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Service Manual Marine

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10. 150 0 o UG RING 2 SOLENOID RETURN THOMAS amp BETTS RAI8 8 DT E Jr L WIRING SCHEMATIC 8 ld oto _ 300 0 _ WIRE 18 AWG XLPE SAE 1128 TYPE GX START CIRCUIT q 87A maa d SOLEN
11. _ WIRING SCHEMATIC TWIN DISC TROLL ENABLE SWITCH PART NUMBER SAE 11128 TYPE GXL FD TROLL CRUISE CUSTOMER SUPPLIED USE 1020282 SOLDER SHRINK UNI o n SEE MODULE POWER CONNECTION CHART ROLL SPEED TIOMETER 1K OHM RANGE 00 05 VOLT MINIMUM TROLI TROLL ENABLE Y 4 75 5 0 V MAXIMUM TROLL SEE NOTES e amp 4
12. 4 77 C AS d jp qo S 1 11806
13. 5 GCS o PM 3036AE ROLLPIN 2916 0 RING 10480 SNAP RING EX os Mes AREE DANSE 2 PM4963AX X A487 P9711A P9742 A922A PX 11725 PM1996R 2 4 11725 11726 2272 20577 O A TWI A2916BV 1 2 DISC MA1038A 1 as P9925 2051EJ PLUG LIEK e lt lt lt XS M19905 1 m NSS NS 92 1190 2 SEE NOTE 4 1O ae es es D A 2888
14. 5 D C B
15. ANAT HA 3 NA NN MA656D SEE NOTE b 56515 1 PM 3533 BT 1 3353 1 2 11826 991 1 1 XB2508 1 1 1 FOR E TROLL FOR PROFILE FOR L H DIRECTION OF ENGINE MODU MODULE ROTATION ONLY a Z 1020584 1 1020586 1 201513 1 ROTATION 1020282 1020282 9 422 2 p MA1039 J 6 MA1039 J 6 X9840 1097 4 1097 4 1003535 71110035554 MA842G FERRULE MA841G 5685 2508 M1927BV ROLL PIN B2505A F EX 825058 5 B2505C 7 B2505D P 9473 VKE 4015 1 9472 VKE 4011 P9743 1 PM2057AJ PM1357W PM9741 PX9737 1927BV PM 1357 D ROLL PIN CA PM 1677N 2 4 9736 NES M 2067 D 2 4 597 36A SEE Nori SEE CHART 1 E e A P9736B Z6 C CH NK o D E P9736C ES NN 59 _ 1 9 40 1 HHRHH MA1 0538F 3 B p 9740_ 1 P 1841P 1 V Q 1 Am M A PM 4330T SDN EK OH pe 1 1 826 2055 IN
16. E Es RIFICE 1021751 57 2 0 RING PORT SEE CHART 2 5 STAMP VALVE ASSEMBLY 119 4 FE NOTE D GASKET 1020531 IDENTIFIER HER N H H VALVE BODY 1020518 PROPORTIONAL CONTR VALVE PERATION PRESSURE REGULATOR INITIAL ADJUSTMENT PROCEDURE F APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS AROUND 1 WARNING D NOT C VALVE CUI 1 WITH N F W 1 VALVE URN ADJUSTMENT CORE PLUG JUST BEFDRE FINAL ASSEMBLY REFER 774 FUR BATTTERY POWER SUPPLY VDLATAGE STEM OF THE 10206704 VALVE COUNTER CLOCKWISE FURTHER INFORMATION 2 OPERATION BE PERFORMED WITH ONLY TWIN DISC UNTIL REACHING POSITIVE STOP ES REPLACED BY 95 CONTR SYSTEMS OR ULE 2 WITH A MINIMU F 1 gpm W DIL TO FLUSH FOR PRE DUI N AND EF RVICE Q PRESSURE RGEULATOR B MANUA IRECTIUNAL C RUL VALVE 9 3 AFTER FLUSHING TURN ADJUSTMENT STEM OF THE 1 WIT ANUA NAL CONTR VALVE IN 1020670 VALVE CLOCKWISE UNTIL REACHING REQURIED CENTERED POSITION PUS ENGAGE PORT PRESSURE SPCIFIED IN MARINE TRANSMISSION PRODUCTION a E 2 WIT ANUA CUNTR VALVE IN EST SPECIFICATION L CENTERED POSITION PUI E NGAI PORT 4 CK ADJUSTMENT STEM IN PLACE USING JAM NUT AND THIRD ANGLE MANUAL DIRECTIONAL CONTROL VALVE E SWITCH 1 SWITCHES ARE RMALLY CLOSED WHEN MANUAL REFER 1 MARINE
17. OPTIONAL TEMPERATURE INDICATING SWITCH CONTROL 107 9 4 25 ENGAGING Y CUSTOME INSTA IN A 3 4x3 4 SECONDARY CLUTCH EA ANGER x 5 x3 4PIPE TEE IN THE HYDRAULIC LINE 1021658H i CARTRIDGE VALVE CONNECTIONS FADING FROM THE MARINE TRANSMISSION PUMP TO THE INLET REFER TO ARE NOT POLARITY SENSITIVE 03 24 4 06 YDRAULIC DIAGRA CONNECTOR MATES WITH METRIPACK x REFER B3649 FOR HEAT EXCHANGER REQUIREMENTS VEO E MIS E E AT NEURAL POSITION X OPTIONAL PRESSURE GAGE CUSTOMER TO INSTALL GAGE IN PILOT HOUSE 188 13 7 41 98 5 3 87 _ AND CONNECT LINE FROM GAGE HERE 1 8 27 PRIMARY CLUTCH NPTF EXTERNAL TH D DRYSEAL AT GAGE DRILL THRU 34 92 1 37 12 HOLES EQUALLY SPACED MECHANICAL USE 8 8 PROPERTY CLASS QUALITY Back UE CURIE CAPSCREWS PER ISO 898 1 MAIN PRESSURE CHECK USE HARDENED FLAT STEEL WASHERS 61 MN E 12 1 5 TH D ISO 6149 ECHANICAL PULL PUSH EFFORT REQUIRED UNDER SCREW HEADS GRADE 111 156N 25 35Lb FROM NEUTRAL POSITION EUR Seb 36 53N 8 12Lb FROM SHIFTED POSITION 420 5 16 56 AN 418 2 16 46 lo O i 1 YE 9 M DRILL THRU p 378 5 BREATHER AND OIL FILLER 6 in PRIMARY SOLENOID 8 HOLES EQUALLY SPACED 14 90 y EN H gt A USE 8 8 PROPERTY CLASS QUALITY 351 4 9 C O IMARY SHAFT CAPSCREWS PER ISO 898 1 m ds TORQUE
18. SOLENOID SWITCH YELLDUW CUSTOMER SUPPLIED 150 Z START SEE ULE POWER CIRCUIT CONNECTION CHART A OO 250 d SOLENOID A SWITCH TRANSMISSION MANUAL 77 IG RING CUSTOMER SUPPLIED VERRIDE SWITCHES obo 1201 THOMAS amp BETTS RA18 8 REF T D M2995K SOLENOID RETURN JULE POWER CONNECTION CHART USE 1 CONNECTIONS WHEN ULE IS CONNECT NON ELECTRONIC LEVER HEADS USE OP 2 CONNECTIONS WHEN IS CONNECTE FCTRONIC GEAR CONTROLLER INDICATORS 38 1 USE OP 3 CONNECTIONS WHEN THE ULE IS CONNECTED ELECTRONIC CONTROL SOLENOID GREEN LED ILLUMINATED WHEN POWER IS GREATER THAN 9 0 RIVER OUTPUTS THE ELECTRONIC CONTROL S SOLENOID AND RETURNS OR NEGATIVE SIGNALS RED LED ILLUMINATE ICATES VALVE COIL COMMANDE SHOULD BE CONNECTED TOGETHER AND CONNECTED THE ETROLL JULE RETURN ELECTRONIC ONE RED FLASHING INDICATES AN OPEN CIRCUIT IN AN ENERGIZED VALVE COIL CIRCUIT 125 0 AY 1 CONTROL SOLENOID DRIVERS MUST HAVE EIR SOLENOID RETURN INTERNALLY CONNECTED DIRECTLY 1 VALVE LEADS SHORTED TOGETHER OR LOW COIL CURRENT SZ ROUND IF THE MODULE MUST BE INTERFACED TO THE ELECTRONIC CONTROL WITH RELAYS RED LEDS FLASH SIMUTAINIDUSLY AFTER ENTERING TROLL FROM NEUTRAL WITH BOTH VOLTAGE AND CURRENT TROLL SPEED SIGNALS PRESENT OR WHEN POWER IS APPLIED 1 ENUID AND WIRE WIRING OPTION 1 WIRING OPTION 2 WIRING OPTIO
19. 20745 B1504AY A996F B2423 B2423A B2423B 5872 SEE NOTE 8 SEE NOTE gy AS REQ D P9738 H P9738A P9738B P9738C S A E AS REQ D Ru PX9739 1 P9739 1 1927BV ROLL PIN PM1357D PORT A A OIL CAPACITY 7 60 ESS P 9843 L 29729 1 OSES AND HEAT EXCHANGER 2 2 50 3 45 b ROTATION ARROW AND PUMP POSITION FOR R H P11031 1 ENGINE IS SHOWN FOR L H ENGINES ROTATION 2 04 1 51T PLATE ARROW POINTING TO RIGHT AND SCREWS P9726A 1 ASSEMBLY INSTRUCTIONS UST BE ADDED TO INDICATE OPPOSITE DIR 1 92 1 507 ASSEMBLE AND TEST PER S570BL AND PUMP TO BE RELOCATED PER INSTRUCTIONS 29723 OTES 1 THRU 8 ARE IN 557084 OWN ON SHEET 2 1 75 1 49 T c N EQUIPMENT 59766 T CON ANION FLANGE 55 XB5917 552 1 5574 FASTENER TORQUE REQUIREMENTS YDRAULIC CLUTCHED P T O SHAFT DRIVE PX 12014 22 407 5692 THRUST BEARING SHIMMING YDRAULIC CLUTCHED P T O PUMP DRIVE PX 12014 A 5765 TAPERED JOINT ASSEMBLY CAT EXCHANGER UNIT SEE SHEET 3 Meee TEE 1 03 3 38T OIL TEMPERATURE SWITCH B3424 FOR INSTALLATION LOCATION SEE E 6629 13MAYO2 HYDRAULIC DIAGRAM
20. 1021303 Document Number MGX5114A Components Transm INCORPORATED TWIN DISC Service Marine 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 1021303 Revision 3 May 2005 Marine Transmission Operator s Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY MARINE PLEASURE CRAFT 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 thirty six 36 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twe
21. GA s SCREW MA960A 4 5 Fe s X a ML i toe d IH 0 1 2 TEILE jd M Sc 0 amp 7 VALVE 1020942 77 a WASHER 2782 BODY 1021659 CAP 10021 44 SPRINGS SEE CHART SEE NOTE D SEE CHART STAMP VALVE ASSEMBLY IDENTIFIER HERE NUT 1002145 RING PISTON 10209394 B VALVE VALVE PRESSURE 2E DEM _ MODIFICATION ASSEMBLY ASSEMBLY BOM kPa SPRINGS HG PROPORTIONAL PART NO IDENTIHER dps Bi VALVE SENSOR PLUG PLUG ee SEE NOTE Lh 10216584 43110 10210008 NCINE M20515 MA 1038E 1020520 KIEZ E 210216588 AMI XL 10210004 NONE 20515 MA TOSBE NONE 1018528 K1418 PINE 10215595 C 43112 2059092 IMUC 1021000 NONE 20515 NONE 1020520 K1429 PORT A 6 MN V PORT E 02165880 0 43195 1021000 1016122A NONE NONE 1020520 K1417 ORT A eU 1021658 43196 AEN 10210004 1016122A NONE NONE 1018528 K1418 vo 4 10216592 F 43197 uas awe 10210004 1016122A 038 NONE 1020520 1420 a 10216880 43198 1020542 NONE 20515 1018528 K1419 1021658 43199 as use 10210004 M20515 MATIBSA NONE 1018528 K1418 y 1021658 J 43200 Nosy 1020542 M20515 MATOSSQ NONE 1018528 K1418 VIEW TWIN DISC s nae vet epe TE GM AA tA Rei T IOWI METRIC
22. A M1945BC 2087D 2693A M2086B M422 8 B2411C 1 27118 bo DOWEL PIN DOWEL PIN PM9338H PM9338H HELI COIL HELI COIL PM1357W PM1357W SCREW HEX HD SCREW HEX HD P 11729 P 11727A 1 11729 11729 11727 M1904CZ 11728 A2916HX PM8147B I B3477B 2708 P9734 M2086P MA487 1904 B2322B PM1996U PX9330 ST PM 11729 11954 1 M2086Bu iln 1 PX9722A P9722 28 75 1 PX9721A P9721 28 75 o ring 9746 9746 31 1 48 1 9719 P9719 31 148 PX9718A P9718 35 1 20 1 9747 P9747 9520516 9748 9748 37 1 03 1 9749 29749 37 1 05 1 NOT SERVICEABLE SEPERATELY FOR SERVICE USE PX10022A PINION HUB ASSEMBLY CONSISTING OF PX9727A PINION ASSEMBLY AND P9876 HUB OUNT INSTRUCTION PLATE D s TH WORDS HIGH PERFORMANCE INPUT S D SENSOR ARINE TRANSMISSI LUBRICANT E SIDES APPLY ANAEROBIC SEALANT MEETING MA908 LOCTITE 242 SPEED SENSOR THREADS ASSEMBLE SENSOR UNTIL NTACTING OF GEAR TOOTH AND THE BACK OUT SENSOR E FULL TURN USE JAM NUT TO SECURE SENSOR POSITION NE 1357
23. BE C 450 REMIS HMM MULTIPLY dou FOR AND 2 0 FOR RAW WATER H E APPHOX OIL FLON TO H E 1 5 LAMIN CIRCE IUNII T MAT KPa 285 PSI H E WATER PRESSURE MIN 1 5 X H E WATEH KPa PST D DATA H E PURCHASER MUST ALSO TELL VENDOR STATE IF RAW OPEN CHANNEL amp SEN OH FRESH CLOSED ENGINE JACKET KEEL COOLER WATER WILL COOL H E STATE MAX WATER TEMP INTO H E TYPICAL RAW WATER 29 C KEEL COOLER BONG 140 ENGINE JACKET WATER HB Fi STATE MIN ALSO MAX L MIN WATER FLOW TO H E INSTALLATION amp SERVICE REQUIREMENTS OIL LINES TRANSMISSION TO H E AND RETURN 4 MAX VELOCITY IN FITTINGS PIPE HOSE AND TUBES 7 6m sec 25 5 2 BURST PRESSURE MIN 10 x PEAK OIL PRESSURE H E HOSE SAE 4847 MEETING USCG 56 60 25 135 C 275 F TEMP RATING 4 H E FAN LINES FROM MECHANICAL DAMAGE ZINC ANODES PROTECT THEM FHE PATER FROM CORROSION CHECK MEANS THE ENGINE JACKET WATER CAN BE USED FOR THIS APPLICATION ONLY IN ADDITION TO FRESH KEEL COOLER OR RAW WATER APPLICATIONS Marine Transmission Service Manual 1021303 Twin Disc Incorporated Description and Specifications Specifications Maximum operating speed 3000 rom Maximum oil sump temperature
24. 143 NUS 143 Forward Clutch Shaft Cross Section 144 Reverse Clutch Shaft Cross Section 144 o Valve Cross SecliO i MEE RM EE 145 Output Shaft Cross Section 22 22 KCRE xA Sau d ds 145 Forward Clutch Exploded View 146 Reverse Clutch Exploded View 148 Output Shaft Exploded View 150 Engineering Drawings 153 List of Engineering Drawings se 153 Marine Transmission Service Manual 1021303 9 Table of Contents Twin Disc Incorporated 10 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc model MGX 5114A marine transmissions Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc International S A Nivelles Belgium or Twin Disc Incorporated Racine Wisconsin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough unde
25. Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the defect with a soft stone replace the gear Inspect gear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear Inspect thrust faces of gears for scores scratches and burrs If you cannot remove these defects with a soft stone replace the gear splined Parts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found Springs Inspect springs for broken or distorted coils Replace the spring if either of these defects is found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses Clutch Plates Inspect clutch plates for signs of overheating pitting or excessive wear of the friction and splined surfaces Replace the clutch plates if one of these defects is found Marine Transmission Service Manual 1021303 91 Cleaning and Inspection Twin Disc Incorporated 92 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly Assembly Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces The following discussion contains frequent reference to the transmissions parts and components Refer to Engineering Drawings Note Photos used here ar
26. 201 0 SWITCH M14X1 5 PM 1357 F 2057 4 20511 D D PM 35535 AU M 2055 AR 2 WAIER IN EAD 1 1 2 11GAS PRIMARY CLUTCH 1055 6 1 SECONDARY CLUTCH SHAFT M 2031 D D 3535 PM 35355 A PM 4840 10616 10618 214 PM 1349 Q 15 0 WA THR 10685 1 11655 PAD 1 1 2 11 GAS 1557 107 0 3355 11627 1 1 ae AN THIRD ANGLE V L PROJECTION SIMILAR TO MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED N x 9700 8 DIMENSIONS ARE mm eao TPT LN DUSS kg Nm MACHINED DIMENSIONS SCALE FOR OTHERS INSTALLATION DIMENSIONS X M CE E NOTICE THIS PRINT CONTAINS HEAT TREAT FIRST USE 7 d S DRAWING PX 11730 SHEE d PROPRIETARY INFORMATI
27. 48 Periodic Visual Inspection esse 50 TrouDIeSsnoOllTIg 53 Troubleshooting of GP Control Valve with Electronic Interface 53 Electronic Interface LED Indicators 53 DisSassembiV 57 Prepare Transmission for Disassembly 57 PRION TO REMOVA c NEEE S 58 Removal of External Parts iiti uten ecco eoo io ooi 59 Internal Subassemblies 65 Disassembly of Primary Clutch 67 Disassembly of Secondary Clutch 75 Disassembly of Output 2 2 2 2 76 Disassembly of Rear Half Housing 78 Disassembly of GP Control Valve with Electronic Interface 79 eem 80 Cleaning and Inspection 87 CVG AIAG sce 87 BENS OS CULO 89 ASSOITIDIV 93 Prior 14 94 Assembly of Housing Sections eese 95 Assembly of Primary Clutch 2 2
28. WARNING Due to the force required 46 66 tons to remove the output gear from the output shaft a protective shield should be placed around the press Also the gear should be restrained so it will not fly off of the shaft when it comes loose 2 Support the output shaft on the front bearing inner race not the cage and press the output shaft from the bearing Figure 46 Pressing Front Bearing from Output Shaft Marine Transmission Service Manual 1021303 77 Disassembly Twin Disc Incorporated Disassembly of Rear Half Housing 1 Remove oil seal 2 Use a piece of steel tubing that is slightly smaller in diameter than the roller bearing outer race and press the outer race from the housing 3 Use an L type bearing puller to remove roller bearing outer races 78 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly Disassembly of GP Control Valve with Electronic Interface The GP Valve is made up of a non serviceable electronic interface and two valve bodies with plugs and cartridges O ring kits are available for servicing the plugs and cartridges however none of the cartridges are field serviceable beyond replacement of the o rings The later version Assembly 1021658 of the hydraulic pressure regulator valve is serviceable and contains an orifice filter plug and a ball check valve assembly that are replaceable E y T 4 4 i i y ur PER Figure 47 GP Valve As
29. gt IN 2 lt ds 5 _ 1 FEMA VALVE E s PRIMARY FRONT amp REAR BEARING PINION SHOWN ENGAGED El NIDe EEG NTA L i Ux 5 i ZA ON TY g 777 7 Mii SSG a YN I PRESSURE REGULATOR B ANSA NN AEN AUXI TARY LUBE SYSTEM Syn A E SUPPLY COMPONENTS AND jm w LUBE HOSES MEET REQUIREMENTS 7225 ZN eee s OF 697 ZEN 2 4 Ln HEEEHEHHHHHIRE 222 272 PRIMARY amp SECONDARY SHAFT LUBE REMOVE 20510 1 2 14 3 FRONT amp REAR BEARING PINION MANIF LD PER MAR OCC EE P SUPPLIED HEAT EXCHANGER MANIFOLD PER MARINE SHOWN DISENGAGED TWIN DISC OR CUSTOMER SUPPLIED AND CONNECTION LINES TRANSMISSION HEAT EXCHANGER AND CONNECTION ip dO 22 gP REFER INSTALLATIDN INSTALLATION DRAWING LINES REFER TO INSTALLATION DRAWING 23 2 DRAWING SO RIPER EC EWC INTE E FE LL E C CD QU o aa 4 lt 260 o x Q TRANSMISSION HYDRAULIC af FILTER CIRCUIT kPa 16 0 mm DIA MIN LD HOSE REDUCER BUSHING N s B 3 4 x 1 2 In gt L INSTALLATION OF OPTIONAL TEMPERATURE INDICATING SWITCH USING PIPE TEE WITH REDUCER BUSHING Ae 3 ELECTRIC MOTOR DRIVEN PUMP 5 10 gpm 19 0 mm DIA MIN LD HOSE
30. i gt 5 i 2 2 HOLES M16x2 UNC i A Sue 25 j EL 33 0 1 30 DEEP WITH 16 7 21 32 z 881 Oo lt CENTER OF 3L 1212 C BORE 7 9031 DEEP FOR ee lt N GRAVITY 4 77 STANDARD EYE BOLTS THESE HOLES H iQ 3 47 2 V MAY BE USED FOR LIFTING MARINE s 137 2 A 3 E NE TRANSMISSION ONLY SN 540 Wa ow i i i ic TI ime i i _ SHAFT 4 zm T A X gt M Jla E i lt 5 D 15 5 LUBE P S NS o L EN clearance To 677 y14x1 5 THD O NNUS PA I 3 5 2 EMOVE PUMP 180 6149 DU Z w e m 26208 Q m A AR z 2 DM OIL OUT TO HEAT EXCHANGER P 0 RENNES 5 4 14 NPTF TH D REMOVE gm D REMOVE CI 0 PLASTIC PROTECTOR BEFORE 5 0 N S T PCTOR BEFORE lt Di 2 2 OPERATING UNIT E 7 5 E T lt 2 JD lt i A amp SEN SE R H ENGINE PUMP AND u G B SECONDARY CLUTCH PLUG POSITION SHOWN R ER FOR_L H ENGINE ROTATE 7 405 1 T SENE 2 Og PUMP 1807 AS SHOWN E PHANTOMED AND RELOCATE OF GRAVITY STEEL SOCKET PLUG AS ES 5 914 SHOWN 4 v TWIN 522202 3 60 lt 1 Mf N J m y N N ts a ENGINE DRIVIN G E Ww OPTIONAL
31. 574 OR 247 3 FOR 157 2 6 19 BOLT EYE 1 SERVICE MANUAL VALUES X ON THIS SIDE 157 2 d 7 Ee 62 65 2 47 263 7 10 38 RS 136 1 19 E M j FLYWHEEL OUTLINE CLUTCH ACTUATING 8 6 APPROX 3 40 A no OM TO 8 65 ra PRESSURE 12 1 5 150 6149 82 65 3 25 235 1 9 26 2554 194 3 FOR 263 6 10 38 6 BOLT EYE _ ON OPPOSITE SIDE x amp 164 0 6 42 7 957 176 0 7 i 6 93 i PRIMARY PC Q i CLUTCH ACTUATING usc i PRESSURE 12 1 5 150 6149 DISTANCE REQUIRED TO REMOVE T OIL GAGE GAGE IS FLEXIBLE AND a ROTATION CAN BE BENT IF NECESSARY K E 1 HOUSING el 1 3 SECONDARY SOLENOID CA 127 INPUT SPEED PICK UP ris ENGAGED CLUTCH ON QS _ SECONDARY NS gt pud gt NE YO amp CNES BREATHER AND OIL epe MECHANICAL 4d EN FILLER HOLE OX BACK UP VALVE 23 2 X og S _ eo 2 OO 1 2 1 OTN MES LS 3 a lt MN f X A i ES i 2 eL 7 GAUGE 4 P O 4 23 wN PT CX enl PRIMARY CLUTCH N X 25 ACTUATING PRESSURE 1 S N ET 2 M14X1 5 TH D ISO 6149 Mi O O UN Li SECONDARY CLUTCH X A Y ACTUATING PRESSURE eN 4 L M14X1 5 TH D ISO 6149 sc A
32. 051 1038E 19455 1018528 250 gt A 19207297 42974 1021000 NUN 0515 11185 ITS IES Ke OU lt a 1021000 lt N CSHOWN gt D B N S 1 lt i BS SUMP _ NOTE 6 X PLUG a SCREW MA961X 6 PRESSURE REGULATOR PLUG MA1038B lt 2 HYDRAULT DIAGRAM GRAPHIC SYMBOLS CLUTCH PRESSURE PORT E X D 12 1 5 HD CONFOR B PORT ISO
