flow of main pressure oil to the engaged clutch which ultimately controls the pressure in the engaged clutch of the transmission The trolling feature is available when the selector valve is in the electric mode but is disabled when the selector valve is in the manual override mode Main pressure oil can flow into the trolling valve through a fixed orifice at all times Oil may exit the trolling valve through a variable orifice The size of the variable orifice depends on the trolling valve lever position When the trolling valve lever is in the detented position the variable orifice is closed Since oil can flow into the trolling valve through the inlet orifice and is not allowed to escape the oil pressure insid
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5. 156 Preliminary Output Shaft Gear Advancement Verification 161 Gear Pan and Bottom Cover Installation 171 Install Clutch Shaft Assemblies 173 Prepare Clutch Shaft Assemblies 2 2 1 221 173 Installing Primary and Secondary Shafts 174 ro u n 176 Adjust Primary Shaft Bearing Clearance 178 Primary Shaft Cover Installation T J J 179 Set Secondary Shaft Bearing Clearance 181 Pump Mount instalation de m 182 Transmission External Components 183 Pump and Suction Screen Installation 183 Trailing Pump and Governor Cover Installation 186 Heat Exchanger Installation 187 Assembly and Installation of Control Valve 192 DEON ae re 201 Oil Filter Housing Installation
6. III LZ 7 E 7 Clutch MO qune LI Lube TTT Port 7 a ru Sealing NO Rings Pinion Gear A Assembly M Tet rust Race Steel 4 Plates 11 ates 10 6 6557 10 Figure 94 Primary Clutch Shaft Component Identification and Location 128 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 1 Inspect the clutch piston dump valves 1 for proper operation Be sure the dump valve balls are free to move The clutch piston dump valves are not serviced separately AR6557 1023 AR6557 1021 Figure 95 Clutch Piston with Dump Balls 1 2 Replace the clutch piston seals 3 Lubricate the clutch piston sealing rings before installing the piston into the clutch housing AAR200A 6557 AAR200B 6557 Figure 96 Installing Cutch Piston Seals 3 3 Lubricate the clutch piston bore with a thin film of grease Install the piston into the clutch housing Gently push the piston by hand until it is fully engaged into the clutch 6 Marine Transmission Service Manual 1020825 129 Assembly Twin Disc Incorporated Note The piston contains two M12 1 75 threaded holes 4 into which screws can be inserted to aid in assembly The piston is also equipped with two dump valves 5 Note Ifthe piston is difficult to install by hand remove the piston assembly and inspect the
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15. 251 1 21482 45 Bearing Driver 252 21482 46 Seal Driver 253 10 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Table of Contents 1 21482 47 Transfer Gear Installation Tool 254 T 21482 49 Bearing Cone Driver 255 21482 50 Clutch Alignment Tool 256 21482 51 Primary Clutch Cover 257 21482 52 Secondary Clutch Cover 258 Engineering Drawings 259 List of Engineering Drawings 260 736628 Marine Transmission General View 261 736628A Marine Transmission General View 262 738228B Marine Transmission General View 263 738229 Marine Transmission Sectional View 264 737634 Marine Transmission General View 265 737635 Marine Transmission Sectional View 266 737934A Marine Transmission General View 267 737265A Marine Transmission General View 268 73
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18. eee rss 202 Transmission Top Cover and Dip Stick Installation 203 Grease Quipu Shan SOAS UU S in ra iir 205 Front HOUSING IMS CANN ce 206 Install Torsional Coupling and Fill Transmission with Oil 207 Marine Transmission Service Manual 1020825 9 Table of Contents Twin Disc Incorporated 209 aile ERR 209 Alignment also reference SAE J 1033 and J 617 210 luit itl e 214 Special Tools 223 EISE Or 10 11 OSAP ERODE DERSE OBOE OEE 223 T 111145 Restraining Bar for Input Sleeve 225 T 111146 Driver Output Shaft Bearing and Spacer 226 21482 06 Retention Block and Screw 227 T 21482 08 Hydraulic Knock out Tool 228 21482 13 Locating Plate 229 21482 17 Trailing Pump Gear and Bearing Removal Tool 230 21482 20 Bearing Driver 231 21482 21 Restraining Tool Output Shaft 232 21482 22 Shaft Support Tool
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28. T2 mns 111 DIL Nita IM A ee NOT RECOMMENDED ss prey GU E it 12 M E LRL 155208 DIL DRAIN FLANGE CGCL ING WATER INLET ANG QUTLET FLANGE THIRD ANGLE PRELIEC TI or 11 1 1 8 K res TX SUSS PROBA TETARY CMP ORMATLON AND LE OS m 4o 1 14 HOT BE USED AMY E 10 75 RN LN CN RPR TE DETRIMENTA THE I8TEPESTS oF 8 3 7 25 1 5 21901 TRA LAGE UE 285 14 2 THIN DISC NCORPORATED 222 RACINE ui 55408 USA s pns wore cs wor eee 107 veste THE L S sovemoenr e zw ci wo zone o OMMERS CONTRACT 2 F E ML ALAA RCE si Lis xn 0 557 PER Ue TIT ER pam GENERAL View y NIMM SHEET J OF 1 Pao AS oir 1 5 JACT 2 13 222122 523 1 LM EUM ILLA I L m Pel OQ UT CHITI YD RI M 7 Fei fF al EH E TS DL 4 Lar a Bipi HIC Cental 51217112 we LI sone wT RT z l
29. 1020825 C E m gt lt lt M 0 0 TE C C E G C z gt O INCORPORATED Service Manual 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 1020825 April 2004 Marine Transmission Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE TRANSMISSION A Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of shipment by Twin Disc Incorporated to original
30. Assembly Place the oil seal sleeve 1 onto the output shaft with the counterbored end toward the output flange The oil seal sleeve must contact the output shaft shoulder Wrap the surface of the output shaft with electrical tape 2 to protect the output shaft seal from damage during assembly Cover the surface of the shaft between the output flange and the oil seal sleeve AAR220A1 6557 AAR220R 6557 Figure 135 Oil Sleeve Installation on Output Shaft 9 Install new output shaft seals into the seal carrier using tool 21578 3 a b Apply MA1015 or equivalent sealer to the outside diameter of the oil seals and the bore of the oil seal carrier Drive the inner seal single lip seal until it is flush with the inside surface of the oil seal carrier Install seal with the spring loaded lip toward the inside of the seal carrier Drive the outer seal double lip seal until it is flush with the outside surface of the oil seal carrier Install seal with the spring loaded lip toward the inside of the seal carrier Apply grease to the oil seal lips and to the oil seal sleeve surface on the output shaft Marine Transmission Service Manual 1020825 157 Assembly Twin Disc Incorporated Output Shaft Seal Carrier Apply MA1015 or Equivalent N Double Lip Seal Single L inge LID Seal cR earner Inside of Seal Carrier MG 6557 17 Figure 136 Output Shaft Seal Carrier Assembly 4 Install
31. GOO TION JF ThE PARTS ONTING SIME IR Tat Wii i dag 2 TH PRO FIT ED PARTS 1G FIG 43 13 SENCVE COVER CE UF AND FLANGE C3 2 144331 H ANGE ZED 39 K FT screw covER AND E FOR REUSE AT 4E OF 14 ERAH ING PUMP ETT TCRQUE 5 0 Threebond 413273 TOROUE SEL i 3 INSTALLA OM 05 TRAILING PUMP REFER TO 16 2 13 NETALLAT ON OF TRAILING 8 ATTACH THE SUNP BASE E GASEETUD BY SCREWS A B ATTACH 192 DLDPAM COUPLING 43 10 THE SKAFT INSTALL THE GASKET 2 ANJ PUMP Hy 5 2 IN THiS KERE MAKE SURE THAT HOLE OF GASEET P 0 HLLIS M Wil AMM Hole USE GREASE DURIMG THE OLDHAM CJ 143 AND TRF SHAFT TO PREVENT THE ZOLPLIKE VALL 2 ASSEMBLY OF MONRETURH VALVE MSERT THE NOKRETURM YALVE 8 FLANGE IE HUA GASKET 60 Bv 5C2E F gt 13 ENGIAEL dip FILING Y ub TRF PRS FIG Z _ NSURE STRAINCR 722 160 Ello GARIN AND INSEATL IHE HILL THF INSTALLATION WORE 15 COMPLETED 2 METRIC C SIMILAR ROM 503155 D s o 1 MOTIGE THES PRINT CONTAINS E1 HFT WALESS OUHERMISE SPECEF ED DATE DEBE 7 ARE 27 07 PROPRIETARY FORMAT FY AND 5 1 CENE 3 2 9
32. Jin a SERRE SERIES SPECIFY LENGTH S PLUG 2 CONNECTOR TEE MA711G SPOOL 1017432 2 PORT A SOLENOID A HYDRAULIC LOCK ONLY PORT B SOLENOID VALVE ASS Y SEE CHART _ SCREW MA1052J 4 am SPRING A2705AH 2 TORQUE TO 54 Ese PORT A PORT B NEUTRAL THESE SOLENOID CONNECTIONS SOLENOID SOLENOID SOLENOID s OR WITHOUT ES ORAN LOCK f PLUG M2051L 2 r OPEL Z T J VALVE BODY ASS Y 1017444A 9 OK SNS A 1017443 N SS SAN BALL MA1034A 11 N VI Y NSSN BALL M1990Y 6 SNN S 595 SHROUD 1001434 GASKET 1017136B 2 D SN PD SIN P I 5 PLATE 1018364 Lg ZZ lt lt lt GASKET 1018365 N S D uw 1018368 1018367 O RING 79 I 9 0 RING A2916FT Ad SWI ic ji t ty ON 2 ES El LA i 25 O E m x GASKET 1017383 SX Z SPOOL 1017433 2 4S E 1 i HYDRAULIC DIAGRAM 71192 OIL TEMPERATURE PICKUP PORT 1 4 18 N P T F DRYSEAL THD THIS KIT FOR USE WITH EXISTING LOWER METRIC VALVE AS INSTALLED ON TRANSMISSION A NOT 5 SEPARATELY O Ed mam 1 PLUG
33. T T b cL tA TA b 018 6557 022 6557 Figure 22 Suction Strainer Cover 4 and Suction Strainer 5 Removal 68 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Oil Pump 1 Remove the oil pump and the jumper tube located behind the pump The jumper tube is sealed at each end with an O ring and is fitted into a suction adapter plate 6 on the rear side of the transmission 2 The oil pump 16 sealed to the pump mounting plate 8 with a gasket 7 Note the orientation of the gasket on the pump mounting plate to assist in the re assembly process 3 Remove the oil pump suction adapter plate 6 Note the orientation of the suction adapter plate to assist in the re assembly process 29 6557 033 6557 Figure 23 Oil Pump Removal Marine Transmission Service Manual 1020825 69 Disassembly Twin Disc Incorporated Heat Exchanger Heat Exchanger P Gasket Locations Ab 8 Zinc Anode Plug Nn 4 4 a nm Rear Cover Front Heat Exchanger Cover Heat Exchanger Drain Port and Drain Port Adapter Inlet for Trailing Spacer and Housing Pump if Equipped O rings 548405HE Figure
34. i 2 ZAL RMIT FARM AML CIRCLED TIE DATS ol Beis a KEAZIMO ON AD DAC WE TiN DUN m 1 40 DOC DEST RET Segre Uy 41 WE Q2 Tel O 15112 mils a CTI DIS AND 1835 4 17 Urs SEED I E TSI 4E 212112 453 EEEN Yay Fal JSTE VR hu 1 5 TASS 01 0 ST T Gc SUNG 221224 TEI OX UM DA 1 T lt lt C AMD 2312037 CF Moe YM EES IED 7F ghi NADA re w arid AD D L 1 i 224 WELL Bay ls S Ta Fr 1 1 dm Ix M o7 17 soo TIME TEN TRSTALLATION EC thet e PT le S3 Thal LET PU Ie 3225 22 SED TO Gr BI SL Sola 13 7 2 lt ORS Foe wi TH rl te 27 ODT 4 7 21 13 ul Lal D 3 17 14 UM 1 _ 2 m WE uei CRY s aos i LEI ABO SMS Abed ai JNU ALL 2 2 4EZRB 7 5 18 Y MOVES 21 Iii YEL A 24 hoc 0 unt a 2 CHE 2 1851023 25 URE RIPE L
35. m 1 QE EE THE 1 5 o m ere m are en ma TE 08 OTHERS Bv DIN ALT SUITS F E D i Al i EPMI lU I T aa ini oma pe DS nri ANM ETD CT t fal tt ie SEAT ba dar iT n ue II SC EN SELLED MIL RL wy L 607 neve Da rm vU Bad bleh i Ll REESE Us A qup 2471 ag A i ri WSs 2 e punit u Pria 55 igh LI 22 1 4 MEM 4 21 mhil QA DENS ag rm YI r F r SLLECTCR VALVE x IL 1a 2 an 5 BIA na m A 1 w 71 1 nA n RN TATUS T AT Oe T E 7 L7 dace 4 7 vc a x gt rettm o T 7 m us t 1 22 m e 1 1 221 1 4 1 1 Nu 21 Zi MIT 1 1 r E 7 D TAiL OF wea ME U 7 ioe Itu OTT by
36. 295 6557 AAR296 6557 Figure 171 Suction Strainer 7 and Cover 8 Installation Marine Transmission Service Manual 1020825 185 Assembly Twin Disc Incorporated Trailing Pump and Governor Cover Installation 1 Install the trailing pump cover 1 and gasket 2 Torque the screws to 46 Nem 84 lbeft Note Ifthe transmission is equipped with a trailing pump install the suction screen into the housing 2 Lubricate and install the trailing pump suction port O ring and cover 3 Torque the screws to 45 Nem 33 Ibeft AAR298 6557 AAR299 6557 Figure 172 Trailing Pump Cover 1 and Gasket 2 Installation d Lubricate and install the governor cover 4 and O ring Torque the screw to 45 33 lbeft AAR303 6557 R301 6557 Figure 173 Governor Cover 4 Installation 186 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Heat Exchanger Installation Heat exchangers furnished by Twin Disc to be used in salt water applications have zinc anode rods installed at the heat exchanger inlet and outlet heads These rods must be checked every 90 days If over 50 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc anode rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or externally grounded electrical current If these conditions do not exist
37. S PALY Casa B M SES PAR LE TL RAR IRE SO LGI TIS ToLo Mg ca ae 18 AFET i58 512085 pot ts 21215 1 05 2 2 7 ChE CEOUOU RUC OM UP CER HEAT Y myk AAIT moa AS TS abl UO TRIES Raa L E 717 SLBA Y ued 117 DIFIR C T 810912 5 2207 LIVES AD SY TAEI dj TnL T E DIFTEREMIIL bo CAAT Ce MAG NS LEAR 24275 3 w RHU idk 20b Care i CNTR a EJE DOES ETAL 219 1436 LIPSENSE ON Lo dE o ATA 148 MEEO 2 PLAE ES id LISE AF2 aF FE k EE MES AT afi TEIM Cm OR TI S7 ios Wah TEP EGG Dak SEMEL Dae ay Merl TRE rer AURA aes T ce nl E SMEG OBES 3E 2 15 0255 3 8 IZ Zra 2 Y uu N UP gi 2 _ BUE PEE BOGAN Ore YER Ay RUISRIIDOU hz 4 BATA BZLT BESS INTO Cal MARIA TRG Gs o TR ALL 4135 TASTI A ARG P wil SID wavs i 4 mY LA TAG ET TOR 2 z BEMENT TPE BOLT AME 0 PAIO eL YL T _ 2 27 AU IDn
38. TO USED jH ANY X 80 75 SCALE HCUORPAORATELD DETRIHENTAL TO THE INTERESTS GF REIT m liz RACINE HE 3403 USA RACING 53403 UGA GEOMETRIC TOLERANT INS 1 HAT HG D 7 00 50 _ DPTION KIT 200105 WT TRAILING PUMP KIT Rev _ D C H FEA 114 1502 THIS NOTICE 15 HULLIFY GR LIMIT RIGHTS PUR THEXTHENT BRAHTED TO 3 5 SO ERNMEHI GR OTHERS COMTAACT M IU I I un 4 tee 1 a iii 1 up _ n aM I 4 tot ota D TI c RIAL ola DI I 8 7 2 aOR RS TOEN lil m 2 15771511 tiie Tig oae Tapa lli F ss 145 oy Q DS 1472232 SL TARTON S7 i Z3 1 LI HN 1 r t r l el 21 pene 1 ho 1 1 1 LI m m rm vA x Ux i AATA 1 4 405 ong rope wey 31 VRLJR S iTS XI 4 7 7 b La Div I TIL CILLOHIU 11 85 CSUR ONG TRE Dum Vl Lu uc 1 l ut IM moon 1
39. VO6ElL WHOA iic 16 2 42018 NOLLN3 L3H OSIA NIML E ae Sm JINVES 101 9NIHSINIJ 144 5 3A130 40 40215 2 S 1H 23 E I E L NN ANIT 38113344331 7 G Gr a r RA 1 Marine Transmission Service Manual 102085 Twin Disc Incorporated Special Tools Hydraulic Knock out Tool T 21482 08 SIM SNIOVH ONIOSIGNIML Ag NOlLdIHOS3d 8 687 12 1 5 5 6199 DW 0099 9N 40 L133HS VZSS9 DW 8 952999 OIN TOOL LNO MOONY ay Tind eros 96 6 L leq 3ZIS MOOLS NOILdIHOSAG 130 0199 X 68 11 JOOLLNO MOONN SN L 1 x GZ LXZLIN 1709 2191930 MIS 2 OIH L3IN 878 3SNVHO 8 z8r Lc 43114 QVO OML IWNOILOVYS 010 NOISN3WIG 1VINIO3G SSYHL NO 100 1315192345 3SIMH3HLO SSJINN 39NVH31OL SH3NHOO dHVHS 11 v3d8 1HVd NJ 8 28912 18 V 4889 DW 8 OS 669 9N qoas 1 8 8 3avsdo 5 36 6199 Sald3S 0099 OW ONOTWWSLXGLEXZLN Z 1109 ATINA SZ EXC LIN HLIM TOOL LNO MOONY 562 uuig7 x X NCI dV L 466 via seor uuugz or 1 J 3s 0 94 3 25 2 95 q O33
40. 12 VDC XAe707AD A2707AD 270 2000 290 10171298 1038 27 x 20 6 Be451B 6 6 6 8 6 10180842 41045 1017134 1018688 2759 24 VDC XA2707AD A2707AD 70 2000 lt 290 10171298 20 64 2451 52050 559 STRAP M2942B hoisos4ael 10175 3 1017569 1017613 1018688 XMe759FL te 27072 27072 703 2000 lt 290 10171298 MA1038EcM27 x 20 64 B2451B 0 10628 MA1062J 2 wc seoore NOTE 01808448 41093 11017133 1017134 B1337F 1018688 NO 2 XMe759FL 1e VDC 27072 27072 2703 1725 250 10171298 038 7 20 6H 451 co 10524 2 1052 2 MG 5202DC INSTALL USING 908 LOCTITE e 40967 1017383 1017179 5 2759 24 Ae7 mu 2655 385 10171294 MAi038EQe7 x 20 6 B2451B 5 MG 6449 RV 17028 ETE POSE RTI 018084 41114 1018688 2 xMe7S9Fl ie VDC 2415 350 10171298 7 x 20 65 B2451B keg 6 6 BACK OFF 1 2 TURN 41115 1018688 2 759 24 VDC azzoesc A27oapu 2415 350
41. 548405MPCS Figure 167 Pump Component Identification and Location 183 Marine Transmission Service Manual 1020825 Assembly 184 Twin Disc Incorporated 1 Place MA1015 on the sealing surface of the pump suction adapter plate 2 Install the pump suction adapter plate 1 if removed Torque the screws to 46 Nem 34 lbeft AR281 6557 Figure 168 Seal and Install Pump Suction Adapter Plate 1 Lubricate the pump suction jumper tube bore 2 4 Install O rings on each end of the pump jumper tube 3 Lubricate the O rings AAR288 6557 AAR289 6557 Figure 169 Jumper Tube 3 Lubrication 9 Install the pump mounting gasket Note The larger of the two round holes is for the pump shaft Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 6 Install the jumper tube 4 into the pump suction adapter plate 7 Install the pump 5 It may be necessary to rotate the primary shaft to allow the pump shaft to align during installation Torque the screws to 46 Nem 34 Ibeft Note The jumper tube 6 should rotate freely by hand with the O rings installed after the pump is mounted and the bolts are tightened AAR290 6557 AAR293 6557 Figure 170 Jumper Tube 4 and Pump 5 Installation 8 Installthe suction strainer 7 9 Install the suction strainer O ring and cover 8 Torque the screws to 45 Nem 33 lbeft Note Do notcrush the suction strainer
42. DR 0 48 RETE OMT AIMS ASST ALL ANGULAR TOLERANCES 1 NAKAMURA MOT HE USED iM AMT 00 C GEOMETRIC TOLERANC IHG 12 16 97 MENTA nS MODEL PER Y14 54 1982 THIN DISC INCORPORATED Te Maries de er MA Se DYUHAULIU DIAGRAM VALVE DITCH DITCH frransmssm CLUTCH ORIFICE SHIMS MOUNTING SCREWS DATE CONNECTOR MANUAL OVERRIDE NEUTRAL START 146 00 1018084 40750 1017133 1017134 B1337F 1018688 2759 24 VDC 7077 27072 e7osT 1725 250 10171298 6 B2451B 1052 1052 MG S202DC mene EER MANUAL OVERRIDE IS IN USE amp 10 00 134 70 1018084 40751 1017383 1017179 2 75 24 vDC ae707BD ae704BU 2415 350 1017129 10 27 x eo em 24518 Ms seiRv PORT SOLENOID MAR I a 10180848 40752 1017133 1017134 1337 1017179 759 24 VDC 707 0 1565 e3o 10171294 MPP 2 4 10535 5 M2089F M2089AG 2 5 18084D 40754 1017133 1017134 1337 1017179 759 VDC A2707AD_ i585 230 1017129 051 9 0936 B2451B yy Me089F 2089 A IE 2 SCREEN 1020479 018084 4075
43. Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Wom or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Marine Transmission Service Manual 1020825 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 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 61 Troubleshooting 6 7 8 9 62 Twin Disc Incorporated Table 11 Troubleshooting Chart continued No neutral Harsh engagement Low lube oil pressure Oil spilling out of breather Clutch plates warped Control valve incorrectly indexed Solenoid malfunction units equipped with electric
44. 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 you find any of these 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 1020825 123 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Bearings Inspect bearings for ro
45. J Install the selector valve and gasket Tighten the screws to 46 Nem 34 Ib ft AAR322 6557 23 6557 Figure 192 Ditch Plate 2 Gasket 3 and Forward Cover 4 Installation Marine Transmission Service Manual 8 1020825 201 Assembly Twin Disc Incorporated Oil Filter Housing Installation 1 Install the oil filter assembly 5 Torque the screws 6 to 46 Nem 34 Ibeft 2 Install the piping assemblies on the transmission a Pump to filter b Filter to transmission housing C Ditch plate to valve no trolling valve installed Install hose if equipped with trolling valve Note See specification section for tubing and banjo fitting torque values AAR016 6557 30 6557 Figure 193 Oil Filter 5 Installation 202 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Transmission Top Cover and Dip Stick Installation 1 The top cover 7 of the transmission housing should be installed with the oil baffle 8 towards the rear of the transmission housing Note The oil baffle attaching studs are sealed with Loctite Threadlocker 277 or equivalent The oil baffle retaining nuts are retained with Locktite 242 or equivalent 2 Place 1015 on the sealing surface 9 of the transmission housing and top cover AAR324 6557 26 6557 Figure 194 Seal Top Cover 7 3 Install the top cover 1 on the transmission housing Tighten the screws to 45 Ne
46. MODEL MG S202DC VALVE 557 CONTROL CWITHOUT TROLLING VALVE B FIRST USE IS OR GRANTED TO THE US GOVERNMENT OR OTHERS BY CONTRACT SYN me RY PES GT 52 USE ASS Y No No VALVE ASS Y VOLTAGE COMMENT AND ADAPTER 1018370 Lock QTY USE APPR 1020025 41492 1 68755 6 2 xM2759FM 24 VDC MG 6557SC 10200254 41513 i 68753 G YES 3 xM2759FM 24 VDC MG 6557SC HOSE 923 WIRING DIAGRAM CONNECTOR 10200258 41514 1 68755 6 5 3 XM2759FM 24 VDC PORT B SOLENOID C e e D NEUTRAL SOLENOID E F USE ONE COPPER SEALING WASHER FROM EXISTING BANJO UNION HERE SCREW MA1052S 4 TORQUE TO 54 OPTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH SOLENOID ASS Y SEE CHART TORQUE 34 CLIP 1017322 CONNECTOR SHROUD 1001825 5 SCREEN 221336 PLATE 1018312 A W VIA C 2 221 if 7 12 H NSP PORE l ij A FPE 1 T uu s pu EN Lu SCREW 961 1 2 HD 4 PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND 4306 i 7 HYDRAULIC LOCK OPTIONAL CONDITION PIN A2711AC 2 SPRING A2702BQ 2 OPTIONAL LEE B VIEW HYDRAULIC LOCK ONLY HYDRAULIC LOCK
47. Marine Transmission Service Manual 1020825 153 Assembly 154 Twin Disc Incorporated 5 Measure the depth of the tapered roller bearing cup into the transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing cup 3 Measure in three evenly spaced locations around the circumference of the bearing If all three readings are identical record the dimension If the readings are not identical adjust the bearings and measure again Bearing Bore Depth 6 Measure the length of the output seal carrier pilot Record the dimension Output Seal Cover Pilot Dimension 221 6557 AAR222 6557 Figure 131 Measuring Components to Determine Output Shaft Bearing Adjustment f Calculate the shim pack required to set the output shaft bearing clearance a oubtract the output seal carrier dimension from the bearing bore dimension Bearing Bore Dimension Seal Carrier Dimension Output Bearing Clearance b Calculate the shim pack thickness required to obtain 0 00 0 05 mm 0 000 0 002 inches bearing clearance when the shim pack is installed Label the shim pack for use when assembling the output shaft subassembly Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 8 Remove the output shaft rear bearings from the main transmission housing to allow for assembly of the output shaft a Place the housing with the in
48. ST TU LTA hea B e bate EL 425 1 2 A PD z Er TE e Fo JEC TECH Slat r 7 s PIN DISE 11 F 5 R 4H TE 4r FRET VSE ator Tdi DISC ED 51443 hh57 u Eo be ls THEI oT me R37 u ae NNI TO MALIFYT OR M T 5 ME HEA ExT ot m 379855 E i SECTIONAL VIEW _ 4 MIU on due ar Jar A 119w ATZEAL TET I vH q ort MM wey 2 t n 1 m 1 1 1 D 8 20 ut gt gt C 4 LUBE NN LUBE COLD RELIEF VALVE VALVE REVERSE VAL VE IZE SOLENOID VALVE FORWARD REVERSE SCREEN FILTER FILTER GEAR PUMP 2 HEAT EXCH CLUTCH RELIEF VALVE METRIC STRAINER PRESS 23 25kgf cm THIRD weve 3 2 47 THIG NOTICE 45 MOT M SOLENOID VALVE SIMILAR TO WEIGHT UNLESS OTHERWISE SPECIFIED DATE PENSIONS ARE mn 370318 Wood b uS MACHINED DIMENSIONS iiis 40 75 as tN ORP OR AT ED FIRST USE x XX 80 45 i RACINE WI 53403 USA
