Home

Service Manual Marine

Contents

1.
2. Operation Twin Disc Incorporated Clutch Clutch B Solenoid Solenoid ASCLI ASCU E nm H F D H D i V Sl Z o S n B i f Y cp eem S M MANUAL OVERRIDE MODE SHOWN IN NEUTRAL MANUAL OVERRIDE NEUTRAL START SWITCH G DE Pry Y de EB HE 5 Section Clutch Clutch section P
3. 5 638 DRILL 1 06 DIA THRU 40 REQ D TYP TYPO _ 4 375 2 335 DRILL 5 16 312 DIA x 1 00 DP pese 3 8 16 UNC 88 DP 8 REQ D DRILL 57 64 890 DIA THRU 4 REQ D SHOWING HOLES x SHADED Oo i mE NE 1 500 A i Ax 2 lt z Se lt 5 638 Vx d e Ay a d 2 4 375 N DRILL 21 32 C656 DIA THRO TYPO TAP 3 4 10 UNC 1 REQ D 2 335 N ZZ dh KISSD RU 4 REQ D ET 14 ED RUD 0 50 GRDUND SURFACES MUST BE PARALLE WITHIN 0005 EACH THER 50 CLEARANCE FOR N UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CDRNERS HYD FITTING STAMP 200 23 1 DET 10 PT 1015285 441 l N 2 500 us gt l 1 E DIA 8 063 de EST DIA TYPICAL 15 000 PLATE lt 1 gt Hels MS 45 49 Rod au d bc lutput Geor to Shaft Puller T e00C3 1 3 amp 4
4. CONNECTOR P PRIMARY CLUTCH SDLENDI SECONDARY CLUTCH SOLENOID p NEUTRAL SOLENOID MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHE f MANUAL OVERRIDE IS IN USE amp MATING WIRING HARNESS 1017403 TRANSMISSION IS IN NEUTRAL ELECTRIC CONTROL MODE SWITCH NOTE CLOSED WHEN MANUAL VALVE EVE WHE AGES STEM IS LOCKED IN ELECTRIC ON ITS A ERMITS FREE MODE VEMENT WITHI 50 CIUTAL ROTATION amp 114m AXIAL MUI PRIMARY SECONDARY REQUIRED FOR C ROUL CLUTCH CLUTCH SOLENOID SOLENOID Tm E MANUAL OVERRIDE 36 MN POSITIO CFOR REMOTE CONTROL BRACKET Wot ue PN 247 i at C m uit PUSITION 753 E INCH Se OD ji 1 4 DIA THRU J f 2 S TO en So 50 pep e 4 ES oS n 25 h ya ENGAGES E ERE FUP CLUTCH bd TL Tt ca E TAI CECTRI LECTOR VALVE
5. LANI I IEEE See ee ew CD ENGINE a BY VENDUR Ji OIL TE A APR RE Ve AE AF OV PSE GC ENGINE UL qu V ISI Y BASE N ON SUMP TEMP CUNDITIUN Ar UP FADY LPERAITLUN LANI Y JF MIN F R 2 C MIN 65 85 C mM SOF MIN 72 227 CAF So 10 C MIN 80 93 C TON BELON 65 C OR ABOVE NOI RECOMMENDED gt DSG 15 RACINE WL 53403 U S A 2415 50 1 Figure 2 Oil Specification Plate 28 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications Table 4 Oil Pressure Specifications Mechanical Valve 250 psi Springs Main Pressure at Valve Primary Secondary Shift Inlet Clutch Min Clutch Min Position kPa psi ps psi Neural 125480 18 51 o fofofo N 0 140 3 20 um m 20260 o we rss Nena o o 1690 1830 245 265 0 0 1690 100 380 Table 5 Oil Pressure Specifications Electric Valve 290 psi Springs Main Pressure at Valve Primary Secondary
6. 64 pm rer CLUTCH Clutch 47322 Clutch A4 Be Solenoid Solenoid ASCU ASCO _ l I p IERE uS cl MANUAL OVERRIDE EUTRAL START SWITCH Em hi I 7 l hot 3 D E A Dod L e o x SS y A AT Hh section C C Clubes section BS A rd sump ELECTRIC CONTROL MODE SWITCH SC LIS SUMP ROR Orifice 2 KNX D gl S MI P x 4 m EVER LUCKED ELECTRIC i E UTRAL PERATIUN H E Filter EU cT us lap c qa IE Sump M MAIN PRESS S SLIME I EE FD Figure 26 Hydraulic Schematic Electric Valve in Manual Mode Marine Transmission Service Manual Twin Disc Incorporated Operation Live PTO Optional The live PTO drives accessories using engine horsepower Since the live PTO connects the accessory to the primary shaft of the transmission via a d
7. TYP d TYPO 4 N E F 2 335 1 500 L 1 500 11 12 SPLIT m d CENT eee DRILL 27 64 421 gt DIA 175 DP N 1 2 13 UNC x 1 62 DEEP 2 DRILL 5 16 6319 DIA THRU 3 8 16 UNC 4 REQ D DRILL THRU amp FOR 1 2 SUC HD CAP SCR 2 REQ D BEFORE SPLITTING DRILL 49 64 7656 DIA x 1 25 DP TAP 7 8 9 UNC x 91 DEEP 8 REQ D STAMP T 20023 1 DET 1 PT 1015285 DIA 15 00 10 25 PI _ __ 85 x 45 x 45 TYPICAL TYPICA c AWO ll 06 R NN 2 205 1 299 25 R 3 000 59 p 9 45 2 205 PA 03 R 4 966 HA _ 2 795 1 COLLAR 1 REQ D MAT 4140 HDN 45 49 Rc 94 DIA 1000 1 06 DIA 1000 TYPICAL TYPICAL 2 000 03 x 45 x 45 SPACER 40 REQ D SPACER 4 4140 HDN 52 59 4140 HDN 52 59 Rc Marine Transmission Service Manual 229 Special Tools T 20023 1 4 of 6 Twin Disc Incorporated
8. MAIN 2 gt 2 N AL SSE NL E 1 4 15 la THAE DRY AL Al ENDER LETAT LENS ECONDARY CLUTCH A u IR Mis X 15 HREAD a IN 6149 RE MUN gt UG D TALI B3424 PERATURE INDICATING W G BULB H B NG UNIT ZO we J4 SE E IY DRAU E E 2 CUP 2 ee WIIH doe THU lt PCUGGE DY UCTIUN B R 2 M2 X 2 HRE ME TRII IR N MM 6149 AUX ARY LUBE UP NEE T IYDRAULI TAGRA Figure 9 Installation Specifications 1 RH ENGINE 1015509 cy E FITTING Z 219 gt
9. Figure 36 MG 5600DR Lube Relief Valve Marine Transmission Service Manual 91 Disassembly 92 Twin Disc Incorporated Lift out the primary and secondary shafts using tools 18050 726 and 18050 727 Disassembly of the primary and secondary shafts are covered later in this section Use caution with the front pinion bearing cones They are loose on the pinion diameter and should remain in the housing On some ratios the diameter of the output gear will allow the bearing to come out with the shaft and it could easily fall off causing damage Set the shafts aside for further disassembly The four capscrews and washers on the front of the housing near the output shaft these were loosened prior to locating the transmission on its front face can now be removed Rotate the output gear until the oil pan is accessible to be removed through the opening in the top of the transmission Figure 37 Location of Four Bolts for Oil Pan Marine Transmission Service Manual Twin Disc Incorporated 10 11 12 13 14 Disassembly Remove the eight M16 2 00x45 capscrews and the rear output bearing retainer with the bearing cup and the shims Use a hoist and lift the output shaft and gear until the gear contacts the housing Place blocks under the gear to hold it in a position where the front of the out
10. WIIH IDORSIUNA SA IP S d A d amp N x O Qj ot WITHOUT ORSIONA STOP CAPSCREW 10416 24 CUUPLING 1016680 lt 21 FWL Figure 5 Remote Vulkan R 1721 No 460 Flywheel UUIPUT FLANGE FACE 1119 9 1016683 18 FWL2 HUB 10166794 u URQUE H C 641 4 9 6731 PI WITHOUT URSIUNA STUP CA P SCREW 10416 C24 COUPLING 1016682 Sel FWL Figure 6 Remote Vulkan R 1721 No 530 Flywheel 34 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications 13179 IO OUTPUT FLANGE FACE ING 1016684 lt 18 FWL RH ENGINE ING 1016685 G FWL L H ENGINE 460 FWL 9 242 9 5 15 LW MALOSSA 24 10166784 Figure 7 Remote CX 72 460 Flywheel FLANGE FACE Es PLING 1016683 48
11. SIDE F HEAT EXCHANGE F THREAD N E 7 i 1 172 11 172 N R IN SI PTF EXCHANGER 1 4 18 gt TH D RESSURE PICKUP POR
12. CUST R INSTALL PRESSURE GAUGE LINE HERE PRESSURE GAUGE BE UNTED IN P HOUSE CSEE MARINE TRANSMISSI DRAWING EARING PINI E 1724 KPa 7108 MARINE TRANSMISSION CONTR VALVE CONDARY SHAFT RUNI amp REAR BEARING PINION CLUTCH LUBE DISENGAGED FILTER R 00 T HEAT EXCHANGER Figure 11 Hydraulic Schematic Manual Control Valve Operation Twin Disc Incorporated Manual Control Valve Assembly Manual Control Valve Neutral 50 Hefer to Figures 12 and 13 Oil enters the control valve body through passage A and fills chamber B The oil causes the pressure regulating piston to partially compress the piston outer and inner springs against the pressure rate control piston This pressurizes the oil in chamber B This pressure varies with engine speed The movement of the pressure regulation piston against the springs exposes port C in the valve body Port C directs overage oil to the lubrication oil circuit Passage D which is the engaging outlet to the primary clutch and Passage E which is the engaging outlet to the secondary clutch are inte
13. Figure 123 Electric Valve Details Marine Transmission Service Manual 197 Installation Twin Disc Incorporated 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 198 Marine Transmission Service Manual Twin Disc Incorporated D D D UD UD UD L Special Tools Special Tools Recommended Pump Set and Fluids T 19987 T 19987 1 19987 19987 18050 726 18050 727 18050 682 18050 685 18050 686 18050 684 T 18050 687 T 18050 693 T 18050 681 T 18050 689 T 18050 691 T 18050 690 T 18050 694 T 21413 1 of 2 T 21413 2 of 2 T 18050 692 T 18050 683 Marine Transmission Service Manual Gear Lifting Fixture Gear Lifting Fixture detail 1 2 and 3 Gear Assembly Fixture detail 4 Gear Assembly Fixture detail 5 and 6 Clutch Pickup Fixture Primary Clutch Pickup Fixture Secondary Bearing Driver Caged Roller Bearing Pick Up amp Driver Bearing Driver for Cup Bearing Driver for Outer Race Bearing Driver Inner Race Driver Seal Bearing Cone Driver Bearing Driver Bearing Driver Bearing Driver Spring Hold Down Retainer Output Flange Fixture Output Flange Fixture Seal Driver Bearing Driver for Cone Special Tools Twin Disc