33. D 5V TROLL Y E LENDID B LN d CUSTOMER SUPPLIED C 5 TROLL VIN m Y CRED LED VI V GND d Y La 5 x SPEED CURRENT INPUT TROLL I IN e GREE 5 Z 4 20 SEE NOTE 1 24 gt GND Y 5 a DEUTSCH CONNECTOR lt gt 5 EXT PAR DT06 8S P018 Of ENGINE SPEED FUTSCH TERMINAL 2 aT ns EE 22 ENGINE SPEED Y A PAR 0462 201 16141 1 lt ae Eu 5 PROP SPEED E EDTSOD WEDGE CK a e ENGINE SPEED SENSOR C a pz resp q y PAR W2S P012 Sie SITE T _ Ges PROP SPEED GND Die REL lt lt EUTSCH CONNECTOR D POWER OK 2 SEN SUL 06 35 012 GREEN LED C lt PROPELLER SPEED SENSUR zu le EL pia PART ND 0462 201 16141 2 lt SUL B gt DAR SA ce eos 7 j nb NIN DUTPUT SE 5 EUTSCH WEDGE LOCK D Y Y T 9 NORMALLY CLOSED e NIN GND cm q ooo a 02097 W3S POle BLACK B lt SOLENOID A NOT IN NEUTRAL RELAY zm SOL B POWER Y es METRI PACK CONNECTOR 2 RED __ i CLUSED IN NEUTRAL D x Q PART 12162193 A lt SHLENHID CUSTOMER SUPPLIED SE PER a a ETRI PACK TERMINAL 40 RED B PART 12124075 BLUE LENOID A ON BLACK 200 mA MAXIMUM e RED LED 300 WHITE E O 500
34. AW 1 PX 11725A 1 e D ZAN P T1791 Al 1 9 11725 F 7 5 P 11726Al 1 H PM1996P 2 NE E B PM2145D CROSS SECTION S is a SHEET PM1349Q din Hy NUMBERS ORIFIC WY SHEE INSTALLATION 2 OF 8 DRAWING E SHEE INSTALLATION 3 OF 8 DRAWING 4 OF MOUNTING PADS SHEE 4 VIEWS 5 OF 8 DRAWING SHEE FLEXIBLE 6 OF 8 COUPLING M1990E SE BALL SPECIAL INSTALLATION 7 ora FOR MTU DDC M1945BC PLUG 476 CUSTOMER NOTES 4011 APPLY ANAEROBIC SEALANT MEETING MA908 LOCTITE 242 Qe O SPEED SENSOR THREADS ASSEMBLE SENSOR UNTIL MATO40C d EA 1 a 2355 1 uote 6 CONTACTING P OF GEAR TOOTH AND THE BACK OUT SENSOR SHEET FLEXIBLE WO FULL TURN USE JAM TO SECURE SENSOR POSITION 8 OF 5 COUPLING vulkan P5244M MASS ELASTIC CONSUI SAI ES DEPT SECTION D D APPLICATION ENGINEERS EP cm FOR LIMITING CONDITIONS WU PROJECTION 7 2 y
35. Marine Transmission Service Manual 1021303 129 Installation Twin Disc Incorporated Figure 97 Checking Output Flange Pilot Eccentricity some boats are not structurally rigid and some carry their load in such a way that they will hog or go out of normal shape with every loading and unloading Where this condition exists it important to apply common sense alignment techniques to minimize the potential damage to any of the components During the process of securing final alignment it may be necessary to shift the engine many times When the final alignment is accomplished mark and drill the holes for the lag studs or locating dowel pins Then with final alignment secured make up the necessary poured steel or hardwood shims and fasten the engine and transmission in place Then recheck the alignment and if satisfactory bolt the coupling together 130 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Installation 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 Electrical
36. Note There is no spacer following the installation of the 5 valve Marine Transmission Service Manual 1021303 101 Assembly Twin Disc Incorporated Assembly of Output Shaft 1 Assemble the output shaft and gear as follows a Degrease the tapered bore of the gear and its mating surface on the output shaft with 1 1 1 trichlorethylene which meets OSHA requirements b Remove all traces of grease and oil from the tapered surfaces Dry with clean paper towels CAUTION Do not chill the shaft nor heat the gear With a felt marker mark a spot the rear end of the shaft Measure and record the distance X at the spot from the end of the shaft to where the gear seats STEP 1 STEP 4 CALCULATE ADVANCE X Y 2 i ADVANCE _ Figure 66 Calculate Advance 102 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly Measure with outside micrometers and record the thickness Y of the gear at the bore Install the gear onto the shaft and use 200 300 Ibs max force to seat it on its taper Measure from the marked spot on the end of the shaft Z to the gear hub The advance X Y Z The advance must be 088 to 120 inches in order to ensure correct assembly Support the output gear under the hydraulic press and press the front end of the shaft to advance the shaft up to the shoulder CAUTION Pressure of 43 59 tons is required to in
37. PX 11730 PX 11730 PX 11730 PX 11730 1020729 1020584 1020586 A7119AD D D D D UD D D 1021658 Marine Transmission Service Manual 1021303 sheet 1 of 4 Marine transmission Cross Section sheet 2 of 4 Marine transmission Installation sheet 3 of 4 Marine transmission Installation sheet 4 of 4 Marine transmission Mounting Pads GP Valve Assembly E Troll Control Module sheet 1 of 2 Profile Control Module sheet 1 of 2 Hydraulic diagram GP Valve Assembly Engineering Drawings Twin Disc Incorporated 154 Marine Transmission Service Manual 1021303 PX11939C 1 PX11939B HOUSING ASS Y wv HOUSING ASS Y SAE 1 2 PX9681C PX9681C 1 4 PX9697 1 PX9696 PRIMARY PINION 1 REQUIRED SECONDARY PINION 1 REQUIRED CONSISTS OF n CONSISTS OF ASSEMBLY ASSEMBLY BUSHING M2073CL RATI BUSHING M2073CL RATIO NUMBER AND NO EETH O NUMBER AND PX9727A P9727 8 PX9728A P9728 8 2250 21 11028 P11028 25 04 1 11029 11029 25 2 04 1 PX9724A P9724 26 PX9725A P9725 26 1 92 1 1 1 1 2 2 2 20 2 2 2 1 2 2 1 4 4 2 1 4 1 4 1 OC Oa Oye Sex 2 s 51B PLUG L HAR 1963 2 PLUG
38. Taper Roller Bearings The primary secondary and output shafts have taper roller bearing which require shimming to adjust the endplay of the respective shafts Oil Pump Drive The oil pump is tang connected and driven by the secondary clutch shaft Marine Transmission Service Manual 1021303 19 Description and Specifications Twin Disc Incorporated Lubrication Features Oil is directed by the control valve through horizontal drillings in the primary and secondary clutch shafts to orifices through which the front and rear roller bearings on the primary and secondary clutch shafts are lubricated There are also orifices in the shafts through which both clutches are cooled Suction Strainer The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and the oil pump in the hydraulic circuit The strainer can be replaced if necessary Filter Assembly A spin on oil filter is located between the heat exchanger outlet and the selector valve in the hydraulic circuit The replacement elementis Twin Disc part number 11652 This should be replaced at 1000 hour or six month intervals whichever comes first Gears All gears are helical carburized hardened and ground for smooth quiet operation All gears are in constant mesh The primary and secondary transfer gears and the output gear are mounted on keyless tapers 20 Marine Transmission Service Manual
39. 0D D D D U UD LU Output Shaft Exploded View Marine Transmission Service Manual 1021303 143 Illustrations Twin Disc Incorporated Forward Clutch Shaft Cross Section DRIVING TRANSFER GEAR CLUTCH SPIDER BALEPLATE CLUTCH FRDMT PLATES BEARING REAR P d 7 X eh JE e n 280277 DELL Eel LIE EE s L FU Ej 2 PISTON CLUTCH RINGS THRUST BEARINGS PISTON RETURN AND R ACES SPRING Note S Valve not shown in center of shaft in this Figure Reverse Clutch Shaft Cross Section CLUTCH PLATES DRIVEN TRANSFER GEAR BACKPLATE AMD CLUTCH SPIDER i EA BEARING REVERSE REVERSE SHAFT PINTON vk M ae E pom T FRONT eras rors AM BEARING tee iT Landaa R X qi PISTON RINGS RETURN SPRING THRUST BEART AGS AMD RACES Note 5 5 Valve not shown in center of shaft in this Figure 144 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Illustrations S Valve Cross Section ZS LZ WN Rd N JME Lo NS Marine Transmission Service Manual 1021303 145 Illustrations Twin Disc Incorporated Forward Clutch Exploded View 1 SHIM AIR 2 ROLLPIN 1 3 SPACER 1 4 SEAL 1 5 BEARING Taper Roller Guter Rac
40. 1021303 Twin Disc Incorporated Operation Hydraulic System with GP Control Valve The oil pump draws oil through the strainer from the oil sump and discharges it through the heat exchanger to the oil filter Filtered oil enters the control valve through the inlet port The incoming oil Assembly 1020729 is supplied to the main pressure regulating relief pilot cartridge and the main regulating valve cartridge satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit The incoming oil Assembly 1021658 is supplied to the main pressure regulating valve and is supplied in parallel paths through a ball check valve and an orifice with filter to quickly regulate and dampen pressure oscillations satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings Main pressure is supplied to the inlet of each proportional valve and to the inlet of the manual direction control valve In Neutral the inlet port of both clutches is connected to the sump Since the area behind the clutch pistons is open to sump the clutches are disengaged When one of the clutches is commanded to engage the proportional valve
41. 135 Installation Twin Disc Incorporated 136 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Special Tools Special Tools List of Special Tools The following pages include the special tool drawings that are specific to these models The special tool drawings included are listed below and continue on the following page TD 300389 Output Flange Puller TD 300388 Endplay Adjustment Fixture 118503 Spring Compression Tool 1020117 5 Valve Test Body B2408AL 5 Valve Test Procedure Marine Transmission Service Manual 1021303 137 Special Tools TD 300389 Output Flange Puller 138 0 45 vid 099 he 2 11 64 vid 0 9 Lec es DRILL 17 32 x a iE e i T am E i 5 Twin Disc Incorporated KNURL LJ z 2 950 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Special Tools TD 300388 Endplay Adjustment Fixture 1 2 EYE BOLT 1 2 13 UNG NUT 1 2 13 TAP Jm Ic Ic auem a M WELD 8 18 DRILL THRU 2 3 8 DIA l i 4 3 4 C R 8 ee me e o c CR NR Marine Transmission Service Manual
42. Figure 85 Install Top Valve Body onto Regulator Valve Assembly 16 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly 5 Install the Electronic Profile or E Troll Module on the top Valve Body and torque the four M6 1 0 capscrews to 9 5 Nm 7 Ft lb Figure 86 Place Profile or E Troll Module onto Valve and tighten screws 6 Connect the electrical wires to the proportional valves and connect any other wires that were removed during disassembly Marine Transmission Service Manual 1021303 117 Assembly Twin Disc Incorporated Adjustment of Main Pressure Valve Assembly 1020729 It is recommended that following the servicing of the GP Valve Assembly off of the transmission that a procedure be followed to ensure the flushing of oil through the valve assembly followed by adjustment of the main pressure 1 Install a main pressure gauge into the port on top of the Top Valve body 2 Remove protective cover cap located at the end of the cartridge This will expose a 1 4 hex head adjustment stem Loosen the jam nut on the stem Cap Adjusting Screw Figure 87 Pilot Relief Valve Assembly 3 Turn this adjustment stem counterclockwise until it reaches a positive stop This allows the engine transmission to be started and flush any debris past the relief valve Note This must be done with the transmission in Neutral 4 Start engine with controls in neutral Main pressure should be a
43. Remove the Allen head capscrew securing the pump suction tube to rear housing Remove the suction tube and O ring Figure 33 Removing Suction Tube 66 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly Disassembly of Primary Clutch 1 Support the primary clutch assembly on the workbench with the output end up 2 Remove the piston rings from the end of the clutch shaft Figure 34 Piston Rings Removed from Clutch Shaft Marine Transmission Service Manual 1021303 67 Disassembly Twin Disc Incorporated 3 Attach a bearing puller to the inner race of the rear roller bearing or under the pinion according to ratio Figure 35 Bearing Puller Installed CAUTION Bearing puller must be installed in a manner which will assure that removal pressure is applied behind the bearing inner cone without binding on the OD of the rear thrust race Loose adjustment of the bearing puller will result in application of pressure on the bearing cage which will destroy the bearing Excessively tight adjustment of the bearing puller will exert pressure on the OD of the rear thrust race which will either damage the thrust race or cause the thrust race to bind on the shaft which could damage the shaft 68 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly 4 Place a protective cover over the end of the input shaft and press off the inner race 5 Remove the primary pinion wit
44. Sp RED BROWN a PROPELLER SPEED SENSOR GREEN BLACI o L4 lt A NYA NORMALLY CLOSED BLACK lt B SOLENOID i NOT IN NEUTRAL RELAY N 2N yp EN CLESED IN NEUTRA RE HER CUSTOMER SUPPLIED e BLACK 200 mA MAXIMUM ri N e HITE e SOLENOID SWITCH YELLUW CUSTOMER SUPPLIED o TO MESES START i _ MODULE POWER CIRCUIT CONNECTION CHART opro SOLENOID A SWITCH TRANSMISSION MANUAL CCUSTUMER SUPPLIED OVERRIDE SWITCHES SOLENOID RETURN a a Figure 98 E Troll Wiring Diagram SOLENOID RETURN TRANSMISSION ae ERRIDE SWITCHES WIRING SCHEMATIC mnp TO START CIRCUIT SOLENOID A ON o RED LED FON HITE 200 MAXIMUM WHITE SOLENOID B ON BLAI A NORMALLY CLOSED CRED ED B ENHID A NOT IN NEUTRAI RE f lt CLOSED IN NEUTRAI MP CUSTOMER SUPPLIED RED RED _ SOLENOID POWER BL ACI MP GREEN LED RED _ i _ MODULE SOLENOID SWITCH idee o ERE CUSTOMER SUPPLIED SOLENOID A SWITCH CUSTOMER SUPPLIED Figure 99 Profile Module Wiring Diagram Final Checks Be sure the transmission is filled with oil before starting See Description and specifications and Preventative Maintenance for proper oil and filling procedure Marine Transmission Service Manual 1021303
45. Twin Disc Incorporated Install the gasket and the oil pump Verify the proper orientation of the pump for the engine rotation See Engineering Drawings PX11790 sheet 2 Ensure that the pump drive tang 1 correctly engaged in the slot in the end of the reverse shaft Torque the M 12 retaining screws to 80 Nm 59 Ib ft Figure 76 Installing Hydraulic Pump Retaining Capscrews 19 Install the output flange being careful not to damage the oil seal when engaging the runway of flange This operation has to be done by aid of special tool TD 300389 and 10 ton hydraulic press An alternative assembly procedure is to heat the flange in a 120 C 250 oven for no more than 30 minutes Coat the spline of the shaft with Molykote grease and carefully lower the heated output flange onto the shaft Be sure that it is bottomed Figure 77 Installing Output Flange 110 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly 16 Measure the gap from the shoulder of output flange on which the retainer washer rests on to the end of the output shaft Add shims 003 to 006 inch thinner than the gap Install rectangular rubber washer and retainer washer Figure 78 Installing Output Flange Retainer Washer and Rubber Ring 17 Apply Loctite 242 to the three M12 x 30 capscrews and secure the retainer washer Torque the retaining screws to 80 Nm 59 Figure 79 Installing Output Flange Retainer
46. alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure Install the mounting brackets on the side mounting pads of the marine gear Install the driving ring on the engine flywheel Bolt an indicator to the engine block and set the indicator stem on the engine flywheel housing Marine Transmission Service Manual 1021303 125 Installation 126 Twin Disc Incorporated INDICATOR INDICATOR STEM MARINE GEAR SUPPORT BRACKET FLYWHEEL HOUSING Figure 93 Marine Gear Alignment Set the indicator gauge at zero 0 Lift the marine gear with a hoist or other Suitable means and place the unit in position against the engine flywheel housing Secure the flange of the marine gear main housing to the engine flywheel housing Use a feeler gauge between each mounting bracket and engine bed rail Add shims between the brackets and bed rails to equal the feeler gauge readings Carefully release the lifting force on the marine gear while observing the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading 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 gau
47. as required by the vessel s approval agency The minimum current capacity should be 5 amps WARNING Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System The customer supplied selector switches for each of the transmission clutches and for troll if equipped must be connected directly to the wires of the Profile or E Troll Module and connected to the power source as shown in the table that follows No other electrical loads should be connected to this circuit Make the following Connections The following power connection chart lists the possible configurations for connecting Electronic Profile or E Troll Module to the power source for the three possible wiring options 1 1 Option 1 connections are used when the Profile or E Troll Module is connected to non electronic lever heads Option 2 connections are used when the Profile or E Troll Module is connected to electronic gear controllers Option 3 connections are used when the Profile or E Troll Module is connected to electronic control solenoid driver outputs The electronic control s Solenoid A and B returns or negative signals should be connected together and connected to the E Troll module return if equipped Electronic control solenoid drivers must have their solenoid return internally connected directly to ground If not the Profile or E Troll Module must be interfaced to the electronic control with relay