49. 233 21482 23 Retainer Input Drive Sleeve 234 1 21482 26 Bearing Driver eese 235 1 21482 30 Bearing Driver 236 21482 36 Input Oil Seal Carrier Puller 237 T 21482 39 Support Bracket Leg 238 T 21482 53 Primary Clutch End Play Fixture 239 21482 54 Secondary Clutch End Play Fixture 240 21578 1 Output Flange Installing Fixture Sheet 3 of 3 241 21578 4 Output Shaft Bearing Driver Sheet 1 of 2 242 T 21482 Output Gear Installing Tool 243 T 21482 02 Output Gear Ram 244 21482 40 Pump Bearing Pulling Tool Sheet 1 of 3 245 21482 40 Clutch Spring Compressing Tool Sheet 2 of 3 246 T 21482 40B Input Hub Removal Tool Sheet 3 of 3 247 T 21482 41 Seal DIVET 248 21482 42 Bearing Driver esee 249 1 21482 43 Bearing Driver 250 21482 44 Adjustable Jack
50. FLUSH WITH SURFACE ATMOSPHERIC PRESSURE METRIC A ATMOSPHERIC PRESSURE 69 OBSOLETE FOR PRODUCTION INTERMEDIATE PRESSURE 699 CLUTCH PRESSURE PROJECTION 2 1 A NOT SERVICEABLE SEPARATELY T amp LEVER X STR TH D D RING 1506149 MAIN PRESSURE DIL INLET WHEN NUT INTERNALLY SUPPLIED THREAD SIZE AT PORT 04 1 4 18 NP T F WHEN 2052 REDUCER BUSHING IS SPECIFIED _ j j j _ j jj j j jj j 0 e 9 02 _ a 12 3 01 zone pare rev zone 20 THESE PARTS ARE PACKAGED SEPARATELY AND SHIPPED WITH UNIT SIMILAR T UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS 20 75 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE NOT INTENDED TO NULLIFY LIMIT RIGHTS DATE 3 23 98 TWIN DISE INCORPORATED RACINE WI 53403 USA 1018084 K RM BJE SERIES APPD A X X 0 25 X XX 0 13 ASSY 1015207 ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING PER ANSI 14 5 1982
51. Filling 1 Remove the filler breather in the top cover of the transmission 2 Fill the transmission s sump with 20 liters 5 3 U S gal of the proper weight and type oil See Description and Specifications for oil recommendations 3 otart the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle 4 With the oil at operating temperature transmission in Neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the oil level to FULL mark on the oil gauge 9 Allow the oil temperature to cool to normal cold oil conditions 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 54 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Preventative Maintenance 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 an
52. L EN CU AR med o ERI 2 iU a I is STAG SEVE kylie 2 gt d Paar n 4 i 1 LI 1 I j wpe 213428 El 1 koa PSG as Luxe Ne L SEMAT NO WL ACER X ee 22 4 i 2 14 2 TF Dans 5451 OF SCLECIIR VALVE E wr onibus E wS U IE UM 2 x i 5 7 a E 1 r 23 bil EYZRPAMGRS x rd L En i US a i FE Y i p m LL 23 27 0 xf a h 1 lE 75055 5 Slo a L 208 m n 1 AE 1 i c ILLIS ere s 2 me 0x 1 1 Oh 5 x 1 2 d T ra Cd o E r E T ACC Pte r LI m i 155 D zi 3247 dU 1 E _ Ac is i
53. Output Flange Installing Fixture Sheet 3 of 3 Output Shaft Bearing Driver Sheet 1 of 2 Output Gear Installing Tool Output Gear Ram Pump Bearing Pulling Tool Sheet 1 of 3 Clutch Spring Compressing Tool Sheet 2 of 3 Input Hub Removal Tool Sheet 3 of 3 Seal Driver Bearing Driver Bearing Driver Adjustable Jack Bearing Driver Seal Driver Transfer Gear Installation Bearing Cone Driver Clutch Alignment Tool Primary Clutch Cover secondary Clutch Cover Marine Transmission Service Manual 1020825 Special Tools Twin Disc Incorporated 225 151 TV LRGLEV JA3315 104 1 YY ONINIVYdISJ3U 5g FC A TT 111145 Restraining Bar for Input Sleeve Marine Transmission Service Manual 1020825 Twin Disc Incorporated Special Tools DjT 25 Aumduas E C ES NWE E 6cNOW 318v 335 iom AA SONVETTOL ONTHSINIS I4VHS Ind lnO 9392745 ONY 40 HM G62 x Og E y 0119 T 111146 Driver Output Shaft Bearing and Spacer Marine Transmission Service Manual 1020825 226 Special Tools Twin Disc Incorporated Retention Block and Screw T 21482 06
54. ty lta 121 28 T RTIA ERE Tl I a an 53 i uli ul ur m 25 7 _ tae Cil p E INST 0012 THE 25 PAGT ln __ whos ASULOEG tu ChE dona Wi Ci dod QUES ASSES B 7 2 1 25 504 175 alL J 5 SAP CT 26 LIESS r RI SR lde gL 17489 ETEME MEALLET i TIF eg nn TaT CRE 05 200 e lam RIFTS ADR TCHCETEORD CI Eat Cl 41262 Tes E NE 128 a m tn BR Dp cU TE 1f5 1 PO DL Lin JSPL LET WE A XD CI L IT ZQSEYE FMF 4 OTT CLT VA VE AU x15 _ 3r h A Lo de AEST Tage PES wli ASFE PRU ESEH DUM Tak HEACZ TRE SAIF IPOD X 2 41 reo Up PAG pow SUR woop m Es m AH a n 1 1 int J 1 r JIL m H ix r u E 4 2 li cC L T le 4 Bop aay ery ETE aD AT ICM 12 24 141 Teoh ep Tie 41 75 7b F DLE Twit RE evan o B AIL Tri mmr 77 a Ds 8 70 NGAR A PSELE SU
55. 1 SW TOOL LNO MSONM OlInvHGAH 0 79 148 7 1 HEO 2 N co e 1 NHHL 2 E VIG 2617 Marine Transmission Service Manual 1020825 228 Special Tools Twin Disc Incorporated Locating Plate T 21482 13 0661 WHOS cl ceric Ll 86 01 1 31V1d 9NILV201 ONI NIML STACOW 0099 OW 6199 OW 7669 DW B SW LV Zz ALWId ONILVOOT QVSYHL GL X OLN dYL O8rZ 68872 L 1 VIG NYHL VIa wwe 99 4 9 TIYA 8068 6667 0 uuo F 0069 066 ZG V i 2 HLS31TI0d4 OL XOLW MAYOS GH OIHISINMHOM3H z ATINA 8960 SLXOIN wwog 229 Marine Transmission Service Manual 1020825 Special Tools Twin Disc Incorporated 21482 17 Trailing Pump Gear and Bearing Removal Tool 4 1 i N 1 2 i ae x CST f 73 ND i 3 59 230 Marine Transmission Service Manual 1020825 Special Tools Twin Disc Incorporated Bearing Driver T 21482 20 02 28712 1 86 12 H3AIHO SNIHV3g ONI OSIA NIML YAHLO HOV3 JO 500 NIHLIM OL 02 28912 3114 avo LN3ONOO 9 48 150
56. 10171298 10 7 x 20 6 2451 6 485 69 63 horeos4ar 11017133 1017134 B1337F 1018688 NO xwe7sert te voc 7072 27072 2703 1725 250 10171298 27 20 69 24518 1058 1058 2 6 52025 THESE SOLENOID CONNECTIONS hoisos4ag 41163 1018688 2 759 1 1 VDC XA27074D A2707AD 270 2000 lt 290 gt 10171298 MAt038Ecwe7 20 6 24518 58 58 424202 ARE NOT POLARITY SENSITIVE SETSCREW M2038W 69 4171 1018688 759 24 VDC 27072 27072 2703 1725 250 10171298 1038 7 2 0 6 Be451B MG 5170DC 40270 1018084 41728 1018688 75 VDC 27072 427072 703 1725 250 1017129 1038 27 x 20 6 B2451B MG 5170DC ave7pas SPRING 270280 2 6909 Q 1018084 41244 1018584 1018594 B31174 1018688 NO xMe7S9ri ie vpc 27072 27072 A2703T_ 11725 250 10171294 1038 7 Be451B MI73eAH 2 738 2 MG 540 HYDRAULIC LOCK ON 10180844 41250 1018688 759 24 VDC XA27072 427072 703 11725 250 10171294 Mai03
57. 27072 a2707Z 2703 1725 250 10171294 1038 B2451B MG 5170DC RoE SERENE Dee RACE M2086R PE ARE NOT POLARITY SENSITIVE 2415 350 10171298 10 8 27 x 20 68 2451 4 GASKET B1334C PORT BY COVER ASSY 1017336 SPRING A2705AH 2 BALL M1990G 22 TORQUE TO 339 NOR ean PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND SOLENOID A CARRIER 1017335 i BALL MI990L D 25 0 Lbf ft HYDRAULIC LOCK CONDITION WM RAULIC LOCK BALL 1990 WIRING DIAGRAM OPTIONAL MATING WIRING HARNESS 1017404 HOLES HD xi Siew S ee 120747 PORT SOLENOID ge ey een POSITION Vs NR WEE 847 2 VALVE BODY ASS Y 1017444 B 252 ELECTRIC 24 7 NNN ISSN PISTUN B1399H 7 7 Y 7 Z my mms A BODY 1017443 PORT SOLENOID C PORT A CONTROL EF Z BALL 11 Bae nA POSITION PIXEL BS IN WG SS PLATE SEE CHART Y Zr lt BALL 1990 6 TIS 3 2 Ad Kids WALA ARE NOT POLARITY SENSITIVE zi X SEAL 778 S annie SHIM SEE CHART VAN p Ju 2 esa 1 SU SIS RESIS SSS oover Os Mehin 2000 2 VALVE GAS
58. 548405 1 Figure 121 Trailing Pump Drive Component Identification and Location Note The housing should be placed with the front face down 1 Lubricate the bore 1 of the transmission housing Install the trailing pump drive shaft 2 through the bearing bore in the transmission housing 160 6557 204 6557 Figure 122 Trailing Pump Driven Shaft 2 146 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 2 Position special tool T 2182 44 3 below the shaft assembly inside the transmission housing to support the gear shaft 4 in the correct position during the bearing installation process Use special tool T 21482 45 5 to press the first bearing onto the trailing pump drive shaft Press on the I D of the bearing when installing E az 4 AAR204C1 6557 204 6557 Figure 123 Trailing Pump Driven Gear Shaft 4 and Bearing Installation 3 Install the spacer and the second bearing into the bearing bore Press the spacer and bearing into position 4 Install a snap ring 6 to retain the bearing on the pump drive idler shaft If the snap ring 7 fits securely into position the bearings and spacer are properly positioned 206 6557 AAR204E 6557 Figure 124 Trailing Pump Driven Shaft Snap Ring 7 Installation Marine Transmission Service Manual 1020825 147 Assembly Twin Disc Incorporated Input Drive Sleeve and Shaft Seal 1 Securely
59. 8 to maintain the input drive sleeve position during rotation of the transmission housing A CAUTION DO NOT damage the input drive sleeve plug when installing tool T 111145 The primary shaft end is precision ground to contact and ride against the plug AAR245 6557 246 6557 Figure 129 Special Tool T 111145 Installation Marine Transmission Service Manual 1020825 151 Assembly Twin Disc Incorporated NOTES 152 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Output Shaft Installation Output Shaft Bearing Adjustment 1 If not previously done position the transmission housing with the output shaft end up Note Output shaft bearing adjustment is completed without springs installed in the pockets 1 of the transmission housing 2 Install the rear output shaft spherical roller bearing cup and cone into the transmission housing 3 Install the rear output shaft tapered roller bearing cone next to the spherical roller bearing Install the tapered roller bearing cup 2 into the transmission housing Use special tool T 21482 13 to clamp parts 221 6557 AAR242 6557 Figure 130 Output Shaft Bearing Spring Pockets 1 and Bearing 2 4 Apply a thin film of grease to the secondary shaft front bearing bore inside the transmission housing Press the secondary shaft bearing cup into the transmission housing bore with T 21482 27 The bearing cup should be a light slip fit
60. CLS EY Main Pump S 27 Oil Level Gauge Overall Length 545 mm p 72 Heat Exchanger 7 Cooling Water Outlet Flange Heat Exchanger Cooling Water Inlet Flange Main Pump Strainer Inlet for Trailing Pump If Equipped and Oil Drain Plug for Heat Exchanger PT1 4 Trailing Pump Location Center of Gravity Grease Drain Plug for Output Shaft Seals Grease Nipple for Output Shaft Seals S Stainless Steel Fastener 2 Output Shaft a mii Direction of Rotation MERE ange in Forward P PT3 8 M6 6557 01A Figure 17 MG 6557A Component Identification and Location Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Drain Oil Transmission Sump Drain the oil from the transmission sump by removing the square head 3 8 PT pipe plug from the bottom rear side of the transmission bottom housing Heat Exchanger Drain the oil from the heat exchanger by removing the pipe plug from the bottom of the heat exchanger rear cover Marine Transmission Service Manual 1020825 65 Disassembly Twin Disc Incorporated Remove Transmission External Components Torsional Coupling Remove the torsional coupling from the input drive sleeve if not previously removed Front Housing 1 Remove the front housing from the transmission main housing The front housing constructed of aluminum is equipped with two pusher screw locations near the housing dowe
61. Twin Disc Incorporated Mechanical Controls lf the manual override valve is connected to a control cable or device 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 operator s 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 devices could cause failure of the selector valve stop permitting improper positioning of the selector valve and resulting in control malfunction Electrical Controls All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connections must be tight and free from any corrosion Final Checks Be sure the transmission is filled with oil before starting See Description and Specifications and Preventative Maintenance for
62. bearing spacer onto the shaft until it contacts the spherical roller bearing race AAR222C 6557 AAR222B 6557 Figure 138 Tapered Bearing Cup 5 Tapered Bearing Cone 6 Spherical Roller Bearing Cone 7 and Bearing Spacer 8 Installation Marine Transmission Service Manual 1020825 159 Assembly Twin Disc Incorporated 10 Ensure the components are properly seated on the shaft Use pressing sleeve tool 1111146 and press to ensure the components are properly seated on the shaft 11 Install tool T 21578 4 9 to the output flange and seal carrier The tool is used to maintain the position of the output shaft seal carrier during installation in the transmission housing Maintaining the seal carrier position protects the seal during assembly into the transmission housing 222A 6557 AR6557 1052 Figure 139 Pressing Output Shaft Component with Tool T111146 and Installing Tool T 21578 4 9 on Seal Carrier 160 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Preliminary Output Shaft Gear Advancement Verification a SHIM ADJUSTMENT OF OUTPUT BEARING 1 Do adjustment A shims before gear assembling The clearance is 0 0 05 mm PROCESS OF GEAR ASSEMBLING 1 Remove oil on the taper location Output shaft and gear Measure C E and G Thickness of the B shims is obtained in according to following formula D G C 0 0 1 mm Put the gear on the output shaft and strike it lightly
63. 075BE Figure 147 Tool T 21482 5 Placement Marine Transmission Service Manual 1020825 167 Assembly Twin Disc Incorporated 21 Install tool T 21482 2 7 over tool T 21482 22 Install tool T 21482 8 on top of tool T 21482 2 AAR6557 076BE AAR6557 078BE Figure 148 Installing Tool T 21482 2 7 and T 21482 8 23 Connect tool 21482 to the output shaft using the socket head capscrews 9 Tighten the capscrews to a torque of 500 Nem 360 Ibeft 24 Connect a hydraulic power 1 supply to tool T 21482 2 25 Seat the output gear on the output shaft taper with 50 000 kPa 7 250 psi Hold the pressure on the assembly for a minimum of five minutes AAR6557 079BE 253 6557 Figure 149 Using Tool T 21482 to seat the Output Gear on the Output Shaft Marine Transmission Service Manual 1020825 Twin Disc Incorporated 26 27 28 Assembly Remove tools 21482 and T 21482 2 Verify the output gear advancement on the output shaft a Measure the distance from the shaft shoulder near the output gear to the end of the shaft Record this dimension as dimension D Dimension D Measure the distance from the edge of the output gear to the end of the output shaft Record this dimension as dimension E Dimension E The differences between these two dimensions E D should be 0 00 0 05 mm 0 00 0 002 inches If the output gear requires further advancement reinstall t
64. 1020825 209 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 Flywheel Engine Flywheel Housing Figure 201 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keeping a thrust in the same direction and note the face deviation of the engine flywheel housing flange The face deviation must not exceed the figures given in Table 12 210 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Installation Table 12 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations 2 Eccentricity 0 48 0 019 0 41 0 016 0 36 0 014 0 014 0 23 0 009 e 007 d 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 4 O R 0 28 0 011 Thousandths Engine Indicator 1 J gt l Flywheel Engine Crankshaft Figure 202 Checking Flywheel Housing Bore Eccentricity Engine Flywheel Housing Marine Transmission Service Manual 1020825 211 Ins
65. 12 VDC 4e707AD 1565 2303 1017129 1038 27 x 20 6 245 ya 105 8 1052 2 4 CLIP CONNECTOR 1017322 1018084 40764 1017383 1018688 759 VDC 72276 5 1018084 40775 1017583 1017569 1017613 1018688 759 24 27072 27072 A2703T 2000 290 10171298 1038 27 20 68 2451 0 10688 2 MA106eJ 2 MG S600DR CLOSED WHEN MANUAL VALVE 4 69 OO O 1018084P 40817 1018688 759 24 VDC XAe7074D 2707 0 A2703AB 2000 lt 290 10171298 1038 7 8245 8 uA E eb A 69 10180840 40842 1017133 1017134 B1337F 1018688 759 VDC 7072 27072 703 1725 250 10171298 1038 27 x 20 6 Be451B 48 1052 2 1058 2 MG S202SC ird a Q 1018084R 40935 1017383 1017179 YES 2759 24 a2707BD ae704BU e41S 3505 10171298 x Beasts 8 6557 s Fin SCREW MA1052P 4 60 1 10180845 40954 1018584 1018594 117 1018688 NO 759 24 vpc xA2707z 27072 703 1725 250 10171293
66. L C C T 3715 5 0 19634130 02 119 PU TT ee 131413348 SSIINN ILON 91009 61 2 1 90209 814 anis 00 31 ndj 8T 1 AYANIHOWW te EE EE Cand 91 00 EI 2 1 Tron tre 1 934 4015 D DNISNOH NIVW OLNI SONISV38 1196 CNGH 8 44922751 LVN DNISS3aHd N3HA 30914 NI TOIA D 3598 09 0 938 D 3SV CAY INITIA C 4 bog JS 21669 UM 403 006 SLV 13 SZ 0 044 61 2 1 dvl VIC C6lev 9 JS 21669 OW 13 403 9296 6 554 dWNd OND lol l Sv X es 00 4442 4 094 61 2 1 VIC 2 9 11180 E ig oe z EX _ E SIA 3 299 ONI 2510 NIAL aa aiva N lidis2s3G 39NVH2 Gp 28vI2 3111 0492 Sy c8vic 1 js seco BN L L L x T T ai ONISV38 ASHLO HOVS 30 S00 NIHLIM 25 669 OW 2 2 1 ON DOL awis ms 00000012 OIMIN3ONUO 349095 38 OL 19 0D iK 2 2 1840 aU E 51294405 5 910 9 119 ILON 91 24 x AJAG S L T ood 11 Se JNeDO 119 31319395 JSIMAJHLO ALON SONTAV Ad 44 14 8 amp HLIM 4 034 O0H90c90SN SUNIdV38 diva
67. Lubricate then install an O ring over the front of the heat exchanger next to the spacer 6 Place the screws into the front cover 1 of the heat exchanger Install the front cover over the heat exchanger Tighten the heat exchanger cover screws evenly to a torque of 38 Nem 28 Ib ft Note Tighten the six screws evenly to prevent damage AR6557 1042BE AR6557 1043BE Figure 179 Heat Exchanger Front Seals 8 and Front Cover 1 Marine Transmission Service Manual 1020825 191 Assembly Twin Disc Incorporated Assembly and Installation of Control Valve 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 180 Dowel Return Spring Spool and Plug 3 Installone spoolinto each ofthe two bores ofthe valve body 4 On units equipped with the hydraulic lock feature install one spring followed by one pin small diameter into each of the spools 5 Install the two O ring plugs into the valve body and tighten to 85 Nem 63 Ibeft 6 Apply lubricant such as Dow Corning 200 30 000cSt fluid to the O rings of the solenoids and plug plug used on units without hydraulic lock Install solenoids and plug if equipped into the valve body and torque them to 34 Nem 25 7 Insert the wires pins into the Weatherpak connector according to the location
68. MIL STIRALMEB rtr 1 5 p he ee Ane Pag TE AMO DUM 2 6 nh lA Ll Fe OMOTO MITRS a edi M uuo aut HAT r 1 ort eta c r T vasca POMA J D m U U Pm TH IR euo b SSE CU Leos E 4 TEM WEAR MG RI 4 eee a Qv n TEM MM Nit ease Is uncle sn l c e c 287 CTCL SG DN s SDRT SR Maa cS AAD ae Ter hOT GEI THIS PRINT 5 iLE PROBSRIETARYT IF ORATION 15 EIT 72 Be USED 1 AST BERNER THE IWSRRES a _ PIAST TWIN DISC MCORPORACED i SACIHF Wl 53413 Mii DB A THIS MOTICE 5 MOT INTENDED 7 GE Leg TG ML SR LIMIT RIGHTS PUREE THEA TRENT we dr Bu3a3 GATHERS CONTRACT SECTIONAL VIEW E DOG R BR x Rus HE IPA s memo HERE SGS o Gur TIE 1 wang mys n APPALT E Bhd pU D MD gt T UD
69. Measure F and check advance D is within the following range D G F 5 25 5 76 mm Install an oil pressure piston at the end of the output shaft and push in the gear to the desired position Check the outline eccentricity Y should not exceed 0 1 mm maximum total indicator reading 8 Check the face deviation Z should not exceed 0 1 mm E E Co N 0 6 M20x1 5 ASSEMBLING 084 AFTER ASSEMBLING PUSH GEAR UNTIL KEEPING SAME LEVEL WITH SHAFT THOUSANDTHS INDICATOR M6 6557 07 Figure 140 Output Shaft Advancement Procedure 1 Clean and inspect the output gear tapered bore a Prepare the gear tapered bore surface for assembly by using a Scotchbrite pad to remove any burrs b Clean the shaft tapered surface and the gear bore with an appropriate solvent Dry the shaft and clear all oil passages in the shaft with compressed air A CAUTION If the gear or shaft is damaged and cannot be repaired without material removal replace the part Marine Transmission Service Manual 1020825 161 Assembly Twin Disc Incorporated A CAUTION The tapered surface of the shaft and matching tapered gear bore must be completely free of grease oil dirt and solvent residue Failure to properly clean mating parts could prevent proper advance of the gear on the shaft and adversely effect torque carrying capacity of the assembled joint 2 Install the trailing pump drive gear and spacer if they wer
70. SN3HID SSI NN 31UN 000 000SIE0 SN SUN 000 2112 2240 3 NJAING ONINV38 193 1 IVA 25 9 OW X04 cds SIS 335 4 034 D LN3AG 13A 1 VIG VIG 05 050 1 934 D 91 8 1 NAHL VIG 169 91 6 11130 0 88912 1 L 3A 330 m 1 293 30 100 NIHLIA 0c 2v8vi2 3114 ava IS LSSI ie lt JIMINSINOD 399095 38 Dl 4001 INSWONIIY HOLNTO 34 66 54 av wrv 30943405 5 910 D gt 119 ILON 25 4669 OM 05 28 182 1 uw m avis eap c E ERES SANADI TIY VIE 315915 NOILJIX SIA 1VW O32 130 2 2 WO AWD NUINId us 1 2445 5 SS3 INN SALON 91007 BE 11 33 2 20 66 5NIHShg8 NOINId MLS 9 OA 9 vvZ8v S ASHWON 10194 Wd 1001 IN3NDONI V JS 2659 403 8 1 4 NADHS NOILISOd NI 4 034 a NOINId 569 OW 3 VW 3LON 17008 343 30 119001 1 6 4402 ONIHSNG VIG VIG 3 IE DD VIG LTY 82662 68622 06S 9 o AJNANL 807 14340 NDILVOD 1001 0S808I L ASHWNN 1001
71. TVvIWIO3q 3OV1d ANY TWNOILOVYS NO 010 NOISNAWIG 1VINIO3Q 3071d 33HH L NO 100 931519345 SSIMYSHLO 5531 01 SU3NHOO dYYHS 11 vag 86 68 12 1 L c8VLo L O c8Vlo L U39WNNN 10014 aaLON 86 28914 1 1001 dWV1S L e8vLc L 06 28 12 1 UJUJG9 UJUJOG uJUJG8 POF WIG l VIC WIG V Marine Transmission Service Manual 1020825 236 Twin Disc Incorporated Special Tools T 21482 36 Input Oil Seal Carrier Puller Marine Transmission Service Manual 1020825 237 Special Tools Twin Disc Incorporated 21482 39 Support Bracket Leg 238 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Special Tools T 21482 53 Primary Clutch End Play Fixture Marine Transmission Service Manual 1020825 239 Special Tools Twin Disc Incorporated T 21482 54 Secondary Clutch End Play Fixture W i NON N W i x N d 240 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Special Tools 21578 1 Output Flange Installing Fixture Sheet 3 of 3 pS NV WN x 22 7 17 24222 Z 1 Marine Transmission Service Manual 1020825 241 Special Tools Twin Disc Incorporated 21578 4 Output Shaft Bearing Driver Sheet 1 of
72. Valve Assembly Trolling Valve Assembly Trolling Pump Assembly trailing Live Pump Mount Power Take off Clutchable Pump Mount Power Take off Marine Transmission Service Manual 1020825 MARINE GEAR SPECIFICATIONS GEAR 11 28 11 51 ADORNA DER OPRIANDE HEDLQIBE ID aan NO 42438 40425 40445 i 40441 41442 AHL 1 z eee FEMI RES TG HERME TOTAL WEiGHT APPROX 42060257 ECL INE FLEX GLE INS iit his ELECTRIC Wis ta 115 2 tate FEED TE 20 REMOVE HEAT EXZHANGERI IL RESZLRE CLUTCH GIL 23 5 k je ATE er 1 25 THA Deu 1 TT LUBE GiL 2 5 IL TEMP 24 BIL YISTESITY DOM T LEE 1245 GILI PAROLES j EN FA 2 01 8 GREASE FIRST CHANGE AT 122 HOURS __ 1 X PIPE i OPERATII AND SLEGDQUCNTLY EVERY 1009 f J0 BFE j O LASS OPERA EN S Wu SHIETING LTyFH Jes IP Mand AL pie M um CHET NE SHIFT TO FORWARD 3EVLa5E FROM REVERSE 10 i ma REVERSE