14. 249 MIGSODODB 250 1018100 2 MG5600DR 251 10181003 252 1018100 4 MG5600DR 253 A7119S Hydraulic Schematic Mechanical Valve 254 A7119X Hydraulic Schematic Electric Valve 255 5570 MG5600 Assembly Instructions 257 5570 MG5600DR Assembly Instructions 265 B3504AH Mass Elastic System MG5600 275 B3504AT Mass Elastic System MG5600DR 276 Marine Transmission Service Manual 11 Table of Contents Twin Disc Incorporated 12 Marine Transmission Service Manual Twin Disc Incorporated Introduction Introduction General Information This publication provides operating information for Twin Disc model MG 5600 and MG 5600DR marine transmissions Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wisconsin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and appl
15. Sef Z 2 H L J p l1ei1odiooul 5510 u AL suoneoiioedg pue uonduoseg Description and Specifications Twin Disc Incorporated Table 9 Limits for Marine Transmission Equipped with Electronic Control Valve with 2000 kPa 290 psi Spring circle units in actual column Main Pressure at Primary Secondary Lube Valve Inlet Clutch Clutch Temp Range Ratio or rpm Min Act Max Min Act Min Act Min Act Max 99 kPa kPa ud kPa kPa kPa kPa kPa kPa kPa qeg F psi psi psi psi psi psi psi psi psi psi Ratio 1960 2137 1960 Primary 2 1 2 701 1 28 2100rpm 1960 2137 0 6561 Secondary 285 310 0 1950rpm um x _ JE E 5 Note It is required that lube pressure with primary clutch engaged must equal lube pressure with secondary clutch engaged within 21 kPa 3 psi All shifts must be done at or below 1200 rpm 40 Marine Transmission Service Manual Jenue N 2I A19S UOISSIUSUEJ 1 LV l TH WATER UT 1 172 11 1 2 NP
16. TWIN DISC INCORPORATED Service Transm Marine Components MG5600 MG5600DR 1020007 Document Number 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 1020007 May 2001 Marine Transmission Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE TRANSMISSION Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer asto which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of shipment by Twin Disc Incorporated to original customer but not to exceed twelv
17. 1015285 SHAFT DUTPUT Marine Transmission Service Manual 225 Special Tools Twin Disc Incorporated T 18050 688 2 of 2 DRILL 27 64 C481 DIA THRU FLAME HDN 1 2 13 2 REQ D 2 i 1 25 DIA QR 3 REQ D i 3 50 N 0 62 Pos ju Wi SQUARE 2 16 03 x 45 2 0 50 125 175 3 25 FE 7 8 8 THREAD AN 100 DIA E i 1 13 1 50 i 4 1 25 8 00 KNURL M24 x 3 THREAD 12 19 3 D B REQ D 11 07 FIRM X FLAME AS SHOWN 8 00 38 x 30 TYPICAL G Y 7 62 DIA N 350 DIA 8 HOLES lt 40 1 WELDMENT ASS Y gt REQ D EQUALLY SPACED ON 360 DIA ROWS AS SHOWN amp HDN NOTE GROUND SURFACES MUST BE PARALLEL BE ARING AIME 15050 66550 WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED DETJREQ MAT DESCRIPTION STOCK S
18. p 800 BEARING DRIVER 1 REQ D 1 25 DIA SECTION A A MAT M S CARB amp HDN 5 X D A 1015522 HOUSING as vou 12 R NOTE GROUND SURFACES MUST BE PARALLEL 77 F m 0 12 WITHIN 0005 OF EACH OTHER TAR At rZ A UR NOTE UNLESS OTHERWISE SPECIFIED BREAK EN EA T zu AEE OPARE CORNERS 112 22 L AF 9 00 DIA 25 X 30 10 41 DIA qmm ep _ DRILL THRU amp C BORE a er FOR 3 8 SOC HD CAP SCR 5 REQ D 11 10 Bearing Driver for Cup T 18050 686 DET IREQ Description amp Stock Size Locator Poly Kitco 10 5 Dia x 1 00 THK Jergens Washer 32004 SOC HD CAP SCR 3 8 16 x 1 00 LG Handle 1 25 DIA x 22 75 LG Bearing Driver carburized and hardened 12 0 Dia x 2 0 THK 3 8 16 5 REQ D FOR DET 5 LOCATOR dng 10 9989 06081 1 5510 UIML 1001 219 4 Jenue N 32IA419S UOISSIUISUPJ SUNEN BOTH ENDS KNURL DRILL 5 16 DIA X 1 25 DEEP FULL 3 8 16 X 1 00 2 REQ D 375 DIA OPTION TO ADD LENGTH DE ROD PICK UP 1 REQ D _ 6 62 DIA B C 8 EQUALLY SPACED HOLES 2 00 DIA NOTE STAMP T 18050 684 amp BEARING 1015512 10 25 DA 4 25 DIA KNURL 790 DRILL 5 16 DIA X 1 25 DP 3 8 16 X 1 12 D
19. CI P ING AST T SP AV uw li pw atc it i Du ee 2 02 B2375 RE L gt we vo DN i INION 85577 101643 i PINTON aSS Y 1016492 28 pr rod FOR 1055101 UNITSTOR 007614 UNIT Pan 719272 A ATAPTER ASST 1017698 GLAR 1116497 GEAR 1216498 GEAR 1013433 GEAR DEES I aDaPTESX H R 10 6484 ij om HUA 1616484 it f lew u j SULLPIN Ml827aH j E 427 47 j x 1 r NIPPLE ne ee eee eee PIMOS ASS d poc GASKET 10155328 m CEAR 016498 E i _ HIB 1316484 FF CAUPLING H2367 RING MISOSEE 22911 ATI 71 i i j CARRIER 1015436 E PIN 1035 t4 GASKET 1013567 NOTZ SRAMIML 8 THIS VIEW SHEWS THE FuMP i AEz amp T MA SESHE ARSANGEMENT CSCI wITII ELARING CUP MECHANICAL VALVE T 1 IH i AU L F SHIM 1015463 __ 2b RHIM 1015464 Las SER NOTF Wh Uig SHIM 1015465 PRIMARY amp SECDNDAZY 5 f am o MANI UL AST 10015510 42 24 MINI ILD 1015569 i c BALL MA1034K t3 UT
20. CONNECT UIL PRESSURE LINE HERE 27 X 20 TE EIRIC PORT CONFORMS ISH 6149 UNT GAGE IN USE Figure 10 Installation Specifications 2 m PRIMARY ACTUATI 18 X 13 ETRID P ISU 6 RE VE PLUG amp INSTALL B34844 EMPERATURE INDICATING SWITCH SENSING BULB HERE BEF URE PERATING UN 2 14 NP LF CDRYSEAL YDRAULIC DIAGRAM D E E PICKUP PURT IS PPOSITE 16 X L5 JARY CLUTCH 5 THD PORT CONFORMS 6149 PRESSURE pre X 20 IH C PURT CONFORMS 6149 UXILIAR UBE SUPPLY SEE HYDRAULIC RAM e TWIN DISC 6 a
21. H 6a _ ro C3 Cr ee ho tT hU eee zl TL k _ Il x n ad nat PO S800 TEAS Om CU H Whe 4016001 1017614 r i 4 E i S Py ELEC FIL CONTEDL we 4 M 5 IL IE L 3 u tee air a w T LENTROL WALE Cac vox Vus 7 i _ ett La z a Ran 70070000000 E uswa Te IO 65 5600 1017614 gt LI 15 Wy 1 2 ku m SS 4 T a I E t e HIER lg E m E 2 F 1 re 44 tat riat T a7 2 i og 1 1 z l 1 3 L 4 i i 1 i 4 3 1 uy ni it oie 1 1 x P LI LI LI I i IE LI 3 K LI o _ Uu 3 r E r 4 1 21 Dd 7 F 1 r 1 E D r E MEE RJ i
22. i i Lo SPRING 6 78 ZU IEE RE EASET DT CHES LUGE TUBE po Mu nn SLCLRUAR Y ds sk CLIC CUBE o CUSTOMER INSTALL E MI cr a SAN UIZENGAGE PRES SIRE LINE E eur F i PRESSURE BE MOUNTED 0p 2 if Ne 14 PILOT USE f 5 pmo SEE MARINE TRANSMES SID 2 INSTALLATICN DRAWING 2 c 7 artuum C ee LUPE HO geleg trig ror ul 1 UE agg EE corteo watve IMBURA 5 avadacoo Jfeferesce volwe hyde o ic 5 _ aia i z ol amp _ amp I b j 2 22 de To gon n Oe E e x i A UA z mz mn i Z u ok m Bp CUSTOMER 11 r_I 1 AER 27 Z IWS ALL SE 2 Z ju x 8 RESSUSE a ee 1 i GAUGE AND 2 ut pa LE T LISE HEE I Mates 1617172 LA SLD KPa MAST ME i 4 MEM 1 TRANSMISSION PXIMaSY SHATT CONTROL VALVE SM Dl 25 TIM GE I Up x UA E es UN MEUTXAL c j Pa iy i Qd B py e P E M Z e
23. i 7 E i I 1 I 1 1 14 LI d ja _ 5 SAE 0 FRONT HOUSING MDLCIAMHILAL LONTROL I eM xA 0707 m ERA Lo icc es VS A em OBET Je 1015239 URS a T Da 5600 raring Teanseission T O oW 1 1 2 _ _ T 1 i I M i H DE 1 1 ro cs 1 PE Ua TEE m gt p teh iJ E x ur Sot 1 1 el g UEU zi co LI I Lo m E ala zu xm o m nc ee 1 Ld L WR ote zo J a TER T 21 1 1 h _ u jos 7th T c to Wen vieta rt C y apo l r Ca Ga Cad MZ I T I I ETT TT T I 1 _ 1 1 _ 4 _ FERT H RISTIMI 00 FRONT HOUSING OPTIONAL ELECTRIC CINTEJL Valve CETIONAL LLEC TIC tot eae TY ods t MO i 2 z L 1015239 SOJO marie renmsmrs
24. 060 _ 3 With the indicator mounted as in the above paragraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing Thousandths T Indicator Engine Z Flywheel Engine Crankshaft Loni 590 Engine Flywheel Housing Figure 101 Checking Flywheel Housing Bore Eccentricity Marine Transmission Service Manual 169 Installation Twin Disc Incorporated 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the above Table for allowable tolerances 5 Bolt 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 4 Engine Flywheel Engine 9 z Housing sJ i LJ a Engine Flywheel H i Hone Crankshaft nacator Figure 102 Checking the Flywheel Face Runout 170 Marine Transmission Service Manual Twin Disc Incorporated Installation 6 With the indicator mounted as in the paragraph above adjust the Indicator tip so that it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot bor