48. psi F 1724 1827 0 4B 117 e eme Mmm 1724 1827 0 0 55 124 eo l o al da 17424 1827 0 1590 48 117 SE Es 1585 1758 1551 0 11 19 ama 1689 1758 0 11 24 1758 1551 11 19 Note It is required that lube pressure with primary clutch engaged must equal lube pressure with secondary clutch engaged within 21 kPa 3 psi Note Oil temperature to be in normal operating range of 66 85 C 150 185 F 24 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Description and Specifications Optional Equipment The following optional equipment for use with the model MGX 51 144A is available through the nearest authorized Twin Disc distributor Power Take off A live power take off pump mount 1 available in sizes SAE J 744 No 127 4 and SAE J744 No 32 4 9768 A clutchable pump mount power take off is available in sizes SAE J 744 No 127 4 and SAE J744 No 32 4 XA7553A clutchable shaft drive power take off is available XA7553 PTO adapter from SAE J 744 size 127 4 to 101 2 XB2403 Mounting Brackets Steel fabricated mounting brackets for rigid mounting are available They are part number 1016428 P Torsional Input Coupling several models of torsional input couplings are available including Vulkan VKE4010 and VKE4011 in both 14 and 11 5 flywheel sizes as well as Centa CF R in both 14 and 11 5 flywheel sizes Heat Exchanger
49. 005 in maximum total indicator reading Thrust on the flywheel should be in one direction at all times to obtain a correct reading a Engine Flywheel Engine a ime EL m Thousandths Indicator gm Crankshaft 2 Figure 92 Checking the Flywheel Pilot Ring Bore Eccentricity Engine pom Flywheel Marine Transmission Service Manual 1021303 Twin Disc Incorporated Installation Alignment Propeller Shaft Before any attempt to align the engine and gearbox to the propeller shaft proper alignment of the propeller shaft must be determined This includes alignment of the propeller shaft through all struts and intermediate bearings Failure to properly align the propeller shaft may result in premature wear on bearings vibrations or possible damage to other components If the length of the shaft from the last support bearing to the gearbox is excessive or aflexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Engine and Marine Transmission Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boatto change its form with various loads and with age 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
50. 1021303 Twin Disc Incorporated Description and Specifications Flexible Torsional Input Coupling The purpose of the torsional coupling is to transmit power from the engine to the marine transmission through a rubber or silicone element that will Dampen torsional vibrations Change the natural frequencies of a system to move critical frequencies out of the operating speed range Accommodate certain amount of misalignment Absorb shock and reduce noise Minimize gear rattle Several couplings are available from Twin Disc and are selected based on the customer supplied engine information Final coupling selection must be confirmed by the packager based on the torque rpm ratings and the results of the system torsional vibration analysis TVA and on engine rotation Care must be taken when servicing that replacement couplings are matched to this criteria Marine Transmission Service Manual 1021303 21 22 Description and Specifications Twin Disc Incorporated Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh water through the heat exchanger The heat exchanger should be installed ina location convenient to both coolant and marine transmission oil Table 1 Heat Exchanger Requirements iM Els oe TSSIBLE 0 men RGR aa an m SAF 30 eee A a SAE 40
51. 1021303 139 Special Tools Twin Disc Incorporated T 18503 Spring Compression Tool Vit Dia Tagy MG5114A Spring COMPRESSOR T 1R 50 id TWIN DISC INCORPORATED FORM 169 RACINE Wl 35 140 Marine Transmission Service Manual 1021303 1980 amp 334 YSN 50 56 IA SNIDOVA 9 ex EID LAM 3 0 dAVHS IV3iela 11 HSINIJ I0 Sc I 3190 1531 SAWA 390141492 AGDE 2861 ISNV amp 3 ONIONVAS TOL 21 13 39 SSINVASTOL AVINONY TV G00 0T XXX X 010 OT 0 0 OTT X X SNDISN3WIG 3NIHOVW 31319395 S3SIAYSHLO SS3 INn 9110201 55 350 15414 NOTLOsrodd 4440 dyl 42 4 Oe e T 9261F AVS 43 431109 ANOLNOO 140 AVS dN N 319 OL 39 310 5 ASOFASLNNOI 43349 09 91 621 91 6 NIN 4440 95 dyl 4 2 4 9I v 926I AVS edd 441105 Leld T 96ES sd 14415 13921403 543 10 XO LNGWNASADS SN JHL OL T3INVSO SLH IJ YO ASTIN OL GC3XIN31INI LON SI SOLLON SIHL YSN 0PES 3NIOVM IN3WlV3Hl 3593919 Gai yandaOONI 2510 NIAL ivaal LV3H awws 1 WIASLYW ciana HIDN3 4411 4 38 VIC 6 96 gt 81 dall8 000 629 88 dyl e INN OI v E 93349 9ST cE Iec SASH ON 1 9 9 1193 0982 ae SOOO NIW
52. 2 2 1 96 Assembly of Secondary Clutch 101 Assembly of Output Shaft 2 2 22 1 102 Installation of Shafts and Clutch Assemblies 105 Assembly of GP Control Valve with Electronic Interface 113 Adjustment of Main Pressure 1 cce eene 118 8 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Table of Contents AES AUIO Pi 121 Prior to Installation ssasisscvsscvscinsanaacccedecsiccsaccssatauassencceeseutezecsacsgateccaaade 121 Alignment also reference SAE J 1033 and J 617 122 125 Electrical Controls Installation 131 Control Harnesses and Wiring guidelines 131 Wiring COMMOCIION 133 PIMA eii lel Co 135 Special TOOLS 137 Ie TE uh 137 TD 300389 Output Flange Puller 138 TD 300388 Endplay Adjustment Fixture 139 T 18503 Spring Compression Tool 140 1020117 S Valve Test BOOV uiii ono ico ves 141 B2408AL S Valve Test Procedure 142 URIS CH
53. 4330 9 491 82 4Nn 9I v E EM EM SPX90 926 39 N3d NG 2 431102 YNOLNOD 1504 NS WS e 30931045 308314109 SR 1 8 2 Sv g S31UH 2 S E9 NAHL 2E EI 532 14 v 02 AVS dfl NV3 19 OL JOVALOdS JSOMdSLNNOI vl 9 8 6 621 91 6 00 Testing of PX11801 Cartridge Valve Assembly 1 VALVE ASSEMBLY TEST A For use when valve only is to be tested at time of unit overhaul B This valve must always be tested as outlined below for all uses The valve is to pass all of these checks and tests before being approved for shipment Please follow applicable routing instructions carefully D Record all data 2 MINIMUM EQUIPMENT SPECIFICATIONS A Oil flow of 19 L min 5 gom capacity with bypass of 2760 kPa 500 psi B Oil viscosity of 90 110 SUS 18 2 20 6 cS Adapter plate 1020117 for proper mounting of cartridge valve to 1 Allow leakage oil at S and Sz to return to sump 2 Provide means to measure flow rates at S and S 3 Provide 2760 kPa 400 psi pressure gauge at Z4 3 VALVE TEST SET UP PX 11801 SERIES CARTRIDGE VALVE PRODUCTION TEST SHEET 1 Using a non marring technique mark the sequence valve with a serial number With the pressure at 4 set 1207 kPa 175 psi Leakage at 1 and S to be no more than 1 0 L min 25 Record leakage flow rate at S and S Slowly increase pressu
54. 5 96 E HNONM M 158 _ as us es 1 _ aw w w woo 2 9 _ 18 _ wen 8 _ 8 m _ we 9 _ M42X2 0 48 2 0 Marine Transmission Service Manual 1021303 29 Description and Specifications Twin Disc Incorporated 30 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Operation Operation General The GP Control Valve with its Electronic Interface is used to obtain neutral and primary clutch engagement and secondary clutch engagement in this transmission When these positions are selected the control valve directs high pressure oil through internal passages to instantaneously and smoothly engage the clutches The pressure rate of rise controlled by the Profile Generator provides a rapid smooth clutch engagement Marine Transmission Service Manual 1021303 31 Operation Twin Disc Incorporated General Overview of GP Control Valve with Electronic Interface The General Purpose GP control valve is a hydraulic valve assembly for use with Twin Disc Marine Transmissions that may include an integral electronic interface control module The valve assembly contains current controlled proportional cartridges J 4 di uu 5 D ut a Figure 2 GP Valve Assembly mounted on Marine Transmission 32 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Operation GP Control Valve Hydraulic Portion The hydrauli
55. 6149 12 15 THD CONFORM PLATE 1018175 ISO 6149 RING D A2916JT lt 2 SCREW 1100 PROPORTIONAL VALVE SEE CHART 2 M6X1 0 X 16 VALVE BODY 1020519 4 PLACES E s SEE NOTE oo MN SS FEE VALVE SEE CHART Tj O TORQUE 36 N m I PS 44 5 9 N P H D AN i un D VALVE ASS 1021873 VALVE 1020670A Q PLUG SEE mes
56. Disc Incorporated Installation As the engine and marine transmission come into their aligned position it will be possible to mate the output flange and propeller coupling and prepare for bolting together Care should be taken not to burr or mar this connection because the fit is very critical Place a 0 05 mm 0 002 in feeler gauge between the flanges of the coupling Move slide the feeler gauge completely around the coupling Rotate the marine transmission flange coupling in 90 degree increments and move the feeler gauge around the flange in each successive position The feeler gauge will fit snugly with the same tension all around the flange coupling in all four positions if the alignment is correct If the alignment varies during rotation additional alignment is necessary or the marine transmission and shaft couplings should be checked for proper face runout Runout must not exceed 0 10 mm 0 004 in Excessive face runout on the marine transmission output flange can usually be corrected by repositioning the coupling on its spline or taper Excessive shaft coupling runout is usually due to inaccuracy of 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 A OUTPUT SHAFT Figure 96 Checking Output Flange Face Runout
57. EXTRA _ m SUPPLIED ONLY WHEN Em IMARY CLUTCH B 4 SO SPECIFIED LN la Im FK N E 21522 H AA F1 4 A 2 pum 1 jJ OUTPUT SPEED PICK UP Rau 267 2PADS a SECONDARY CLUTCH Ac 7 711051 6 SHAFT 6 N 1 05 4 00 i 50 8 j OPTIONAL TEMPERATURE E 2 00 15 0 CLEARANCE P nur alo ee 101 6 5g TO REMOVE H DRAIN PLUG 00 e d OIL DRAIN PLUG pot 4 00 Pm M27x2 TH D ISO 6149 2 Paps x FLYWHEEL OUTLINE MUSI 2 CONFORM TO S A E J620 70 T I 10 1 5 7 6 30 DEEP Zt ZN 355 31 0 _ 1 O 5 SUCTION SCREE M16x2 22 0 86 DEEP Docs ol 5 E 135 1 5 32 172 7 6 USE ALL I2 HOLES FOR MOUNTING USE nM qo ui Oe eae P E Hom 50 i Es E JSE 264543 alee 8 HOLES EQUALLY SPACED ENGINE Eh ore ti 8 8 PROPERTY CLASS QUALITY CAPSCREWS 2 NIS Oli USE 8 8 PROPERTY CLASS QUALITY 2 04 PER ISO 898 1 AND TORQUED 15 161 op CAPSCREWS PER ISO 898 1 159 0 6 26 203 2 8 00 114 0 2 PADS S574 OR SERVICE MANUAL VALUES dr AND TORQUE TO 574 OR 7 ENGINE E E 4 49 152 40 SERVICE MANUAL VALUES 161 5 6 36 338 6 SREI 279 4 11 00 1785 i 1020116 18 84 THIRD ANGLE 573 4 PROJECTION 22 58 li NOTICE THIS PRINT CONTAINS M
58. Provide your model number serial number and bill of material number to obtain information on your unit If necessary contact the Product Service Department of Twin Disc International S A Nivelles Belgium or Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com Marine Transmission Service Manual 1021303 15 Introduction Twin Disc Incorporated Warranty Equipment for which this manual was written has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual For details of the warranty contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Inc Racine Wisconsin U S A 16 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Description and Specifications Description and Specifications General The 5114 is a Quickshift configuration reverse and reduction Marine Transmission having a 7 down angle for near level engine installation The MGX 5114A offers conical helical gearing for quieter operation and is currently available in the following ratios 1 03 1 1 20 1 1 48 1 1 75 1 1 92 1 2 04 1 and 2 50 1 These transmissions are controlled by hydraulics through the electronic control module Both the primary and the secondary clutches are operated by main pressure oil supply The bearings clutches and gears are lubricated and cooled with low p
59. T E ta Figure 5 Top Hydraulic Valve Body Assembly Regulator 2 2 Val Body 4 gt LI Temperature Sensor TT Pilot Relief Valve Main Regulator Spool Figure 6 Main Regulator Hydraulic Valve Assembly 1020729 Figure 7 Main Regulator Assembly 1021658 36 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Operation GP Control Valve Electronic Control Interface Profile or E Troll Module Note Some installations will consist of the hydraulic portion of this valve and the Electronic Control Interface will be replaced by an appropriate electronic control system The electronic portion of the GP Control Valve fastens to the hydraulic portion of the GP Control Valve and is located on the top surface i If the ambient temperature of this mounting location exceeds 180 F the Electronic Control Interface must be relocated to a cooler area Contact Twin Disc for proper harnessing instructions This module contains the electronic circuitry to control the proportional cartridges that are used to engage the clutches based on the commands from the operator Clutch apply pressure rate of rise profile is factory set with the use of internal circuitry The initial fill level is factory set with an adjustment screw that is embedded tn the bottom surface of the Profile or E Troll Module and sealed This can be field adjusted if
60. TRANSMISSION ASSEMBLY DRAWING 8 SIMILAR C ROL VALVE IS I CENTERED BIL F MATERIAL FUR VALVE UNTING GASKET AND SCREWS REVISED AND REDRAWN SUPERSEDES 1020729 DATED 8 9 02 POSITI WHEN LEVER IS ACTUATED FROM 1020525 CENTERED POSITION CURRENT 20 AMPS N _DQ_ L MATERIAL WEIGHT wR UNLESS OTHERWISE SPECIFIED DATE Ae 12561 7 28 04 B6 CN11978 11 18 03 NOTICE THIS PRINT CONTAINS V 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE PROPRIETARY INFORMATION AND IS DIMENSIONSS ARE MN 8 9 02 I DRAWING L BS 12457 5 28 04 E B6 1 61 8 14 03 BE USED ANY MANNER dis PE SCALE Wd N D SS K Fe IECN12413 5 7 04 D 1170317 30 03 is m FIRST USE xut 2 1 RO ECN12314 3 24 04 C ECN11589 5 2 03 dup ASSY _ ese eeu Il Bh MEE RS 0207289 O P 2 IN 7 aL MGX 5114A PER ANSI 14 5 1982 CHK xx CN1205812 18 03 B ECN11368 4 08 03 IS CE IS N NTENDED 5 CN12015 A 321 NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME ALC wal G E 4 0 12 03 03 Ll 1 30 03 GRANTED THE U S GOVERNMENT MP L APPD F X NUT SERVICEABLE SEPARATELY Rev sheet 20 CH DATE REV ZONE DATE R OTHERS BY CONTRACT 2 GAM SHEET 1 of 1
61. Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly 14 Remove the piston ring from the outer periphery of the clutch piston from the outer bore of the small area of the piston and the O ring from the inner diameter Outer Seal Ring Small Area Outer Seal Ring O Ring Figure 44 Piston Piston Ring and O ring Removed Remove valve 15 Remove the pipe plug from the center bore on the input end and remove the spacer s valve A small wire with a hook on the end can be used to help pull the valve out or air pressure may be applied to the clutch apply port between the sealing rings Marine Transmission Service Manual 1021303 73 Disassembly Twin Disc Incorporated CAUTION Do not remove front tapered roller bearings on primary or secondary shaft unless replacement of the parts is necessary Close tolerances between inner bearing cone and rear face of transfer gears prohibits installation of bearing puller behind inner cone If the bearing must be removed proceed as follows a oplit the bearing cage of front taper roller bearing and remove the rollers b Install a cheese cutter type bearing puller onto the bearing cone gripping against the shoulder on the cone C Heat bearing inner race by flash heating and remove inner race and cone CAUTION Prolonged or excessive heating must be avoided so the input and or secondary shafts will not be annealed Do not remove the d
62. Washer and Capscrew Marine Transmission Service Manual 1021303 111 Assembly Twin Disc Incorporated 18 Install the output speed pickup bracket using two M8 x 22 screws with washers Torque the retaining screws to 23 Nm 17 lb ft 19 Slide input coupling onto splines of input shaft If the unit is to be shipped with the coupling on the shaft it must be attached to prevent it from sliding off and causing damage Figure 80 Installing Input Coupling 20 Install the output speed pickup on E Troll units only Turn speed pickup until it touches the gear tooth o d and back off two complete turns and tighten the jam nuts to 27 Nm 20 lb ft 21 Install the input speed pickup on E Troll units only Turn speed pickup until it touches the gear tooth o d and back off one complete turn and tighten the jam nut to 27 Nm 20 Ib ft If no speed pickup is used install the plug and o ring and torque to 88 Nm 65 Ib ft 4312 Transmission Service Manual 1021303 Twin Disc Incorporated Assembly Assembly of GP Control Valve with Electronic Interface Prior to assembly all parts must be properly cleaned Carefully inspect all o rings for any damage and replace as necessary Lubricate all o rings and replace both gaskets 1 Valve Assembly 1020729 Assemble the Main Regulator Valve body A Install the Main Pressure pilot relief valve into the valve body and torque to 27 Nm 20 Ft Ib B Install the Main Valve int