73. WITHCUS NG ILALL JAN PATEH 13 db HNP IAEF Ri Siva PE ACI GAI ANE Je CULO a Mi STAT DE n n 05 mr Lops Let PRET Pos DIRS 3A erar rok ok Sei ien DW TOE SIDE ABANS H 15 A BIME METRIC BLES Erg Foe a R rufas 4 H B 158087 SOL GE E4 PAJER IR ELEL M JEE 3 SL CS Ra das ETAT PEAR n SO LAT p LAREDO PACK MZ ap Gon its MARUTI Au Ilse 20 1 1 r r ne un MoO lcE ALS FAINT CONTA IWS MATER fa i FED ALANS RENTAL THE 5 OF m neat y E 2150 1 53403 Loa i AXES TRIS 18 407 ID L n OR LIFT ale PS PACE Mur HT hun Sua GRANIEQ 11 THE U S L z T j PS P OTHERS Bt CONTRACT SESTIONAL VIEN d r r ee s LIJ gt u R L aal Cua EET GTIPEPU SE SPECIFIED nr xm 4 11 3 E ACuCHET D PERS UNS 1 iG 1 AIRE 5101 TO
74. aligned The wave spring pairs are installed with their ends oriented in a random manner Note Some early units only have one wave spring per clutch plate n 1 d RMVCO26FGS RMVCO28FGS Figure 112 Clutch Plate 1 and Wave Spring 2 Installation Marine Transmission Service Manual 1020825 139 Assembly Twin Disc Incorporated Install the remaining clutch plates and wave springs in an alternating fashion until all clutch plates have been installed 11 steel plates 10 friction plates 10 pairs of wave springs Note A steel plate is located next to the piston and the clutch backing plate Installation Note Friction Plates When installing clutch friction plates install the plate with the rounded edge 5 away from the piston The rounded edge makes installation of the pinion gear splines easier to align as the pinion gear is installed into the transfer gear AARMVC 029F AARMVC 001F Figure 113 Clutch Friction Plate Edge 5 Rounded Edge and Sharp Edge Shown 140 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Steel Plates When installing steel clutch plates 4 install the plate with the rounded edge toward the piston The rounded edge is easier to install into the transfer gear splines when installed in this manner AAR6557 067 AAR6557 068 Figure 114 Clutch Friction Plate 4 and Steel Plate 4 Installation 7 Install the clutch ba
75. all of the clutch plates 186 6557 AAR183 6557 Figure 103 Clutch Backing Plate 1 and Pinion Assembly 9 Marine Transmission Service Manual 1020825 133 Assembly Twin Disc Incorporated 10 Install the bronze 2 thrust washer with 18 radial grooves next to the pinion Note If the pinion is fully engaged with all of the clutch plates the round snap ring groove will be visible above the bronze thrust washer 11 Install the round snap ring 3 onto the shaft to retain the bronze thrust washer AAR200N 6557 182 6557 Figure 104 Bronze Thrust Washer 2 and Round Snap Ring 3 Installation 134 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 12 Verify the pinion has measurable end float 13 Invertthe shaft assembly positioning the sealing ring end of the shaft up Install the rear tapered roller bearing if removed Heat the clutch shaft rear bearing cone 4 to a temperature of 120 C 250 F Place the bearing on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing against the clutch housing as the bearing cools Handle the bearing with care The bearing is HOT AAR193A 6557 Figure 105 Rear Bearing Cone 4 Installation Marine Transmission Service Manual 1020825 135 Assembly Twin Disc Incorporated Secondary Clutch Shaft Assembly Secondary Shaft Bronze Thrust Washer Wave Spring Bro
76. and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Where grease is specified use a lithium based grease NLGI 2 oubmerge all new clutch friction plates in clean transmission oil for a minimum of one hour prior to installation This transmission uses liquid sealer in many locations The approved sealant is Loctite 518 MA1015 applied per S774 a thin layer of sealant is all that is required with Locktite Primer N MA1012 Avoid getting sealant into the O ring counter bores This transmission uses thread lockers MA908 and 1007 at specified capscrew locations Note In the discussion that follows the input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing from the rear toward the front A CAUTION Appropriate eye protection must be worn during transmission assembly To avoid personal injury proper safety equipment must be used during installation of any heated bushings bearings and other components Marine Transmission Service Manual 1020825 127 Assembly Twin Disc Incorporated Primary Clutch Shaft Assembly Primary Shaft Wave Spring Bronze Backing 10 Pairs Thrust Washer Bronze Thrust Washer Plate 6 Grooves ge 18 Grooves rifice Plug CHR Z Piston with PETIERE O Retaining Ring
77. and the transmission housing The wood blocks will prevent damage to the trailing pump drive and driven gears when the output gear separates from the output shaft 8 Wrap the threads of the injection adapter screw 1 with teflon sealing tape and install the screw into the oil injection adapter Marine Transmission Service Manual 1020825 87 Disassembly Twin Disc Incorporated 9 Hold the oil injection adapter to prevent rotation during operation and use an impact wrench to drive the screw into the oil injection adapter until the output shaft and output gear tapered surfaces separate If the shaft and gear do not separate during the initial injection repeat steps 6 through 9 The gear and shaft will separate with extreme force potentially causing great physical harm Use EXTRA CAUTION and proper safety procedures R131A 6557 AR132 6557 Figure 50 Filling Oil Injection Adapter with Oil 88 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 10 Thread an M20 1 5 eyebolt 2 into the center hole in the end of the output shaft and support the shaft from above with a crane The eyebolt must be able to fit through the bore 85 mm of the output gear 3 The hooks of the crane must be removable after the shaft is lowered from the transmission Other suitable equipment may be substituted if available a Remove restraining tool T 21482 21 b Hemove the remaining screws from the shaft seal retaine
78. and trailing pump suction strainer cover 5 Each cover is sealed with an O ring 158 6557 60 6557 Figure 58 Governor Cover 4 and Trailing Suction Strainer Cover 5 94 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Input Shaft Seal Remove the input shaft seal from the main housing Input Shaft Front Bearing Cup If the input shaft front bearing cup 3 replacement is required weld a bead midway around the circumference of the bearing cup with an electric welder causing it to shrink for removal AR145 6557 Figure 59 Input Shaft Front Bearing Cup 3 Removal Marine Transmission Service Manual 1020825 95 Disassembly Twin Disc Incorporated Primary and Secondary Clutch Shaft Output Shaft and Ditch Plate Disassembly Primary Clutch Shaft Disassembly Primary Shaft Wave Spring Bronze Backing 10 Pairs Thrust Washer Bronze Thrust Washer Plate 6 Grooves 2 18 Grooves 7 rice Flug belo wiih U TETTE NEM Z E Dump Ball Retaining Ring o 7 Clutch _ j 1 Port 1 TM HIH IH Mi ii HO l g ph Rit 195 Assembly Friction Thrust Race Steel D 10 Plates 11 ates 10 M6 6557 10 Figure 60 Primary Clutch Shaft Component Identificati
79. customer but not to exceed twelve 12 months of service whichever occurs first This isthe or intended to be given by T win 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 Incorporated be either the repair or replacement of any T win Disc Incorporated part or product found by T win 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 as the flat rate labor hours established by T win Disc Incorporated in the blished T win Disc Flat Rate Schedule required to remove disassemble i repair reassemble reinstall and test the T win Disc Incorporated product only Authorized reasonable travel and living expenses will be considered for ent Under no circumstances including a failure of the exclusive rem shall T win Disc Incorporated be liable for economic loss consequential incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair 2 Thewarranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from ab
80. it is evident the corrosion is due to local electrolysis If the zinc anode rods are corroded with foreign materials they should be cleaned with a wire brush Heat Exchanger P H Gasket Locations 21 OO OO VA Fry E ey Y Zinc Anode J Plug f 12 Rear EE Cover Front Heat Exchanger Cover Heat Exchanger Drain Port and Drain Port Adapter Inlet for Trailing Spacer and Housing Pump if Equipped O rings 548405HE Figure 174 Heat Exchanger Component Identification and Location Marine Transmission Service Manual 1020825 187 Assembly 188 Twin Disc Incorporated 1 Install the heat exchanger base 5 and gasket Torque the mounting screws to a value of 46 Nem 34 Ibeft AAR302 6557 AAR305 6557 Figure 175 Heat Exchanger Adapter Plate Housing 5 2 Install the gasket 6 and heat exchanger 7 The gasket is placed between the flange 8 on the heat exchanger and the base 9 AAR306 6557 AARS308A 6557 Figure 176 Heat Exchanger Gasket 6 and Core 7 Installation Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 3 Install the heat exchanger 1 with the
81. mark made during disassembly at the top Place the heat exchanger into the transmission housing with the divider 2 located horizontally in the housing The divider in the heat exchanger along with the rear cover 3 and gasket 4 separates the inlet from the outlet of the heat exchanger Note If the heat exchanger is not properly installed in the transmission housing the transmission could overheat AAR309 6557 AAR311 6557 Figure 177 Heat Exchanger Core 1 Placement Marine Transmission Service Manual 1020825 189 Assembly Twin Disc Incorporated Apply grease between the rear cover and gasket of the heat exchanger Attach the heat exchanger gasket 5 to the rear cover with the grease Install the heat exchanger rear cover The heat exchanger positioning can be verified by viewing the heat exchanger through the inlet outlet ports 7 The divider should not be out of position when viewed through the inlet outlet ports Torque the screws evenly 38 Nem 28 Note Improper tightening of the heat exchanger rear cover could Cause damage to the cover AAR312 6557 AAR313 6557 Figure 178 Heat Exchanger Cover and Gasket 5 Installation Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly D Place the transmission housing in the upright position a Lubricate then install O ring overthe front ofthe heat exchanger 9 b Install the spacer next to the O ring
82. of the adapter TW 11 Figure 93 Removing O ring from Adapter Marine Transmission Service Manual 1020825 119 Disassembly Twin Disc Incorporated NOTES 120 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Cleaning Cleaning and Inspection Cleaning and Inspection Note Replace all oil seals gaskets O rings piston rings seal rings and snap rings as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents or by steam cleaning Parts must be dried and oiled immediately to prevent corrosion 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 forth through the passages and then flushing them with cleaning solvent Use clean solvent to flush oil pumps and valves Flush all hoses tubing and coolers 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 1020825 121 Cleaning and Inspection Twin Disc Incorporated 122 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 hardene
83. piston seals 188 6557 AARR191 6557 Figure 97 Clutch Piston Installation 4 Insert the steel thrust race 7 onto the shaft Ensure the steel thrust race is seated against the shaft shoulder Install the inner bronze 8 thrust washer with 6 radial grooves onto the shaft AAR200F 6557 200 6557 Figure 98 Installing Steel Thrust Race 7 and Bronze Thrust Washer 8 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 9 Install the clutch plates a Install steel 1 clutch plate next to the piston b Install a friction plate Place two a pair wave springs 2 around the outer circumference of each friction plate Each pair of wave springs 16 installed with the ends aligned The wave spring pairs are installed with their ends oriented in a random manner Note Some early units only have one wave spring per clutch plate RMVCO26FGS RMVCO28FGS Figure 99 Clutch Plate 1 and Wave Spring 2 Installation Install the remaining clutch plates and wave springs in an alternating fashion until all clutch plates have been installed 11 steel plates 10 friction plates 10 pairs of wave springs Note A steel plate is located next to the piston and the clutch backing plate Marine Transmission Service Manual 1020825 131 Assembly Twin Disc Incorporated Installation Note Friction Plates When installing clutch friction plates install the plate with the r
84. proper oil and filling procedure Marine Transmission Service Manual 1020825 Twin Disc Incorporated List of Special Tools Special Tools Special Tools The following pages include the special tool drawings that are specific to this model The special tool drawings included are listed below and continued on the following page L D D D D D D D Marine Transmission Service Manual 81020825 T 111145 T 111146 21482 06 21482 08 21482 13 21482 17 21482 20 21482 21 21482 22 21482 23 21482 26 21482 30 21482 36 21482 39 21482 53 21482 54 Restraining Bar for Input Sleeve Driver Output Shaft Bearing and Spacer Retention Block and Screw Hydraulic Knock out Tool Locating Plate Trailing Pump Gear and Bearing Removal Tool Bearing Driver Restraining Tool Output Shaft Shaft Support Tool Retainer Input Drive Sleeve Bearing Driver Bearing Driver Input Oil Seal Carrier Puller Support Bracket Leg Primary Clutch End Play Fixture Secondary Clutch End Play Fixture 223 Special Tools T 21578 1 21578 4 21482 21482 02 21482 40 1 21482 40 1 21482 40 21482 41 1 21482 42 1 21482 43 21482 44 21482 45 21482 46 21482 47 21482 49 21482 50 21482 51 D D O O D D D D D D 21482 52 224 Twin Disc Incorporated
85. shaft brake or other shaft locking device must be used WARNING To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove ignition key from the switch WARNING Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these points could cause failure at the lift point or points and result in damage or personal injury 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 1020825 Twin Disc Incorporated Introduction Preventative Maintenance Towing The Preventative Maintenance section of this manual provides schedules for recommended maintenance of the equipment WARNING Under the conditions described below the propeller shaft must be locked in place to prevent backdriving or an optional trailing pump must be added 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 t
86. that will da Dampen torsional vibrations da Change the natural frequencies of a system to move critical frequencies out of the operating speed range Accommodate a certain amount of misalignment Absorb shock and reduce noise d Minimize gear rattle The coupling has been selected based on the customer supplied engine Information Final coupling selection must be confirmed by the packager based on the torque rpm ratings and the results of the system torsional vibration analysis TVA and on engine rotation Care must be taken when servicing that replacement couplings are matched to this criteria Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh water through the heat exchanger The heat exchanger is located in the transmission housing Replaceable zincs for corrosion protection are located on the heat exchanger rear and front end caps Marine Transmission Service Manual 1020825 23 Description and Specifications Twin Disc Incorporated Specifications Maximum operating speed 2500 rom Operating oil sump temperature 65 70 C 149 158 F when using SAE 40 oil Oil type and viscosity See nameplate below Oil capacity 20 liters 5 3 gal Approximate dry weight 415 kg 915 Ib Oil pressure See Tables 1 Oil temperature to be in normal operating range Ri PLACE AFTER 100 HOURS OF
87. the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be made before the driven component is installed After installation of the driven component the crankshaft endplay should be measured again The endplay at the second measurement should be the same as the first A difference in these two endplay measurements could be an indication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage caused by engine to Twin Disc component interference regardless of the cause of interference This engine crankshaft endplay check is considered mandatory The transmission housing flange and pilot the engine flywheel and the flywheel housing must be checked for trueness Clean the engine flywheel and flywheel housing mounting surfaces thoroughly before any measurements are made Note To isolate engine vibration and prevent transferring it to the hull through the propeller shaft the distance from the marine gear output flange to a fixed stuffing box or the first fixed bearing must be a minimum of 20 times the shaft diameter If the distance 15 less than this a flexible coupling may be necessary to isolate the engine vibration Marine Transmission Service Manual
88. the transmission housing If equipped The trailing pump is located on the rear side of the transmission in the lower right hand corner H034 6557 R148 6557 Figure 29 Trailing Pump Removal if equipped Top Cover with Oil Baffle Remove the transmission top cover 7 The top cover contains the filler cap breather Note On the bottom surface of the top cover is an oil baffle 8 to prevent oil leakage through the breather Do not remove the baffle from the top cover unless replacement is necessary AR164 6557 65 6557 Figure 30 Top Cover Removal Marine Transmission Service Manual 1020825 73 Disassembly Twin Disc Incorporated Remove Primary and Secondary Clutch Shaft Assemblies Remove Primary Clutch Shaft Rear Cover 1 Place the transmission on blocks with the output flange 2 at the top Be sure transmission is supported securely A IMPORTANT Allow a minimum of 200 mm clearance below the transmission housing to allow the future removal of the input drive sleeve while the transmission is in this position 2 Remove the screws retaining the primary clutch shaft cover 1 a Gently tap the shaft cover to break the sealer bond from the transmission housing b Remove the cover 1 the shims 3 and the bearing spacer 4 Tag the components with identifying information 052 6557 AR054 6557 Figure 31 Primary Clutch Shaft Cover Removal 74 Marine Transmission Service Manual 1020825
89. 0825 213 Installation Twin Disc Incorporated Installation Alignment Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is common for a boat to change its form with various loads and with age Engine and shaft alignment can also change on a boat due to varying loads and the boat s age The following steps may be taken to secure proper marine transmission alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure 1 Install the mounting brackets on the side mounting pads of the marine gear 2 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 SHIM HERE BEDRAIL Figure 205 Marine Gear Alignment 214 Marine Transmission Service Manual 1020825 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 ea
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92. 11 SAOVAYNS 9 5 CO TIY 3LON SYANYOO TIV 915412345 ASIMYSHLO SS3 INN ILON 1426 082 9 13315 1001 LVN L H3AIHO HLONAT 51671 961 11014 THONM 7 uuoy NYHL Vig P ge ES 2 02221 AP 10972 2 WIG 2 2 2 297 m a o0 X 9 Oud T1v8 9028 _ H3AIJG WQS STACOW 6199911 9 ZSS9DW 231 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Special Tools Tool Output Shaft ining Restra T 21482 21 SIM ONIOSIGNIML Ag NOILdIWOSAG 0 08910 1 OS 288991 dV39 LNdLNO 548 UN dU dr 86 82 29601 NOILdIHOS3Gd LVN D3 130 UIOVdS 51 ONINIVYLSSY 2 SOHS MLS 4 5 TIV V43ag q3IdID3dS ASIMYSAHLO SSJINN 1 SL qoas 1 SNINIVHISdH Z Lee v P UJUJO 28 1 7 61 ww d 1811 gem wos 29672 2 9 N 4 i LUWOE 867 GOSH Z 18171 928 wwoe THAN 0 Yi Z 0 08 12 34114 GVO 31310345 ASIMYSHLO SS3TNn SH3NHOO dHVHS T 21999 OIN UON Lud 2 8 2 1
93. 11 6557 Figure 153 Remove Tool T 111145 172 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Install Clutch Shaft Assemblies Prepare Clutch Shaft Assemblies Assembly The assembly of the primary and secondary shafts should have been done previously as described in that section of this manual Primary Shaft Lube Clutch Port Port Sealing 3e Rings Piston with Dump Valve Bronze Thrust Washer 6 Grooves Friction Wave Sprin Plates 10 10 Pairs a I S m Steel Plates 11 Backing Plate 1 Pinion Gear Retaining Ring Assembly Bronze Thrust Washer 18 Grooves Figure 154 Primary and Identification and Location Marine Transmission Service Manual 1020825 Secondary Shaft Lube Pump Drive Passage Coupling Sealing Rings Piston with Dump Valve Bronze Thrust Washer 6 Grooves Wave Spring 10 Pairs Friction Plates 10 C r Steel 7 Plates 11 LI II Ir Ir nyonpnmgnmnunmunnin rri Backing Plate Pinion Gear Assembly Thrust Washer 18 Grooves Bearing Carrier M6 6557 08 Secondary Clutch Shaft Component 173 Assembly Twin Disc Incorporated Installing Primary and Secondary Shafts 1 Install lifting eyes M10 1 5 into the primary shaft clutch housing 1 2 Lubricate the splined end of the primary shaft with
94. 2 zu B 4181 24 T f F 4 x 242 Marine Transmission Service Manual 1020825 31134 avo 2 28912 1 30 600 1001 33S WVA NIHLIA 01 OIMIN3ONUO 3awnos 38 1 33 5 SWIC 39 TW 31DN 581 05 1332X3 SW3NNUJ davHS TV vata 3 OL LON 330SS32d 31112345 5531 SET 0627 19 ixi SV 30803 40 SNOL 061 PUA DL WAAR 13315 H1DN331S HOIH JVIS3LVW 4934 1709 HLONSALS HOIH 1912345 OF 29 X OZW os 7 729 0 1 7 1 934 D 3596 1 lt gg p 77772272 p 4745 VIC 166 NX SQ E l yG 8 8 I I I 1 7 2 2 N 7 7 EN M o Aa 511048 S TX02W S 5214130 LAVHS OL 33NIV139 ONIL TOE 4 934 914 99872 26 SN ONILII 4034 25 4 1 VIC wwc g ONILAI 204 4 034 22 ST X OIW 4 1 VIG 8 TINAA 3 NAH 0919 LYW
95. 207 0 266 in A CAUTION If the calculated advance falls outside the range given above check to ensure all measurements calculations are correct If no errors are found it will be necessary to change parts Contact the Product Service Department of Twin Disc Incorporated 9 Ensure the output gear bore is clean and free of grease and other contaminants Install two M10 1 5 eyebolts into the output gear 1 and place it in the transmission housing with the trailing pump drive gear 2 towards the rear side of the transmission housing Align the output gear with the output shaft bore in the transmission housing A CAUTION The tapered surface of the shaft and matching tapered gear bore must be completely free of grease oil dirt and solvent residue Failure to properly clean mating parts could prevent proper advance of the gear on the shaft and adversely effect torque carrying capacity of the assembled joint Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 10 Place the shim pack 3 on top of the output gear bore 4 Ensure the shims are centered on the bore of the output gear EL L T q j i e n Ei E M x as ae EM 4 pr 4 E 1 T n d E E 1 E 1 AAR228D 6557 AAR228B 6557 Figure 143 Output Gear 1 Placement in Transmissio