25. vazi LH 1016670 mE ps a 1017609 10126094 10176098 e T CISb 70A 11166 LHR RMS AI LPL T d _ CAPSCREW MIT3eR 141 AN To MICDAEK 45 ELEM Lu 1017611 76118 10176 B MUSE A um CAS veo ee A LI a x MX MECHAH PAL vaL vC NLY HOSE AT MECHANICAL VALVE MASE SAE MASE SAE SEE CHART anh a _ E w Madden A Ar SA S MASS ge nog Te M D F t 1 ia imr HOSE Pr RIMECHARICAS SAL F MAE SAR FITTING 20 72 0 0 15 MATD3SE TRICAL A VE Made 34 MA eA RUE Dag WASHER MAYD35SE HOSE ELECTRICAL VAL ME G gt EI Abs imo UPS eon T S MM u BASKET 229 HOSE E BLA valve Ade AL Macs 2c a u S Sod Ul ZU 1 amp THESF HOSTS ARE USED WITHOUT IHE2F8US 51 VALVE WHEN ADAPTER 1017217 T wm SEE CHART BPTIONAL THERYUSTAT VALE IS USED SEE CALLOJT IN capereew po DIESE u 7RAINZR E2409 wlew RIGHT ALSI SEE UTHER EBzXED AREAS FOF ZING AZGIGBK 2 ee E IL 3L c T PXL UIHER DIFFERENCES BETwEEM MECHANICAL amp ELECTRIC YAL VES gt 4
26. Coi un E I _ _ 2 _ T l E E V l Ha E i DE i 4 2 c r 2 1 i 1 i Pi I T 1 E l I l z 7 I Do gt E I I I 1 4 LI I o n _ _ 1 n i L T i mE r U LI eni l _ I UC umo gt UU ZEN PIE n B I E E 1 mra 4 i Lc 4 1 Tx _ LI 1 1 E I un 2 ua I 1 a T e T E 8 f 1 Z M je Ls E jd a E i 2 i n 1 f 22A Ol 1 24 mH pnm r 1 2 y 9 1 l 1 2 Do LL ii wi Feu ER x Dru 3 a u dx F i 1 m _ 4 i 3 i I i m RETE 1 I rows i E T J i z I B Joye e ps 2005 la T I il gt Loose Say rt al r 2 TD i oe
27. 19 25 5 8 X 1 3 4 FLAT STOCK 4 69 j 1 2 EYEBOLT 1 2 X 2 FLAT STOCK 0 50 REF LIFTING TOOL FOR CLUTCH REMOVAL IN BOAT 23 00 24 00 5 8 X 1 3 4 FLAT STOCK 5 8 THREADED ROD 9 25 MEL 3 4 UNC BOLT WELDED IN PLACE L 3 50 11 23 Lifting Tool for Clutch Removal in Boat T05600 DET REQ MAT Description amp Stock Size mam 224 Marine Transmission Service Manual Twin Disc Incorporated Special Tools T 18050 688 1 of 2 2 50 Jipa 880 DIA THRU 3 REQ D 1 m DRILL 7 8 875 DIA THRU 217 1 8 4D REQ D Z L4 a Q UNS 0 75 FLAME HDN SQUARE 0 62 i 0 03 IN AS SHOWN gt gl ED ROD lt gt REG D 1 8 THREAD IREAD MAT DRILI AM 5 1015479 585 CONE 557 1015478 S8SHL ASS Y
28. ee jj 1 1 L P ral TI 2 1 4 o _ Nl n aod t 4 l L Ix TR ir Toa ton a r LI 1 na 1 1 dor d T 1 ox 1 I 120 Lul TIC CMM L T gt 2 ML 1 I 2 UE Rej PU qoum m l P O _ p aj C m gt uL m s e ec Aim T r i47 d DO M I i I iia i Fre ITI lt i a Ih s il e MEN l 1 Inu 4 e ATHE we C T US u jon ES c II x i 7 a ac Lu _ _ r T UID 7 LJ L dt Jo I l UT FT i _ II il 19 bee 3 C o L P C H o Wi k I I n i3 SHEWA WETH SAE HD FRONT AILS NG eia s tes MECHANICAL a sak 8 000 RR tee m t bem 0040 den 4 sul lU nut Mii s ID MARIME 5 pM Fa T PIN ASST us ur s s ed Fo E j f gi F Y i x 1154 i _ GEAR LIGAER f amp BEAR 1317629
29. n i Dd 7 LI roe d 7 E m 1016001 1017614 s op EXP ME T lt x 5 qn M a TUE i 2 a i ui Au T r it i i zi I 1 I m 1 1 2g 1 1 K a E E 2 s F ia a E 71 t T D a sl 4 T qi o gt ar I e RC Det OW ek e r NEN jon 1 TS 40 I Di EN 7 Uu y mea 4 2 __ _ I F r i 7 Te IR m T wea _ l i ns UN L lt n m mnm m a _ 1 i ptr L Ibm TT MY em OE 1 E wert r AL a _ Ten Ti an 1 eas vU 1 1 m 1 _ 4 Uu uv Iw AST kl ate m PR T t EL 4 rl wht I ao i _ I I LI 1 m a 1 T 51 E 15 m oom H ut 5 mE d EC s Ou 4 e ML Lg ue Ep 0n EN v 3 ibus ae C o TENE
30. 1015478 BEARING CUP 25 X 30 475 1 4 87 DIA 62 DIA 1 62 1 00 1 REQ D 15 25 DIA RS NOTE AFTER LOCATING CUP MA 590 DT LOWER PICK UP amp REMOVE FROM GEAR OPENING pue 699 06081 1 NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 5 CLAMP HOLD DOWN 1 MAT UHMW PE POLYETHYLENE EE E A 4 REQ D 11 09 Bearing Pick Up amp Driver T 18050 685 DET REO MAT Description amp Stock Size Flat Washer FOR 1 2 S H C SCR SOC HD Cap Screw 1 2 13 x 4 5 LG Clamp Hold Down Kitco 2 0 W x 3 5 H x 5 0 LG Jergens Flanged Nut 19907 Jergens Flat Washer 32006 Jergens Shoulder Bolt 18505 POLY Base Pick Up 15 5 DIA x 2 00 TK 1001 219 4 5510 Jenue N 923IAJ9S UOISSIUISUPJ SUNEN LLZ DRILL 5 16 DIA X 1 25 DP TAP 3 8 16 X 1 00 DP 4 9 00 DIA B C 5 EQUALLY SPACED 2 HOLES DRILL 5 16 312 DIA THRU TAP 375 DIA OPTION TO ADD ROD FOR PICK UP 1 6 75 DIA 6 EQUALLY SPACED HOLES 3 00 DIA A KNURL FULL LENGTH OF 22 50 DIA SHAFT mild 42 FOR 11 56 DIA 4 1015477 10 69 DIA 350 4 38 X 45 12 X 30 P KNURL 1 100 113 1 25 0 25 amp ka
31. Figure 86 MG 5600 Lube Relief Valve HUUSING ALVE BEARING CARRIER MANIF UL D Ne Figure 87 MG 5600DR Lube Relief Valve Marine Transmission Service Manual 145 Assembly 146 Twin Disc Incorporated Install several shims into each bearing bore in the bearing retainer to obtain a trial measurement Install the cups for the rear tapered roller bearings on the primary and secondary shafts into the bores in the bearing carrier against the shims Install two guide studs into the face of the housing Using caution that the bearing cups do not fall out install the bearing carrier over the studs and onto the dowels in the housing face Use a soft hammer to seat the bearing cups against the bearing rollers if necessary The bearing retainer should not contact the gasket if enough shims were installed for the trial measurement Use a feeler gauge and measure the gap between the bearing carrier and the gasket Measure in several locations and determine the maximum gap Remove the bearing carrier and bearing cups and reduce the shim pack thickness by an amount equal to the measured gap plus 0 05 mm to 0 15 mm 0 002 in to 0 006 in Reinstall the bearing carrier onto the transmission There should not be a gap between the bearing carrier and the gasket Instal
32. TE 2 I 1 f i i e nut n 2 772222222 M z ot g 4 pn xr Z z x EM lt lt ze ai de p 0 3 Bg s rr il P Y TUE EG TIEN Al 2 2 21 CT SN Z d qe Wl Ho MH d VA 2 NP aca Ux SHE 1 L 1 UXT LUBE 555174 ADDS tad C Lo E COMPONENTS AND TE INSTALL or 77 E rr PINAR SHAE MARINE TRANSMISSHN i RAE Si FER 0E HE MT amp REAR FERRIC CIWIDN r CONTROL Wel YE 7 EXTINGUISHING AND FIRE Rz315 AT amp CLETEH 2 SEQUIREYENTS ICE NT IE 12a TION REZLIRED By THE 1 5 22037 GUARD aD ENGAGE D i at SPECIFIES IM FPDP RAL LUS3E RELIEF SECULATIONS 46 T7 mene 00x Wh E Bp KPo H i MN 1 EI u i Low aw 77 box MASA Hid x i PLUG FRUM d T RARSMIMXSILIM INS ALLATIIN naa LUBE LINE O JPE FLOW INTL Z Sm TES i TRKAMRSMISS DN dYZRA LIZ a d Z ay PASS CIRCUIT DL J38 KPa Y b j www 5 S lt Hj ine HE TK I D E nT VALVE 25 192 DIA MIN nh l __ ROSE Ral ILI
33. 1017613 JICH PLAIE WL DHS DITCH PLATE 1917592 Medak i GASKET 7ze2 Pom LAPSUPLWw 03 Pun CaPSCREW ce 7 CONTROL WALE 1IOL3084H raa Ds CONTROL wALvE OIEA Igv pz ASSY DRAWING FOR COMPONENT gt Te 3 eec GASKET PEF VIEW ABOVE xU CAPSCREW MASSE 4 WASHER PEP ABC VT SPACER 10 76205 GAS K lt T SUY FIN 9410950 2 CAPSCRF W 14 HED PLUG LCEPOSITE TM Sw TCH Bagda IU FOS TEMPERATURE INDICATING SWITCH CAINE 7 7 LESE SEE NOTE 2A SKEET MECHAHLZ AL VALVE CAPSCRPW Ce zy LAF EC REW ae SEO ou Ud 2 DU _ 996 1 i IL Auli ESLE WALYE ASSY wem m FOR COMPONENT PASTS gt cM i 3 21 VALVE fn c i PER wa ASST oye 2 00 Y p E 1 UAPYUEL W MAGA 54 77 E Ur tl A 4 1 L qa PING Ag OISEX EE
34. ADAPTER HI966A SPRING ABT BAC s HUS 1016494 il x HUE 1076684 1 RISO 5 041 RATIO Z4T 1 5041 RATIO E8T RAFFLE aster 1019668 iy BALL MAIOJAC j I MEME 1 LC19667 gy MADVXCRIW MAYLE D gt PTMITIN ASST 4 5221 PINIZN ASSY 1512633 2 l QOO FSE se t T s GEAZ 1005495 t m ZAF 112526 T v3 HUP 101474 1 E illl C 6 484 ux ur 4 UC 5 04 1 RATIO 1 4731 33T 1 PAS HER oe 7 Ps A SIE OD ib n cercana gay aves ye i Ir SCREW 9607 529 d PLAIUS LOBE bo gi PINION ASST 17234 cry x QLAR 10 00467 ll x Grea 1017651 EN RING PIN y i xw 1210484 j1 3 PLE 1016383 ZEN i 4031 RATIO 33T j 3341 FATIG 37T SCREEN MA993 ADAPTER 1215291 ue TAXC ayy ceo BINIIN ASS cn MSN GASKET 10 5501 1 fU va WE QNEM SUSY eao GD FEAL lt dla O view capscrew Q TN d i x HEE MAARA li x bub 1015484 i riot iy DINE MASDAR GE 98 1601 m 3514 RATIO 377 PART 2T i a i j
35. Hb iu D ZU ut a or e d 4 a T 1 n 1 T iE I co vou B 08 uM qn ry Q fe d i See Eie sli n gt I 7 if d i 1 ee 8 r x TT m UM D I 1 uu IL K 2 i ucl 1 M a 5600 5 E 1 f zi l gt gt za 41 tr t z ra tas 2 n a L 11 4 f Qe L a V i 71 m EM e uj TE Don x 7 k 5 Du i yos rt u E 4 c 1 1 z 1 TU M m l i nl 5 a aa PC E 1 y rug De ir T5 a 3 UE x M Bet 207 u AT 7 1 m i Doa n p J gt 7 EE wernt 11 i To E E n 1 T p r T 1 J r l 1 e u