63. necessary by authorized personnel with the proper instrumentation There are different control module types for Quickshift marine transmissions MGX both with and without the trolling E Troll feature All electrical wiring for the marine transmission system controls are routed through this interface module The vessel battery power 12 vdc or 24 vdc is supplied to the electronic interface only and never directly to the hydraulic proportional valves Two red led lights are used to identify the proportional cartridge valve that is energized and a green led is used to identify when power is provided to energize one of the clutches Flashing lights are used in troubleshooting Signals are provided to power a customer supplied relay to allow engine starting only when in neutral A Transmission oil temperature sensor is not required for the Quickshift marine transmission MGX models Engine speed and Propeller Speed sensors are required for transmissions with E Troll The following figures show the various versions of Electronic Profile or E Troll Module i VI A HN ING Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System Marine Transmission Service Manual 1021303 37 Operation Twin Disc Incorporated Solenoid A Red LED Power Green LED Solenoid B on Red LED Figure 9 Electronic E Troll Module MGX E Troll 38 Marine Transmission Service Manual
64. o OTG INSTALLATION OF OPTIONAL TEMPERATURE INDICATING SWITCH USING PIPE TEE WITH REDUCER BUSHINGS MA1040B DRAIN PLUG M33 x 2 0 THREAD REFER TO INSTALLATION DRAWING caes ANGLE caes MG 3114A S CLUTCH HYDRAULIC DIAGRAM 9 GRAPHICAL J LC SYMBOLS M 2 I MATERIAL UNLESS OTHERWISE SPECIFIED PRUE REN AAD s DIMENSIONS ARE Um TIN DISG O BE USED IN ANY MANNER 50 75 INCORPORATED RINENTAL TO THE INTERESTS OF SEAT GREAT 1225 RACINE 53403 USA 5114 S CLUTCH MG 5114A eee EIRIC AS 2 Al HYDRAULIC DIAGRAM THIS NOTICE IS NOT INTENDED NANE PICTORIAL GRANTED TO THE US GOVERNMENT DIAGRAM HYDRAULIC serm To 1 STRAINER R SCREW 961 6 PLUG MA1038B O RING A291 6JT 2 MAIN PRESSURE CHECK 2 PM M12x1 5 THD CONFORMS PORT 45 2 TO ISO 6149 2 v7 BODY 1020519 UL x VALVE SEE CHART TORQUE TO 36 N m lt nv 10210004 SHOWN mE t SEE NOTE C u or SEENOTE B QM ol x N PLATE 1018175 SCREW MA 10GB GASKET 1020531 FILTER P10786 PROPORTIONAL VALVE SEE CHART 21 SEE NOTE A PLUG 2 CLUTCH PRESSURE PORT KA 2x1 5 THD CONFORMS m TO ISO 6149 GASKET 1021643 COVER 1021662 A PROPORTIONAL CONTROL VALVE OPERATION 1 WARNING DO NOT CONNECT VALVE CO
65. 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 PRIMARY 002 6600 Figure 14 Example of Power Flow with Primary Clutch Engaged Marine Transmission Service Manual 1021303 45 Operation Twin Disc Incorporated secondary In secondary the same parts are turning that were turning in neutral When the secondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates together The secondary input pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when the unit is in the secondary position Secondary Clutch Engaged SECONDARY 003 6600 Figure 15 Example of Power Flow with Secondary Clutch Engaged 46 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance In boat Maintenance and Repair Certain
66. propeller shaft the distance from the marine gear output flange to a fixed stuffing box or the first fixed bearing must be a minimum of 20 times the shaft diameter If the distance is less than this a flexible coupling may be necessary to isolate the engine vibration Marine Transmission Service Manual 1021303 121 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 a Blu HHA A 7 Engine Ani Flywheel emt Crankshaft Engine Flywheel Housing Figure 89 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 14 Table 14 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations ia Eccentricity 0 48 0 019 0 41 0 016 0 30 0 012 0 28 0 011 6 20 90 2 0 36 0 014 122 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Installation 3 With the indicator mounted as in the previous par
67. the backplate Using a dial indicator set zero at the bottom position for the backplate Apply air pressure to the clutch apply hole located between the two sealring grooves Measure the clutch clearance on the dial indicator Clutch clearance must be between 2 30 4 00 mm 091 157 in lf the clutch clearance is out of the specified range shim the clutch using steel clutch plates 2 34 2 38 mm 0 092 0 094 in thick friction plates 3 07 3 20 mm 0 121 0 126 in thick or cores from friction plates 1 54 1 57 mm 0 061 0 062 in thick Note When shimming using a friction plate or a core plate the additional plate must be located between the backplate and the last active friction plate When shimming using a steel plate the additional plate must be located between the last active friction plate and the last active steel plate The two front thrust bearing races are designed with different inside and outside diameters Install the front thrust bearing onto the input shaft in this order thrust race with the smaller 0 the pilots on the shaft needle bearing and thrust race with the larger O D gm lt j mI LI i 5 rs zd 8 Figure 61 Installing Front Thrust Needle Bearing and Thrust Races Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly 13 Pre align splined teeth on steel clutch plates and install the forward pinion onto the inpu
68. top of the transmission 2 Fill the transmission s sump with 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 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 oll if necessary to bring the oil level to FULL mark on the oil gauge Allow the oil temperature to cool to normal cold oil conditions perhaps overnight Check the oil level while cold at low idle engine speed while in neutral This is the proper oil level with cold oil Make note of this correct oil level in cold conditions for future reference Marine Transmission Service Manual 1021303 49 Preventative Maintenance Twin Disc Incorporated Periodic Visual Inspection 50 General Check the mountings for tightness or damage such as cracks Tighten loose mountings and replace damaged parts Check pressure and temperature gauge where applicable Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required Inspect unit nameplates for looseness and corrosion Tighten mounting screws that are loose and replace nameplates that are corrode
69. 0207894 42223 021000 038 1020520 350 H 10161224 4c eb 10161225 N 1038E E LOLS D238 LA Y B al 2 C C2 ab D 2 ON SUMP Z CO lt gt FIL Rp ae m D CJ 4 Vo 2 PM PO PO PO gt I 119 4 j 1 Wr vom N Es MEINER EX PROPORTIONAL VALVE Elea cede rus D 2 ris 80 Minos dee MANIF EE n 4 1020729D 4212 1021000 TUSSE I Oxe D Sou z i 2 1020729 42516 10205
70. 021303 127 Installation 128 Twin Disc Incorporated When a heavy boat is dry docked it naturally undergoes some bending Therefore it is always good practice to unbolt the marine transmission coupling to prevent bending of the shaft With the engine and transmission in position on the engine bed arrangements must be made to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine can be raised by screwing down or lowered by backing off on the jacking screws to obtain the desired adjustment oteel plates must be inserted under the jacking screws so that the bolts will not damage the engine bed Lifting can also be accomplished by the use of chain hoists or properly placed jacks Adjustable shims also are available and can simplify the alignment process particularly for future realignment It may also be necessary to move the engine and transmission to one side or the other on the engine bed to obtain horizontal alignment This can be done with a jack placed horizontally between the engine and the foundation At the same time a 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 STRAIGHT EDGE Figure 95 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1021303 Twin
71. 1 METERS BC 2 ECNI2561 7 28 04 e us 1021658 A BP 2537 8 28 04 002 PEERS MERDA a7 Seo Na VALVE ASS Y eap tn quiim ME 4 1 1021303 R3 05 05 TW d POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
72. 20 0 1020586 SEE PAGE 2 SIMILAR TO DO NOTICE HIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE V PROPRIETARY INFORMATION AND IS EE 7 16 02 W Dji E 1 ECN12835 11 15 04 AUAM E RU 5 NUT kg MO UMEN NES SCALE N x SS e WIRE SPI ICE PAR H 1020282 D 1 amp e 12521 6 30 04 TW E C I RP RATE HEAT TREAT FIRST USE un _ SERE Remuera sue DH DEUTSCH CONNECTOR C Ac ECNII890 110 15 03 RACINE WI 53403 USA one M RUSSEL l 0 METRIPACK CONNECTOR 1 1 ECN11523 4 29 03 1 E CHK 7 S H SURFACE TREATMENT NAME RNS RT 16 11418 4 22 03 GRANTED THE U S GOVERNMENT APPD REV SHEET NE NO DATE SHEET ZONE NO DATE 5 BY CONTRACT MGX PROFILE MODULE M B Gee SHEET 1 OF REV E F D C A AN gt _ ___ _ _ ___ XS NW gt ZZ mu Siurch GS ae M Ec yd alb 1G FEMA VALVE zm SON ANNAN NS TS gt gt Loy p 2 NZ 0022
73. 3 Ordering Parts and Obtaining Services 14 Source of Service Information eee eee 15 16 Description and Specifications 17 General T TT 17 POWER RAUNOS EE IEEE 18 Changing Rotation 18 mob 18 Construction Feature S 19 Features crismon 20 SSC IEC AU OWNS 2 Ee OE aan 23 Optional Equipment 25 Assembly Specifications 11222 27 Torque Values for Fasteners cesses 28 31 IR ARR EAE 31 General Overview of GP Control Valve 32 GP Control Valve Hydraulic 33 GP Control Valve Electronic Control Interface Profile or E Troll Module 37 Hydraulic System with GP Control Valve 39 Power Take offs Optional eere eee 43 43 Marine Transmission Service Manual 1021303 7 Table of Contents Twin Disc Incorporated Preventative Maintenance 47 In boat Maintenance and Repair 47 General Maintenance
74. 85 185 F Operating temperature range 66 85 C 150 185 F Oil type and viscosity SAE viscosity number 40 meeting SAE API service class CD engine oil certified to meet TO 2 transmission oil specification or type C 3 transmission fluid Also approved is SAE API service class CC engine oil Note Multi viscosity oils i e 10W 30W etc must not be used in TWIN DISC Marine Transmissions Oil Capacity 7 6 Liters 2 0 US Gallons plus volume in hoses and heat exchanger Approximate Dry Weight 205 Kg 94 Lbs excluding heat exchanger hoses companion flange and trolling valve Oil Pump Capacity 45 4 Liters min 12 gpm Oil pressure See following tables Oil temperature to be in the normal operating range Electronic Control Module operating voltage range 9 to 32 Volts DC Electronic Control Module operating temperature range 40 C 40 F to 85 C 185 F Output Speed Sensor airgap Two turns out from touching the o d of the speed wheel Input Speed Sensor airgap One turn out from touching o d of transfer gear Marine Transmission Service Manual 1021303 23 Description and Specifications Twin Disc Incorporated Table 2 Oil Specifications 250 psi Spring LIMITS FOR MARINE TRANSMISSION EQUIPPED WITH A CONTROL VALVE SET AT 1724 kPa 250 psi VALVE INLET PRIMARY SECONDARY Cooling ACT Temp kPa kPa kP kPa kPa C ipsi psi 08 psi psi
75. AND SHEET 3 8 S s 7 i w OUTPUT SPEED SENSOR p HYDRAULIC 12182 DIAGRAM NN 1020552 1 2057 2 Q GEAR RATIOS SIMILAR TO 2027 1 1 05 1 1 20 1 1 48 1 1020116 1 75 1 1 92 1 2 04 1 2 50 1 lt MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE _ VUL gt ROPRIETARY INFORMATION AND IS MACHINED DIMENSIONS 7 2001 N D IS 7054 19DECOS OT TO BE USED IN ANY MANNER 205Kg LBS IN XX 0 030 SCALE IN CO O RATED R P DETRIMENTAL TO THE INTERESTS OF RUN TOOTO 1 2 RACINE WI 53403 USA 6986 290CT03 7346 4JANO5 HEAT TREAT FIRST USE X XXX 0 005 7258 16SEP04 TWIN DISC INCORPORA ED ASSY ALL ANGULAR TOLERANCES 1 DRN JCP RACINE WI 53403 USA
76. ATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE VV NCH DIMENSIONS AND 2 MARINE e 0 000 p PROPRIETARY INFORMATION AND 15 MACHINED DIMENSIONS 26MARO2 oJ bx DISiG POUNDS SHOWN IN TRANSMISSION 59 124 K 2 TO BE USED IN ANY MANNER 205Kg LBS IN xx 0050 SCALE INCORPORATED BRACKETS lt FLYWHEEL NO Rc lt 004 ICENTER OF GRAVITY DETRIMENTAL TO THE INTERESTS OF EM EE s 1 2 SE 552 4 530 2 511 175 11 9 466 725 438 15 22 4 25 4 6 1 11 2 448 X TWIN DISC INCORPORATED ASSY 25 21 75 20 875 20 125 15 32 18 375 17 250 88 1 00 16 24 1 44111 551 o RACINE Wi 53403 USA GEOMETRIC TOLERANCING 1 1 PES AW 1 290 552 4 530 2 511 175 11 9 352 425 333 4 22 4 39 6 4 0 6 11 2 11 0 1 227 2 89 03 46 28 THIS NOTICE IS NOT INTENDED CHK VR mE TESTING ARE CODED gt 21 75 20 875 20 125 15 32 13 875 13 125 88 1 56 16 241 44 433 8 944 3 505 1 822 TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME MARINE 489 0 466 7 447 675 10 7 352 425 333 4 22 4 39 6 4 0 6 T2 GRANTED TO THE U S GOVERNMENT APPD 2 290 19 25 18 375 17 625 27 64 15 875 15 125 88 1 56 161 241 44 433 2 OR OTHERS BY CONTRACT MGX 2 1 4A TRANSMISSION PJC SHEET 2 REV B
77. BEARING Taper Roller inner Race BEARING Taper Raller Outer Race PISTON RING AJ zd NOT APPLICABLE THIS LINIT Note S Valve not shown in center of shaft in this Figure Marine Transmission Service Manual 1021303 Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1021303 149 Illustrations Output Shaft Exploded View 150 1 3 4 5 b 7 9 DESCRIPTION ROLLPIN SPACER BEARING Taper Roller Outer Race BEARING Taper Raller inner Race SHAFT Quput GEAR Output BEARING Taper Roller inner Race BEARING Taper Roller Quter Race SEAL Oil FLANGE Output RING Rectangular Rubber WASHER Retainer CAPSCREW Hex Head ed di A Twin Disc Incorporated Marine Transmission Service Manual 1021303 Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1021303 151 Illustrations Twin Disc Incorporated 152 Marine Transmission Service Manual 1021303 Twin Disc Incorporated List of Engineering Drawings Engineering Drawings Engineering Drawings The following pages include the engineering drawings that are specific to these models The engineering drawings included are listed below Note Any part numbers listed in the following engineering drawings are for reference only Please refer to your bill of material for part numbers specific to your model
78. CTED DIRECTLY 1 381 SROUND IF NOT THE MODULE MUST BE INTERFACED HE ELECTRONIC CONTROL WITH RELAYS WIRE WIRING OPTION 1 WIRING OPTION 2 WIRING OPTION 3 125 0 QM SOLENOID B CONNEC HE CONNECT TO THE DUTPU CONNECT TO THE SWITC POSITIVE TERMINAL IN THE GEAR CONTROLLER CONTROL S SOLENOID B F THE ENGINE THAT IS USED ENERGIZE PHSITIVE DRIVER BATTERY THROUGH THE SOLENOID B UTPUT LED INDICATORS 38 1 WITCH CONTACTS USED TO ENERGIZE GREEN LED ILLUMINATED WHEN POWER IS GREATER THAN 9 0 VULT ENDID B RED LED ILLUMINATED INDICATES VALVE COIL COMMANDED ON ONE RED FLASHING INDICATES AN OPEN CIRCUIT IN AN ENERGIZED VALVE COIL CIRCUIT SOLENOID CONNECT 1 CONNECT TO THE SAME CONNECT 1 HE RETURN EGATIVE TERMINAL GROUND POINT USED BY CONTROL S SOLENOID 24 1 F THE ENGINE HE GEAR CONTROLLER OR NEGATIVE OUTPUT NOTE WHEN THE NOT IN NEUTRAL CIRCUIT IS NOT USED INSULATE AND SECURE THE BATTERY E ENGI NTR CIRCUIT BLACK AND WHITE WIRES SOLENOID A CONNECT TO THE CONNECT TO THE OUTPU CONNECT 1 SWITC POSITIVE TERMINAL IN THE GEAR CONTROLLER CONTROL S SOLENOID 25 F THE ENGINE THAT IS USED ENERGIZE POSITIVE DRIVER BATTERY THROUGH THE 01 ID A UTPUT SWITCH CONTACTS 3 2 USED TO ENERGIZE 4 PLACES SOLENOID B 2 FOR USE ON INAL 12 24 VDC SYSTEMS 24 0 A 21 0 6 0 E METRIC L PART FACTORY SETTINGS m 445 THIRD ANGLE 1020586 PROJECTION
79. Controls Installation All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connectors must be tight and free from corrosion It is strongly recommended that the Control Harnesses and Wiring guidelines be followed to ensure proper installation of all wiring Control Harnesses and Wiring guidelines Install all control wires and harnesses as follows 1 The connector end of the control wire or harness must be secured to its own support six inches back from each connector The wire or harness must be secured at 18 inch intervals to its own frame supports between the wire or harness ends 2 Keep wire or harness away from hot surfaces moving parts and locations 3 Attach wire or harness to machine making the connector the highest point of the wire If not possible install wire or harness with drip loop 4 Protect wire or harness with grommet loom or flex guard at any rub point particularly when passing a sheet metal hole 9 Locate wire or harness away from potential hazards For example a screw cutting through the jacket and shorting a conductor to the chassis welding drilling etc Marine Transmission Service Manual 1021303 131 Installation 132 10 11 12 13 14 15 Twin Disc Incorporated Prevent the wire from becoming a step or hand rail When mating connectors make sure they will mate properly Co
80. DAILY CHECK OIL LEVEL WITH ENGINE RUNNING AND ARINE TRANSMISSION NEUTRAL EVERY 1000 SERVICE HUUR R NTHS WHICHEVER CHM 1951 DRAIN AND REF ILI USING WITH CLEA IL REMOVE AND REPLACE FILTER ELEMENT REMOVE CLEAN AND REPLACE SUCTI SCREEN IN REAR COVER WARRANTY IS VOID UNLESS TRANSMISSION IS LUBRICATED AND MAINTAINED AS SPECIF IE SERVICE MA UAL AVAI RE QUES oF FER 2 ARIN RANSMISS I UBRICANT PLATE SHIPPED WITH UNIT al NCORPORAI lt MADE IN BELGIUM RACINE 53403 Us PATENT NO 6 445 256 Figure 1 Example of Nameplate Marine Transmission Service Manual 1021303 17 Description and Specifications Twin Disc Incorporated Power Ratings Changing MGX 5114A transmission can be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation direction when viewing rear of engine Always reference the Bill of Materials BOM or Specification number when ordering service parts Rotation When shipped form the factory each unit is designated for use with a particular engine rotation Within their rated capacities these units may be operated continuously in either forward or reverse Theunit can be adapted to either left or right hand engine rotation To adapt to opp