96. 24 Heat Exchanger Component Identification and Location 1 Remove the rear cover 1 and gasket from the heat exchanger 2 Mark the heat exchanger core 2 at the top to ensure it will be replaced into the transmission housing correctly Note The rear heat exchanger cover 1 is equipped with a divider 3 separating the inlet of the heat exchanger from the outlet of the heat exchanger 040 6557 AR6557 18BE Figure 25 Heat Exchanger Core Indexing 2 and Cover Removal 1 70 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 2 Remove the front cover 4 spacer 5 and two O rings from the heat exchanger Note The front cover of the heat exchanger uses a spacer 5 to locate the heat exchanger correctly in the transmission housing The spacer is sealed on each side with an O ring 5 6557 7 6557 Figure 26 Heat Exchanger Front Cover 4 Removal 3 Remove the heat exchanger core and gasket 41 6557 R043A 6557 Figure 27 Heat Exchanger Core Removal Marine Transmission Service Manual 1020825 71 Disassembly Twin Disc Incorporated 4 Remove the screws retaining the heat exchanger adapter housing and sealing gasket 087 6557 091 6557 Figure 28 Heat Exchanger Adapter Plate 6 Removal 72 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Trailing Pump if equipped Remove the trailing pump from
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98. 3 Install the lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 14 Rotate the lever if necessary on the stem to the position shown on the valve installation drawing see Engineering Drawing Section of this manual Install the screw and nutto clamp the lever to the stem Tighten the screw and nut to 9 5 Nem 7 ftelb 15 Install the neutral pressure regulating spring into the bore of the control valve if removed Marine Transmission Service Manual 8 1020825 199 Assembly Twin Disc Incorporated 16 Install the screen into the pocket Install the steel ball onto the neutral pressure regulating spring Figure 190 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 Nem 17 ftelb Figure 191 Installing Orifice Plate left and Trolling Valve Onto Valve Body right 200 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Ditch Plate Installation 1 Install the control valve ditch plate 2 and gasket 3 on top of the transmission housing Tighten the screws to 46 Nem 34 Ibeft 2 Install the forward cover 4 and gasket on top of the ditch plate Tighten the screws to 46 Nem 34 Ibeft
99. 5 1017133 1017134 7 1017179 no 75 12 VDC xA2707Bz e7078W A2703BA 1380 lt 200 1017129 Fl Qosa A B2451B lt 9 1 M2os9F 56 mime 6 DPTIDNAL of lc 1018084 017133 1017134 1337 1018688 759 24 VDC 27072 427072 ae703T 1725 250 10171294 1038 27 x 20 6 2451 Meog9r 2 0 2 wc ssm De VEN B of 10180846 40757 1017133 1017134 1337 1018688 759 12 VDC XAe7072 27072 2703 1725 250 10171294 1038 27 20 64 24518 2 Meossr 2 g 1018084 1017583 1017569 1017613 1018688 759 24 27072 27072 2703 2000 lt 290 10171298 MA1038Ecn27 20 6 B2451B 0 2 10620 2 5600 niox g 1017583 1017569 1017613 1018688 2759 12 VDC XAe7072 27072 2703 2000 290 10171298 1038 27 x 20 6 B2451B 0 2 10686 2 5600 1017133 1017134 BI337F 1017179 759 24 vDC A2707AD 595 230 10171294 MA1038EGMe7 X 2 0 6 B2451B g 10528 2 528 2 wey CONNECTOR SHROUD 1001825 091018084 40763 1017133 1017134 7 1017179 75
100. 53433 USA THIS 15 HOT 14 OF LIMIT Fale TRELTMEHT GRATED THE 11 5 He OTHERS By 1 2 1 0 1 QIIDH HH ZZ 121110 278 85 75 a S eri 3062 i ee 5 4 E M 5 3 7 5 EN 2 82275 SECTION FOR REVERSE SHAFT PUFF oid 3 aLi ENTE AD BLING FOR WITHOUT SLINO COVER FOR WiTHOUT TRA LING PUMP OIL STRA KER 124 net Be n Xa 1 1 1 1 1 1 LI MOT id USCS ANT THE INTEFEE E WEN DISC T amp EORPORA TED RAGE W aab Va THIS 1 r5 InTEMDETI TO OR LIMET RIGHTS THE US a OF CTHERS By CONT TESLA uw THe IF li ARE OK DINERS 1 mu MEAT 25 13 1L R mxxL ME BSF oo a Tathan Ha NEM LECTIONAL VIEW EF is BE 15 5 BASLER E E C E OR RF HER x 1 LEH gitn 2 na SET 1 OF TWIN DISE n X 76 BOLTS HEAD 1 4 amp DHESIVE AGENT SEQUINALEST Thre
101. 6 28 85 2100 Secondary 2255 2455 327 356 2255 327 193 586 28 85 Marine Transmission Service Manual 1020825 25 Description and Specifications Twin Disc Incorporated Optional Equipment 26 The following optional equipment for use with the model MG 6557A is available through the nearest authorized Twin Disc distributor Optional Trailing Pump A trailing pump kit is available that bolts onto the rear of the marine transmission A drawing is included in the Engineering Drawings Power Take off A live Pump Mount power take off and a hydraulically clutchable power take off are available and mount on the rear of the transmission They rotate at the Same speed and direction as the engine Mounting Brackets Fabricated mounting brackets are available Torsional Input Coupling Several models of torsional input couplings are available Electric Control Valve The electric control valve is standard with either 12 vdc or 24 vdc actuating solenoids Coupling Flange A coupling companion flange is available Trolling Valve A mechanical trolling valve is available for mounting on the electric control valve The part number is 1020025 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Description and Specifications Table 3 Bearing End Play Specifications Assembly No Minimum Maximum Assembly No Ll Minimum Maxmum 0 00 mm 000 in 40 05 mm 40 002
102. 629 543 400 119 831319345 5 5541 ALON ZT 1 034 62 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 and continued on the following page Note Any part numbers listed in the following engineering drawings are for reference only Please refer to your bill of material for part numbers specific to your model 736628 Marine Transmission General View 736628A Marine Transmission General View 738228B Marine Transmission General View 738229 Marine Transmission Sectional View 737634 Marine Transmission General View 737635 Marine Transmission Sectional View 737934 Marine Transmission General View 737265 Marine Transmission General View 737266 Marine Transmission Sectional View 737893 Marine Transmission General View E 737894 Marine Transmission Sectional View 549341 Marine Transmission Sectional View 737966 Marine Transmission Sectional View da A7119W Hydraulic Diagram Electric Valve 349460 Hydraulic Schematic Transmission Marine Transmission Service Manual 1020825 259 Engineering Drawings D D D D 0 1018084 1020025 1687530 549091 737004 737064 Twin Disc Incorporated Valve Assembly Control without trolling valve
103. 7266 Marine Transmission Sectional View 269 737893 Marine Transmission General View 270 737894 Marine Transmission Sectional View 271 549341 Marine Transmission Sectional View 272 737966 Marine Transmission Sectional View 273 A7119W Hydraulic Diagram Electric Valve 274 349460 Hydraulic Schematic Transmission 275 1018084 Valve Assembly Control without trolling valve 276 1020025 Valve Assembly Trolling 277 1687530 Valve Assembly Trolling 278 549091 Pump Assembly trailing 279 737004 Live Pump Mount Power Take off 280 737064 Clutchable Pump Mount Power Take off 281 Marine Transmission Service Manual 1020825 11 Table of Contents Twin Disc Incorporated NOTES 12 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc MG 6557A marine transmission Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wis
104. 8Ece7 x 20 6 Be451B 6 520 69 41e51 1018686 75 1 12 vpc xA2707z 427072 703 1725 250 10171294 Mai038Ece7 x Be451B 6 5 0 EAS PIN A2711AC 2 SPOOL 1017432 2 4096 1017179 759 24 Voc 2707 0 703 860 lt 270 10171294 038 x 2451 mc siaisc 4 NOTE LOCK 2 HYDRAULIC LOCK ONLY 69 hoigog4aP 4195 1017179 XxWe7s9ri ie VDC 270740 2703 4 1860 lt 270 10171294 1038 7 x Be451B MG 5141SC_ AEDS LEVER MAY BE LOCATED ANYWHERE PLUG MA1038E 2 B 41337 1017383 1017179 YES 759 24 VDC Aezu4pu 2550 370 10171298 1038 27 x 20 6 B2451B 4 MG 6557 VEMENT WITHIN THE Sor CTHTAD RACE M2086DF PISTON SEE CHART 41446 1017383 1017179 YES 2759 24 VDC Aezp4gu 2450 lt 355 10171294 10 8 7 x 0 6 8245 5 EES ROTATION amp 11 4mm AXIAL MOTION BEARING M2087AD Purse Ee ta asas 41718 1018688 yEs _3_ xw2759FM24
105. E AE e Ca PROJECTION z FiGURES IN DRAWING SHOW TIG TEMED ORGUE FOP S 4 3 kg m 215 8 8 BAIN 3 218 B sw 5 SHOWS SEA PACK 9 2 BOLTS HEXAGON J MARKEZ 2D SHOWS SE 4 COATI LIGUID PACKING ON THE PUR ON PARKED TD ASC ASSEMBLE IFEM R 1 vex TEE eum DJMENSIONS ARE 8 18 98 x 0 e HEAT TREAT FIRST USE n r 143 RACIME WI 53403 USA i NA si 2 DEL 6 5 100 PER ANS 14 5 1582 oii SURFACE TREATHENT 4 c 44 1 SECTIONAL VIEW G TWIN DISC INCORPORATED pee eee t 3403 USA em Tre NOTICE 15 INTENDED lee GR NTED TO THE 9 5 G VERHHEHT OTHERS BY CONTRACT SECT EON zc et fo ST 4 aN d lae fpa i ONLY 417 1 Mat e i F LEXAMOM Sa M idi 8 8 SER na cz E a de 2 POR AEA EXCHANSCR RIFLE Fe ota AF Mea 22 5 2 TY 4 SECTION FOR REVERSE SHAFT 8 MAIN PUMP FIAT BLIND CHEG Wl THGLT zi Ih TRAILING FLM
106. ET MIL STEED lt gt A 1 2 1 NY 2 L Pee ARSE POS SDS 7 com 1 ao T c P OCHL M ING h l P 9 D HXADORTOS wit TTE I Year BET Dk E IR Wa dd Nak EADS el TH ANGLE 2R IEGT 1 MALE 021 ING WATER INLET AND OUTLET FLANGE ML ICEI THIS PRINT HATER IAL THF ORAAT OR AMO 15 AG T BE LEED CE TRIBES TAL T THE CHTERESTS DF PT k I B rra TAIN DISE vocem TIN 0750 INCCAPDRATED ese D 8863 0089 21 11 mw oe 0 ETE TE m fain DOG LRL FLA SDRFEAMEPM rt mL POS Eo a PER mul Tra T 17 38228 3 THES 5 TELE i maLIEY OR LIHIT 5 GEANTED T THF U 5 CSWEHmHMMFHT Br CONTRACT rr GN FOR HEAT ZXC ANGZR REVERS S4aF7 AS THIS 3 DETRIMER AL THE 1 Jr Telk 2150 0 53403 TOUTE 15 MET
107. FOE J LAS LUI r re bt 7 E n mI F I loa m M 5 JEM pa merar TS 211 La E ER 1 1 0 Y a n lI gt 4 RM i zx Ql TUL FRERES MIDS E 1 na EL li 2 iUa 2 5 gt a tte 3 5 4 414 _ a E m v n ni il a TT uen t 21447 22 PC a Iha Qoa FO saa m s 2a da r T 1 epa 22 wot sa um 4 JMO Ten Dow E qu z PEE E 4 0 r Anz x 7 H as n n n 9o 7417 7 8 3 rz 4 2 e 7 a CA mag Cu ITT LIT OLD Sa x a al iri Wowk p 121754715 2 7 vl 5 T om V yen o 5 163155 5 413 5412 1 5 5 4 XECOMMENDED FLANGE COOLING MATER INLET AMD OUT
108. HLIM NOINId OLNI 5 553444 NMOHS 41 Ol VO 20S6S T 5 1 044 22 4444 001 X 91 8 6 1 43340 621 X VIT Gale 91 6 11140 IC 28v12 1 SIA 2510 NIAL SGHLO 293 40 00 NIHLIA 1 38912 1114 192 ss 25 469 DN 2 349095 38 OL 53294405 8 414 0 0 9 119 1 n amt TY wam 79155 TUE 2 2 amis 3715 40015 148558 1 es CC KS 5 43 00 davHS 11 NYE 0629 131419395 3SIAN3HID 5537 31DN VIT 629 I9 961 vig SSS 60v8v S 1 JS 1669 OW ALI m 1 934 85 NAHL VIC v 91 1686 667 27 7 27 1 1996 199 6 8 6 97 v201 8 90 9 amp 910 526 966 SIM 3 2 31914 AWWNG H21012 A32 aw Tina 5 Nd4 Tar 86 1 2 189 09 3ZIS 8 N lldiM2S3T 034130 aa se x wia ege iva 111 S Herb Ic 8v S 1 Js 2669 OW 403 VIG 068 oG o8vic 1 TAM 95 589 1 gt San sen 3 50100 aNNOA D 119 10 VIC ZEv 91 4 Tad 4 HOV3 30 600 NIHLIM JIMIN3ONDO 3Jeavnas 38 OL cG 28vlc 3111 CVO 25 2659 OW 28 48912 1 06 9 7147
109. 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 least relative out of true parallel measurement Figure 208 Checking Output Flange Face Runout Marine Transmission Service Manual 1020825 Twin Disc Incorporated Installation Figure 209 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 ha
110. KET 10171368 CYESS N 55422752 RC ZE WSS i IK P 7777 LIEST NESE LS N s Lester il E HY BE oM S enr Y B d x NO CEPI ARS ry 50 lt D i 5 aie N ar KDR lt ETT TEER EN NIRS NS lt 5 SSN CONNECTOR SHROUD 1001434 64 9 2 ia ww RTA SER AMAT NN N DITCH PLATE GASKET PE S PES WAU ALLEL OO SSS NN SS SEE CHART a ru H E 5532 A 27 T 77 TRANSMISSION GASKET ae TL LIN i ur A es PORT Aor L ML n BALL 1990 e ome 11551 A SCREW MALO42A 4 TB SPRING 2702 M Te C SHIM 1020005 5 REQ D SPRING 1801 BALL Mi990E D SETSCREW A2870K 0 RING A2916DK VALVE BODY ASSY 1018095 TRO RING A2916AT DER PEATE SEE CHART BODY 1018094 EN SPRING 2705 WASHER A2782AS SCREW SEE CHART BOE i 72232237 SYN NAN 2 T f S e LUI NNN gt HOSEA WN TEE P APPLY 895 THREAD SEALANT ek we SPOOL 1017433 2 TAS PORT INSTALL USING MA908 lt LOCTITE TORQUE TO 300 lbf ft z NUT M2027C SCREW 1042 4 DS pP MANO HYDRAULIC DIAGRAM A7119W SHEET 1 OF 2 M2000L
111. LET FLANGE om DETAIL OF FLANGE a THIS P S C PROPEI MEER 5 HE USED 74 INT Tali DISC e jew m m dej wm D WI 53425 sQ ICE MOT TD hi L y T 5 MATION 131 15 DETRIMENTAL TQ THE 157EREST DF re DEPORTED RIGHTS TI TRE 1 3 lw CEMENT OTRERS GY kel F E T SPEED 186 ag TSR 7 AMPs TR RAF T Ar va DTM BIA EM OIN f Cr x METRIC ANGLE PROJEZT ICH UNLESS dna E REE IUE 10 ror sd AUT mite EE el E 0 GENERAL VIEW 15 BSE Cr nR R han iru ls FIRS LEE LEA FED TRE 2 n 2 Pelt arr rl p Tau 2 Ii dEXAGZLU MXN TU BLIND COVER FOR wIldOUT 3 1227 iff fy Y SECTION FOR REVERSE SHAFT 8 MAIN PUMP 55 BLING COVER COR
112. Lock Units The resulting reaction is a force on the spool that overcomes the spool s return spring force Should the solenoid become de energized while the spool has its clutch pressurized oil pressure will keep the spool in that position This keeps the transmission in gear as long as the engine is running 40 Marine Transmission Service Manual 1020825 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 9 Neutral Solenoid Engaged Marine Transmission Service Manual 1020825 41 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 outward 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 ca
113. M2051L THESE PARTS ARE TO BE PACKAGED REDUCER M2052AA SEPARATELY AND SHIPPED WITH UNIT TEE MA711C 5 MATERA i za TIN 512 T ES pem DETRMENTAL TO THE NESTS OF ag Lus e i a el ADAPTER MA1053G J TWN Disc INCORPORATED oe EAE PS Z ar 1020025 mv zw oae Ci ITEM PARTS NO NAME ili BBasB A YALVE __ 2 3058003200 RING SNAP 22 23 1 3 2 7 17 2 18 15 14 1 52545 E 511 1 52540 8 Til 7 1 63608 PISTON s l el 15080 sw Isl SDB AFTON SANE 1 0480027049 RING we FIT 11 11 08000 RING E TYPE SNAP si 12 1 412842 COVER onnee ET SOCKET HEAD BALL STEEL al m 23 1 61158 0 GASKET Il __ 29 G0 C 5 5 08 07 3 42 DEO YT T Ta MATER TAL MODEL KL 3 3 1 1 ll HEAT TREATMENT NAME _ L E Wu 2 VALVE TROLLING AS TTD DEAWN DRAWN K HAYASHI HAVASI SCALE ANGL DRAWING HO A CO PROJECTION 1 BERFE e DESCRIPTION SIGNATURE ARA ion 4 50905 111 5 amend 5 a cmm NIIGATA CONVERTER CO LTD
114. Mei038Exwe7 x 45 1732 2 1732 MG 540 TORQUE TO 542 10180841 40955 1017383 1017179 2759 24 2028 2655 385 10171293 1038 7 20 6 B2451B 5 MG 6449 NOTE 6 180840 40956 1017383 1017179 2 2759 24 VDC az7oapy 2550 63703 10171298 1038 27 x 20 64 24518 4 MG 6557 SECURE LEVER THE DEPRESSED TOP VIEW 10 8084V 40957 1017383 1017179 NU 2 2759 24 VDC 2450 lt 355 10171294 7 x 20 6H 2451 5 5 meee TIRU 1018084 40958 1017133 1017134 B1337F 1018688 NO 2 XMe759FM24 27072 27072 703 1725 250 10171298 1038 27 x 20 6 Be451B 1052 2 10524 2 MG S202DC 5 1 4 HOLE IN LEVER amp M8 THREADED 1018084x 40964 101713 1017134 1337 1018688 2759 24 VDC XAe707z 627072 2703 1725 250 10171294 1038 27 20 6H B2451B 2089 M2089AR 2 HOLE BEHIND PULL TIGHT TRIM OGO 1019084y _ 41028 1018688 2759
115. ON 1001 SL 5 1 d3OVdS Lee v Y S 71971 X Y yatt 7 Marine Transmission Service Manual 1020825 232 Special Tools Shaft Support Tool Twin Disc Incorporated T 21482 22 22 28 2 1 SIM INIOVH ONIOSIGNIML Ag 31va NOILdIHOS3G FONVHO 22 28 12 3114 vl 3OV1d OML TVNOLLOVH4 NO 010 iss Vp 2339 usa SH3NHOO Tv xv3ug Sassi sa ca SH3NHOO dHVHS TV JAVHS QN3 18H LHOddfls aaidloads 3SIMH3HLO 5641 ILON OS 559 OW na 22 28712 1 1 avis 1104 25 48 86 82 ejeg 3715 MOOLS NOILdIWOS3G LVN 130 HL 042 X VIG 00 8 LHOddNS und L BN3TAH13A1Od uluog x F LXOZIN SOHS MLS L 9682 889 298 XVA 64 875 78 ANOHd 06009 1l 34V 1SAVHO 10410 431VHOdHOO GEOL SOILSV1d OOLIM GASVHOUNd 38 NYO WIYSLVN P NYHL VIG 786 i P 92 WUG 88 2 ane 26979 66 0 1 E 1 92 7 9v E 2 NYHL via 2 2 998 22 EN 2 1811 SAOV 1d WOIdAL X S LXOLW oS X 8407 44 1 x Wid veg coe 2 lt uu9
116. P 10 0 25 0 6 0 MG 516 MG 5161 10 0 28 0 8 0 518 1 10 0 32 0 10 0 MG520 1 MG 5202 MG5203 MG5204 10 0 32 0 10 0 MG5205 MG 530 MG530M MG5301 12 0 32 0 16 0 MG 540 20 0 62 0 20 0 MG5600 20 0 62 0 20 0 MG6000 10 0 32 0 10 0 MGN 80 MGN 232 MGN 233 MGN 272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN 472 MGN 493 10 0 32 0 10 0 MGN 650 MGN 800 MGN 1000 MGN 1400 MGN 1600 20 0 62 0 40 0 PUMP ALL MODELS 1 0 VALVE ALL MODELS 1 0 5 September 4 2001 TDW P2003A Qu AS Twin Disc Incorporated Table of Contents Table of Contents EAT OGUCUIONY ourien eE EE 13 General Information 13 Safety and General Precautions 13 Preventative Maintenance 15 RE TN 5 15 Ordering Parts and Obtaining Services 16 Source of Service Information 17 EE 18 Description and Specifications 19 19 PONET i im RR 20 Construction Features 21 Lubricatioih gor uu 22 SPECI CA U OS eoim tense didis 24 E T ii LG uuu uuu u 26 Torqu
117. REPLACE EVERY 1000 HOURS OF OPERATIC SERIAL NO LS Ts SER DS d IN JAPAN T 73408 Figure 2 Nameplate with Oil Specification 24 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Description and Specifications Table 1 2351 2551 kPa 341 370 psi Transmission Oil Pressure Specifications Mechanical Valve 2454 2648 kPa 356 384 psi Springs Input Shift Main Pressure at Valve Primary Secondary Lube Speed Position Inlet Clutch Min Clutch Min 255310 3745 o 19min 28min 7 ies s 181 195114 aon 2100 Neutral 4901179 71 171 93689 28 100 2100 Primary 24542648 356884 2351 341 193 506 2885 2100 Secondary 2454 2648 356 384 0 0 2351 341 193 586 28 85 Note It is required that primary and secondary clutches must be within 97 kPa 14 psi of each other Note Some early production units operated with lower oil pressures The following table applies to these units only Table 2 2255 2455 kPa 327 356 psi Transmission Oil Pressure Specifications Mechanical Valve 2255 2455 kPa 327 356 psi Springs Input Shift Main Pressure at Valve Primary Secondary Lube Speed Position Inlet Clutch Min Clutch Min 255310 3745 0 o 2 19min 8 min 19 min 2 19 min 2100 0 fioseso 28100 2100 2255 2455 327 356 193 58
118. SCL ENC ID RESTRIC 853 SHIFT ACROSS SEUTRAL SHALL T EC D FARA SDI EN ts ENGINE SPEED LOWER THAN 505 GF THE BA FH SPEED WATER RAW WATEA Ural 4 HEAT EXCHANGER TEMPERATURE ING FCTIDMAL YIEE BILL OF AR PUFF TCA pra x OPERATING 2 2400 DETAIL SELECTOR VALVE TPA 82 7 ACEL EELEI T m wx uE Devas 1 L 1 FAMAE Petes SOLOS 1 lun sierra a nS LE ARH PHESE RE LEE Gauge oO ENAID _ aes a 1 PLUS Uu LET 5455 alll GEI CLUTCH 47g mL PSESS p2ssezllcH ber 5 l n MAME PDAS i 117 i Distant T ela TEE i B r a AEA d EIL JF WAT ICH if 7 2 DIL IMET BSEK FEP X BOUT SITL PIPE d OIL INLET Ve EF ED DOPO L ETIMS m WWTLED REVEREZ FL EE gt E Sik i CME GRRE x U U zm 1 1 I EEF 7
119. SD 179 ALON 3ZIS 5 nodosa 63413 291 9 1 1 gavo 8 5 3 00 daVvHS 119 8934 131412345 3SIAS3HID SSIINN ILON 00110 80 t 00110080vN S IV3S TIVISNI JS 2669 1935 30415 00110 80 061 amp 1494 1935 TIVLISNI 3LUN 4 06 x CAD 119 1 90 TT 90 2 2277 X Cas S 06 X aT CLE VIG 10 LL9 S 009 VIG VIG 0 v 0 v 11 XK 539414 2 Gy 90 v y 6 AJAI 1935 40 3015 SIHL 00110080 13 4 7935 11915 ILON SIA 3 1299 2510 NIAL aa aiva N lidis2s3G 39NVH2 cv c8vic l F IS 669 H2V3 30 500 NIHLIA DNI3V38 OIMIN3ONDO 349095 38 OL 42 11 5 011 53394405 0 ANNOY 11 TINA 3215 80015 114143530 LYW Ot 140 SLT x VIG CNIH 9 gavo 51 1 Y SBJNaDO 5 119 NYE l 11 31413345 JSIMASHLO 5531 0 6 12 1 43 44 0 1044 1444 1 4 7948 SNISS eld 4 AJALA ONISIV 38 JS 1669 DW 404 05 eT 1 VIG Gov VIG 00 S NNNNINNNS G0 Gv X 0571 4LON JLUN cv c8vico 4114 CVO amp S
120. Shaft Insert 6 Secondary Clutch Shaft Inset Shown Marine Transmission Service Manual 1020825 103 Disassembly Twin Disc Incorporated Output Shaft Disassembly 1 Slide the oil seal carrier away from the output shaft bearings 7 until it contacts the output flange 2 Place a split bearing puller 8 around the shaft between the output shaft seal carrier and the tapered roller bearing on the shaft assembly The puller will remove both bearings simultaneously from the shaft Place a shaft protector 9 between the puller assembly and the end of the shaft to protect the shaft end during disassembly 3 Ensure the bearing puller is properly placed to prevent damage to the bearings and other components of the shaft during disassembly AR214 6557 R213 6557 Figure 72 Output Shaft Bearing 7 Removal 4 Tag the components 1 with identifying information Remove the output shaft seal sleeve 2 from the shaft AR215 6557 AR220A 6557 Figure 73 Output Shaft Components 1 and Seal Sleeve 2 104 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 9 The seal sleeve 2 uses an O ring on the inner surface sealing the sleeve to the shaft AR216 6557 ARMVCO007FGS Figure 74 Output Shaft Seal Sleeve 2 6 Hemove the bearing shims 3 and output seal carrier 4 Tag the components with identifying information AR218 6557 Figure 75 Output Shaft Bearing Shims and Seal Carri
121. Size Recommended Torque N m Lb ft Table 10 Banjo Fittings amp Sealing Plugs with Copper Washers Torque Values for Banjo Fittings amp Sealing Plugs with Copper Washers Recommended Torque N m Lb ft Marine Transmission Service Manual 1020825 31 Description and Specifications Twin Disc Incorporated Clutch Plate Wear Limits Clutch steel plates Minimum thickness 2 10 mm 0 083 in Clutch friction plates Minimum thickness 3 15 mm 0 124 in 32 Marine Transmission Service Manual 1020825 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 1020825 33 Operation Twin Disc Incorporated Hydraulic System with Electric 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 Lub
122. Twin Disc Incorporated Disassembly 3 Remove the six O rings located in the manifold counterbores 58 6557 59 6557 Figure 32 O ring Removal From Manifold Remove Pump Mount 1 Remove the screws retaining the secondary shaft rear cover a Gently tap the pump mount 6 to break the sealer bond from the transmission housing b Remove the cover and the shims 8 Tag the components with identifying information Remove the two O rings located in the manifold counterbores 060 6557 AR063 6557 Figure 33 Pump Mount 6 and Shim 8 Removal Marine Transmission Service Manual 1020825 15 Disassembly Twin Disc Incorporated 2 Remove the screws retaining the manifold to the rear of the transmission housing 069 6557 AR6557026BE Figure 34 Dowel Pins 9 3 Tighten the nut on the dowel pin 9 to pull the dowel out of the transmission housing Tighten the nuts until they bottom on the end of threads Pulling the dowel pin from the transmission housing will assist in removal of the manifold AR6557025BE AR6557029BE Figure 35 Dowel Pin Removal 76 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Remove Manifold 1 The manifold 2 is equipped with two pusher screw 1 locations near the dowel pins to assist in the removal of the oil manifold Thread two M10 1 5 x 60 mm fully threaded cap screws lubricated into the pusher screw locations to push the o
123. U sg p SHEET 1 GF lal 1 ARERI JMI OPS TET tto St p XU UKA Jona Mor gee T a DE LD IPU FLANGE 52315 1 42 ice M ENSE Dress TRIN DOSE mat PESPRIETARY IF anb 15 Farm ED DI ES 1095 7 BE USED M ANT HIMHER IH K 9 P HF Ah 1 FE 3 CETRIMESTAL T THE 1 OF i De x aStr 1 1 WEL 3 6557 00 8 TERE Ihe DETAIL OF SELECTOR VALVE B 5 p res ali Umi DzTA OF PTV CUNT al Zm mug MU P SAE 2744 SIZE 709 rc 4 1 Cote Peme d v 7 B 55 A me 1 yog HEIL 1 E lB 1 2 a x 9 v ATTA i 203 cam JD E IN Fe NE BF Ae AM Dm u 2 _ TA uw _ TAILLE CIEL 72 a Exitus LBS TAM nh Laga sha 1 DACH S oL 4 a 7 a Tu HAD PROJECT ISH 3IMILAR TC m THIN DISC NCORPORATED W