36. MM TFERM STA TIC BrPASZ PARTS gt A N 7 I x i M _ INSTRUCDIEM FLA LS U EL 63D TE R ALAELE FROM B3EATHER SELL LHIT ee ED SPRING AZTODAR P L MEDSIL 7 ING 700 FOR ENGINE PLATE 291513 v che MOLD a ON SHEET 1 PLUG M2Z7EEH m i r BUSHING ROTATION ONL Y SCREW MdggH ATTACH AS SHUM POR LH i of _ n nona MA S C QM ENGINE ELI ATIUM RING APDUIGBY SPRING ASST 442 07 BU 4 no r SPRING A2702911 LAPE AIEA i POINTS TE RIGHT BH392 x i SPRING 270384 PITTING ASSY XMF6416 A 1 4 PLATE BEALS HEARING M42167 N r SPRING A703 FITTING 26414 7 4 f AN PING AED 77 RT LTRK RING A2916 AT VA PLATE E34 BB 1 hoo X FITTING MASSE PLATE 2090992 i 4 x i Pin MIOS7B ONNN HOLE 3j d EREATAES H LEVER 204087 BALL HIo30H SFE CHART JC Y 1 2 CHAIN MIO Soul 1___ 1 11 96 MEAL L A y BIL T MA0278 42 CAPSCREW MI73l x ZAPSCKREWw Mec le 3 CAPACKEw MOUSSA 41 n SLEW CHR COLLAR Bl amp amp 8225 te E PISTON B2
37. Note Do not order parts from the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number on the unit s nameplate 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 win Disc warranty 16 Marine Transmission Service Manual Twin Disc Incorporated Introduction Source of Service Information For the latest service information on Twin Disc products contact any Twin Disc distributor or service dealer This can be done on the Twin Disc corporate web site found at http www twindisc com Provide your model number serial number and bill of material number to obtain information on your unit If necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com Marine Transmission Service Manual 17 Introduction Twin Disc Incorporated Warranty Equipment for which this manual was written has a limited w
38. REQ MAT Description amp Stock Size 6B 2 ROD 38 x 4 12 LG Nut 2 00 x 4 1 2 UNC Weldment A Puller Base SOC HD CAP SCREW M24 x 3 x 80 mm LG A Puller Rod A Plate Ran Base 13 5 8 Dia x 2 1 4 THK Pusher Plate 1001 219 4 15 12 RETRACTED LENGTH PRESS DRILL 5 16 3125 DIA X 1 25 DP 3 8 16 X 1 00 DP 2 REQ D 180 USE FOR LIFTING 4 0 50 2 44 MID STROKE in1xij Bue j1ndino 2101 SLtIZ L 6 NUT WELDMENT NUT WITH HANDLES THREAD SIZE 2 4 1 2 UNC GRADE 8 A 194 GRADE 2H HEAVY HEX FULL NUT NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS pe1e10dJoo2u 5510 UIML Jenue N 923IAJ9S UOISSIUISUPJ SUNEN 22 s ee 06 R 2 00 4 1 2 UNC 2A 6 19 2 000 THREADS TO BE GROUND 1 00 L DIA AFTER HEAT TREAT i q 1 250 HEX FLATS BELLCENTER 10 45 7 06 X 45 BOTH ENDS TYP PULLER ROD 1 REQ D A SAE 4340 H AIRCRAFT QUALITY HEAT TREATMENT 2 165 TYP HARDEN amp TEMPER TO RC 44 48 8 75 DIA DRILL 5 16 3125 DIA X 1 25 DEEP TAP 3 8 16 X 1 00 DEEP 2 REQ D 3 REQ D FOR M24 X 3 BOLTS CHECK HARDNESS ON 2 000 DIA ONLY DO NOT TOUCH THREADS INSPECTION CHECK ALL SURFACES WITH MAGNIFLO EQUIPMENT 13 50 DIA DRILL
39. T Y m M FILTER 64 B Sc SURLY EE WASHER MALUSSC 442 TU CAPSCRE Ww MASSAG CIGI GASKET WI 74 Ey cipes 7 RING A8SO16EH WASHER MAI 3JSH t307 WASHER MAIO3GH i42 unc i HOSE 7 IU MASSA A nn TM T ELEMEKT G3LIUP XMg934 TUBE ASSY XESGUI JOD PDPPET 204367 FITTING Medians 2 qe PES c ADAPTER 82300 d SPRING 214389 DT uma WASHZR AP w M7 qj oe F CAPSCREW MEZ 4 mw CAPSEREW MAgS amp 8 12 2 FITTING dI Tm ee TO PLUG MAIDIE oma PLUS 4 15 2 ig T B CONTREL val EC PIN MALOGSF P3 7 gt 1 l CAPSCREW MASEL CH meon GASKFT 1007513 PLu COPSCRE MAgSED i FLUG MA1038C Tih PLAT ASSY 1012363 31DE PLATZ 1017582 SWITCH 334244 M F H MAIU34B POAT UI DTI JJH DE VDERHA TUBE _ INDICATING SWITCH CC gt NECTION i 101 553 SEE MITE SHEET _ HN CAPSCREW 2 27 CAPSCREW MAlCbES I de i I ES a
40. THESE HODES ARE USED WITHOJT THERMOSTAT VALVE WHEN es SEEN M i ELECTRIC VALVES EU eT Lm om s 2 8 MM 22 OPTICAL THERMOSTAT watvE IS USED SFF HOSF CALLDUT IN i ADAPTER 017210 m OPTICNAL VIEW AT FIGHT ALSO SEE D HER BOXED ARCAS ror 1 MEUD EAM Caa eee ee OTHER DIFFERENCES ELI WEEN MECHANICAL ELECTRIC vALYES PLUG He 31x M Cu PING lt us LI Dau mm 777 E G THERMLIISTA amp I VALVE PARIS L Y i INSTRUC HION PLATES TOD _ KE L _ _ uu BE READABLE F POM __ ss SUC TION IUBE SEE CHAZT 4 PING BREATHER SIDE OF UNIT EIE _ _ j SFE NOFF e SHFFT 1 3191 _ TRAINEE Boag ss duas PLMP SED CHART _ FOR LH ENGINE PLATE 821213 ATTACH AZ SHOWN UN MAJM HOUSING eins TE FITATIEN sl Y MABAB pi S FOR LM ENGINE ROTATION ONLY a i i l L RING BATIL EN For 1016001 Ur T FD FIGHT NN io S T7 x SN CAPSCREW MECOAF 45 x PLATE Be415 x 1 1 NS GAUGE BL203D TE Vo xf y 7 FITTING ASST MESALA m 4 QUA OCET LIN FITTING MPESA ON 2 STEM WASHES 81035 4 RING d x PLATE 2040580 4 T 3631
41. d d 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 Gears d 112 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 Marine Transmission Service Manual Twin Disc Incorporated Cleaning and Inspection Splined Parts
42. 10 11 12 13 14 Twin Disc Incorporated Install the thrust washer over the end of the stem Press the oil seal into the cover assembly until flush with the adjacent cover surface Install the o ring into the counterbore in the cover assembly Apply grease to the stem o ring and oil seal lip Install cover assembly and gasket onto valve body Be sure to align the oil drain hole in the gasket with the hole in the valve bogy Figure 97 Hole in Gasket and Hole in Cover Must Align 15 16 17 18 19 20 Install four M8 x 25 socket head capscrews torque to 23 Nm 17 Ib ft Install washer over stem and against oil seal Install spring over stem against washer Install lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew may be damaged Torque the lever s attaching screw to 9 5 Nm 7lIb ft Install external retaining ring onto stem Install the steel balls and electrical switches into the bores in the sides of the valve body Note that the small diameter ball is inboard of the large diameter ball at each switch location Marine Transmission Service Manual Twin Disc Incorporated 21 22 23 24 Assembly Installthe pressure regulating piston into valve body with spring pocket Install pressure regulating springs into valve body and into piston s
43. 12 Exert 890 N 200 lbs downward force onto the clutch shaft while rotating it several revolutions in each direction Stop so that the dial indicator probe is resting on the felt tip pen mark and zero the dial indicator Remove the downward force and exert 1334 N to 1557 N 300 Ibs to 350 Ibs of lifting force on the shaft Rotate the shaft several revolutions in each direction stopping with the dial indicator probe again resting on the felt tip pen mark and record the dial indicator reading Marine Transmission Service Manual 147 Assembly 148 13 14 Twin Disc Incorporated The reading is the clutch shaft endplay Repeat for other clutch shaft and record dial indicator reading The shaft endplay should he between 0 05 mm to 0 15 mm 0 002 in to 0 006 in Note the shim change that is necessary to achieve the desired endplay If changes are necessary for model MG 5600 repeat steps 9 through 12 If changes are necessary for model MG 5600DR repeat steps 6 through 12 Use the dial indicator to confirm that desired endplay was attained and record final results There should be two 10 mm diameter dowel pins protruding from the rear of the secondary shaft If they have been removed they must be installed Install the oil pump drive adapter onto the secondary shaft and secure with two capscrews M8 1 25 x 20 and torque to 37 Nm 27 Marine Transmission Service Manual Twin Disc Incorporated Assembly Insta
44. SUE gt 9 ti Se te cnm to llli E BA Yol aT tosses 1 Phase imu ti 1 L F Dd t a FM eve 1 d 1 y HDTES THES iL SHOWS HE 4 CB tel PUMP SFALER USED cdi w T THE ELECTRIC wale To eta rm THiS SPACER S HOT GSE WITH ii STI s ull arl BID THE MECKANILAL WAL WE oes qued 7 ICEL SHEET w o tna VALL GU T I x Da 1 n Tr gt TT a ZEE i MEE A el 1 tod 1 12 20 n eu t Meus 2 gt F 2 mots k 1 2 L tas 1 L 1 n r r 7 rl r Li LI la 1 3 T m 42014 22 UST cac E 1 whe see gy via wa rael 1 _ to zo noh ada ioc ang x 4 d 1 I F asi TT i 2 L 47 7 z eM E ab AR IU nV d DASS Uu s 1 2 231 Utt 7 Sea LI LI 4 I ro na d r _ eee 2
45. _ 7 T gE L 1 1 15 ii 1 1 T r 2 ua m f Vra 7 7 T 77 F _ _ 17 i SY FO e wit t _ 2 LI 1 y gt 1 r 1 I u 1 4 i 1 n M aed 2222 Cu a aL pondo CS aAA Cu c TM n f 4 42 1 B COEN La EA Po ane 7 mms NEM Led ngu m 1015239 MG BARIME TRAHS ISSIDM Jo rr x S wn MM ONES T dr a SA no Amm 1 os E LI DER fw 7a i te C sd iin s i ee 1 I DO FN i E Was n i 1116 zu l S i 1 i SUC m ut Uh i pot n l LI L E I d nip A r REEL CAT SF JA gt 43 1015239 1 MG 560 trae 3 eme P DU Xe i M x 1 a Tub aS Em