81. E 3 PM1357E 3 SCREW HEX HD SCREW HEX HD PM205 AJ 4 P AJ 4 WASHER FLAT WASHER FLAT 0 PX11939A 1 11939 7 D W s 4 9681 PX9681C 9697 PX9696 27115 2 27115 DOWEL DOWEL PM9338H PM9338 HELI COIL HELI COIL PM1357W 1 PM1357W SCREW HEX SCREW HEX HD PM1357 5 PM1357E SCREW_HEX SCREW HD 2057 PM205 AJ WASHER FLA WASHER FLA 7945 1 MIS45AM 1 ber CUP PLUG CUP PLUG 9 s C WY SEE NOTE e oT GW pe Ro FY SS 3 as i NE Nd HIGH PERFORMANCE ARINE TRANSMISSION LUBRICANT 2 SECTION cC C 2 ur gt d 2 g 2 Vas 1020553 1 2027 1 2081 4 1
82. EGULATOR 1 a x Y n x 3 a T ay 1 T oo oy LE ad XS Lc Me NM TWIN DISC 79 CUSTOMER NOU SUPPLIED EXCHANGER ANT 154 INES bw d RE NP i REFER TO ATAL ATION AN tU 5 DRAWIND DEAE IE Tas get sU Xa 16 V SQUE S TER 2 T E a m s 0 gt V PLAN m P Qu o4 SO N87 LATION OF OPTIONAL TEMPERATURE ee T 2 z INDICATING amp w TC4 USING PIFE i Qe TH REDUCER BUSHINGS MAIO408 DRAIN PLUG k M33 x 29 THREAD 4 ER TO INSTALLATION A IRA w Figure 11 Hydraulic Schematic MGX5114A JIC Symbols Marine Transmission Service Manual 1021303 41 Operation 42 Twin Disc Incorporated Manual Direction Control Valve Operation The manual direction control valve is locked in the NEUTRAL center position during normal operation There are three possible positions of the manual direction control valve stem If conditions exist that the operator wishes to manually operate the transmission for any reason the operator can remove the locking pin from the direction control valve and push the stem into the valve for the engagement of clutch A or pull it out of the valve for the engagement of clutch B The manual direction control valve has an integral switch with contacts that are closed only when the ma
83. IL DIRECTLY TO BATTERY POWER SUPPLY VOLTAGE 2 OPFRATION PERFORMED WITH ON Y TWIN DISC CONTROL SYSTEMS OR MODULES B MANUAL DIRECTIONAL CONTROL VALVE OPERATION 1 WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PUSH TO ENGAGE PORT 2 WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PULL TO ENGAGE PORT C MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH SWITCH IS NORMALLY CLOSED WHEN MANUAL DIRECTIONAL CONTROL VALVE IS IN THE CENTERED POSITION AND OPEN WHEN LEVER 5 ACTUATED FROM CENTERED POSITION 2 CURRENT 20 AMPS 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE DRAWING PRESSURE REGULATOR ADJUSTMENT 1 REMOVE 1002144 CAP AND LOOSEN 1002145 NUT 2 CLOCKWISE ROTATION OF 10209394 PISTON INCREASES PRESSURE COUNTER CLOCKWISE DECREASES PRESSURE A LOCK PISTON IN PLACEF USING JAM NUT AND RFPIACEF CAP E REFER MARINE TRANSMISSION ASSEMBLY DRAWING OR BILL OF MATERIAL FOR VALVE MOUNTING AND SCREWS APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS AROUND CORE PLUG JUST BEFORE FINAL ASSEMBLY REFER 774 FOR FURTHER INFORMATION GC MODIFICATION KIT TO UPGRADE EXISTING 1020729 1020696 PLUG SEE CHART 2005 SERIES VALVE ASSEMBLIES TO 1021658 SERIES VALVE ASSEMBLY OPTIONAL INLET PORT 22 IMEEM E M27x2 0 THD CONFORMS Lop SCREW 4 TO ISO 6149 51 n COVER 1021661 SPOOL 1021660 senem
84. IVE TERMINAL IN THE GEAR CONTROLLER CONTROL S SOLENOID A PART N FACTORY SETTING F THE ENGINE THAT IS ERGIZ PUSITIVE DRIVER BATTERY THROUGH THE SOLENOID A UTPUT 020584 ME IRI SWITCH CONTACTS L i 21 0 USED ENERGIZE GN THIRD ANGLE il SOLENOID A 10205848 5 AGE e WEF PROJECTION nof SIMILAR NOTE FOR USE ON MOMINAL 12 24 VDC SYSTEMS LUCI 20 0 2 2835 11 15 04 TICE THIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE V PROPRIETARY INFORMATION AND IS FE DIMENSIONS ARES MM 2 25 03 Ed e 12521 6 30 04 N 2 USED w 5 NUT ko n VOCUM UE SEEN T C 11 M 2186 EM E THE ERESI X X 0 25 WIRE SPLICE PART 1020282 PEN ENS 2 1015703 WIN DISC INCORPORATED 68 FIRST USE NM MEE NE B DH DEUTSCH CONNECTOR FCN11590 6 03 03 er 2 Esa 4 METRIPACK CONNECTOR F1 11523 4 29 03 IS NOTICE IS N NTENDED EE Une ANST ATEON ee CRIS ER z so NULLIFY OR LIMIT RIGHTS NTR RN Schenk EI G 2 F6 ECNI3131 3 23 05 S 20408 422208 JERANTED TO THe MIS SHEET ZONE DATE SHEET ZONE CH NO DATE R OTHERS BY CONTRACT MGX ETROLL MODULE M B Gee SHEET 1 OF 2 REV d D C B
85. MODEL NG P X 7 E 7190 09JUNO4 THIS NOTICE IS NOT INTENDED CHK VR O NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME MARINE 7156 26APR04 GRANTED TO THE U S GOVERNMENT m APPD REV CH NO DATE REV CH NO DATE REV CH NO DATE OR OTHERS BY CONTRACT MOGX 5114A TRANSMISSION JCP H 1 REV _R U gt o NDICATING m 1 6621 25APRO2 PO ae ED IN UNITS EQUIPPED WITH w a L THO D FOR INSTALLATION LOCATION USE ABOVE 2500 HYDRAULIC DIAGRAM AND SHEET 3 B OPTIONAL FOR S A E 1 OPTIONAL FOR SPEED SENSORS NOT SERVICEABLE SEPARATELY 6910 1JULYOS 6611 OSAPRO2 6900 23JUNO3 6604 26MARO2 H 6583 28FEBO2 G 6875 21MAYO3
86. N 3 SWITCH INPUTS A SAME TIME 38 1 PEE D 1 1 1 Wu GREY F E E ENEE EN RED ALTERNATELY FLAS INDICATES EITHER OR BOTH SIGNAI ISSING SWITCH RETURN NEGATIVE TERMINAL GROUND POINT USED BY POINT AS THE CONTROL S F THE ENGINE BATTERY THE GEAR CONTROLLER OR POWER GROUND SIGNA i 5 NOTE 1 WHEN TROLL SPEED CURRENT INPUT IS USED CONTR RO D Ses RANGE AND GREEN TROLL SPEED POTENTIOMETER INPUT WIRES MUST BE lt 1 2 U PU C NNEC ECTRICA gt eLIED GE ER WI ER SHRINK C N ECT R AND SECURE D F THE ENGIN THAT IS USED ENERGI POSITIVE DRIVER 2 WHEN TROLL SPEED VOLTAGE INPUT IS USED TO CONTROL TROLL SPEED BATTERY THRDUGH TH 5 ID B JTPUI HE VI AND GREEN WIRES MUST BE INSULATED AND SECURED SWITCH MR SE eL e USED ENERGIZE 9 0 3 PROPELLER SPEED SENSOR MUST BE TWIN DISC SUPPLIED PART eee NOTE 4 TO INITIATE TROLL WITHOUT THE 0 5 VOLT DEAD BAND AT MINIMUM TROLL _ CENNECT 1 CHNNEGT SH SAME CHNNECT TE THE ADD A 100 OHM RESISTOR BETWEEN THE POTENTIOMETER AND THE GREEN WIRE 2 RETURN EGATIVE TERMINAL GROUND POINT USED BY CONTROL S SOLENOID NOTE 5 WHEN THE NOT IN NEUTRAL CIRCUIT 1 USED INSULATE AND SECURE THE E F THE ENGINE GEAR CONTROLLER OR ATIVE OUTPUT BLUE AND BLACK WIRES A BATTERY NGINE CONTR CIRCUIT SOLENOID A CONNECT CONNECT TO THE OUTPUT CONNECT TO TH 24 0 SWIT POSIT
87. OID ON C Lo 9 miu lt CRED LED 48 RI PACK CONNECTOR lt 2 Bl ACK PERS 84 o d Y T 12162193 el Je 4 gt T ETRI PACK TERMINAL 40 WHITE 200 mA MAXIMUM 2 gt NIN GND WHITE g cs a GND LONA SEE WS SOLENOID B ON BLACK Zi ia Ve NORMALLY CLOSED Lot pep See ES w CRED LED IN NEUTRAL RELAY gt UU BLACK LENUID A UN RO q 186 CLOSED IN NEUTRAL o x lt L gt gt a EN w MP CCUST ER SUPPI IE 2 a OL e z ion SOL POWER cet n lt 2 2 SUL POWER T PED LENOID B a o 2 3h W K mmn OL BLACK 21 a d GREEN LED RET z USE 1020282 SOLDER SHRINK SOLENOID SWITCH Pep 2 4 a CONNECTORS AS REQUIRED CUSTOMER SUPPLIED J SOLENOID A SWITCH CUSTOMER SUPPLIED 500 0 0501 7 ULE POWER CONNECTION CHART USE OP 1 CONNECTIONS WHEN THE IS CONNECTED NON ELECTRONIC LEVER HEADS USE OP 2 CONNECTIONS WHEN THE ULE IS FLECTRONIC GEAR CONTROLLERS CS USE DP 3 CONNECTIONS WHEN THE IS CONNECTED ELECTRONIC CONTROL SOLENOID NZ RIVER OUTPUTS THE ELECTRONIC CONTROL S SOLENOID AND RETURNS OR NEGATIVE SIGNAL SHOULD BE CONNECTED TOGETHER AND CONNECT THE ETROLL ULE RETURN ELECTRONIC CONTROL SOLENOID DRIVERS MUST HAVE THEIR SOLENOID RETURN INTERNALLY CONNE
88. ON AND IS X XX 0 13 DRAWN NOT TO BE USED IN ANY MANNER ASSEMBLY N ALL ANGULAR TOLERANCES 1 RZ DETRIMENTAL TO THE INTERESTS OF GEOMETRIC TOLERANCING TWIN DISC INCORPORATED MODEL N PER ANSI Y14 5M 1982 CHECKED D X 1 1 7 5 RACINE WI 55405 USA SURFACE TREATEMENT NAME TO NULLIFY OR RIGHTS MGX 5114 A MARINE TRANSMISSION APPROVED GRANTED THERE E CONTRA 3 REVISION R FORMAT 1 FAT EXCHANGER REQUIREMENTS REFER 5649 FOR HEAT EXCHANGER REQUIREMENTS WHEN MOUNTING ENGINE TRANSMISSION IN BOAT ALL THE OUNTING PADS ON THE ENGINE MUST BE USED PEUS T LL T RANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO AY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW 11750 CONFIGURATION IS NOT SUITABLE FOR REMOTE 21 0 DRILL THRU OUNTING RECOMME Y AO
89. PM10685A heat exchanger is available shipped loose as KS629 or mounted as 5452 Marine Transmission Service Manual 1021303 25 Description and Specifications Twin Disc Incorporated Companion Flange Assembly The XB 5917 companion flange assembly consists of the companion flange and nuts and bolts Electric Control Valve The GP Electric Control Valve and proportional valves are standard on the MGX5114A and can be controlled with either 12 VDC or 24 VDC input power Trolling Valve The e troll controller is available for the MGX5114A and includes input and output soeed pickups mounted on the transmission 26 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Description and Specifications Assembly Specifications Table 3 Gear Advance Specifications Primary Transfer Gear Advance Minimum Actual Maximum 4 11 182 in o 5 79 mm 228 Minimum Actual Maximum 4 11 mm 1 162 in 5 789 mm 228 inl Output Gear Advance Minimum Actual Maximum 2 24 mm 088 In 3 05 mm 120 in Table 4 Bearing Preload End Play Specifications Tapered Roller Bearinc Minimum Maximum Total Shim 05 mm 0 10 mim PRIMARY com en 5 mm 0 10 mm SECONDARY 002 In INTERMEDIATE MGX 51141V ony got 05 mm 0 10 mm or oom i etm O O Note All endplay specs are negative preload n Table 5 Clutch Specifications Note See Special Tools Section
90. YF I 1 1 1 11801 2 M1927CV MT 2 NOR P9735 2 NOL 4 11802 3 M1945AG 1 VALVE CARTRIDGE X Ii JM X Dou ET 55555555551 55555555553 Nl ey 4 if J SAE 2 SEE NOTE 8 1021658H A 1052 U 1055 6 B15 57 J P9926 B2130B PM1996T M2048AH A291 6JT IND P d E 996 T 1 8 PM 1896 U 5 11627 2 11655 1 2006 1 PM 1349AA 1 PM2009R 1 9733 1 PM2306A 1 9 8726 5 REQ D
91. a g 2 A 12 PM 2018 0 12 pMEZU0SZX s 400 0 mE 400 0 E 450 0 450 0 a 164 8 2 480 5 493 2 5 BY IWIN DISC NN Su THIRD ANGLE PROJECTION SIMILAR TO 9700 MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE N FOR OTHERS INSTALLATION DIMENSIONS DIMENSIONS ARE mm 25MAYO2 Im DISE SEE DRAWING PX 11730 SH 2 kg Nm MACHINED DMERSONS Scat O0 R P0 RAT D NOTICE THIS PRINT CONTAINS HEAT TREAT FIRST USE 2 1542 RACINE WI 55405 USA PROPRIETARY INFORMATION ED L6 DRAWN RZ n DETRIMENTAL TO THE INTERESTS OF ASSEMBLY N TWIN DISC INCORPORATED MODEL PER ANSI Y14 5M 1982 CHECKED D xX a 1 1 ff He RACINES WI 59405 22 USA SURFACE TREATEMENT NAME TO NULLIFV OR LIMIT RIGHTS MARINE TRANSMISSION MGX 5114 APPROVED GR OTHERS BY CONIBACT MENT IE ii SHEET 4 REVISION FORMAT 1 230 E VALVE VALVE 2 a MBLY ASSEMBLY VALVE eres 7 Wr AR icm E ME TORQUE TO 33 N m PART NU IDENTIF TE 1 T er 1
92. aces and shim retainers from the housing Note Do not interchange the forward and reverse shim retainers They must be replaced in the bores from which they came Place a pack of shims in each bearing bore so as to measure an interference of 0 051 to 0 102 mm 0 002 to 0 004 in for the clutch shaft and 0 051 to 0 13 0 002 to 0 005 in for the output shaft Figure 73 Installing Shims 10 11 Example Endplay recorded 1 194 mm 047in Interference required 0 076 mm 003 in nominal Shim thickness required 1 194 076 1 27 mm 047 4 003 2 050 in Replace shim retainers and bearing out races into their respective bores in the front housing Replace front housing and gasket on the rear housing and secure with twelve M10 x 35 screws and washers Torque the screws to 45 Nm 34 Ib ft Turn the unit rear side up on the work bench Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly 12 Install the gasket and the manifold and secure with the M12 capscrews Torque the screws to 80 Nm 59 Ib ft Ensure that the piston rings are correctly in place on the ends of the clutch shafts Figure 74 Installing Manifold Assembly 13 Install the oil filter screen and O ring plug and secure with the screw and washer Torque the M 12 retaining screw to 80 Nm 59 Ib ft Figure 75 Installing Screen Filter Marine Transmission Service Manual 1021303 109 Assembly 14
93. agraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing i Thousandths Indicat Engine 3 ar TA Lll Engine T 159 24 Flywheel Crankshaft Engine Flywheel Housing Figure 90 Checking Flywheel Housing Bore Eccentricity 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the previous Table for allowable tolerances 9 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 7 Engine j Flywheel Engine ee Engine Flywheel HA Engine le Thousandths Indicator Crankshaft Figure 91 Checking the Flywheel Face Runout Marine Transmission Service Manual 1021303 123 Installation 124 Twin Disc Incorporated 6 With the indicator mounted as in the paragraph above adjust the indicator tip so that it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot bore eccentricity of the engine flywheel should not exceed 0 13 mm 0
94. anual Direction Control Valve with switch or the Plug Assembly from the Top Valve Body vw JI Eum i Override Valve with Neutral Switch Locking Pin z E LEN ST 3 Lj I TUO iim Lo BIN i 1 Plug if applicable Figure 52 Manual Direction Control Valve or Plug 82 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly 5 Remove the M6 1 00 x 16 Allen head capscrew the retaining plate and the proportional Valve Cartridges from the Top Valve Body A slight rotating motion while pulling will help to with the removal of the valves Proportional Valve A Figure 53 Remove Proportional Valve Cartridges Marine Transmission Service Manual 1021303 83 Disassembly Twin Disc Incorporated 6 Valve Assembly 1020729 Remove the Main Pressure Regulator Pilot Relief Valve and Main Valve from the Main Regulator Valve body Regulator Main Regulator Spool Pilot Relief Valve Figure 54 Remove Main Pressure Regulator Valve Components 84 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly 6 Valve Assembly 1021658 Remove the Main Pressure Regulator from the Main Regulator Valve body A Remove the regulator adjusting screw cap and loosen the jam nut B Turn the adjusting screw counter clockwise to reduce the spring load on the valve Evenly loosen the four M 8 x 25 capscrews and remove the cove
95. at pins and sockets only with dielectric compound to seal out moisture and corrosive substances Twin Disc part number MA890 or Dow 4 Compound Locate and use the connector orientation key Circular connectors must be hand tightened Wire or harness bend radius must not be less than twenty times the wire or harness diameter Avoid twisting or winding the wire or harness along its axis during installation or removal Whenever mating connectors always inspect each for damage or defects For example bent pins pushed back sockets broken keys etc Check that sure seal connectors have clip clamps in place Check the wire or harness tie downs Keep wires securely fastened to vessel frame Check the condition of the wire or harness at any rub point and wherever the wire or harness passes through a sheet metal hole Check wire or harness for cracks effects of vibration abrasion brittleness or abuse Marine Transmission Service Manual 1021303 Twin Disc Incorporated Installation Wiring Connections General The vessel wiring for the Profile or E Troll Module must be of sufficient size to prevent excessive voltage drop no greater than 0 5 Vdc between the battery connections positive voltage and ground and the Profile or E Troll Module The modules operate from nominal 12 VDC or 24 VDC batteries The battery power connection must be protected by an electrical over current protection component fuse or circuit breaker
96. ated 6 The warranty Is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment Only aTwin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within t
97. bor is defined asthe flat rate labor hours established T win Disc reassemble reinstall and test the T win Disc Incorporated product only Authorized reasonable travel and living expenses will be considered for payment inall model except 340 and MG360 Under no circumstances including a failure of the exclusive rem shall T win Disc Incorporated be liable for economic loss co uential 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 The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorpor
98. c portion of the GP Control Valve is made up of two blocks a lower main regulator valve body and an upper valve body The upper valve body contains two electrically actuated proportional valves and a manual direction control cartridge valve The lower valve body contains the hydraulic pressure regulating valve and a temperature sensor if the application requires it There are two different versions of the lower valve assembly The hydraulic pressure regulating valve in earlier versions Assembly 1020729 consist of two cartridge assemblies a pilot relief cartridge assembly and a main spool cartridge assembly The hydraulic pressure regulating valve in later versions Assembly 1021658 is not a cartridge assembly but is comprised of a spring and spool with an adjustment cover The regulating valve body contains a ball check valve assembly in parallel with an orifice with a filter that provides rapid fill and damping for the rear cavity of the regulator valve A kit is available to upgrade the earlier version to the later version manual direction control cartridge valve contains a switch that is closed when the valve is in the neutral position Separate identical proportional cartridges are used for the primary and secondary clutch actuation When the primary or secondary clutch is selected by the operator the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate of rise profile is control