124. aining the spherical roller bearing in the transmission housing AAR255B 6557 255 6557 Figure 151 Retaining Ring 4 Installation Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Gear Pan and Bottom Cover Installation 1 Install the gear pan 5 into the main transmission housing around the lower portion of the output gear Torque the bolts to 46 Nem 34 Ib ft 2 Place MA1015 on the sealing surface of the bottom cover 6 Place enough sealant on the housing to adequately seal the transmission bottom cover Note Apply nickel anti seize compound to threads before torquing the screws stainless steel to 34 Nem 18 A IMPORTANT Be sure to seal the surfaces around the two screws that pass through the center of the bottom cover Leaks will result if the bottom cover is not properly sealed 260 6557 AAR260 6557 Figure 152 Gear Pan 5 and Bottom Cover 6 Installation Marine Transmission Service Manual 1020825 171 Assembly Twin Disc Incorporated 3 Rotate the transmission and place it with the output side at the top Use adequate blocking to protect the input sleeve splines and the front surface of the transmission housing Be sure transmission is Supported securely 4 Remove the electrical tape from the output shaft surface 9 Remove special tool 1 111145 8 used to hold the input drive sleeve in position while rotating the transmission housing AAR25
125. ance between the area at the pressure regulator the springs and the area behind the rate of rise piston Neutral main pressure of approximately 40 psi is maintained by relieving excess oil behind the rate of rise piston through the ball and spring regulator Figure 4 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1020825 Twin Disc Incorporated Operation Control Valve Assembly in Primary or Secondary Pressurized oil is directed to one of the transmission s clutches to engage The pressurized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the passage to the opposite clutch The pressurized oil also forces the ball of the ball and spring regulator against its seat on the orifice plate stopping the flow of oil from the rate of rise chamber to sump Since oil continues to flow into the rate of rise chamber through the orifice the oil pressure in the rate of rise chamber increases This increased oil pressure forces the rate of rise piston to stroke over to its stop in the valve body compressing the pressure regulating springs even more w n s rise piston Figure 5 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 15 controlled by the orifice size regulator spring stiffness and the final main pressure after completion
126. aring cones with tool T 21482 31 AAR273 6557 AAR271 6557 Figure 160 Install Dowel Pins 3 and Bearing Cups 4 and 5 Marine Transmission Service Manual 8 1020825 177 Assembly 178 Twin Disc Incorporated Adjust Primary Shaft Bearing Clearance 1 Measure the depth 6 of the primary shaft tapered roller bearing cup in the transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing Cup Measure in three locations around the circumference of the bearing bore The three readings should be identical If the dimensions are not identical realign the bearing cup Record this dimension Bearing Bore Depth Measure the length of the primary shaft rear cover pilot 7 and bearing spacer 8 Measure from the bearing contact point to the rear mounting surface of the cover Measure in three locations around the circumference of the rear cover The three readings should be identical Record this dimension Hear Cover Pilot Dimension Calculate the correct shim pack required to set the primary shaft rear bearings a oubtract the primary shaft rear cover and spacer dimension from the transmission housing to rear bearing cup dimension Bearing Bore Dimension Cover Spacer Dimension Pinion Shaft Clearance b Calculate the shim pack thickness required to obtain 0 05 preload to 0 05 mm 0 002 preload to 0 002 inches clutch shaft clearan
127. ary clutch shaft between the bearing cup and the rear cover nil l x Fr b 1 WI AR6557 1049BE AR6557 1045BE Figure 164 Measuring Components to Determine Secondary Clutch Shaft Bearing Adjustment Marine Transmission Service Manual 1020825 181 Assembly Twin Disc Incorporated Pump Mount Installation 1 Install the secondary shaft shim pack 7 on top of the rear bearing cup Place the thickest shims on the outside of the shim pack and the thinnest shims in the center of the shim pack 2 Install the secondary shaft O rings into the counter bores 8 in the manifold housing AAR278R 6557 AAR279 6557 Figure 165 Secondary Clutch Shaft Bearing Shim 7 and O ring 8 Installation Place 1015 on the sealing surface of the pump mount secondary shaft rear cover Note Place sealant on the sealing surface of the pump mount and pump suction port 4 Install the pump mounting 9 cover Secondary shaft rear cover Torque the screws to 46 Nem 34 lb ft R6557 003BE 280 6557 Figure 166 Seal and Install Pump Mount 9 182 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Transmission External Components Pump and Suction Screen Installation P Gaskets L Apply Liquid Sealant MA1015 Cover ae i Suction 22 Wi Cover x Spring Pump Suction Adapter Plate
128. bly is required 098 6557 AR099 6557 Figure 38 Lifting Primary 5 and Secondary 6 Clutch Shafts From Transmission Housing Marine Transmission Service Manual 1020825 79 Disassembly Twin Disc Incorporated Remove Input Drive Sleeve Assembly 1 Place a support wooden block under the input drive sleeve 7 so it is raised enough that the bearing cone no longer contacts the bearing cup Use a brass drift punch to drive the bearing cone onto the input drive sleeve assembly Once the spacer rotates freely by hand remove the snap ring and spacer 8 from the input drive sleeve assembly 101 6557 103 6557 Figure 39 Input Drive Sleeve 7 2 Place a spacer inside the input drive sleeve The spacer will protect the inner surface of the input drive sleeve during removal Install a hydraulic ram in the transmission housing Install a plate on the back surface of the transmission housing Note DO NOT remove the plug from the end of the input drive sleeve It is difficult to remove without damaging it 80 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Input Drive Sleeve Removal Plate Attach the Plate Using The Maximum Thread Engagement of the Bolts Output Drive Hydraulic Flange Ram q rp LU LI Wood Block Input Drive r Sleeve Wood Plug Block M6 6557 02 Figure 40 Input Drive Sleeve Removal Marine Transm
129. btained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near yOu Note Do not order parts using the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number the unit s nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old resulting from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty 16 Marine Transmission Service Manual 1020825 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 Marin
130. 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 FEMALE MALE STRAIGHT EDGE Figure 207 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1020825 217 Installation 218 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
131. ce when the shim pack is installed The calculated shim pack will be installed on the primary shaft between the spacer and the rear cover AR6557 1048BE AR6557 1047BE Figure 161 Measuring Components to Determine Primary Clutch Shaft Bearing Adjustment Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Primary Shaft Cover Installation Note Verify new piston sealing rings are installed on the primary shaft quantity 5 and secondary shaft quantity 4 before cover installation 1 Install the spacer 1 next to the primary shaft rear bearing cup Install O rings clutch ports and lube ports into the counter bores 2 in the manifold housing 2 Install the shim pack 3 on top of the spacer Place the thickest shims on the outside of the shim pack and the thinnest shims in the center of the shim pack AAR284 6557 054 6557 Figure 162 Primary Clutch Shaft Bearing Spacer 1 O ring 2 and Shim 3 Installation Marine Transmission Service Manual 1020825 179 Assembly 180 Twin Disc Incorporated 3 Lubricate the bore 4 of the primary clutch shaft rear cover 4 Place MA1015 on the sealing surface 5 of the primary clutch shaft rear cover 9 Install primary clutch shaft cover 6 Torque the screws to 46 Nem 34 Ib ft 71 AAR285 6557 AAR287 6557 Figure 163 Seal 5 and Install Primary Clutch Shaft Cover 6 Marine Transmissio
132. ch mounting bracket and engine bed rail Add shims between the brackets and bed rails to equal the feeler gauge readings Carefully release the lifting force on the marine gear while observing the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading moves from zero lift the marine gear and insert additional shims Continue this procedure until the marine gear is completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of the engine flywheel housing secure the mounting brackets to the engine bed rails Before securing the mounting brackets to the engine bed rails the propeller shaft should be checked for alignment Note The transmission output flange and companion flange bolts must be torqued to the proper value as identified in Description and Specifications Marine Transmission Service Manual 1020825 215 Installation Twin Disc Incorporated Torsional Input Coupling Alignment Free Standing Units Alignment of freestanding transmissions must begin by aligning the transmission output flange to the propeller shaft The engine must then be moved to properly align the engine flywheel to the transmission input hub Engine and Marine Transmission Alignment When mounting the engine and transmission in the boat all of the mounting pads on both the engine and transmission m
133. ck off 1 2 turn Figure 182 Installing Dog point 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 Astepped 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 183 Installing Detent Ball Setscrew 194 Marine Transmission Service Manual 1020825 Twin Disc Incorporated 10 11 12 13 14 Assembly Install the thrust washer over the end of the stem Press the oil seal into the cover assembly until flush with the adjacent cover surface Install the O ring into the counterbore in the cover assembly Apply grease to the stem O ring and oil seal lip Install cover assembly and gasket onto valve body Be sure to align the oil drain hole in the gasket with the hole in the valve body Figure 184 Holes in Gasket and Cover Must be Aligned 15 16 17 18 19 20 21 Install cover capscrews and torque to 23 Nem 17 lbeft 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 s
134. cking plate 5 Press the backing plate firmly into the clutch housing to ensure the splines of the clutch are aligned 8 Place the internal snap 6 ring next to the clutch backing plate 6557 069 ARR6557 1012 Figure 115 Clutch Backing Plate 5 and Internal Snap Ring 6 Marine Transmission Service Manual 81020825 141 Assembly Twin Disc Incorporated 9 Install two clamps 7 on the clutch housing and backing plate Use the clamps to evenly compress the clutch until the internal snap ring can be installed properly into the clutch housing Install the snap ring Remove the clamps 10 Lubricate the area of the clutch shaft 8 that will contact the pinion bushing Install the pinion assembly 9 Gently rotate the pinion as the pinion is lowered into the clutch plates until the splines are fully engaged in all of the clutch plates AAR6557 1010BE AR6557 1008BE Figure 116 Clutch Backing Plate and Pinion Assembly 9 11 Install the bronze 2 thrust washer with 18 radial grooves next to the pinion 12 Heatthe secondary clutch shaft front bearing carrier 3 to a temperature of 120 C 250 F Install the bearing carrier on the clutch shaft and push it firmly into position against the shaft shoulder as it cools Handle the bearing carrier with care The bearing carrier is HOT Note The bearing carrier 3 should contact the shaft stop shoulder as it is installed To verify the bearing carrier is position
135. co owl TE 1232 t Utt DDT as m OT i in 2 PRIM TA 2 1 a gt SOC E e 5 METRIC F H e c mouit T a ina 1 H n 1 A i i i ahs 1 EE IHIRZ ea LAL AS FCF Ika rec S REO OCHRE one n 40 75 d an 1 i b 4573 Soe TENTES i 3 5 0 lt 1 1 at armad GERERAL VIEW r midi 14 os ZL 7 ADIN Ps x a c a SU SEC OM FOC HEAT EXCHANGER i _ uu we ALL lae lea ee 5 HIE a jam naman L EN m gt Ith E B Lana li MEO ES Cw Nen flo SECTION REVERSE SHAFT amp MALIN PUM B EN Borage BAI mA I x 7 5 21 Qu 1 Hf D UA NS 71 qe ya bo A cJ COVER FOR WITHOUT BL COVER FOR WITRGUT TRAIL ING
136. consin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and application of the material in this manual will result in consistent performance from the unit and help reduce downtime Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Inc will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unacceptable maintenance working practices Marine Transmission Service Manual 1020825 13 Introduction Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure safe operations under prevailing conditions Proper guards and other safety devices that may be specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Inc WARNING Selecting NEUTRAL disengages transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a
137. cription and Specifications Twin Disc Incorporated Lubrication Features 22 The MG 6557A transmission bearings and clutches on the primary and secondary shafts are lubricated through oil passages drilled in the shafts The output shaft bearings transfer gears primary and secondary pinions and their bearings are gravity and splash lubricated Suction Screen The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and oil pump in the hydraulic circuit The strainer can be replaced if necessary Filter Assembly A canister style filter is located between the oil pump outlet and the selector valve in the hydraulic circuit The replacement element should be replaced at 1000 hour or six month intervals whichever comes first The replacement filter part number is N144200000 All gears are helical carburized hardened and skived or ground for smooth quiet operation All gears are in constant mesh The primary and secondary transfer gears clutch spiders are shrunk fit onto the primary and secondary shafts Do not remove these gears during service The output gear is mounted on a keyless taper Marine Transmission Service Manual 1020825 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
138. ctly 2 Install the new insert into the aluminum cover Remove the guide studs and install the three screws and torque them to 23 Nem 17 Ib ft AAR283 6557 Figure 119 Shaft Seal Ring Insert 6 144 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Ditch Plate Assembly 1 Install the lubrication oil pressure relief valve 1 Install the steel ball the retainer and spring into the bore of the ditch plate Install the sealing plug and capscrew retainers Torque the capscrews to 22 Nem 16 Ib ft 2 Install the lubrication oil priority valve 2 Install the spring valve spool the remaining spring and the plug into the bore of the ditch plate These two springs are identical R6557 017BE R6557 016BE Figure 120 Ditch Plate Pressure Relief Valve 1 and Lube Priority Valve 2 Marine Transmission Service Manual 1020825 145 Assembly Twin Disc Incorporated Trailing Pump Driven Gear Installation Trailing Pump Drive J LA 5 Output Drive 1 19 Gear Trailing Pump Shaft Drive Gear Trailing _ amp Cover For Units 11 Dri Without Trailing riven Gear Pump and Governor Pump Drive Bearings and al Spacer
139. d 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 1020825 Twin Disc Incorporated Operation Neutral When in Neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Driving Gear Primary Shaft secondary Shaft a Driven Gear NEUTRAL Output Gear Figure 14 MG 6557A Power Flow in Neutral Marine Transmission Service Manual 1020825 49 Operation Twin Disc Incorporated Primary When the Primary position is selected hydraulic pressure 15 applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel plates are spline connected through the clutch hub assembly to the pinion Because the primary input pinion is in mesh with the output gear the output gear and shaft will rotate in anti engine direction The secondary input pinion will be backdriven engine direction when the unit is in the primary position Primary Clutch Engaged Figure 15 MG 6557A Power Flow with Primary Clutch Engaged 50 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Operatio
140. d 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 These situations affect the life of the coupling element Marine Transmission Service Manual 1020825 55 Preventative Maintenance Twin Disc Incorporated When inspecting the flexible coupling look for evidence or conditions identified in the following steps Q 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 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 Q Bolts nuts bent worn or stripped threads Inspect the hub looking for the following da Damaged or worn splin
141. d factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated E Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit September 4 2001 TDW P2003 gt 5 TWIN DISC INCORPORATED FLAT RATE HOUR ALLOWANCE sy Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated COMMERCIAL MARINE TRANSMISSIONS ALL RATIOS MODEL SERIES R amp R UNIT REBUILD CLUTCH REPAIR BOTH PACKS MG 502 MG 5010 MG5011 MG5005A MG5015A 10 0 8 0 MG 506 5061 MG 5050 MG5055A 10 0 11 0 MG 507 MG 5081 MG5085 MG5090 10 0 12 0 MG 5091 10 0 12 0 4 0 MG5112 MG5113 10 0 17 0 MG 509 MG 5111 MG5114 10 0 17 0 4 0 MG5114A MG5114RV 10 0 17 0 MG 514C MG514M MG5141 MG514CH
142. d 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 silicone Clean surfaces with solvent to remove oil and grease residue da Test for clean surfaces by applying a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface ina film If the water puddles or forms beads use fresh solvent and reclean Marine Transmission Service Manual 1020825 Twin Disc Incorporated Inspection Cleaning and Inspection Housings Cast Parts and Machined Surfaces d d Replace cast parts housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts DO NOT remove excess material by sanding This will cause loss of press of bearings or races
143. d 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 1020825 125 Cleaning and Inspection Twin Disc Incorporated NOTES 126 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly General Assembly During service of this unit all O rings gaskets and seals must be replaced Refer to cleaning and inspection information in this manual prior to assembly 1115 good practice to compare the new parts with those being replaced during the assembly process to make sure you don t mistake the quantity or size Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces Pipe threads called out as PT on drawings and in this text are different from NPT threads PTthreads
144. e Manual 1020825 113 Disassembly Twin Disc Incorporated 6 Remove the filter screen from the valve body Figure 86 Removing Filter Screen 7 Remove the two socket head O ring plugs from the bores in the end of the valve body 8 Remove the two spools from the valve body 9 Remove one dowel 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 did Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 1017555 Trolling Valve Optional Equipment 1 Remove the trolling valve attaching screws i aW M E h dl hy 3 I Figure 87 Removing Trolling Valve Attaching Screws 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 the gaskets orifice plate and steel ball from control valve 4 Remove the screw and nut clamping the lever to the stem D 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 be damaged Marine Transmission Service Manual 1020825 115 Disassembly Twin Disc Incorp
145. e Transmission Service Manual 1020825 17 Introduction Twin Disc Incorporated Warranty Equipment written about in this manual has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual or contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Inc Racine Wisconsin U S A 18 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Description and Specifications Description and Specifications General Drawings that identify installation information for the MG 6557A marine transmission are located at the end of this manual This unit is only available as an engine mounted unit that attaches directly to the engine flywheel housing The output shaft is 10 degrees down angle to the input shaft 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 sg air at ne MADE IN JAPAN Figure 1 Nameplate for MG 6557A Marine Transmission Marine Transmission Service Manual 1020825 19 Description and Specifications Twin Disc Incorporated Power Ratings The MG 6557A transmissions can be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation when vie
146. e Values for Fasteners 28 Plale Wear u u 32 33 51 1 11 LO DE 33 Hydraulic System with Electric Control Valve 34 Trolling Valve Optional 44 Power Take off Optional 46 Trailing Pump Optional 47 306111 ix elu M 48 Preventative Maintenance 93 Troubleshooting 59 Troubleshooting Chart J D ERU IU UL 59 Marine Transmission Service Manual 1020825 7 Table of Contents Twin Disc Incorporated DISASSEMIDIV serrare anesan anaE 63 Prepare Transmission for Disassembly 63 Component Identification 64 Ple m 65 Remove Transmission External Components 66 Torsional COUPIO u 66 r yi LL S u IUS 66 Selector Valve and Oil Filter 67 68 PHI IM NE 69 PE E I I 70 Trailing Pu
147. e ay hn 4 SAE J744 METRE lt i i p m mm m m 2 E m t 044 c Pi vty 2 m ee Ou 5 Ml lt 2 MN Ph 11 lus rr tC PASS M 2 i ni x E 101324 ye 511754 2p 2 7 1 Go pre 4 QU SOT lt LEBEN 1 Uu 1 WELSH ig l eo per wa nee awe 40 GR ROM 2107 5 pM ue 27 _ 1 1 CREDAS E T ru T 7 077 7 1 ma i il i 4013 2 ua a m T 200 x E T 2 2 E 5 mate Cp ow 2 107 1 2 rou 4 01 x 1 In P F J a bm pov 2 am Sa a Tea Ik dici Dos ent LLL 1 n 2 C DU 4 s A tm ET r i Sora F Y TA Inh Sha SSH Bo 20079 Coe ber M aT wee 1 MAP nu lw n 77 Js EON Fis 4 7 UM 77 vU S PORD 22 27