46. a ES EM SU 0 ns syria i s i n Soe TN por d EMT T AL IFS V TU FLEETS SRC EACUS DV um zx F n i gt T ZIEL T T EXE L EE HDSES Tr MEZ GR D z 5 aH 1u n whe foe A A xe GA j o SAR J517 TUE 1505 HOSE SEL qoa SU IHING Qk UI r Te ae ed dud d i er quer Ay pe LA n nan i AS PECI I8 TELE OF TIDER A 1 1 I CER ef rv li RRM YT ma AS w c P BRUM MANTEL FEY 1 TRan Misi ity INDTALLATIZ ART lc DADO wise re La METS JE x _ i s L T IKE H IET FLI w NEN Z Lm DLP pex 70 0 077 60001 TESNSMILIIDM ATI IC LN NU UNUM t gt r nl SEAT T r 1 gt e Za SEDIOeRT 4 m m on SIAR TTA C hr on p m un LOT ML ee 1 z E Us 1 E m m e SH 7 FD 1 L2
47. 1 TE _ I ERN 1 1 IPI a a r T TT D ac 1 jd b fr ksl a DR zl I L a un ma wk sp r i CA rski it SU Ta t 7 3F SPEJL SELIASSEL 1 i cu _ 1 um Tx S m He 73 1 li fi L t il LUE i LI U i E Day LJSE 1 ELI ALL LL ULXi ge Ca n D ont T reje meme T 1 P i PRIOSSUTE CI mods ima _ i FUEL 7 I MARIST TUAWLVILLIDA N TAL amp 77 M s Tm i A LI TEE T 1 nn LqADT mLAP L aC L EF ies Lue l 4 4 i i _ D r ATT 1 3P ATIIS LI LI I T 2 i aat u 1 P
48. 2 Remove the rate of rise piston pressure regulating springs and pressure regulator piston The pressure regulator adjustment shims are in the spring pocket of the rate of rise piston 3 Hemove the O ring plug O ring detent spring and detent 4 Mark the lever and the stem to indicate the position the lever was installed on the stem Loosen the screw clamping the shift lever to the stem and remove the lever It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem lever or bearing might get damaged 100 Marine Transmission Service Manual Twin Disc Incorporated Disassembly 5 Mark the stop and the stem to indicate the position the stop was installed on the stem Drive the rollpin out of the stop with a drift punch and remove the stop Figure 44 Drive Roll Pin Out of Stop 6 Remove the valve cover and valve stem 7 Slide the valve stem out of the valve cover 8 Remove the gasket and O ring from the valve cover 9 Remove the bearing from the valve stem Marine Transmission Service Manual 101 Disassembly 102 Twin Disc Incorporated Selector Valve Assembly Electric Valve Steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Loosen and remove four of M8 x 25 socket head capscrews and remove orifice plate cover and gasket Figure 45 Orif
49. E WERT 10 SERV HLIUR R DA CHECK DIL LEVEL WITH ENGINE RUNNING AND ARINE TRANSMISSION NEUTRAL REESE GK LT TING UBRICATE SHAFT SEALS WITH WATER PUMP GREASE PREVENT BILGE WATER ENTERING HBUSING VERY 1000 SERVII UR 25 HS HICHEVER CUM s DRAIN REFILL HOUSING WITH CLEAN OIL REMUVE AND REPLACE FILTER ELEMENT WHERE APPLICABLE CLEAN SUCTIDN SCREEN T WARRANTY IS VOID UNLESS TRANSMISSIDN IS LUBRICATED AND MAINTAINED AS oc SPECIFIED IN THE SERVICE MANUAL AVAILABLE UN REQUE EFER TO MARINE TRANSMISSION LUBRICANT PLATE SHIPPED WITH UNIT BILL OF MATERIAL NO MUST BE GIVEN WHE DERING PARTS ov SG me MADE IN USA RACINE WL 53403 U S A e Figure 1 Nameplate for MG 5600 Marine Transmissions 20 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications Power Ratings The 5600 series transmissions be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation when viewing rear of engine This series of marine transmissions can be driven by a left hand rotation engine however horsepower ratings may be affected in some configurations Contact an authorized Twin Disc distributor for more information Transmission clutches are hydraulically applied using main oil pressure
50. FWL 131752 ND 530 FWL C 641 4 9 6731 PILLI CAPSCREW 1055 24 HUB 10166 784 Figure 8 Remote Centa CX 72 No 530 Flywheel Marine Transmission Service Manual 35 Description and Specifications Twin Disc Incorporated Table 6 Gear Advance Transmission Primary Transfer Gear Advance 3 33mm 131in 29mm 169 in Transmission Secondary Transfer Gear Advance 333mm 131i 429mm l69in Transmission Output Gear Advance 11 86mm 467 in 13 54mm 533 in Transmission Output Flange Advance 36 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications Table 7 Bearing End Play Reduction Gear Input Shaft Tapered Roller Bearing Endplay 0 05 mm 002 in 0 15 006 in Reduction Gear DM Shaft Tapered Roller Bearing Endplay 0 05 mm 002 in 0 15 mm 006 in Transmission Shaft Tapered Roller Bearing Endplay 0 05 mm 002 in 0 15 mm 006 in Transmission Shaft Roller Bearing Endplay 0 05 mm 002 in 0 15 mm 006 in Transmission Shaft Bearing Endplay 0 05 mm 002 0 15 006 in Marine Transmission Service Manual 37 Description and Specifications Twin Disc Incorporated Table 8 Limits for Marine Transmissions Equipped with Manual Control Valve with 1725 kPa 250 psi Spring circle units
51. Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found Springs Inspect springs for broken or distorted coils Replace the spring if either of these defects is found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses Clutch Plates Inspect clutch plates for signs of overheating pitting or excessive wear of the friction and splined surfaces Replace the clutch plates if one of these defects is found Refer to wear limits in Description and Specifications Marine Transmission Service Manual 113 Cleaning and Inspection Twin Disc Incorporated 114 Marine Transmission Service Manual Twin Disc Incorporated Assembly Assembly The MG5600 series transmission requires the use of a SKE THAP 300 Oil Injection Kit See Special Tools or similar device to install the output flange and output shaft Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces The following discussion contains frequent reference to the transmissions parts and components Refer to Engineering Drawings Marine Transmission Service Manual 115 Assembly Twin Disc Incorporated Prior to Assembly 116 Use the following reference The input side of the transmission is the front and the output side is the rear Left and right sides ar
52. MARINE TRANSMISSION MG 5600 Drawn ALC BJE _ ASSEMBLIES 1015239 1016001 amp 1017614 Checked DAS Approved TBC Original Issue Date 04 10 95 PROCEDURE Latest Issue Date 09 26 00 V ASSEMBLY CHECK SHEET MG 5600 Model BOM Number Serial Number Assembly Date Primary Transfer Gear Advance Minimum Actual Maximum 3 33 mm 4 29 mm 131 in 169 in Secondary Transfer Gear Advance Minimum Actual Maximum 3 33 mm 4 29 mm 131 in 169 in Output Gear Advance Minimum Actual Maximum 11 86 mm 13 54mm 467 in 533 in Output Flange Advance Minimum Actual Maximum 10 16mm 12 35 400 in 486 Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 4 of 8 S570AH ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION 5 5 MARINE TRANSMISSION MG 5600 Drawn ALC BJE _ ASSEMBLIES 1015239 1016001 amp 1017614 Checked DAS Approved TBC Original Issue Date 04 10 95 PROCEDURE Latest Issue Date 09 26 00 V ASSEMBLY CHECK SHEET 5600 Primary Tapered Roller Bearing Endplay Minimum Actual Maximum 0 05 mm 0 15 mm 002 in 006 in Secondary Tapered Roller Bearing Endplay Minimum Actual Maximum 0 05 mm 0 15 mm 002 in 006 in Out
53. MG5114A MG5114RV 10 0 17 0 MG 514C MG514M MG5141 MG514CHP 10 0 25 0 6 0 MG 516 MG 5161 10 0 28 0 8 0 MG 518 1 10 0 32 0 10 0 MG520 1 MG 5202 MG5203 MG5204 10 0 32 0 10 0 MG 530 MG530M MG5301 12 0 32 0 16 0 MG 540 20 0 62 0 20 0 MG5600 20 0 62 0 20 0 MG6000 10 0 32 0 10 0 MGN80 MGN 232 MGN 233 MGN 272 MGN 273 MGN332 MGN 334 MGN 335 MGN 432 MGN433 MGN472 MGN493 1 0 0 32 0 10 0 MGN 650 MGN 800 MGN 1000 MGN 1400 MGN 1600 20 0 62 0 40 0 PUMP ALL MODELS 1 0 VALVE ALL MODELS 1 0 5 July 1 1998 TDW P2003A Qu AS Twin Disc Incorporated Table of Contents Table of Contents 210700 ol uuu u uu uu u 13 General Information J J T 13 Safety and General Precautions 13 Preventative Maintenance 15 Eie c u eg eens es oan ee ase mms renee u x 15 Ordering Parts and Obtaining Services 16 Source of Service Information 17 VW jim yu OTI 18 Description and Specifications 19 uuu E 19 21 Pee DENS 22 Construction Features J J anna J 23 Uu