99. connected to the two not in neutral wires of the Profile Generator The contacts of the manual direction control switch closed in neutral must be wired in series with the energizing coil of the not in neutral relay Plug the appropriate connectors from the Profile Generator into the appropriate Proportional Valves Plug the appropriate connectors from the Profile Generator into the Engine Speed sensor and the Propeller soeed sensor if equipped When the not in neutral circuit is not used insulate and secure the blue and black wires Marine Transmission Service Manual 1021303 Twin Disc Incorporated SULENOID CRED LED POWER GREEN LE SIULENUID CRED LED Installation WIRING SCHEMATIC TROLL ENABLE SWITCH CLOSED TROLL MODE OPEN CRUISE MODE u CUSTOMER SUPPLIED SEE MODULE POWER CONNECTION CHART RED 5 TROLL SPEED POTENTIOMETER 1K OHM IRANGE 0 0 TO 0 5 VOLT MINIMUM TROLI GREEN 475 50 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 CUSTOMER SUPPLIED IULET 4 nm TROLL SPEED CURRENT INPUT 20 MA SEE NOTE 1 TAN Su TAN ENGINE SPEED SENSOR bm
100. ct 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 Preventative Maintenance Frequent reference to the information provided in the Marine Transmission Operator s Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment 12 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Introduction Backdriving or Towing Backdriving also called windmilling occurs when an engine is shut down and the propeller shaft is being driven by the flow of water across the propeller which in turn rotates the components in the marine transmission During prolonged backdriving conditions the transmission does not receive proper lubrication Conditions where backdriving may occur Vessel is being towed One or
101. d Inspect and oil the exposed stem of the Manual Direction Control Valve for corrosion protection 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 Assure baffles are installed properly so hot air is ported out of the housing Visually inspect the element after the first 100 hours of operation and every 2000 hours thereafter or every six months whichever comes first Torsional vibration misalignment degradation by contaminants oil heat ultraviolet radiation and excessive system torque can cause cracks or other signs of distress to appear on the surface of the rubber The above described items affect the life of the coupling element Perform a complete inspection whenever the transmission is removed from the engine for any reason When inspecting the flexible coupling look for evidence or conditions identified in the following steps Cracks in the surface of the rubber be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling or deterioration of the rubber to metal bond See above Marine Transmission Service Manual 1021303 Twin Disc Incorporated Pre
102. directs main pressure to a passage in the clutch shaft The oil is directed toa small area chamber behind the clutch apply piston and also against the sequence S valve that is located in the clutch shaft The pressure on the small area of the clutch apply piston quickly moves the piston to engage the clutch at a low capacity level The pressure rises until the S valve opens allowing the high pressure oil to be supplied to the large area of the clutch apply piston providing a rapid increase in the clutch capacity The rate of rise is controlled electronically and prefills the engaging clutch at a predetermined level and then increases to full pressure following a predetermined timing sequence The initial prefill level is factory adjustable by means of an adjustment screw embedded in the bottom surface of the electronic interface Field adjustment of this feature should never be attempted without special equipment and knowledge of its use to prevent serious mechanical damage to the marine transmission or vessel Clutch release occurs when the proportional valve is de energized and the oil from the small area of the clutch apply piston is allowed to flow to sump through the control valve and the oil from the large area of the clutch apply piston is allowed to flow to sump through a dump ball in the clutch housing and through the S valve through a passage in the shaft into the transmission sump The electronic interface portion of t
103. e 1 6 BEARING Taper Roller inner Race 1 7 SHAFT ASSEMBLY Input 1 RING Piston 1 9 ROLLPIN 10 PISTON Clutch 1 11 O RING 1 12 SPRING Clutch release 1 13 RETAINER Spring 1 14 RING Snap 1 15 RACE Thrust 1 16 BEARING Needle Thrust 17 RACE Thrust 1 18 PLATE Sintered side only 19 PLATE Stee 10 20 PLATE Sintered 11 21 BACKPLATE Clutch 1 23 RING Snap 1 23 PINION ASSEMBLY Forward 1 24 RACE Thrust 1 25 BEARING Needle Thrust 1 26 RACE Thrust 1 27 BEARING Taper Roller inner Race 1 2B BEARING Taper Roller Outer Race 1 29 PISTON RING 2 APPLICABLE THIS UNIT Note S Valve not shown in center of shaft in this Figure 146 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1021303 147 Illustrations Reverse Clutch Exploded View Twin Disc Incorporated 148 amp D DIE DID a ed DESCRIPTION SHIM ROLLPIN SPACER LAPSCREW Hex Head PLUG Orifice Pipe WASHER Retainer BEARING Taper Roller Outer Race BEARING Taper Raller inner Race SHAFT ASSEMBLY Input ROLLPIM RING Piston PISTON Clutch O RING SPRING Clutch release RETAINER Spring RING Snap RACE Thrust BEARING Needle Thrust RACE Thrust PLATE Sintered one side only PLATE Steel PLATE Sintered BACKPLATE Clutch RING Snap PINION ASSEMBLY Reverse RACE Thrust BEARING Needle Thrust Thrust
104. e bottom 2 Mark the output flange and companion flange so they will always be assembled identically 3 Disconnect the output and companion flanges 4 Disconnect linkage wiring and plumbing and remove any items that would interfere with the removal of the transmission 9 Support the transmission with a hoist and remove the mounting capscrews 6 Support the rear of the engine with blocks if necessary 7 Remove the 12 capscrews that secure the transmission to the engine 8 Push the transmission away from the engine Remove the transmission Remove the input coupling from the engine flywheel ADAPTER a OIL FILTER CIL DRAIN PLUG OL GAUGE Figure 17 Marine Transmission Rear and Front View 58 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly Removal of External Parts 1 Remove the input coupling assembly from the input shaft Figure 18 Removing Input Coupling 2 Remove the snap rings from the coupling hub and separate the hub from the coupling Figure 19 Coupling Hub Removed Marine Transmission Service Manual 1021303 59 Disassembly Twin Disc Incorporated CAUTION The hydraulic pump can be installed two different ways therefore before removing the pump place indexing marks on the pump and the manifold to insure correct installation Do not remove the pump pipe plug Do not disassemble pumps They are not serviceable 3 Remove the four cap
105. e for the purpose of illustrating the procedure and may not appear to be consistent with the previous assembly steps Marine Transmission Service Manual 1021303 93 Assembly Twin Disc Incorporated Prior to Assembly Use the following reference The input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing the output side of the transmission from the rear Note Special end play tools can be made by grinding 0 05 mm 0 002 in from the outer diameter of the bearing cups that are used on the input end of the three shafts These are MA590CK 6 7500 in MA590CS 5 0000 in and MAS90BF 4 8125 in Prior to heating the mating bearing cones and freezing the cups bearing overall length measurements should be made to determine if any adjustments must be made to the end play calculations based on variances between the unit s bearing cups and the special ground bearing cups Identify and place the following bearing components in an oven at 120 C 250 for 30 minutes output shaft rear tapered roller bearing cone and the rear bearing cones for both clutch shafts oubmerge all new friction clutch plates in transmission oil for a minimum of one hour prior to installation Identify and place the following bearing components in a deep freeze 51 C 60 F for at least two hours prior to assembly both output bearing cups and both rear clutch shaft bearing cups 94 Mari
106. e 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 1021303 87 Cleaning and Inspection Twin Disc Incorporated 88 Cleaning Bearings Do not remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease CAUTION Never dry bearings with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently it is important to keep bearings clean Do not remove grease from new bearings Keep the wrapper on new bearings until they are installed Do not expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Sealed Joints For previously sealed joints scrape surfaces to remove old gasket material or loctite Clean surfaces with solvent to remove oil and grease residue Test for clean surfaces by applying 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
107. embly pump is not ser viceable Raise engine speed Hemove and clean strainer Check oil level and correct Correct cause of air leak Disassemble and repair as required Remove disassemble clean and repair the Pilot Relief Valve Remove clean or replace the Main Regulating valve This valve cannot be disassembled Replace oil pump Replace heat exchanger Twin Disc Incorporated Troubleshooting Table 12 Troubleshooting Chart continued GP Valve Equipped Transmissions Remedy 3 4 5 High main oil pressure High temperature Excessive Noise Pilot Relief Valve out of adjustment Main Regulating Valve orifice missing Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Worn or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Marine Transmission Service Manual 1021303 Adjust the Pilot Relief Valve Replace if necessary Main Regulating Valve Cartridge Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure pressure is normal remove disassemble and repair slipping clutch If pressure is low replace Proportional Valve and service tra
108. ensor Temperature Replace Profile Generator Adjust if proper equipment is available Replace pump Remove clean inspect and install the suction screen Inspect and correct cause of suction leaks Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil See Paragraph 1 Replace Proportional Valve Verify that green voltage Supply light and red clutch energized lights are bright Twin Disc Incorporated Disassembly Disassembly The following procedure is for complete disassembly of the unit Prior to this procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility Prepare Transmission for Disassembly Note During service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the old O rings gaskets and seals with the appropriate components being disassembled for future reference during the inspection and assembly process to make sure you don t forget the quantity size etc FONT HALF reap FORA RD CLUTCH inoue HALF HOUSING REVERSE CLUTCH GROUP Figure 16 Relationship of Transmission Components Marine Transmission Service Manual 1021303 57 Disassembly Twin Disc Incorporated Prior to Removal 1 Drain the oil from transmission by removing the O ring plug on the rear side at th
109. for Bench Test Fixture and Calibration Instructions Sequence Valve Gracking Pressure l 8kPa 210ps Clutch Clearance laximum 2 3 mm 081 in mm 157 in 2 3 mm 091 i 157 in Marine Transmission Service Manual 1021303 27 Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Note All threads and bearing face to be lubricated with light oil film prior to assembly Use SAE Grade 5 and Property Class 8 8 torque values for all screws that are threaded into aluminum Table 6 U S Standard Fine and Coarse Thread Capscrews Bolts and Nuts Thread SAE Grade 5 SAE Grade 8 o m w 14 16 27 32 48 55 75 88 113 131 Diameter Table 7 Metric Coarse Thread Capscrews Bolts and Nuts Thread Property Class 8 8 Property Class 10 9 Property Class 12 9 Size Nm m m M6 65 75 2 4 2 4 8 16 18 21 25 23 26 31 35 25 29 34 40 32 36 43 49 44 51 60 68 51 59 70 80 28 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Description and Specifications Table 8 Tapered Pipe Plugs with thread lubricant In Steel or Cast Iron NPTF Size Nm or 5 Ib ft or 5 Nm or 596 If ft or 596 o o 1 12 1112 115 Table 9 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Diameter Or 5 Or 5 Diameter Or 5 or
110. fresh solvent and reclean Marine Transmission Service Manual 1021303 Twin Disc Incorporated Inspection Cleaning and Inspection Housings Cast Parts and Machined Surfaces Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding or grinding This will cause loss of fit of bearings or races Inspect oil passages for obstructions If you find an obstruction remove it with compressed air or work a wire back and forth through the passage and flush it with solvent Inspect machined surfaces for burrs scratches nicks and foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part Inspect ground tapers for scratches galling or scoring damage If any of these are present replace the part Inspect ground tapers for burrs or nicks If you cannot remove the defect with a soft stone replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels 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 Otherw
111. ge 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 1021303 Twin Disc Incorporated Installation Engine and Marine Transmission Alignment to Propeller Shaft CAUTION When mounting the engine and transmission in the boat all of the mounting pads on both the engine and transmission must be used Failure to do so may result in damage to the transmission or the engine flywheel housing Hecomrmandecd Figure 94 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 Marine Transmission Service Manual 1
112. h rear two thrust races and the thrust needle bearing NEEDLE SUME BEAR Figure 36 Removing Pinion Thrust Needle Bearing and Thrust Race TIR 6 Hemove the front two thrust races and needle bearing Figure 37 Front Thrust Needle Bearing and Thrust Races Removed Marine Transmission Service Manual 1021303 69 Disassembly Twin Disc Incorporated 7 Remove the internal snap ring from the inside of the primary clutch housing 8 Remove the clutch back plate Figure 8 7 Figure 38 Clutch Backplate and Snap Ring Removed 9 Remove the clutch plates Figure 39 Clutch Plates Removed 70 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly 10 Place special tool 18503 over the clutch release spring Use hydraulic press to press tool downward and compress the spring Figure 40 Compressing Clutch Release Spring 11 Remove the snap ring from the shaft Figure 41 Removing Clutch Release Spring Retaining Snap Ring Marine Transmission Service Manual 1021303 71 Disassembly Twin Disc Incorporated 12 Remove the clutch release spring and spring retainer pm LET _ SENS d m M Figure 42 Clutch Release Spring and Retainer Removed 13 Remove the clutch piston by installing two 5 16 18 UNC threaded rods into the holes provided and lifting out the piston Figure 43 Removing Clutch Piston T2 Marine
113. h red lights flashing Not applicable After entering troll from neutral simultaneously with both voltage and current troll signals present or power 15 applied to Solenoid A and B switch inputs at the same time Bothred lights flashing altemately Not applicable Either or both speed signals missing Marine Transmission Service Manual 1021303 53 Troubleshooting 2 54 Twin Disc Incorporated Table 11 Troubleshooting Chart GP Valve Equipped Transmissions Remedy Low main oil pressure No oil pressure or erratic low pressure at control valve 1 1 Partially clogged oil strainer 1 1 Contamination Pilot Relief Valve seat Contamination in Main Val ve Cartridge Broken piston clutch shaft s Damaged or worn oil pump assembly rings on 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 Pilot Relief Valve or Main Regulating Valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Marine Transmission Service Manual 1021303 Remove and clean strainer Disassemble the Pilot Relief Valve and clean Service the transmission oil filter Clean or replace the Main Valve Cartridge and service the transmission oil filter Hemove the collector and inspect piston rings Replace damaged or worn oil pump ass
114. he control valve allows only one proportional valve to be energized at a time thus only one clutch can be engaged at a time Marine Transmission Service Manual 1021303 39 40 Operation Twin Disc Incorporated and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Note Installations with this valve include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 75 or better 1 af Ms UENIRE Parc MEC oto Son Ir Sita ES Se Dejs l9 Sore Pa PALHAS GTR ANC DL RSEILIILS ES 71 ISs3T amp e TPMPPRACOGG3FE SITAATIN 2l al 2 T uU ILL wi N ERA 4 y 351 7a _ _ Figure 10 Hydraulic Schematic MGX5114A Marine Transmission Service Manual 1021303 Twin Disc Incorporated Operation M oa 1 M i 4 1 me a Z T i Nos Nada FEMA LE WALYE f T i X E ist M 6 2 m 4 ZZ PRESSURE R
115. he shaft 3 Install a new piston ring and O ring onto the clutch piston 4 Install the clutch piston aligning the two roll pins in the driving transfer gear with the holes provided in the clutch piston Outer Seal Ring Small Area Outer Seal Ring O Ring Figure 57 Installing Clutch Piston 5 Install the clutch release spring and spring retainer Note tha the forward retainer is thinner than the reverse retainer Figure 58 Installing Clutch Release Spring and Retainer 96 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly 6 Compress the spring using a hydraulic press and Special Tool 118503 and install the snap ring into the groove provided on the input shaft Figure 59 Installing Clutch Release Spring Retaining Snap Ring 7 Install the clutch plates as follows Install a friction faced clutch plate and alternate with steel and friction plates until the ten steel and eleven friction plates are installed finishing with a friction plate Note Submerge all friction plates in clean SAE 40 engine oil for one hour minimum prior to installation 8 Install the clutch backplate and snap ring Figure 60 Installing Clutch Backplate and Snap Ring Marine Transmission Service Manual 1021303 97 Assembly 98 10 11 12 Twin Disc Incorporated Place the shaft vertically with the backplate at the top of the clutch assembly Apply a load of 100 200 23 45 lbf to