148. e removed from the output gear Apply Loctite 242 or 243 to the threads of the capscrews and torque them to 28 Nem 20 Ib ft Note that some units have roll pins instead of capscrews 3 Measure the output gear bore depth dimension including spacer as follows Place the output gear and spacer on a flat uniform surface such as a layout table Measure from the edge 5 of the output gear to the surface of the layout table DO NOT include the thickness of the trailing pump drive gear Measure in three locations around the circumference of the output gear bore The three readings should be identical Record this distance as dimension C reference drawing Gear Thickness Dimension C 4 Measure the output shaft shoulder to spacer dimension as follows Measure from the shaft shoulder to the front edge of the spacer 6 located next to the spherical roller bearing Measure in three locations around the circumference of the shaft The three readings should be identical this distance as dimension E reference drawing Dimension E AAR234 6557 Figure 141 Output Gear Thickness Measurement 5 162 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Measure the output shaft end to shoulder dimension as follows Measure from the front end of the output shaft to the front edge of the shoulder 7 on the shaft Measure in three locations around the circumference of the shaft The thr
149. e the trolling valve rises to match main oil pressure This oil pressure inside the trolling valve pushes the piston assembly over to compress the large diameter spring behind it The compressed spring pushes the flow control piston against its return spring allowing unrestricted flow of oil to the engaged clutch Unrestricted flow of oil to the engaged clutch results in full clutch apply pressure Detent position Inlet orifice Clutch behind cover dese I Variable exit orifice closed Flow control piston Figure 12 Trolling Valve in Non trolling Position Marine Transmission Service Manual 1020825 Twin Disc Incorporated Operation Rotation of the trolling valve lever into the trolling mode opens the variable orifice allowing some of the oil in the trolling valve to flow to sump This reduction in oil pressure within the trolling valve allows the piston assembly to move toward the lever end of the valve reducing the amount of compression in the spring behind it Since the spring is no longer fully compressed the flow control piston moves in its bore and restricts the flow of main pressure oil to the engaged clutch This causes the clutch apply pressure to be reduced allowing the clutch plates in the transmission to slip The amount of pressure reduction and resulting clutch slip is u
150. eBora P 2 2 J 5 8 8 7 72 50115 T T W 11 4 3 JIS 4 11 0 TD T wee I5 amp ket JIS 20 0 TREE a 5 BOLTS 1 HI HEXAGON SOCKET HEAD ED i7 E IQR ITP ILL s SECTION FOR EXCHANGER 4 3 kar m 0215 8 8 231 80 15 HEXAGON HEAD SPRING 2 2 1115 8 8 MEN 2 BOLTS FEXAGON FEAD kgi n 8 85 2 3 2 HEXAGCN SOCKET HEAD SECTION FOR REVERSE SHAFT amp MAIN PUMP TES 4 3 CIS 8 8 ne 8 B L HEXAGON HEAD II 1 D 1 I IL gi NIE IL lll 22 WA 115 8 8 73 8 BOLTS HEXAGON HEAD I FILL GREASL iskaq e usd 53 7 5 kgf m 715 8 8 9 15 HEXAGON HEAD E BLIND COVER FOR WITHOUT BLIND COVER FOR WITHOUT NOTES TRAILING PUMP OIL STRAINER l ADJAUZT SPACE CY AND D FOR EACH SHAFT 11 SHIME 8 SPACE 5 CA AND SHOULD FF 0 05 40 05 mm GPace SH2J BE 0 lt 40 05 T SPACE CIRE 35 70 OTHER DRAWINZ 3 29285 USE THICK SHIM lt OVDR Imm ON THE SIDE 2r GROOVE JF THERE 15 VE THIRD ANGL
151. eads of these stainless steel fasteners before torquing to specification See Standard Sheet S574B for a more complete listing of stainless steel fastener torque values Metric Coarse Thread Stainless Steel Capscrews Bolts and Nuts Thread Size Recommended Torque N m Lb ft 28 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Description and Specifications Table 7 Tapered Pipe Plugs with thread lubricant Torque Values for Lubricated Pipe Plugs Recommended Torque N m 10 41 27 8 50 5 IT Notes The lubricant is to be John Crane insoluble plastic lead seal No 2 or equivalent or Loctite No 92 or equivalent and plugs are to be capable of removal without damage Overtightening may cause initial leakage plus potential removal damage An option of a maximum of two full turns after finger tightening the plug may be used if required and if removal conditions are met Marine Transmission Service Manual 1020825 29 Description and Specifications Twin Disc Incorporated Table 8 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal lb ft lb ft Thread 9 0 5 Or 9 5 Diameter Diameter ww wen w m 30 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Description and Specifications Table 9 Tubing Nuts Torque Values for Tubing Nuts Nominal Tube
152. ed correctly the end of the bearing carrier should be flush with the end of the shaft Place a straight edge across the top of the shaft and bearing carrier If all components are installed correctly no air gap should be observed between the straight edge and the end of the shaft 142 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly AAR200N 6557 AAR200L 6557 Figure 117 Bronze Thrust Washer 2 Rear Bearing Carrier 3 Installation 13 Verify the pinion has measurable end float 14 Invertthe shaft assembly positioning the sealing ring end of the shaft up Install the rear tapered roller bearing if removed Heat the clutch shaft rear bearing cone 4 to a temperature of 120 C 250 F Place the bearing on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing against the clutch housing as the bearing cools Handle the bearing with care The bearing is HOT AAR193A 6557 Figure 118 Rear Bearing Cone 4 Installation Marine Transmission Service Manual 1020825 143 Assembly Twin Disc Incorporated Primary and Secondary Shaft Seal Ring Insert Installation 1 Heat the aluminum cover 5 to 120 C 250 F Cool the cast iron insert 6 to 20 C 5 F Handle the components heated and cooled with care The cast iron insert will be located with three capscrews Use three guide studs to index the insert in the cover corre
153. ed with 18 radial grooves both sides around the thrust washer for lubrication purposes Marine Transmission Service Manual 1020825 101 Disassembly Twin Disc Incorporated 3 Hemove the pinion bushing assembly 4 Tag the pinion assembly with identifying information This will ensure the gear will be installed in the same location where it was removed ARR6557 1006BE ARR6557 1007BE Figure 69 Bearing Carrier 2 Pinion 4 and Thrust Washer 3 Removal 4 Repeat steps 5 through 13 as previously shown for Primary Clutch Shaft Disassembly E DO NOT remove the drive pin 3 from pump drive coupling 4 unless part replacement is required The pump drive coupling pin is retained by staking in two locations at both ends of the pin 197A 6557 170 6557 Figure 70 Piston Sealing Rings 1 Clutch Shaft Rear Bearing 2 and Pump Drive Pin 3 102 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Primary and Secondary Clutch Shaft Insert Removal Note Complete the following procedure only if part replacement is required Secondary clutch shaft insert shown The insert removal process is identical for primary clutch shaft insert 1 Remove the screws 5 retaining the shaft rear cover insert 6 2 Weld a washer in the bore of the steel insert with an arc welder d Heat the aluminum cover 120 C 250 F 4 Pull the insert from the cover R283 6557 Figure 71 Clutch
154. ee readings should be identical Record this distance as dimension G reference drawing Dimension G Calculate the correct shim pack reference drawing dimension B required to set the output gear advance on the output shaft as follows Calculate the shims Dimension E Dimension C 0 00 0 1 mm Shims Dimension B Dimension E Dimension 0 0 00 0 004 in Shims Dimension B The calculated shim pack 8 will be installed on the output shaft between the spacer and the output gear DO NOT install the shim pack at this time The shim pack will be installed as the output shaft is lowered into the transmission housing 232 6557 AAR233B 6557 Figure 142 Shaft End to Shoulder 7 Measurement and Shim Pack Installation Marine Transmission Service Manual 1020825 163 Assembly 164 8 Twin Disc Incorporated Measure the expected gear advance to ensure it falls into the range 5 25 6 76 mm 0 207 0 266 in as follows a Place the gear on the output shaft Seat the gear on the shaft by tapping it with a dead blow hammer to measure expected gear advance Measure from the front end of the output shaft to the front edge of the output gear Record this distance as dimension F reference drawing Dimension F Calculate the expected gear advance dimension D reference drawing Dimension D Dimension G Dimension F Dimension D should fall into the range of 5 25 6 76 mm 0
155. en the piston and springs Figure 78 Screen Rate of Rise Piston and Regulator Springs 6 Remove pressure regulating springs f Remove pressure regulating piston with an external retaining ring pliers Figure 79 Removing Regulating Piston with Pliers 108 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 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 It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 10 Remove the washer and spring from the stem Marine Transmission Service Manual 1020825 109 Disassembly Twin Disc Incorporated 11 Remove four of M8 x 25 socket head capscrews 12 Remove the cover assembly with the gasket from the valve body 13 Remove the O ring and oil seal from the cover assembly Figure 80 Removing O ring from Cover 14 Remove the two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body some models 15 Remove the detent setscrew spring and steel ball from the valve body Figure 81 Removing Detent Setscrew and Spring TO Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 16 Remove the dog point setscrew Note that the setscrew is r
156. er 4 Marine Transmission Service Manual 1020825 105 Disassembly Twin Disc Incorporated Ditch Plate Disassembly 1 Remove the lubrication oil pressure relief valve 5 by removing the two hex head cap screws and washers Thread M8 1 25 screw into the sealing plug and pull it from the ditch plate Remove the spring retainer and steel ball from the bore of the ditch plate 2 Remove the hex head screw and sealing washer from the lubrication oil priority valve 6 Remove the spring valve spool and the remaining spring from the bore in the ditch plate 6557017BE 6557016BE Figure 76 Ditch Plate Pressure Relief Valve 5 Lube Priority Valve 6 Note Some early units may have a built in relief valve 106 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Selector Valve Assembly Electric Valve The steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of the steel ball 1 Loosen and remove four of M8 x 25 socket head capscrews and remove orifice plate cover and gasket Figure 77 Removing Orifice Plate Cover Gasket 2 Remove orifice plate 3 Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket Marine Transmission Service Manual 1020825 107 Disassembly Twin Disc Incorporated 9 Hemove screen Remove rate of rise piston Note that shims are located betwe
157. ervice Manual 1020825 137 Assembly Twin Disc Incorporated 200 6557 AAR200B 6557 Figure 109 Installing Cutch Piston Seals 3 4 Lubricate the clutch piston bore with a thin film of grease Install the piston into the clutch housing The piston contains two threaded holes M12 1 75 in which screws can be inserted to aid in assembly Gently push the piston by hand until it is fully engaged into the clutch 6 Note The piston contains two M12 1 75 threaded holes 4 into which screws can be inserted to aid in assembly The piston is also equipped with two dump valves 5 Note Ifthe piston is difficult to install by hand remove the piston assembly and inspect the we 3 Ve m AAR188E 6557 191 6557 Figure 110 Clutch Piston Installation Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 9 Insert the steel thrust race 7 onto the shaft Ensure the steel thrust race is against the shaft shoulder Install the inner bronze 8 thrust washer with 6 radial grooves onto the shaft AARR6557 1015BE AARR6557 1016BE Figure 111 Installing Steel Thrust Race 7 and Bronze Thrust Washer 8 6 Install the clutch plates a Install a steel 1 clutch plate next to the piston b Install a friction plate Place two a pair wave springs 2 around the outer circumference of each friction plate Each pair of wave springs 16 installed with the ends
158. es Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners 56 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Preventative Maintenance Heat Exchanger Check Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days If over 50 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist it is evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush In Boat Repair Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures are qd 0 D O D Removing installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Removing and installing the control valve Removing and installing the manifold Removing servicing and installing the clutch shaft assemblies Marine Transmission Service Manual 1020825 57 Preventative Maintenance Twin Disc Incorporated O
159. ess to make sure you don t forget the quantity size etc A CAUTION Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Pipe threads called out as PT on drawings and in this text are different from NPT threads PT threads and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Most pusher screws used in the disassembly of this transmission are threaded through aluminum parts ALWAYS LUBRICATE the threads of the pusher screw before threading it into the mating part When installing pusher screws avoid rapid tightening with an impact wrench or similar device If an impact wrench is used with the pusher screws the threads may gall or seize in the aluminum part Tighten pusher screws in an even manner to avoid damaging components Marine Transmission Service Manual 1020825 63 Disassembly Twin Disc Incorporated Component Identification Oil Manifold Input Shaft Direction f Rotati Outlet to Secondary Clutch Oil Pressure Secondary Shaft Oil Pressure Selector NPTF 1 4 Plug Rear Cover NPTF 1 4 Plug Valve Oil Filter aM Outlet to Primary Clutch Oil Pressure 1 4 Plug PRIMARY SHAFT REAR COVER P Zinc Annode ES Plug as i S v 6650906050 OSO A OEC o9o9 lpo9a9i N 8090 a 2 TC Beal S
160. etained with MA908 threadlocker 79 SEA ees 8 ME Figure 82 Removing Dog point Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 83 Removing Thrustwasher Two Types are Shown Disassembly Twin Disc Incorporated 19 Remove the stem from the valve body 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 84 Removing Roll Pin Retaining Shuttle Seat 21 Thread a M8x1 25 screw 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 Twin Disc Incorporated Disassembly Disassembly of Upper Valve Body Half Electric Section 1 Remove the Weatherpak connector from the valve body by sliding it in the direction of the opening in the shroud 2 Mark the wires with the location letters that are on the Weatherpak connector Open the end of the Weatherpak connector to allow removal of the pins and wires J Remove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool The tool is Packard Electric P N 12014012 Figure 85 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them D Remove the third neutral solenoid units with hydraulic lock or plug units without hydraulic lock Marine Transmission Servic
161. ft Insert Removal 103 Output Shaft Disassembly 2 1 11222 104 Ditch Plate Disassembly 106 Disassembly of Upper Valve Body Half Electric Section 113 1017555 Trolling Valve Optional Equipment 115 8 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Table of Contents Cleaning and Inspection 121 u au unus 121 1017 1 YU c E 123 Assembly 127 Eae 127 Primary Clutch Shaft Assembly 128 Secondary Clutch Shaft Assembly 136 Primary and Secondary Shaft Seal Ring Insert Installation 144 Ditch Plate Assembly T 145 Trailing Pump Driven Gear Installation 146 Input Drive Sleeve and Shaft Seal 148 Output Shaft Installation 153 Output Shaft Bearing Adjustment T J J 153 Assembling the Output Shaft Subassembly
162. grease Install the primary shaft assembly into the transmission housing with a hoist Carefully align the input drive sleeve and shaft splines 2 during installation Note In some instances it may be necessary to press the primary shaft splines into the splines of the input sleeve A IMPORTANT Be sure the primary shaft is fully engaged in the input drive sleeve before attempting to install the secondary shaft 261 6557 262 6557 Figure 155 Lowering Primary Clutch Shaft into Transmission Housing 3 Install the front bearing cone 3 for the secondary shaft Apply a thin film of grease to the inner bore of the bearing cone 174 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 4 Apply a thin film of grease to the front bearing carrier on the secondary shaft Install the secondary shaft assembly 4 into the transmission housing The bearing carrier of the secondary shaft is a slip fit into the bore of the front bearing cone Note Assembly will be difficult if the clutch shaft assembly is not perfectly aligned Note The transfer gears on the primary and secondary shafts will protrude above the manifold sealing surface approximately 5 mm 0 20 inches B T 4 a 512 E 263 6557 AAR264A 6557 Figure 156 Secondary Clutch Shaft Bearing Cone 3 Lowering Secondary Clutch Shaft into Transmission Housing 9 In
163. he 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 Q Vessel is being towed da 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 applicable for all MG 6557A transmissions when any ofthe above conditions are present Lock the propeller shaft to prevent rotation Add an optional trailing oll pump into the lubrication circuit Refer to the hydraulic system schematics for more details on the optional trailing pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Marine Transmission Service Manual 1020825 15 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services WARNING All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Henewal parts service parts kits optional equipment and product service assistance may be o
164. he tools and reapply pressure to advance the output gear lf the gear cannot be advanced the proper distance the shim pack thickness should be checked Checking the shim pack dimension will require disassembly If the shim pack thickness is correct and the output gear cannot be advanced the proper distance consult the Product Service Engineering Department at Twin Disc If the spherical roller bearing 2 was removed from the bearing carrier 3 heat the bearing to 120 C 250 F Install the spherical roller bearing on the bearing carrier Allow the bearing assembly to cool to room temperature prior to further assembly Handle the output shaft spherical roller bearing with care The bearing is HOT Lubricate the output shaft transmission housing bore and the output shaft with a thin film of grease Marine Transmission Service Manual 8 1020825 169 Assembly 170 Twin Disc Incorporated 29 Install the spherical roller bearing and carrier on the end of the output shaft Carefully align the components with tool T 21578 1 to ease installation Gently tap the outer bearing race and the bearing carrier if necessary to align the assembly during installation Note If the spherical bearing becomes out of alignment the assembly will become impossible AAR255AA 6557 R255A 6557 Figure 150 Spherical Bearing 2 Installation in Transmission Housing 30 Install the retaining rings 4 next to the spherical roller bearing ret
165. il manifold away from the transmission housing A IMPORTANT Always lubricate the pusher screw 1 threads before use Always tighten pusher screws in an even manner 2 Remove the manifold from the transmission housing A CAUTION Use caution in removing the manifold from the transmission housing The forward and reverse shaft bearing cups could fall out of the manifold as it is being removed 072 6557 AR075 6557 Figure 36 Manifold 2 Removal Marine Transmission Service Manual 1020825 77 Disassembly Twin Disc Incorporated 3 Remove the primary shaft and secondary shaft rear bearing cups 4 from the manifold Note The primary and secondary shaft bearing cups are different from each other Tag the components with identifying information 4 Remove the O rings located in the transmission housing behind the manifold 079 6557 R083 6557 Figure 37 Primary and Secondary Clutch Shaft Bearing Cup 4 and Housing O ring Removal 78 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Remove Primary and Secondary Clutch Shafts 1 Install two lifting eyes M10 1 5 into the primary shaft transfer gear 5 and lift the shaft out of the transmission housing 2 Install lifting eyes M10 1 5 into the secondary shaft transfer gear 6 and lift the shaft out of the transmission housing Note Set the Primary and Secondary clutch shaft assemblies aside until further disassem
166. in Note A negative endplay indicates a pre load condition Table 4 Front Housing and Output Flange Runout Limits total indicator reading SAE 1 front housing pilot diameter 0 30 mm 012 in SAE 0 front housing pilot diameter 0 41 mm 016 in Output flange face near O D 0 10 mm 004 in Output flange pilot diameter 0 10 mm 004 in This note applies to a continous 270 arc if the balance of the pilot is negative in readings otherwise it means all 360 Marine Transmission Service Manual 1020825 27 Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Note Lubricate all threads and bearing face with light oil film prior to assembly Table 5 Metric Coarse Thread Capscrews Bolts and Nuts Property Class 8 8 Property Class 10 9 Property Class 12 9 Size lll Lm Nm 65 75 12 14 10 12 14 16 16 18 21 25 23 26 31 35 25 29 34 40 32 36 43 49 44 51 60 68 51 59 70 80 55 63 74 86 77 88 104 120 89 103 121 139 132 151 179 205 189 217 256 294 219 253 298 342 257 295 348 400 364 418 493 567 429 493 581 669 445 511 603 693 626 720 848 976 737 848 1000 1150 714 820 987 1113 1235 1421 16 4 1926 1475 1697 2000 2301 Table 6 Metric Stainless Steel Capscrews Bolts and Nuts Note The use of nickel anti seize compound is required to prevent corrosion due to galvanic action Apply nickel anti seize compound to the thr
167. ission torque the screws to 54 Nem 40 Ibeft Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Assembly of Trolling Valve optional equipment 1 Press a new oil seal into the counterbore in the end of the adapter Install a new O ring into the groove of the adapter Figure 186 Installing O ring onto Adapter 2 Install a new O ring into the groove of the stem 9 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 counter clockwise twisting motion The spring should be installed onto the roll pin so that the first coil contacts the end of the stem D Apply assembly grease to the stem from the O ring to the reduced diameter end Install the stem into the adapter with the reduced diameter end entering the adapter first Adjust the position of the stem if necessary to bring the helical slot into alignment with the dog point setscrew hole 6 Install the large diameter washer used on some models inside the bore of the adapter and over the inner spring until it lays flat on the end of the stem 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 8 1020825 197 Assembly Twin Disc Incorporated 8 Apply assembly grease to the adapter where it contacts the trolling valve body and install the adapter in