54. Model MG 5600DR has two capscrews 35 mm long and two capscrews 140 mm long Torque these capscrews to 165 Nm 122 Ib ft 2 Install control valve assembly using four socket head capscrews M10 1 5 x 150 torque to special value of 54 Nm 40 Ib ft 160 Marine Transmission Service Manual Twin Disc Incorporated Assembly Input Reduction Components for Model MG 5600DR 1 Block support the transmission assembly with the input end up Use caution to avoid damage to the output flange and other external components 2 Install sealing o ring in the groove in the rear of the input reduction rear housing Use a light coating of grease to aid in retaining the o ring in the groove 3 Using guide pins in two capscrew holes lower rear housing over the pilot diameter of the main transmission housing and insert a total of seventeen eight of M16 2 00x60 and nine of M16 2 00x110 capscrews with copper washers Torque to 275 Nm 203 Ib ft 4 Install the chilled rear bearing cups into the rear housing Insure that they remain bottomed as the temperatures stabilize 5 Install heated bearing cone assemblies onto the two input reduction gears if not previously installed 6 Lower the internally splined reduction gear over the transmission splined shaft This should not require force or heat to assemble re Lower the input shaft and gear into the bearing cup and into mesh with the mating gear
55. SHAE E 9 es se 47 4e IN OR NONE SECONDARY PINION CLUTCH HUB NEEDLE BEARING 1 57 aa 37 32 ROOT DIA m H PINION BEARINGS DRIVING PLATES PRIMARY m 7 820 444 X 10 DUTPUT FLANGE OUTPUT SHAFT C J esser rans 1380 28307 I r F RATIOS BRAKE DISC GR 4031 53153 53 53 53 539 mrn w iso 107 TH sn ss TTT 1 REFER TD 1015239 CLOSE COUPLED SHEET 3 OR 1016001 lt SHEET 5 FOR WRF AMD TORSIONAL 5 DATA ALL WR APPLY DIRECTLY TO MAMCD MASS T RELATE ELSEWHERE USE RATIO OF UNIT RATIO OF bDzZF 1 00 THIRD ANGLE MASSES HAVE RELATED MISCELLANEOUS HARDWARE INCLUDED IN whk wr DF DIL IS OMITTED PROJECTION UNLESS DTHERWw SE SPECIFIED DATE MACHINED DIMENSIONS 1 16 95 WA duxi DISE u SCALE XX t 0510 NINE lt 1 IN RF DR E D X XXX 0 005 RACINE Wl 52403 Usa ALL ANGULAF TOLERANEES i BRN lt GEOMETRIC TDLERANCING PEF ANSI YI4 5M 1982 CHE HwM 4 SHEET 1 OF 1 REY MATERIAL HEAT TREAT MOTICE THIS PRINT CONTAINS PROPRIETARY MFORMATION AND S MOT TD BE USER AMT HAMNER DETRIMENTA 10 THE INTERESTS OF TWIN DIST INCORPORATED RADNE wI 333403 THIS MOTILE 5 MT INTENDED TU MULL OF LIMIT RIGHTS
56. TO RELATE ELSEWHERE USE THE FOLLOWING REFER TO CHART FOR RATIO OF E D RATIO OF 108 RATIO OF K G AND K P s 5041 THIRD ANGLE ALL MASSES HAVE RELATED MISCELLANEOUS HARDWARE INCLUDED IN wR wR OF DIL IS OMITTED PROJECTION d 1 SIMILAR TD MATERIAL UNLESS OTHERWISE SPECIFIED DATE NE MACHINED DIMENSIONS 523 98 WIN DSS SCALE 10018 ee ALL ANGULAR TOLERANCES 41 NOTICE THIS PRINT CONTAINS PROPRIETARY INE DATIN AND s 3 1015100 GEDMETRIC TOLERANCING 7b T aid MGSe 005R PER ANSI YIM 3 D 4 TWIN DISC SURFACE TREATMENT THIS WETICE 15 HOT INTENDED i APPT ss MASS ELASTIC SYSTEM SEED 1 De i 1020007 05 01 TW Y 1 POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
57. em E E NIPPLE UTPUIT SEALS pe1e10dJoo2u OSIA UIML 2 uonduoseg Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Note All threads and bearing face to be lubricated with light oil film prior to assembly Table 10 U S Standard Fine and Coarse Thread Capscrews Bolts and Nuts Thread SAE Grade 5 SAE Grade 8 20 24 27 32 35 41 48 55 Diameter 51 58 55 65 75 88 81 95 83 97 113 131 1163 1355 1375 1625 1865 2203 42 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications Table 11 Metric Coarse Thread Capscrews Bolts and Nuts Thread Property Class 8 8 Property Class 10 9 Property Class 12 9 Sue nm ia m M6 65 75 12 14 10 12 86 16 18 21 25 23 26 31 35 25 29 34 40 32 36 43 49 44 51 60 68 51 59 70 80 Table 12 Tapered Pipe Plugs with thread lubricant wm s o s wa m 9 La ow o o Marine Transmission Service Manual 43 Description and Specifications 44 Nominal Thread Diameter Or 5 Ib ft Or 5 N CO O o O1 O1 Nominal Thread Diameter or 5 96 Marine Transmission Service Manual Twin Disc Incorporated Table 13 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Ib ft Or 5 9o Twin Disc Inc
58. orifices to lubricate and cool the clutches and bearings There is a lubrication oil relief valve to limit the maximum lubrication oil pressure This pressure is regulated to approximately 690 kPa 100 psi on the MG 5600 and approximately 827 kPa 120 psi on the MG 5600DR In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation The pressure in the rate of rise chamber is controlled by a ball that is spring loaded against the orifice plate The passage behind the ball and spring is connected to the sump atmosphere in Neutral and to main pressure when either clutch is engaged A shuttle ball connected to both clutch pressure ports permits pressurizing this passage with oil from the engaged clutch without allowing oil to flow to the disengaged clutch The electric control valve can be used in a manual override mode in the event of an electrical power failure When the control valve is energized or shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively in
59. t E SEE D a T w u bl ao a 7 _ EL T Tt Es e MMC K Lr AI tl j uE 11 e o p Nu AMT i i i i a _ gt _ 7 7 i o Dl As 2 quer T v P SIME TLS DISE 1 MG S60008 TRAHIS PEP 1018100 Ct no r z 1 LI T E I I m 4 T I I I b I Zal I I LI a n r I 2 1 r 1 i a I m I 1 I Wu O m I t 4 LI LI al 1 Pm Fis SEE Ta il sss DI 4 3 E SOCUDR C Ren4SMLITSIUN TELE n 27 4 1 MEME I UT a 1 1 SOL 1 I 1 1 wwrpVHTJ ee T L
60. the transmission does not receive proper lubrication Conditions where backdriving may occur Vessel is being towed One or more engines on a multiple transmission vessel shut down while under way Sailboat under sail with auxiliary engine shut down Vessel tied up or docked in a heavy current The following solutions are applicable for all MG 5600 Series transmissions if any of the above conditions are present Lock the propeller shaft to prevent rotation Add an electric driven auxiliary oil pump into the lubrication circuit Refer to the hydraulic system prints for more details on auxiliary pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Marine Transmission Service Manual 15 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services WARNING All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Henewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you
61. 1 00 DIA THRU i 10 00 DIA C BORE 1 50 DIA X 1 73 DP 8 88 DIA a _ 09 X 45 12 X 45 ek TYP 3 63 0 25 i i 7 DRILL 5 16 3125 DIA ee ae 508 1 PUSHER PLATE 1 REQ D 1 063 _ 3 8 16 X 1 00 DEEP a i 2 REQ D 3 003 DIA 3 008 7 00 AB PULLER BASE 1 REQ D MAT M S HDN 45 49 RC NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 11 20 Output Flange Fixture T 21413 2 of 2 REQ Description amp Stock Size 5 1 i A Puller Base HDN 45 49 Rc 9 00 Dia x 3 75 THK 3 1 A Puller Rod 3 25 Dia x 27 30 LG 1 1 i Pusher Plate 45 49 Rc 13 62 Dia x 2 75 THK in1xijJ Bue j3 1ndino 2102 p l1ei1odiooul 5510 u AL 1001 IeI 5 ds CCG Jenue N UOISSIUISUEJ SUNEN 12 88 DIA 12 38 DIA 06 X 45 90 KNURL 10 25 DIA 31 06 1 I aas CERT 12 amp h 2 00 U CUT L 0984 06 X 45 11 799 DIA 12 X 15 CD SEAL DRIVER 1 REQ D DOUBLE DUTY DRIVER TYP 2 PLACES MAT M S CARB amp 1015513 OIL SEAL REQ D NOTE PRESS SEAL INTO CARRIER WITH DRIVER FLANGE DOWN FIRST SEAL TO BE INSERTED NOTE PRESS SECOND SEAL INTO CARRI
62. 13 Install the assembled output seal carrier and secure with the eight capscrews M16 2 00 x 45 torqued to 275 Nm 203 Ib ft 130 Marine Transmission Service Manual Twin Disc Incorporated Assembly Assembly and Installation of the Primary and Secondary Shafts The procedure is the same for both clutch shafts unless otherwise noted 1 Clean the tapered surface of the clutch shaft and the tapered bore of the transfer gear Use an OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Loctite 7070 cleaner is recommended Wipe dry with clean paper towels Do not touch the cleaned tapers Determine if the secondary shaft and transfer gear can be advanced properly Support the clutch shaft in a vertical position standing on its front end Use a depth micrometer and measure the distance from the rear end of the shaft to the shaft shoulder at the small end of the taper Record this distance as dimension A Install the transfer gear on the clutch shaft taper with the small diameter of tapered bore up Seat the gear on the shaft taper with 445 N to 890 N 100 Ibs to 200 Ibs of force Use a depth micrometer to measure the distance from the rear end of the shaft to the machined face of the transfer gear at the small diameter of the tapered bore Record this distance as dimension B Calculate the expected advance equal to A B The calculated advance must be 3 33 mm to 4 29 mm 0 131 in to 0 169 in If the calcu