116. he 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 January 16 2002 TDW P2004 M Ets TWIN DISC INCORPORATED em pisc FLAT RATE HOUR ALLOWANCE ecd ms MARINE PLEASURE CRAFT Hourly Labor Rates Must Be Acceptable to Twin Disc Incorporated MODEL SERIES R amp R UNIT REBUILD MG340 MG 360 0 0 0 0 MG502 MG5010 MG5011 MG5005A MG5015A 10 0 8 0 MG506 MG5050 MG5061 MG5062 MG5055A 10 0 11 0 MG507 MG5081 MG5085 MG5090 MG5091 10 0 12 0 MG509 MG5111 MG5112 MG5114 10 0 17 0 MG514C MG5141 10 0 25 0 MG5202 MG5203 MG5204 MG5222 10 0 32 0 MG5225 MG6000 10 0 32 0 MGN 80 MGN 232 MGN 233 MGN272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN472 MGN 493 10 0 32 0 PUMP ALL MODELS EXCEPT MG340 amp MG360 1 0 VALVE ALL MODELS EXCEPT MG340 amp MG360 1 0 55 January 16 2002 TDW P2004A Qu ACS Twin Disc Incorporated Table of Contents Table of Contents ITP OGUGCUOM 2E TETTE 11 General InformatiOl ESE ean 11 Safety and General Precautions 11 Preventative Maintenance 1 1 41 12 Backariving TOWING 1
117. imary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in anti engine direction Application of the secondary clutch locks the secondary pinion to the secondary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in engine direction Note The following power flow illustrations are shown merely as examples of power flow and may not pertain specifically to your unit Marine Transmission Service Manual 1021303 43 Operation Twin Disc Incorporated Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Drive Gear Driven Gear Pinions Primary Shaft Secondary Shaft MS OT HD F p Fr EI E ras Output Gear NEUTRAL 001 6600 Figure 13 Example of Power Flow in Neutral 44 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Operation Primary When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel
118. ise replace the parts This applies where a matched set of parts is not involved Marine Transmission Service Manual 1021303 89 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Bearings Inspect bearings for roughness of rotation Replace the bearing if the rotation is rough Inspect bearings for corrosion and for indication of wear of balls or rollers Inspect for scored scratched cracked pitted or chipped races If you find one of these defects replace the bearing Inspect bearing bores and shafts for grooved burred or galled conditions that would indicate the bearing has been turning in its housing or on its shaft If you cannot repair the damage with a crocus cloth replace the part Bushings and Sleeves Inspect bushings for size and out of roundness Inspect for scores burrs 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 90 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Cleaning and Inspection Gears
119. lation or testing Temperature Sensor Port w Filter jme Check Valve Spring Cap Figure 82 Assemble Main Pressure Regulator Components 114 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly 2 Assemble the Top Valve Body Install the two proportional valve assemblies into the valve body install the retaining plate and torque the M6 1 00 x 16 socket head capscrew to 9 5 Nm 7 Ft Ib Install the Manual Direction Control Valve into the valve body and torque to 27 Nm 20 Ft Ib Install the M12x1 50 o ring plug into the valve body and torque to 16 Nm 12 Ft Ib Connect the wires for the Neutral Switch Proportional Valves M12x 1 50 Manual Override o ring plug Top Valve Body Figure 83 Assemble Top Valve Body Components 3 Install a new gasket and the Main Regulator Valve Assembly to the transmission or ditch plate using the four twelve point capscrews Torque the capscrews to the level specified for the appropriate sized capscrew into aluminum threads See the torque specifications in Description and Specifications Figure 84 Install Regulator Valve Body to Transmission Marine Transmission Service Manual 1021303 115 Assembly Twin Disc Incorporated 4 Install new gasket and the Top Valve Body Assembly on the Main Regulator Valve Assembly using six M10 1 50 x 70 hex head capscrews and torque to 46 Nm 34 Ft Ib
120. led electronically by the GP Control Valve Electronic Interface Profile or E Troll Module to provide a rapid smooth oil pressure increase in the clutch hydraulic passages during engagement in C AU TION The proportional valve coils are low resistance devices that are current driven The use of an uncontrolled power source may supply too much current and damage the proportional valve Note Installations with this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 75 or better Besides the valve s requirement on filtration the filter must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1021303 33 Operation Twin Disc Incorporated 1 lt gt M A 4 gt 4 gt Figure 3 Hydraulic Schematic GP control valve Assembly 1020729 34 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Operation be d a lt gt 2 lt gt 11 IN d wwe e Figure 4 Hydraulic Schematic GP control valve Assy 1021658 Marine Transmission Service Manual 1021303 35 Operation Twin Disc Incorporated Proportional Valves Manual Override Valve 1
121. 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 a heavy current Any of the following solutions are applicable for all MGX 5114A transmissions if any of the above conditions are present Lock the propeller shaft to prevent rotation WARNING If a clutch pack has been damaged causing heavy drag the prop shaft must be locked in place to prevent backdriving The dragging clutch can produce high amounts of heat and further damage can occur Add electric driven auxiliary oil pump into the lubrication circuit Refer to the hydraulic system prints for more details on auxiliary pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Operate the engine for five minutes once every eight hours with the oil at the proper level If the engine is inoperable plug the dip stick tube and completely fill the transmission with oil and drain oil back down to the normal operating level Repeat this operation every eight hours Marine Transmission Service Manual 1021303 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services WARNING All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or
122. ne Transmission Service Manual 1021303 Twin Disc Incorporated Assembly Assembly of Housing Sections 1 Install roller bearing outer races and press them into the rear housing Oil after installation 2 Coat the output seal bore of the rear housing and the outside diameter of the output seal with a thin film of M2828 anaerobic sealant do not apply excessive sealant as seal and or bearings may be damaged Apply a film of oil or assembly grease to the seal surface Press the oil seal into the bore with the spring loaded lip of seal toward the inside of the housing Press seal into bore until outer face is flush with the housing face 3 Coat the input seal bore of the front housing and the outside diameter of the input seal with a thin film of M2828 anaerobic sealant do not apply excessive sealant as seal and or bearings may be damaged Apply a film of oil or assembly grease to the seal surface Press the oil seal into the bore with the spring loaded lip of seal toward the inside of the housing Press seal into bore until outer face is flush with the housing face Marine Transmission Service Manual 1021303 95 Assembly Twin Disc Incorporated Assembly of Primary Clutch Plug the 5 valve end of the shaft but do not install the valve 2 Install the heated front bearing inner race onto the input shaft if removed Note Heat the front bearing cone in a 135 C 275 F maximum oven for 30 minutes prior to installing it on t
123. ne Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly 10 Remove the piston ring sleeves and O rings from the manifold Figure 27 Piston Ring Sleeves and O rings Removed 11 Turn the unit rear side down on suitable wooden blocks with the front SAE adaptor horizontal Remove the screws securing the front housing to the rear and using the jacking screws provided separate the front and rear housings Lift off the front housing and gasket Figure 28 Removing Front Housing Capscrews Marine Transmission Service Manual 1021303 63 Disassembly Twin Disc Incorporated 12 Remove the oil gauge and tube Figure 29 Removing Oil Gauge Tube 13 Drive out the plug in the secondary clutch location from the front housing 64 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly Internal Subassemblies E Remove the screws and washers securing the oil dam to the rear housing and remove the oil dam Figure 30 Removing Oil Dam Retaining Screws 2 Screw an eyebolt into the end of the primary input clutch shaft and lift out the clutch assembly Figure 31 Removing Forward Clutch Assembly 3 Screw an eyebolt into the secondary clutch shaft and lift out the clutch assembly Marine Transmission Service Manual 1021303 65 Disassembly Twin Disc Incorporated 4 Lift out the output shaft assembly Figure 32 Removing Output Shaft Assembly 5
124. nsmission Service Manual 1021303 119 Assembly Twin Disc Incorporated 120 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Installation Installation Prior to Installation CAUTION Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be made before the driven component is installed After installation of the driven component the crankshaft endplay should be measured again The endplay at the second measurement should be the same as the first A difference in these two endplay measurements could be an indication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage 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
125. nsmission oil filter Overhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve Overhaul marine transmission Hemove 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 55 Troubleshooting Twin Disc Incorporated Table 13 Troubleshooting Chart continued GP Valve Equipped Transmissions Cause Remedy 6 No neutral Harsh engagement or no engagement Low lube oil pressure Oil spilling out of breather Low Clutch Pressure Apply 56 6 1 Clutch plates warped Disengaged clutch has apply pressure Faulty Proportional Valve Faulty Temperature Sensor if equipped Profile Generator defective or out of adjustment Pump flow output too low Pump suction strainer plugged Air leak on suction side of Lube relief malfunction valve Broken piston rings Oil level too high Wrong type of oll Low Main Pressure Defective Valve Low voltage to Profile Generator Proportional Marine Transmission Service Manual 1021303 Remove clutch plates Overhaul unit Replace Proportional Valve Service transmission oil filter Replace Valve Proportional Replace S
126. nty four 24 months of service whichever occurs first Thisisthe only warranty made by Twin Disc Incorporated and 15 in lieu of an and all other warranties express or impliedincluding the given by T win Disc Incorporated T his warranty applies only to Bale non commercial non revenue earning marine pleasure craft applications delivered by Twin Disc Incorporated to the original customer on or after May 1 1995 The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated application engineering Twin Disc Incorporated is not responsible for any specific application installation of performance standard Any analysis program by Twin Disc Incorporated based upon customer supplied information is done solely as an accommodation to the customer and is not to be interpreted or construed as an approval for specific application or a guarantee of performance Twin Disc Incorporated cannot be held liable or responsible for incorrect information supplied or deviations from specifications provided by customer T he exclusive rem ovided T win Disc Incorporated whether arising out of warra Within the applicable be either the repair or replacement of any T win Disc Incorporated part or product found by T win Disc Incorporated to be defective For all models except MG 340 and MG 360 this include the labor to perform that work and to remove and reinstall or i it Inthiscontext la
127. nual direction control valve is in the NEUTRAL position This switch must be wired such that the engine cannot be started while clutch A or clutch B is engaged i C AU TION Engagement of a clutch with the Manual Direction Control Valve should only be done with the engine at idle speed Locking Pin Figure 12 Manual Direction Control Valve Marine Transmission Service Manual 1021303 Twin Disc Incorporated Operation Power Take offs Optional There is a separate manual part number 1020075 which describes the operation installation troubleshooting and service of the optional Power Take offs PTO s for this marine transmission Live Power Take off The live PTO drives accessories using engine horsepower Since the live PTO connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven whenever the engine is running Power Flow Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is splined to the forward end of the primary forward clutch shaft causing the primary shaft to rotate in engine direction during engine operation Power is transmitted to the secondary shaft by means of the transfer gear teeth on the outer diameter of the primary clutch housing These teeth are in constant mesh with gear teeth on the of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The pr
128. o the valve body and torque to 33 Nm 24 Ft Ib C Install the 3 8 nptf pipe plug or optional temperature sensor into the valve body and torque to 23 Nm 17 Ft Ib D Install the M27x2 0 o ring plug into the valve body and torque to 75 Nm 55 Ft Ib Regulator Valve Body M27x2 0 N o ring E plug 3 8 npt plug or Temp Sensor Main Regulator Spool Pilot Relief Valve Figure 81 Main Pressure Regulator Components Assembly 1020729 Marine Transmission Service Manual 1021303 113 Assembly Twin Disc Incorporated 1 Valve Assembly 1021658 Assemble the Main Regulator Valve body A Install the filter into the threaded hole of the valve body and torque to 7 5 Nm 5 5 Ft lb removed install a new check valve assembly into the bore of the valve body and drive it with a drift until it is flush with the face of the body Install the 3 8 nptf pipe plug or optional temperature sensor into the valve body and torque to 23 Nm 17 Ft Ib Install the gasket and cover without the adjustment screw to the valve body with four M8 x 20 capscrews and torque to 23 Nm 17 Ft Ib Install the spool with washer and spring into the bore Install the gasket and cover with the adjustment screw using four M8 x 25 capscrews Evenly tighten the capscrews and torque 23 Nm 17 Ft Ib Install the cap onto the adjusting screw finger tight as the main pressure must be set at the time of instal
129. osite engine rotation remove the heat exchanger hose from the rear end of the pump Remove the pump turn it 180 and reinstall it Remove the plug from the rear of the pump and install where the heat exchanger hose was Install the heat exchanger hose where the plug was When changing from RH rotation to LH rotation install an engine rotation plate Arrow to indicate the new direction of rotation Direction of Drive The primary input clutch shaft and driving transfer gear always rotates in engine direction The secondary clutch shaft and driven transfer gear always rotate in anti engine direction because the driven transfer gear is meshed with the driving transfer gear on the primary clutch shaft When the primary clutch is engaged the primary input pinion rotates in engine direction The output gear which is secured to the output shaft is meshed with the primary input pinion and so the output gear and shaft are driven in anti engine direction When the secondary clutch is engaged the secondary input pinion rotates in anti engine direction The output gear is meshed with the secondary input pinion and therefore the output gear and shaft are driven in engine direction Marine Transmission Service Manual 1021303 Twin Disc Incorporated Description and Specifications Construction Features Housings MGX 5114A housing consists of a front SAE 1 or SAE 2 housing and a rear half housing They are sealed together with a gasket