168. ission Service Manual 1020825 81 Disassembly Twin Disc Incorporated 3 Press the input drive sleeve 9 out of the tapered roller bearing cone 1 Inspect the condition of the bearing components Tag the components with identifying information 108 6557 09 6557 Figure 41 Input Drive Sleeve 9 and Bearing 1 4 Remove the secondary clutch shaft front tapered roller bearing cone 2 and bearing cup from the housing The secondary clutch shaft front bearing cup 3 is retained with a light slip fit in the housing Inspect the condition of the bearing components Tag the components with identifying information 107 6557 AR6557 037BE Figure 42 Secondary Clutch Shaft Front Bearing Cone 2 and 3 Removal 82 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Remove Output Shaft Remove Transmission Bottom Cover 1 Remove the retaining screws from the bottom cover 4 of the transmission housing Be sure to remove the screws near the center of the cover A IMPORTANT The screws used to retain the bottom cover of the transmission are stainless steel 2 The transmission housing bottom cover is equipped with two pusher screw locations at opposite corners to assist in the removal Thread a M10 1 5 x 60 mm fully threaded cap screw lubricated into a pusher screw location to push the bottom cover away from the transmission housing 110 6557 H112 6557 Figu
169. l pin locations to assist in the removal of the housing Thread two M10 1 5 x 60 mm fully threaded screws lubricated into the pusher screw locations to push the front housing away from the main transmission housing A IMPORTANT Always lubricate the pusher screw threads before use Always tighten pusher screws in an even manner 2 Remove the O ring 1 located between the front housing and main transmission housing 07 6557 012 6557 Figure 18 Transmission Front Housing and O ring 1 Removal 66 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Selector Valve and Oil Filter 1 Disconnect oil supply tube from the filter housing and the selector valve 2 Remove the selector valve R6557 1063BE R6557 1065BE Figure 19 Selector Valve Removal S Hemove control valve ditch plate 2 and gasket H161A 6557 AR162 6557 Figure 20 Ditch Plate 2 Removal Marine Transmission Service Manual 1020825 67 Disassembly Twin Disc Incorporated 4 Remove the oil filter 3 and the oil filter bracket 16 6557 020 6557 Figure 21 Oil Filter 3 Removal Suction Strainer 1 Remove the suction strainer cover 4 from below the pump and remove the suction strainer The cover of the suction strainer 5 is sealed with an O ring The suction strainer is located inside a spring to hold the suction strainer into position a x ils
170. ltimately controlled by the trolling valve lever position Trolling mode Variable exit orifice opened Flow control piston Figure 13 Trolling Valve in Trolling Position Marine Transmission Service Manual 1020825 45 Operation Twin Disc Incorporated Power Take off Optional There are two types of Power Take Offs available for this marine transmission Both are designed to drive hydraulic pumps meeting SAE J 744 with flange size 127 and shaft size 32 4 SAE C 4 bolts Live Pump Mount Power Take off The live pump mount power take off drives accessories using engine horsepower Since the live power take off 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 Pump Mount Power Take off The hydraulic clutched power take off also allows accessories to be driven using engine horsepower Since the power take off is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The power take off is engaged by the power take off electric control valve that can be engaged manually if necessary The hydraulic clutched power take off operates with oil pressure supplied by the transmission s hydraulic system 46 Marine Transmission Service Manual 1020825 T
171. m 33 Ibeft 4 Lubricate the sealing ring of the oil filler cap 2 and install it in the top cover of the transmission AAR327 6557 AAR164 6557 Figure 195 Install Top Cover 1 and Filler Cap 2 Marine Transmission Service Manual 8 1020825 203 Assembly Twin Disc Incorporated 5 Install the oil level gauge tube into the housing if removed Place tool T 21578 2 3 over the top of the oil level gauge tube and gently tap the oil level gauge tube into the transmission housing AR6557 1038BE AAR316 6557 Figure 196 Using Tool T 21578 2 to Install Oil Level Gauge Tube 204 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Grease Output Shaft Seals Fill the cavity between the two single lip and double lip output shaft seals with grease as follows a Remove the pipe plug 4 on the output shaft seal retainer housing The pipe plug is located on the opposite side 180 opposed of the grease fitting 5 on the housing The pipe plug provides a place for air to escape while greasing the seal cavity b Use a grease gun 6 to fill the cavity with grease When grease escapes the seal retainer through the pipe plug opening the cavity Is filled C Heinstall the pipe plug AAR328 6557 AAR329 6557 Figure 197 Grease Output Shaft Seals Marine Transmission Service Manual 8 1020825 205 Assembly Twin Disc Incorporated Front Housing Installation 1 Apply MA1015 on the front
172. 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 192 Marine Transmission Service Manual 1020825 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 S 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 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 x Figure 181 Installing Shuttle Ball Seat Roll Pin 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 Marine Transmission Service Manual 1020825 193 Assembly 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 ba
173. mp if equipped see eee eere e 73 Top Cover with Oil her e 73 Remove Primary and Secondary Clutch Shaft Assemblies 74 Remove Primary Clutch Shaft Rear Cover sse 74 Remove PUMP cc a 75 Fe 7 EE 7 Remove Primary and Secondary Clutch Shafts 79 Remove Input Drive Sleeve Assembly eee eere eese 80 Remove Output Shalt 83 Remove Transmission Bottom 83 Remove Output Shaft 2 4 4 4 84 Remove Trailing Pump and Shaft 92 Remove Pump Cover and Shaft Q J J 92 BETIN REMOVA Sica aia ER RG S 9 t uu E ILI 94 Input Shaft Front Bearing CUP s ssisssissasissiisansninsinan oa 95 HIGIDIO O l 22 95 Primary and Secondary Clutch Shaft Output Shaft and Ditch miim ED a 96 Primary Clutch Shaft Disassembly 2 96 Secondary Clutch Shaft Disassembly 2 2 101 Primary and Secondary Clutch Sha
174. n 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 16 MG 6557A Power Flow with Secondary Clutch Engaged Marine Transmission Service Manual 1020825 51 Operation Twin Disc Incorporated NOTES 52 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance 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 l
175. n Service Manual 1020825 Twin Disc Incorporated Assembly Set Secondary Shaft Bearing Clearance 1 Measure the depth of the secondary clutch shaft tapered roller bearing cup in the transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing Cup Measure in three locations around the circumference of the bearing bore The three readings should be identical If the dimensions are not identical realign the bearing cup Record this dimension Bearing Bore Depth 2 Measure the length of the pump mount pilot Measure from the bearing contact point to the rear mounting surface of the cover Measure in three locations around the circumference of the pump mount The three readings should be identical Record this dimension Pump Mount Pilot Dimension Note The secondary shaft does not use a spacer between the rear bearing cup and the rear shaft cover Calculate the correct shim pack required to set the secondary clutch shaft rear bearings a Subtract the secondary clutch shaft rear cover dimension from the transmission housing to rear bearing cup dimension Bearing Bore Dimension Cover Dimension Pinion Shaft Clearance b Calculate the shim pack thickness required to obtain 0 05 preload to 0 05 mm 0 002 preload to 0 002 inches clutch shaft clearance when the shim pack is installed 4 The calculated shim pack will be installed on the second
176. n and Shim Installation 11 Fill the nine spring pockets in the bearing bore of the transmission housing with grease Note The grease will be used to retain the springs in the spring pockets while the transmission housing is rotated 12 Install a spring in each of the spring pockets of the transmission housing Ensure each spring is firmly held in its bore within the housing 13 Install the spherical bearing cup into the transmission housing next to the springs The spherical bearing cup is a slip fit in the transmission housing AAR229 6557 AAR228 6557 Figure 144 Output Shaft Bearing Spring 5 and Bearing Cup 6 Installation Marine Transmission Service Manual 8 1020825 165 Assembly Twin Disc Incorporated 14 Ensure the surface of the shaft taper is clean and free of grease and other contaminants Lightly grease the output bore 7 of the transmission housing and the O ring 8 of the seal retainer on the output shaft subassembly Slowly lower the shaft subassembly into the transmission housing through the shims and the output gear assembly CAUTION Carefully lower the shaft into the transmission housing as the seal carrier is installed into the housing Damage to the shaft seals could result if appropriate care is not taken during the installation process 15 Gently tap the end of the output shaft with a dead blow hammer if necessary to guide the seal retainer into the housing Note will be a
177. n in removing the spherical roller bearing from the end of the output shaft If bearing alignment is maintained the bearing can be pulled gently from the end of the shaft Remove the bearing from the bearing carrier only if parts replacement is required 125 6557 26 6557 Figure 48 Output Shaft Front Bearing 6 Carrier Removal 9 Install special tool T 21482 21 restraining tool Install the special tool oil injection adapter tool T 21482 8 into the end of the output shaft a Identify the location of the oil injection port 8 The proper port is the threaded hole in the end of the shaft that contains a continuing passage through the shaft to the shaft tapered surface at the output gear Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly b Fill the shaft passage with SAE 40W oil e Wrap the threads of the oil injection adapter 9 with teflon sealing tape Thread the oil injection adapter into the oil injection port in the end of the shaft AR6557053BE AR131 6557 Figure 49 Oil Injection Port 8 Location and Oil Injection Adapter Tool 9 Installation 6 Fill the oil injection adapter with SAE 40W oil Lightly tap the oil injection adapter to remove air entrapped in the passage Refill the passage with oil as required until the passage is filled and all traces of air are removed 7 Insert two wooden blocks about 20 mm 3 4 inches thick between the side of the output gear
178. ng steps must be performed in rapid succession a Heat the input shaft front bearing 3 to a temperature of 120 C 250 Place the bearing on the input drive sleeve Marine Transmission Service Manual 1020825 149 Assembly Twin Disc Incorporated A CAUTION Use caution when working with heated components b Install the steel spacer 4 on the input drive sleeve EL j am i a 1 6557 1073 212 6557 Figure 127 Input Sleeve Bearing 3 and Spacer 4 Installation C Install the snap ring 5 on the input drive sleeve to retain the bearing and snap ring d Remove the spacers from below the input drive sleeve e Press the input drive sleeve into position with the snap ring against the spacer 6 using special tool T 21482 29 Note The spacer should be tight against the snap ring and should not rotate 150 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly AAR212E 6557 AAR212D 6557 Figure 128 Snap Ring 5 Installation and Positioning Input Drive Sleeve 3 Apply a thin film of grease to the secondary shaft front bearing bore inside of the transmission housing Press the secondary shaft bearing cup into the transmission housing bore with special tool 21482 27 The bearing cup should be a light slip fit 4 Install special tool T 111145 across the primary shaft rear opening 7 in the transmission housing with a threaded rod
179. nnot reach the clutch pressure passages in the transmission The main oil pressure regulator shuttle ball neutral pressure regulator and rate of rise functions remain exactly the same as when the valve is in the electric mode In the manual override position shifting is controlled by rotating the lever on the manual override stem In the Neutral position both clutches are vented to sump by two pockets in the stem Figure 10 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 42 Marine Transmission Service Manual 1020825 Operation Twin Disc Incorporated MO FEY sz vz SSHUd g TE 441 13H FETT LI a Lar f TOS WEIN i p i Swe KA lt
180. nze 18 Grooves Backing 10 Pairs Thrust Washer Plate 6 Grooves _ Orifice Plug Ed Piston with Dump Ball Pump Drive Clutch LIU TTY Cou lin PU pe Port pang AM im T TT B PT aL o Passage gt Ka N Rings Pinion Gear Assembly Friction Thrust Race 2e Plates 10 Plates 11 M6 6557 09 Figure 106 Secondary Clutch Shaft Component Identification and Location 1 Inspect the clutch piston dump valves 1 for proper operation Be sure the dump valve balls are free to move The clutch piston dump valves are not serviced separately 136 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly AR6557 1023 AR6557 1021 Figure 107 Clutch Piston with Dump Balls 1 2 Install the pump drive coupling 5 into the rear end of the shaft if removed Place the coupling in the end of the shaft and press the retaining pin through the components When the retaining pin is flush 6 with the shaft stake it in two locations at both ends of the pin AAR197A 6557 70 6557 Figure 108 Pump Drive Coupling 5 and 6 Installation 3 Replace the clutch piston seals 3 Lubricate the clutch piston sealing rings before installing the piston into the clutch housing Marine Transmission S
181. of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the rate of rise piston is against the stop pressure regulating springs are compressed the most the main oil pressure reaches approximately 356 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 1020825 37 Operation Twin Disc Incorporated 38 Electric Operation The transmission normally operates with the control valve in the electric mode Two spools each controlled by a solenoid operated pilot valve control clutch engagement When a solenoid is energized it opens the pilot valve and allows main pressure oil to flow to the end of the spool The pressure acting on the end of the spool overcomes the return spring at the oppo
182. of the transmission housing completely around the output shaft opening 7 A CAUTION DO NOT block lube ports 8 located in the front housing with silicone sealer 257 6557 256 6557 Figure 198 Seal Transmission Housing Around Output Shaft Opening 7 2 Install an O ring in the transmission housing counterbore 9 9 Install the transmission front housing 1 onto the transmission housing The front housing is located on the transmission housing with two dowel pins Drive the front housing near the dowel pins if necessary Torque the screws to 46 Nem 34 Ib ft AAR258 6557 AAR259 6557 Figure 199 Install O rings 9 in Transmission Housing Counter Bores and Transmission Front Housing 206 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Install Torsional Coupling and Fill Transmission with Oil 1 Install the torsional coupling on the input drive hub A IMPORTANT Liquid sealant must cure for a minimum of 24 hours prior to contact with oil AAR164R Figure 200 Fill Transmission with Oil 2 2 Fill the transmission with oil 2 before operation Marine Transmission Service Manual 8 1020825 207 Assembly Twin Disc Incorporated NOTES 208 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Installation Installation Prior to Installation Most Twin Disc products mount directly onto the flywheel of the engine or are attached to
183. oil seal carrier 3 onto the output shaft 9 Install the correct previously selected shim pack 4 onto the output shaft AAR239 6557 AAR238 6557 Figure 137 Oil Seal Carrier 3 and Shim Pack 4 Installation 6 Install the output shaft tapered roller bearing cup 5 The following steps of this procedure require components to be heated prior to installation Use caution when handling the heated components 158 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly Install the output shaft tapered roller bearing cone 6 a b Heat the output shaft tapered roller bearing cone to 120 C 250 F Place the tapered roller bearing cone onto the output shaft with the small diameter end of the bearing toward the bearing cup Slide the bearing onto the shaft until it contacts the shoulder of the output shaft seal sleeve Install the output shaft spherical roller bearing cone 7 a b Heat the output shaft spherical roller bearing cone to 120 C 250 F Place the spherical roller bearing cone onto the output shaft with the large diameter of the bearing toward the bearing installed previously Slide the bearing onto the shaft until it contacts the rear tapered roller bearing cone Install the bearing spacer 8 a b Heat the bearing spacer to 120 C 250 F Place the bearing spacer onto the output shaft with the small diameter end towards the spherical bearing cone Slide the
184. on Marine Transmission Service Manual 1020825 91 Disassembly Twin Disc Incorporated Remove Trailing Pump and Shaft Remove Pump Cover and Shaft 1 Place the transmission in the upright position Be sure transmission is supported securely 2 Remove the trailing pump cover 7 from the rear of the transmission AR148 6557 AR149 6557 Figure 55 Trailing Pump Cover 7 Removal 3 Remove the external snap ring 8 from the trailing pump driven shaft 4 Use special tool T 21482 17 to drive the shaft out of the bearings and into the housing using M10 x 1 5 x 50 mm screws in opposing trailing pump holes 92 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Use extreme caution when removing the trailing pump drive shaft to prevent damage to the drive slot in the end of the shaft The trailing pump drive shaft and gear are not serviced separately The trailing pump drive gear and shaft are serviced as an assembly as a single part number AR151 6557 153 6557 Figure 56 Trailing Pump Shaft Removal Bearing Removal Pull the trailing pump shaft bearings and spacer 3 out the back of the transmission housing The spacer is located between the two ball bearings 156 6557 AR157 6557 Figure 57 Trailing Pump Shaft Bearing and Spacer 3 Removal Marine Transmission Service Manual 1020825 93 Disassembly Twin Disc Incorporated Other Components Remove the governor cover 4
185. on and Location 1 Position the shaft with the clutch sealing rings downward 2 Remove round retaining ring 4 from the shatt 96 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 3 Remove the bronze thrust washer 5 Note The rear bronze thrust washer is equipped with 18 radial grooves both sides around the thrust washer for lubrication purposes 82 6557 AR184 6557 Figure 61 Retaining Ring 4 and Bronze Thrust Washer 5 4 Remove the pinion assembly 6 Tag the pinion assembly with identifying information This will ensure the gear will be installed in the same location where it was removed 5 Install two clamps 7 on the transfer gear and backing plate to compress the clutch wave springs Compress the clutch until the internal retaining snap ring in the clutch can be removed 83 6557 AR186 6557 Figure 62 Pinion Assembly 6 and Clamping 7 Clutch Backing Plate Marine Transmission Service Manual 1020825 97 Disassembly Twin Disc Incorporated 6 Remove the internal snap ring 8 from the clutch retains the clutch backing plate Remove the bar clamps from the clutch assembly 7 Remove the clutch backing plate 9 from the clutch 187 6557 88 6557 Figure 63 Internal Snap Ring 8 and Clutch Backing Plate Removal 8 Remove the steel clutch plates quantity 11 the friction clutch plates quantity 10 and the wave springs 1 quanti
186. orated 6 Remove the detent setscrew spring and detent ball AT nar Figure 88 Removing Detent Setscrew left and Detent Spring and Ball right 7 Remove the dog point setscrew from the valve body Figure 89 Removing Dog point Setscrew 116 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 8 Slide the stem and adapter out of the valve body together as one piece Push the stem out of the adapter so the spring end of the stem exits the adapter first Note that the inner spring will come out with the stem a TN Figure 90 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 91 Removing O ring from Stem Marine Transmission Service Manual 1020825 117 Disassembly Twin Disc Incorporated 10 Remove the inner spring and roll pin from the stem only if part replacement 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 There may be washer s in the bore of the piston some models Figure 92 Removing Spring and Piston from Valve Body 18 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 13 Remove the O ring from the groove and the oil seal from the end
187. ounded edge 5 away from the piston The rounded edge makes installation of the pinion gear splines easier to align as the pinion gear is installed into the transfer gear AARMVC 029F AARMVC 001F Figure 100 Clutch Friction Plate Edge 5 Rounded Edge and Sharp Edge Shown Steel Plates When installing steel clutch plates 4 install the plate with the rounded edge toward the piston The rounded edge is easier to install into the transfer gear splines when installed in this manner AAR6557 067 AAR6557 068 Figure 101 Clutch Friction Plate 4 and Steel Plate 4 Installation 132 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 6 Install the clutch backing plate 5 Press the backing plate firmly into the clutch housing to ensure the splines of the clutch are aligned 7 Place the internal snap 6 ring next to the clutch backing plate 6557 069 AAR187 6557 Figure 102 Clutch Backing Plate 5 and Internal Snap Ring 6 8 Installtwo clamps 1 on the clutch housing and backing plate Use the clamps to evenly compress the clutch until the internal snap ring be installed properly into the clutch housing Install the snap ring Remove the clamps 9 Lubricate the area of the clutch shaft 8 that will contact the pinion bushing Install the pinion assembly 9 Gently rotate the pinion as the pinion is lowered into the clutch plates until the splines are fully engaged in