63. 1300 1699 rpm 1700 2100 rpm Engine Rotation RH LH MG 5600 Assembly 1015239 1016698 1016699 1016700 1016703 MG 5600 Assembly 1016001 1016698 1016699 1016700 1016703 MG 5600 Assembly 1017614 1016698 1016699 1016700 MG 5600DR Assembly 1018100 1016699 1016699 1016699 Table 2 Oil Pump Flow Number om Lm em om gt _ Table 3 Pump vs Engine RPM Engine rpm for 1500 rpm Pump Speed 7 011 2088 6 56 1 1953 6 02 1 1795 24 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications Lubrication Features The MG 5600 series transmission has a lubrication tube located inside the main housing The tube extends from the front to the rear of the inside of the housing The lubrication tube has drilled holes in the tube that spray oil on the transfer gears and the primary and secondary pinions Bearings and clutches on the primary and secondary shafts are lubricated through drilled passages in the shafts Output shaft bearings are gravity and splash lubricated The input reduction gears and bearings are lubricated by splash lubrication resulting from the input gear dipping in oil trapped in the housing by a standpipe and supplied by a passage in the front of the primary clutch shaft Suction Screen The marine transmission has a serviceable suction strainer located in the oil pump suction tube at the housing end The strainer can be replaced if ne
64. 5 2 1 1 1 1 1 m TEPEE _ a 6r Ll i US n 1 4 cj n u MINOS D 1 wlll 2 7 L _ _ Dal 4 L EL un M0 Mol V n Bc s o a mE m E riu 1 0 21 L l2l 240004 ea E5s 1 lI i ecd IN GM d annm sss T a aka Ve Tire 1 je e BEA n Il D le do Rev NUM Lesan gorap Gus BED 1 PARTO USES UM t 008 1 gt ope Do llasa ri aed ee TEN oF De 1015239 4 V B oru cr SEI QA8SBISS3EIM D T oi pe lu i t 77 RIND 62916 Bx a PUMP CHART HP PATTING 2 FITTING 424B3AL ENGINE FULL Liab FITTING QU oo SUSE 5 Lt sof fd gt _ HOSE MAIS EAE IN SPEED a 7 7 FITTING XEP ALDAWY 300 1297 30C LG FITTING AW Th 1 LIL RH 1016638 EGGS 116700 BING Agu DS en Ima n 10 6722 1016203 d P 5 1166681 vol m ant Gies m ae RING 4231604
65. A Attach a dial indicator to the housing with the probe resting on the O D of the output flange pilot Check the pilot runout by rotating the output flange The total indicated runout must not exceed 0 10 mm 0 004 in Figure 91 Check Pilot Runout of Flange 152 Marine Transmission Service Manual Twin Disc Incorporated 11 12 13 14 Assembly If the total dial indicator runout exceeds 0 10 mm 0 004 in proceed as follows With a felt tip pen draw a line across the end of the output shaft and face of the output shaft counterbore to mark original installed position of the output flange versus the output shaft Hemove the output flange See Disassembly and reinstall it 90 degrees from the original position Recheck the runout of the flange face and the flange pilot using procedures in steps 9 and 10 above If the runout is within the limit specified the installation is complete If the runout continues to exceed the tolerance repeat the procedure in 12 above at positions 180 degrees and 270 degrees from the originally installed output flange position Repeat procedure 12 until the runout is no more than 0 10 mm 0 004 in If the output flange runout cannot be reduced to acceptable tolerances contact your local Twin Disc Distributor for information or recommendations Flug Rata of Rise Piston Lavar Bushing shim Pin Valve Body Outer Spring Valve Stem Spring Inner Spring Piston Check Ball Bearing Detent Lraps
66. All bearings clutches and gears are lubricated and cooled with low pressure oil Always reference the Bill of Materials BOM or Specification number when ordering service parts Marine Transmission Service Manual 21 Description and Specifications Twin Disc Incorporated Power Flow 22 Model MG 5600 Input power to the transmission is through a torsional coupling mounted on the engine flywheel coupling is splined to the forward end of the primary forward clutch shaft causing the primary shaft to rotate in engine direction Power is transmitted to the secondary reverse clutch shaft through transfer gear teeth on the outer diameter O D of the primary clutch housing These teeth are in mesh with gearteeth on the O D ofthe secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction 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 Model MG 5600DR Input power to the transmission
67. Free Standing Transmissions Information taken directly from CENTA Technical Manual Remote Centa CX 72 Coupling The following steps must be followed at any time that the coupling is being worked with 1 Take precautions to prevent accidental start up of the equipment 2 Use appropriate lifting equipment for handling the heavy parts 3 Identify the parts by referring to the drawing that follows 4 Inspect the coupling for any damage prior to assembly 5 Clean all connecting surfaces of the coupling parts engine flywheel and transmission input flange 6 The engine and transmission must be properly aligned Marine Transmission Service Manual 183 Installation Twin Disc Incorporated Initial Coupling Installation See Figures 117 and 118 1 Mount the output flange 9 to the input shaft of the transmission Establish the proper axial spacing between the engine and transmission and align the engine to the transmission Table 17 Alignment Specifications for Centa Coupling Allowable axial displacement Ka mm continuous JL transient 114 Allowable radial displacement A Kr mm continuous 2 0 transient 10 0 Allowable angular displacement Kw 2 continuous 0 2 transient 2 Note that the following subassembly comes pre assembled This consists of the rubber elements 1 flywheel flange 2 centrifugal protection ring 3 fail safe ring 4 link flang
68. Incorporated T 05600 Lifting Tool for Clutch Removal in Boat T 18050 688 1 of 2 Bearing Driver Cone 1 18050 688 2 of 2 Bearing Driver Cone T 20023 1 of 6 Output Gear to Shaft Puller T 20023 2 of 6 Output Gear to Shaft Puller T 20023 3 of 6 Output Gear to Shaft Puller T 20023 4 of 6 Output Gear to Shaft Puller T 20023 5 of 6 Output Gear to Shaft Puller T 20023 6 of 6 Output Gear to Shaft Puller 200 Marine Transmission Service Manual Twin Disc Incorporated Special Tools Recommended Pump Set and Fluids Twin Disc recommends following products for use in the assembly and removal of tapered shafts using the oil injection method THAP 300 Air Driven Pump Set This set consists of the air driven pump with accessories such as an adapter block pressure gauge high pressure pipe or pressure hose with quick connection couplings and connection nipples The set includes one of each air driven pump THAP 300 adapter block 226402 pressure gauge 1077589 and high pressure pipe 2m 6 5 ft 2279574 Figure 124 THAP 300 Air driven Pump Set Marine Transmission Service Manual 201 Special Tools Twin Disc Incorporated Mounting Fluid LHMF 300 and Dismounting Fluid LHDF 900 SKF LHMF 300 and LHDF 900 are recommended when using SKF hydraulic equipment like hydraulic pumps HMV nuts oil injection equipment etc The fluids contain anticorrosives and are non aggressive to seal
69. JO S L Z007 L pa ei0dioou 5510 UIML 1001 219 4 Jenue N 3IA419S UOISSIUISUEJ L SUNEN 45 50 Rc THIS LENGTH 0 83 m 69082 1 0007 U CUT 0050 C2 x EN m OR 3 7 8 9 UNC 2 03 L SQUARE RUD 42 REQ D STRESSPR F 34 41 LENGTH _ DET 13 amp DET 17 z L 062 HDN 45 50 Rc THIS LENGTH 5 on 03 x 45 I U CUT i I I I I I I I I I I i f N amp i 7 8 9 UNC L 1000 DIA F 1 8 UNC 03 R __ 62 SQUARE 17 ROD 4 REQ D MAT p SIRESSPRUUF Cul a i E HUTPUT GEAR TH SHAFT PULLER OSM 5 amp 6 DET REQ DESCRIPTION SIZE Mu 17 4 ROD HDN 45 49 RO 1 000 X 360 16 s JL 02 QJ 13 4 BR ROD