130. pproximately 100 psi or less Allow the fluid to flush the valve for approximately 1 minute 5 Turn the 1 4 hex head adjustment stem clockwise to achieve the main pressure setting Ahelpful practice is to turn the adjustment stem slightly beyond the desired setting approximately 5 psi and then adjust for the target pressure This aids in reducing variance in pressure setting due to torsional wind up of the spring Note If main pressure is to be set with cold oil adjust the main pressure approximately 5 to 10 psi higher than the desired value with hot oil 6 Tighten the jam nut to a torque of 20 Nm 15 Ft Ib install the protective cap and torque it to 14 Nm 10 Ft Ib tie Transmission Service Manual 1021303 Twin Disc Incorporated Assembly Valve Assembly 1020729 1 Install a main pressure gauge into the port on top of the Top Valve body 2 Remove protective cover cap located at the end of the adjusting stem This will expose a slotted adjustment stem Loosen the jam nut on the stem Figure 88 Main Pressure Regulating Valve Assembly 1021658 3 Start engine with controls in neutral Note This must be done with the transmission in Neutral 4 Turn the slotted adjustment stem clockwise to achieve the main pressure setting See the specifications in Description and Specifications 5 Tighten the jam nut to a torque of 20 Nm 15 Ft Ib install the protective cap and torque it to 14 Nm 10 Ft Ib Marine Tra
131. products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you Note Do not order parts from the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number on the units nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty 14 Marine Transmission Service Manual 1021303 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
132. r assembly and gasket followed by the spring s and spool D Remove the four M 8 x 20 capscrews and remove the cover and gasket Remove the orifice and screen assembly for cleaning F Remove the ball check assembly only if necessary Removal will require destruction and replacement of the assembly Temperature Sensor Filter Check j j 4 Figure 55 Remove Pressure Regulator Valve Components Cover Cover with Adjustment Spool Spring Figure 56 Remove Main Pressure Regulator Valve Components Marine Transmission Service Manual 1021303 85 Disassembly Twin Disc Incorporated 86 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Cleaning Cleaning and Inspection Cleaning and Inspection Note Replace all oil seals gaskets O rings piston rings seal rings snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents or by steam cleaning Parts must 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 valves etc Flush all hoses tubing coolers etc particularly if th
133. re 69 Installing Oil Dam Retaining Screws and Output shaft Assembly Marine Transmission Service Manual 1021303 105 Assembly Twin Disc Incorporated 4 Install the forward and reverse clutch groups into the rear housing Figure 70 Installing Forward Clutch Assembly 9 Install the gasket onto the rear housing and install the front housing and twelve M10 x 35 screws and washers Torque the screws to 45 Nm 34 Ib ft Figure 71 Installing Front Housing Capscrews 106 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly 6 Check the endplay of all three shafts as follows a Install the endplay adjustment fixture TD 300388 to the front end of the forward shaft and attach a dial indicator securely onto the housing so that the indicator finger rests on the end of the clutch shaft Apply to the shaft a downward load of at least its own weight Maintain this load while rotating the shaft several times and set the indicator to Zero Use a fish scale and apply an upward load of at least twice the weight of the shaft The indicator movement will be the endplay Record the forward shaft end play Repeat operations b and on the reverse and output shafts Hecord the respective endplays Figure 72 Checking Endplay Marine Transmission Service Manual 1021303 107 Assembly Twin Disc Incorporated Remove the front housing from the unit Remove the special ground bearing outer r
134. re at 4 until flow rate at S is 2 3 L min 6 Add or remove the 1020111 shims as necessary to achieve the minimum sequence pressure of 1344 34 kPa 195 5 psi for MGX5114A and a flow rate of S of 2 3 L min 6 gpm Record final pressure at Z with flow rate of 2 3 L min 6 at S4 4 Increase flow rate at S to 3 8 L min 1 0 Pressure at 4 to be within range charted in 1 2 Record final pressure at Z with flow rate of 3 8 L min 1 0 at S4 PX 11801 SERIES CARTRIDGE VALVE PRODUCTION TEST SHEET Sequence Valve Serial Number Leakage at S with pressure at Z set at charted pressure given in section ll 2 Leakage at S with pressure at Z set at charted pressure given in section ll 2 Pressure at Z with flow rate of 2 3 L min 6 at 1 Pressure at Z with flow rate of 3 8 L min 1 0 at S DUE Tester Date Twin Disc Incorporated Illustrations Illustrations List of Illustrations The following pages include illustrations that are specific to this model The illustrations included are listed below Note Any part numbers listed in the following illustrations are for reference only Please refer to your bill of material for part numbers specific to your model Forward Clutch Shaft Cross Section Reverse Clutch Shaft Cross Section S Valve Cross Section Output Shaft Cross Section Forward Clutch Exploded View Reverse Clutch Exploded View
135. ressure oil 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 ng vax o S B i SMISSION EQUIPMENT NO BILL OF MATERIAL NU MUST BE GIVEN WHEN ORDERING PARTS OIL CAPACITY 4 MIN OIL PRE URE WHEN CRUISING UBRICA EMERY HOUR R
136. riving transfer gear from the input shaft The shaft and gear are supplied as an assembly 74 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly Disassembly of Secondary Clutch Disassemble and assemble the secondary clutch in the same manner as the primary clutch Take care not to install the secondary clutch spring retainer onto the primary clutch or vice versa The retainers are not the same Note The s valve on the secondary clutch shaft is retained by an orificed plug and there is no spacer between the plug and the valve Marine Transmission Service Manual 1021303 15 Disassembly Twin Disc Incorporated Disassembly of Output Shaft CAUTION Do not remove tapered roller bearing or output gear from the shaft unless replacement of parts is necessary 1 If disassembly is required proceed as follows a Place the output shaft and gear assembly under a hydraulic press supported on the gear with the rear splined end upwards Ensure there is sufficient space under the shaft for it to pressed from the gear and bearing b Place a protective disc on to the end of the output shaft and press on the shaft until it comes free from the taper on the gear Figure 45 Pressing Output Shaft from Rear Bearing Inner Race and Gear C Continue pressing until the shaft drops free from the rear bearing 76 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly
137. rstanding 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 unaccepted maintenance working practices Marine Transmission Service Manual 1021303 11 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 shaft brake or other shaft locking device must be used WARNING To prevent accidental starting of the engine when performing routine transmission maintenance disconne
138. s Marine Transmission Service Manual 1021303 133 Installation Troll Enable Connect Switch Return if equipped Solenoid Switch B Solenoid return Solenoid Switch 134 A Twin Disc Incorporated Table 15 Module Power Connection Chart Wiring Option 1 Wiring Option 2 Wiring Option 3 to the negative terminal of the engine battery Connect the positive terminal of the engine battery through the switch contacts used to energize solenoid B Connect to the negative terminal of the engine battery Connect to the positive terminal of the engine battery through the switch contacts used to energize oolenoid A Connect to the same ground point used by the gear controller or the engine control Connect to the output in the gear controller that is used to energize Solenoid B Connect to the same ground point used by the gear controller or the engine control Connect to the output in the gear controller that is used to energize Solenoid A Connect to the same point as the control s power ground signal Connect to the control s Solenoid B positive driver output Connect to the control s solenoid negative output circuit Connect to the control s Solenoid A positive driver output The customer supplied normally closed not in neutral relay must be located in a position to not be affected by vibration The coil must have 200 ma maximum current draw The coil must be
139. screws securing the hydraulic pump to manifold assembly and remove the pump and gasket Figure 20 Removing Hydraulic Pump 4 Disconnect the wiring and remove the electronic module and six capscrews that secure the GP valve top plate to the lower plate Remove the gasket and four capscrews that retain the assembly to the housing and remove the GP valve lower half Figure 21 Removing GP Valve Assembly 60 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly 5 Place the unit on the front housing side Remove the screw securing the plug cover into the manifold and screw an eyebolt into the tapped hold in the cover Remove the cover Remove the screen filter Figure 22 Removing Screen Cover and Screen 6 Remove the three capscrews from the end of the output shaft and remove the retaining washer rectangular rubber ring and shims Figure 23 Removing Output Flange Retainer Washer Capscrew and Rubber Ring f Pull off the output flange Figure 24 Removing Output Flange Marine Transmission Service Manual 1021303 61 Disassembly Twin Disc Incorporated 8 Remove the capscrews still securing the manifold onto the rear housing Figure 25 Removing Capscrews on Manifold Assembly 9 Remove the manifold from the rear housing taking care not to damage the piston rings on the end of the clutch shafts Remove the manifold gasket Figure 26 Removing Manifold Assembly 62 Mari
140. sembly mounted on Marine Transmission Marine Transmission Service Manual 1021303 79 Disassembly Twin Disc Incorporated Disassembly 1 Disconnect the connectors at the proportional valves the neutral switch and the temperature sensor if equipped and loosen the four M6 1 0 capscrews that retain the Electronic Interface Module to the Hydraulic portion of the valve assembly If the Electronic Interface is not being replaced it can be set aside without disconnecting the remaining wires from the installation Figure 48 Electronic Profile Module typical 2 Remove the six M10 1 50 x 70 capscrews that retain the top valve body assembly to the transmission and remove the top valve body assembly with gasket if not previously removed 80 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Disassembly Proportional Valves Manual Override Valve 4 7 _ E j ta ss Figure 49 Top Hydraulic Valve Body Assembly 3 Remove the four capscrews that retain the main regulator valve assembly to the transmission housing or ditch plate and remove the valve assembly and gasket 4 P m Main Regulator Valve Body P p T Temperature Sensor Main Regulator Spool Figure 51 Main Regulator Hydraulic Valve Assembly 1021658 Marine Transmission Service Manual 1021303 81 Disassembly Twin Disc Incorporated 4 Remove the M
141. stall the output gear Therefore the press should be shielded as a precaution 2 Place the output shaft and gear assembly between centers and check the runout Maximum allowable runout at gear face is 005 T I R If runout exceeds 005 remove the gear following the steps give for removal above Turn the gear 180 and reinstall it following the steps above for installing the gear Check runout again Marine Transmission Service Manual 1021303 103 Assembly Twin Disc Incorporated 3 Heat inner races of roller bearings in a 120 C 250 F oven for not more than thirty minutes 4 Install the inner races Allow them to cool and then seat them pressing on the cone only against the shoulders on the shaft 57 z mh Figure 67 Pressing Front Bearing Onto Output Shaft and Installing Inner Races 104 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly Installation of Shafts and Clutch Assemblies 1 Install the oil suction tube Install the M6 x 12 socket head capscrew and torque to 9 5 Nm 7 lb ft Figure 68 Installing Oil Suction Tube 2 Install the shim retainers and special ground tapered roller bearing outer races into the front housing Note Do not install adjusting shims at this time m Install the output shaft group into the rear housing Install the oil dam and secure with the two screws and washers Torque the two M10 x 20 retaining screws to 46 Nm 34 Ib ft Figu
142. t 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 52 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting of GP Control Valve with Electronic Interface The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Electronic Interface LED Indicators The electronic interface control modules have one green and two red LED indicator lights The green power light is illuminated only when the transmission is in gear The following table lists the reasons for the various conditions where lights are illuminated This should guide in troubleshooting problems See the wiring schematics in the Installation Section Troubleshooting Tables begin on the next page Table 10 LED Light Status Light Status Profile Generator E troll Module Non trolling Supply Voltage gt 9 0 Volts Supply Voltage gt 9 0 Volts Red light on Valve coil commanded on Valve coil commanded on Ore red light flashing Open circut in an energized Open circuit in an energized valve coil circuit valve coil circuit or Valve coil leads shorted together or Low coil current Bot
143. t shaft aligning the steel plates with the splines on the pinion Figure 62 Installing Pinion on Clutch Shaft 14 Calibrate the S Valve following the procedure shown in Special Tools section Lubricate the external o ring 15 Install the s valve into the bore in the center of the input shaft followed by the spacer and orificed set screw Apply Loctite 242 and torque the M18 x 1 5 setscrew to 14 Nm 10 Ib ft Figure 63 Install S Valve Marine Transmission Service Manual 1021303 99 Assembly Twin Disc Incorporated 16 The two rear thrust bearing races are designed with different inside and outside diameters Install the rear thrust bearing onto the forward pinion in this order thrust race with the smaller O D the O D pilots in the pinion bore needle bearing and thrust race with the larger O D this thrust race pilots on the shaft Figure 64 Installing Rear Thrust Needle Bearing and Thrust Races 17 Install the heated inner race onto the input shaft Qu 4 Figure 65 Installing Heated Rear Bearing Onto Clutch Shaft 18 Install the piston rings on the clutch shaft 100 Marine Transmission Service Manual 1021303 Twin Disc Incorporated Assembly Assembly of Secondary Clutch Assemble the reverse clutch in the same manner as the forward clutch Take care not to install the reverse clutch spring retainer onto the forward clutch or vice versa The retainers are not the same
144. the suction line to the pump and the oil filter is located in the pump outlet line Both should be checked and cleaned at the stated intervals With a new transmission change the oil and filter element and clean the suction strainer screen within the first 50 hours of operation Change oil and filter element and clean the screen after each 1000 hours thereafter or more often if conditions warrant For a rebuilt transmission check the filter element and suction screen after eight hours of operation If the filter and screen are 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 and filter after 1000 hours of service or more often if conditions warrant Marine Transmission Service Manual 1021303 Twin Disc Incorporated Preventative Maintenance Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located in the manifold below the pump See Engineering Drawings for suction strainer location See discussion under oil change interval Type Oil Recommended see Description and Specifications Filling 1 Remove the filler breather in the
145. transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures 0D D D O Note Hemoving and installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Removing and installing the control valve Removing and installing the manifold Further disassembly reassembly of the primary or secondary shafts will require removal from the engine and the use of tools and equipment normally not available on board the vessel Marine Transmission Service Manual 1021303 47 Preventative Maintenance Twin Disc Incorporated General Maintenance 48 Overhaul Interval A complete overhaul and thorough inspection of the unit should be made at the same time as the scheduled engine overhaul Refer to Cleaning and Inspection for more detailed inspection instructions Oil System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil in it With the engine running at low idle and the transmission in Neutral check the oil again The oil level should be near the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval Maximum Note A suction screen is located in
146. ventative Maintenance Deterioration 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 flex plate or coupling plate elongated or deformed This could be caused by improperly assembled parts loose parts vibration or improperly torqued parts Bolts nuts bent worn or stripped threads Inspect the hub looking for the following Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found Marine Transmission Service Manual 1021303 51 Preventative Maintenance Twin Disc Incorporated Heat Exchanger Check Inspect heat exchanger oil lines for leaky connections kinks cracks or other damage Replace damaged lines Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days If over 50 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do no

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