188. ow idle and the transmission in Neutral check the oil again The oil level should be near the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval With a new transmission change the oil and filter element within the first 50 hours of operation Change oil and filter element after each 1000 hours thereafter or more often depending on conditions For arebuilt 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 depending on conditions Draining Drain the transmission by removing the drain plug with the magnet at the rear side of the bottom cover Marine Transmission Service Manual 1020825 53 Preventative Maintenance Twin Disc Incorporated Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located at the lower end of the pump See Engineering Drawings for suction strainer location Type Oil Recommended see Description and Specifications
189. perly 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 oee 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 1020825 Installation 221 Twin Disc Incorporated
190. position the transmission on blocks with the input shaft front end down with clearance to allow installation of the input drive sleeve from below a Apply MA1015 sealer to the outside diameter of the input seal Install the seal in the main housing Press the input seal into the housing from the bearing cup side of the carrier until flush with the machined surface inner surface of the carrier Wrap the snap ring groove of the input drive sleeve 1 with electrical tape to protect the seal surface during installation Apply grease to the input seal lip Apply a grease film to the input drive sleeve seal surface Install the input drive sleeve into the housing from below Care must be taken to prevent damage to the input shaft seal Do not position the input drive sleeve into the seal too far AR6557 1068BE AR6557 1069BE Figure 125 Installing Input Drive Sleeve 1 148 e oupport the installed input drive sleeve in position while installing bearings Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly f Lubricate the inner bearing surface 2 on the input drive sleeve prior to bearing installation A CAUTION As the input drive sleeve is positioned into the seal retainer take care to prevent damage to the input seal 6557 1070 6557 1071 Figure 126 Preparing Input Sleeve for Bearing Installation 2 Install the primary shaft front bearing Note The followi
191. put side on top b Use the output shaft spacer 1 77227 and tool T 21482 38 to press the bearings from the main housing Note The tapered output bearing cup is a slight interference fit in the main housing Removing the bearing assemblies will require some force Output Shaft Rear Bearing Removal Tool 1 21482 38 Spacer 1 77277 Input Sleeve Retainer Note Slight Interference Fit Cup To Main Housing M6 6557 05 Figure 132 Removing Output Shaft Rear Bearings Marine Transmission Service Manual 1020825 155 Assembly Twin Disc Incorporated Assembling the Output Shaft Subassembly Output Shaft Sub assembly Single Lip Seal Seal O ring Carrier Bearing Cup Double Lip Shims Seal E Spacer Ne 7 49 gt led O ring eal Spherical a Roller Bearing SIS L Tapered Cover Surface with Roller Bearing Electrical Tape During Assembly M6 6557 06 Figure 133 Output Shaft Component Identification and Location 1 Install the oil seal sleeve onto the output shaft Install an O ring 9 into the groove in the inner bore of the oil seal sleeve Lubricate the surface of the O ring with grease Apply a thin film of grease to the output shaft surface from shaft midpoint to seal sleeve shoulder R6557 064BE RMVC 007FGS Figure 134 Oil Seal Sleeve O ring Installation Marine Transmission Service Manual 1020825 Twin Disc Incorporated Note
192. r Lower the output shaft assembly 4 out of the transmission housing through the bore of the output gear AR133 6557 6557 Figure 51 Lowering Output Shaft 4 Out of Transmission 11 Slide the output gear 3 out of the transmission housing until two M10 1 5 eyebolts 2 can be installed into the gear to allow it to be lifted 135 6557 136 6557 Figure 52 Removing Output Gear From Transmission Marine Transmission Service Manual 1020825 89 Disassembly Twin Disc Incorporated 12 Place the transmission in the upright position Be sure transmission 15 supported securely 13 Remove the nine coil springs 6 from behind the output shaft spherical roller bearing cup in the transmission housing 5 AR6557 060BE 141 6557 Figure 53 Output Shaft Spherical Bearing Coil Spring 6 Removal 90 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 14 Remove the trailing pump drive gear from the output gear only if parts replacement is required a A spacer is used between the trailing pump drive gear and the output gear on transmissions b Refer to Output Shaft Disassembly information of this manual for detailed shaft disassembly information Output Shaft Trailing Pump Gear Output Gear Spacer OkO JN B Socket Head Capscrew Trailing Pump Gear Spacer M6 6557 03A Figure 54 Output shaft Component Identification Location and Variati
193. rdwood shims and fasten the engine and transmission in place Then recheck the alignment and if satisfactory bolt the coupling together Marine Transmission Service Manual 1020825 219 Installation Twin Disc Incorporated 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 accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer 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 220 Transmission controls must be checked for proper function and alignment after any transmission selector valve is pro
194. re 43 Transmission Bottom Cover 4 Removal Marine Transmission Service Manual 1020825 83 Disassembly Twin Disc Incorporated 3 Remove the retaining screws from the gear pan 5 Remove the gear pan R114 6557 AR115 6557 Figure 44 Gear Pan 5 Removal Remove Output Shaft 1 Place the transmission in an upright position Be sure the transmission is supported securely Use tool T 21482 21 to restrain the shaft Remove the output seal carrier screws 2 Rotate the transmission to place the front of the output shaft 7 at the top output drive flange downward Be sure transmission is supported securely Remove the external snap ring 8 from the front of the output shaft 117 6557 118 6557 Figure 45 Output Shaft Seal Retainer 9 and Output Shaft 7 84 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 3 Remove the internal snap ring 1 from the transmission housing 119 6557 AR120 6557 Figure 46 Internal Snap Ring Removal 4 Remove the output shaft front bearing carrier 2 from the output shaft Insert two M8 1 25 cap screws 4 into the threaded screw locations of the bearing carrier end plate and pull on the screws to remove the bearing carrier AR120A 6557 121 6557 Figure 47 Output Shaft Front Bearing Carrier 2 Marine Transmission Service Manual 1020825 85 Disassembly 86 Twin Disc Incorporated A CAUTION Use cautio
195. rication 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 leaking oil from affecting the pressure regulation Marine Transmission Service Manual 1020825 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 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 3 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 i
196. rre TEL MALLA T O TEEN yp vp GULE 247 cones omni e dl wl 204 Abe ni mno BARES as we m Ki r ITA aT fe RET CITE IE LZW Rd P223 1T Delum 4 T min UM d E m o3 ASSUM SELECTOR VALVE 421821 inasi MEI e a r CREASE Weim oi z X us ARE 5 56060 27614 En tat i a 270 Oil DRAIN Fi Anar if ae L Lya Ya Peo n m PJT ET T GU UEM ues MS ee x CIL mig DAADE MFR SEP AL I V af iD u D SEES 5683119 CELDT PUT ILU 5 RAIDEUTIBS 4 2 M 1 E 1 P 2 i 1 7 Due Lb ED E eld am or 4 P 2 ily ni i Fn e a om M M OU l M U M O i i m 0 m APORTE Sec TDIMIBID TI 1 1 Sra Rot ma thle L era
197. s 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 1020825 35 Operation 36 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 This additional spring compression further resists the movement of the pressure regulating piston resulting in a force bal
198. 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 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 1020825 Twin Disc Incorporated Disassembly Disassembly Prepare Transmission for Disassembly Note During the service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the used components O rings gaskets and seals with the appropriate components for reference during the inspection and assembly proc
199. site end causing the spool to stroke over and connect the clutch passage with main pressure passage Figure 6 Pilot Spool Passages Marine Transmission Service Manual 1020825 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 7 Flow Path in Override Spool Main pressure from the energized solenoid operated pilot valve also acts ona pin on the return spring side of the opposite spool to ensure the opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Marine Transmission Service Manual 1020825 39 Operation Twin Disc Incorporated Hydraulic Lock Feature some models Some control valve models have a hydraulic lock feature and are identifiable by athird solenoid operated pilot valve This feature keeps the engaged clutch pressurized as long as the engine remains running if electrical power fails or a malfunction occurs while the clutch is engaged The hydraulic lock is accomplished by allowing pressurized oil from the pressurized clutch passage to flow inside the spool Oil pressure inside the spool forces the dowel pin against the O ring plug Neutral solenoid Spring HYDRAULIC LOCK UNITS Figure 8 Hydraulic
200. slight interference fit between the main housing and the seal retainer Note When the shaft is installed a small gap 9 will be present between the transmission housing and the seal retainer This gap is a result of the springs installed between the transmission housing and the spherical bearing cup AR6557 1056BE AR6557 1074BE Figure 145 Output Shaft Assembly Placement in Transmission Housing 166 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 16 Install the seal retainer screws and tighten them evenly Torque the screws to 80 Nem 59 Ibeft 17 Raise the transmission housing Support the output gear with special tool 111146 1 Lower the transmission housing until the output gear only the gear not the housing is supported firmly by the tool 18 Seat the shaft taper in the bore of the output gear Use a mallet to tap firmly on the end of the output shaft flange 2 seating the tapered joint CAUTION Monitor the position of the trailing pump drive and driven gear during output shaft installation to prevent interference of the gear teeth RIRE 4 W m 7 AAR244 6557 AAR251J 6557 Figure 146 Seating Output Gear on Output Shaft 19 Support gear with wood blocks Install restraining tool T 21482 21 20 Rotate transmission with the input end up Remove restraining tool T 21482 21 Install tool T 21482 5 over the output shaft assembly 6 R247 6557 AAR6557
201. stall the sealing rings on the primary 5 and secondary 6 shafts Apply a light coat of grease to all of the sealing rings 7 270 6557 73 6557 Figure 157 Clutch Shaft Sealing Ring Installation Marine Transmission Service Manual 1020825 175 Assembly Twin Disc Incorporated Install Manifold 1 Place a thin film of MA1015 on the sealing surface 8 of both the manifold and housing 2 Place MA1015 around the dowel pin holes 9 in the main transmission housing AAR265C 6557 AAR265B 6557 Figure 158 Seal Manifold Surface 8 and Dowel Pin 9 Locations 3 Install six O rings clutch ports and lube ports into the main transmission housing counter bores 1 4 Install the manifold 2 onto the main transmission housing AAR265A 6557 AAR264 6557 Figure 159 Install O rings 1 in Transmission Counter Bores 176 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 9 Install the manifold to housing screws loosely Loosen the dowel pin nuts on the manifold Drive the dowel pins 3 into the housing to locate the manifold properly on the transmission housing Tighten Snug only the dowel pin nuts to hold the manifold in place Torque the manifold screws to 46 Nem 34 Ibeft 6 Install the primary shaft rear bearing cup 4 Install the secondary shaft rear bearing cup 5 7 Lightly press the primary and secondary shaft rear bearing cups into position on the be
202. t s Damaged or worn oil pump assembly Incorrect linkage adjustment to control valve assembly Clogged or plugged orifice in orifice plate of control valve assembly Shimming required between regulator springs and rate of rise piston Engine idle speed too low Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Regulating valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Remove and clean oil strainer Disassemble the valve and clean the piston Remove the collector and inspect piston rings Replace damaged or worn oil pump assembly pump is not 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 1020825 Twin Disc Incorporated 3 4 5 Table 11 Troubleshooting Chart continued High main oil pressure High temperature Excessive Noise Regulating valve stuck Improperly shimmed Lube relief valve malfunction Improper oil level
203. tallation Twin Disc Incorporated 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See Table 12 for allowable tolerances 5 Bolt a thousandths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the surface to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter Engine Flywheel Housing Engine leen E wheel Thousandths Indicator Engine Crankshaft Figure 203 Checking the Flywheel Face Runout 212 Marine Transmission Service Manual 1020825 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 m Flywheel k Thousandths Indicator if Engine Crankshaft pom Flywheel Aag Figure 204 Checking the Flywheel Pilot Ring Bore Eccentricity Marine Transmission Service Manual 102
204. tation roughness Replace the bearing if the rotation is rough Inspect bearings for corrosion and for wear indication on balls or rollers Inspect for scored scratched cracked pitted or chipped races If you find one of these defects replace the bearing Q 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 124 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Cleaning and Inspection Gears Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the defect with a soft stone replace the gear Inspect gear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear Inspect thrust faces of gears for scores scratches and burrs you cannot remove these defects with a soft stone replace the gear splined Parts Inspect spline
205. tem or dog point setscrew may be damaged Torque the lever s attaching screw to 9 5 Nem 7 Ibeft 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 8 1020825 195 Assembly 22 Twin Disc Incorporated Install pressure regulating springs into valve body and into piston spring pocket Install the shims that were removed into the bore of the rate of rise piston Install the rate of rise piston over the springs and into valve body Install neutral pressure regulating spring into the pocket of valve body Figure 185 Neutral Pressure Regulating Spring Location 2o 26 gs 28 29 Install screen if equipped and install orifice plate gasket onto valve body Install orifice plate and steel ball against spring onto valve body Install orifice plate cover and gasket onto valve body Install cover capscrews and torque to 23 Nem 17 Ibeft Install gasket over lower valve body half oet upper valve body half over lower valve body half Insert the valve attaching screws through valve body halves to keep parts in alignment until installation onto the transmission When installing the valve onto the transm
206. to facilitate removal DO NOT remove the rear bearing unless replacement is required 193 6557 1934 6557 Figure 67 Piston Sealing Rings 9 and Clutch Shaft Rear Bearing 1 100 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly Secondary Clutch Shaft Disassembly 1 Position the shaft with the clutch sealing rings downward Secondary Shaft Bronze Thrust Washer Wave Spring Bronze 18 Grooves Backing 10 Pairs Thrust Washer LO Tami Bearing Plate 6 Grooves _ Orifice Plug iw I IT E 2 20 i Dump Ball LL Pump Drive III A Clutch A f f a l _ dl x 1 7 aS Sealing Rings Pinion Gear Assembly A Thrust Race Steel Friction Plates 11 Plates 10 M6 6557 09 Figure 68 Secondary Clutch Shaft Component Identification and Location 2 Remove the rear tapered roller bearing from the bearing carrier The bearing is a slip fit on the bearing carrier Remove the bearing carrier 2 from the end of the shaft Use the pinion to pull the bearing carrier bronze thrust washer and bearing carrier simultaneously CAUTION Use caution to prevent damage to bronze thrust washer when remov ing bearing carrier from the shaft assembly Note bronze thrust washer is equipp
207. to the valve body Be sure to align the setscrew holes in the adapter with those in the valve body Figure 187 Installing Trolling Valve Parts Into Trolling Valve Body 9 Apply 908 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 3 mm from the valve body when the dog point of the setscrew is fully engaged in the helical slot Figure 188 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 198 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Assembly 11 Install the detent ball and spring into the remaining hole in the valve body Apply MA908 threadlocker to the threads of the detent setscrew and install until flush with the valve body d 4 CN C 5 s vu ui L 25 H wo gt 11 7 Ma EIC E 4 7 M 4 rs 1 7 t o v 3 5055 SS e ass ut 5 Figure 189 Installing Detent Ball Spring and Setscrew 12 Check the torque required to overcome the detent The torque should be 1 1 1 7 Nem 10 15 inelb Adjust the detent setscrew if necessary to achieve the proper torque to rotate the lever out of the detent position 1
208. ty 20 Note Some early units use only a single wave spring between clutch plates There are only 10 wave springs on these units ARMVCO26FGS ARMVCO28FGS Figure 64 Clutch Wave Springs 1 and 2 98 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Disassembly 9 Remove the inner bronze thrust washer 4 The inner bronze thrust washer closest to the clutch piston has six radial grooves on each side AR188C 6557 AR188D 6557 Figure 65 Clutch Plates 3 and Bronze Thrust Washer 4 10 Remove steel thrust race 7 from the clutch The steel thrust race is located below the bronze thrust washer Note Rotating the thrust race during removal will ease the process 11 Some clutch pistons are equipped with threaded holes to insert pulling screws 8 assisting in the removing the clutch piston Thread two M12 1 75 x 200 mm cap screws into the clutch piston Remove the clutch piston from the clutch Note If the clutch piston does not have threaded holes compressed air can be used to remove the piston 191 6557 6557066BE Figure 66 Steel Thrust Race 7 and Clutch Piston 6 Removal Marine Transmission Service Manual 1020825 99 Disassembly Twin Disc Incorporated 12 Invert the shaft placing the rear end of the shaft upward Remove the clutch piston sealing rings 9 from the end of the shaft 13 Removal of the rear tapered roller bearing 1 requires destruction of the bearing
209. use neglect improper maintenance or accident 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated 6 Thewarranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated C As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment D OnlyaTwin Disc Incorporated authorize
210. ust be used Failure to do 50 may result in damage to the transmission or the engine flywheel housing Recommended Figure 206 Recommended 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 with flexibility and may change shape as the loading varies 216 Marine Transmission Service Manual 1020825 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 arrange to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine can be raised by screwing down or lowered by backing off on the jacking screws to obtain the desired adjustment oteel plates must be inserted under the jacking screws so that the bolts will not damage the engine bed Lifting
211. verhaul Interval A complete overhaul of the unit should be made at the same time the engine is overhauled Periodic Visual Inspection Check the mountings for tightness damage such as cracks Tighten loose mountings and replace damaged parts Q Check pressure and temperature gauge where applicable Inspect the oil lines and heat exchanger for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required 58 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Troubleshooting Troubleshooting Chart The following chart is intended as a guide for determining the cause of oroblems that could be encountered and the corrective actions The transmission 15 one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is important that the entire power package be considered when problems are encountered Tables begin on the next page Marine Transmission Service Manual 1020825 59 Troubleshooting Table 11 Troubleshooting Chart Twin Disc Incorporated 2 60 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 shaf
212. win Disc Incorporated Operation 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 occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller The trailing pump is driven by the output shaft and oil flow from the trailing pump flows through a check valve into the transmission s lubrication circuit below the heat exchanger Marine Transmission Service Manual 1020825 47 Operation Twin Disc Incorporated Power Flow 48 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 secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction an
213. wing rear of engine This series of marine transmissions can 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 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 20 Marine Transmission Service Manual 1020825 Twin Disc Incorporated Description and Specifications Construction Features Housings The MG 6557A series transmission has a one piece main housing Front housings in sizes SAE No 1 and SAE No 0 are available A top cover a bottom cover and a manifold complete the housing enclosure The pump mounts on the secondary shaft and the primary shaft has a cover Bearings The primary and secondary clutch shafts are supported and located by tapered roller bearings The pinions are supported on bushings and the end movement limited by thrust washers Bearing clearances for each clutch shaft are set by using a single shim pack at the rear tapered roller bearing on each shaft Tapered roller bearings and a spherical roller bearing support the output shaft and have bearing clearance adjusted by using shims at the rear bearing retainer Oil Pump and Drive The oil pump is spline driven by the secondary clutch shaft Marine Transmission Service Manual 1020825 21 Des

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