70. Service Manual Twin Disc Incorporated Disassembly 9 Remove the internal snap ring at the front of the clutch housing and remove the clutch backing plate Figure 40 Backing Plate and Snap Ring 10 Remove the clutch plates 13 friction and 12 steel plates maintaining the respective order for inspection purposes Marine Transmission Service Manual 97 Disassembly 98 11 Twin Disc Incorporated Place the clutch and shaft assembly in a press with the input side up Using special tool 18050 694 compress the clutch release springs and remove the retaining ring Slowly release the pressure on the press and remove the shaft from the press Remove special tool T 18050 694 and the spring retainer Remove the clutch release springs from the pockets in the face of the piston Carefully apply compressed air to the hydraulic pressure port to force the piston from the piston bore Remove the clutch apply piston Figure 41 Remove Snap Ring left and Remove Piston right 12 13 Remove the the piston ring from the groove in the shaft seals 1 0 of clutch piston and the piston ring from the groove in the O D of the clutch piston Do not separate the clutch housing transfer gear from the shaft unless the shaft or the clutch housing must be replaced and the mating part remains serviceable To remove the clutch housing place the shaft and clutch assembly on a press with the front end of the shaft down Place a sleev
71. Tap the cups down to seat on the bearing cones with a soft hammer or brass bar Install the manifold gasket over the guide studs and against the bearing carrier Install with the silicone bead up No additional sealant should be used Marine Transmission Service Manual 143 Assembly Twin Disc Incorporated 7 Install the shim retainers next to bearing cups installed above Align the shim retainer rollpins in a line across the center of the primary and secondary shafts 8 Push the tapered roller bearing cups with shim retainers firmly against the roller bearing cones on rear of the primary and secondary shatts Using a depth micrometer measure the distance from the manifold gasket face to the shim retainers measured distance is possible shaft endplay Use assorted shims to develop a shim pack for each shaft to reduce the shaft endplay to 0 05 mm to 0 15 mm 0 002 in to 0 006 in Install the calculated shim packs at each shaft location Figure 85 Shim Retainers with Roll Pins 144 Marine Transmission Service Manual Twin Disc Incorporated Assembly Model MG 5600DR 2 Install the lube relief valve assembly into the lube relief hole Note that this hole has a step in it to retain the lube valve from falling through into the unit HUUSINI BALL Ww 22 WASHER
72. To isolate engine vibration and prevent transferring it to the hull through the propeller shaft the distance from the marine gear output flange to a fixed stuffing box or the first fixed bearing must be a minimum of 20 times the shaft diameter the distance is less than this flexible coupling may be necessary to isolate the engine vibration Marine Transmission Service Manual 167 Installation Twin Disc Incorporated Alignment also reference SAE J 1033 and J 617 1 Bolt a thousandths increment dial indicator or gauge to the engine flywheel so that the indicator is perpendicular to the face of the engine flywheel housing and the indicator stem is riding on the face of the flange Thousandths Indicator Engine nnd 1 ln rg Eur tw pil Flywheel Engine Crankshaft IL Ji Engine Flywheel Housing Figure 100 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 15 168 Marine Transmission Service Manual Twin Disc Incorporated Installation Table 15 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Eccentricity 0 48 0 019 4 2 041 0016 w sa s 014 s stay 4 0609
73. WELD amp LOCATE DRILL 27 64 4219 DIA THRU SHD ER EYE BOLT TAP 1 2 13 UNC 1 REQ D 6 00 WELD ROD TO PLATE AS SHOWN DRILL 13 32 4062 DIA THRU 2 REQ D AS SHOWN STAMP ON EDGE ONLY OR BOTTOM 1 j STAMP TOOL NUMBER 18050 726 SHAFT NUMBER 1015423 MODEL NUMBER MG 5600 12 X 45 G NOTE UNLESS OTHERWISE SPECIFIED 0 75 ALL SHARP CORNERS WITHIN 005 OF EACH OTHER pee NOTE GROUND SURFACES MUST BE PARALLEL 3 50 DIA 11 06 Clutch Pickup Fixture Primary 7 18050 726 PERLE UNE Description amp Stock Size Oa PICK UP PLATE 1 REQ D MAT M S CARB amp Shoulder eye bolt 1 2 13 UNC Extension 50 Dia x 4 25 LG i Pick Up Plate 3 62 Dia X 88 THK enjxij dnxyoid uoini9 92 06081 1 pe1e10dJoo2u 5510 u AL 1001 219 4 806 Jenue N 3IA419S UOISSIUISUEJ L SUNEN NOTE SPOT WELD amp LOCATE DRILL 27 64 4219 DIA THRU EEE TAP 1 2 13 UNC 1 REQ D l 6o00 DRILL 11 32 3437 DIA THRU WELD ROD PLATE 2 REQD AS SHOWN AS SHOWN 3 94 STAMP ON EDGE ONLY OR BOTTOM STAMP TOOL NUMBER 18050 727 SHAFT NUMBER 1015430 MODEL NUMBER MG 5600 NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF EACH OTHER 1epuooes e1njxi4 ZZ 0S08L L 3 50 DIA 1 CLUTCH P
74. a straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE FEMALE m mam a d STRAIGHT EDGE Figure 107 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual Twin 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
75. damage to other components If the length of the shaft from the last support bearing to the gearbox is excessive or a flexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Transmission Controls Transmission controls must be checked for proper function and alignment after any transmission selector valve is properly indexed in relation to the operator s control lever Failure to do so could cause control system malfunction resulting in personal injury and or damage to equipment and property oee specific marine transmission installation drawings for detail and dimensional information needed for the proper installation of control linkages power engaging devices or electrical connections 194 Marine Transmission Service Manual Twin Disc Incorporated Installation Mechanical Controls Movement of the operator s selector lever to the forward neutral or reverse position must result in the transmission control valve selector being positioned in the forward neutral or reverse detent location Cables and linkages must be supported properly and not have any excessive slack that will allow relative movement between the operators selector lever and the transmission control valve selector lever Figure 122 Installation Detail
76. e ELECT SWITC Section A 4 Sump b CLUTCH ENGAGED A Sump y EI ES So ROR Orifice ons L oe a s L St ONEU RAU chip N uoc lle eie GU Prope oy E 22 22 AN ote S naf 2 1 adi Z CLUTCH A ENGAGED NEUTRAL REGULATOR ge Pump J 22 En wm AEE Ja mm SEES Sump M MAIN PRESS S SUMP MANUAL MUDE 58 Figure 20 Hydraulic Schematic Electric Valve in Electric Mode Marine Transmission Service Manual Twin Disc Incorporated Operation Control Valve Assembly in Neutral Some of the main pressure oil from the oil inlet chamber flows through a passage to the orifice in the orifice plate The small flow of oil through this orifice fills and begins to pressurize the rate of rise chamber Both clutches are connected to sump when the control valve is in Neutral oince there is no pressure acting on the shuttle ball from either clutch the passage behind the ball and spring regulator is also connected to sump This allows the oil pressure in the rate of rise chamber to be regulated by the ball and spring since the overage oil can flow to sump The oil pressure in the rate of rise chamber acting on the rate of rise piston causes it to stroke over partially
77. from VULKAN Manual E12048E Refer to Figures 116 through 121 on the following pages Note The engine and transmission must be aligned prior to Installation of the coupling The following allowable tolerances are taken from the Vulkan Service manual Complete alignment instructions are available from Vulkan W AXI RS m Lea Allowable Axial Tolerance 0 020 inch Allowable Radial Tolerance Rigid 0 015 inch Elastic 0 040 tor 0 040 inch Allowable Angular Tolerance 0 015 degrees Figure 116 Allowable Alignment Tolerances for Vulkan Coupling Note The coupling assembly must be partially disassembled prior to installation between the engine and transmission Marine Transmission Service Manual 187 Installation 188 10 Twin Disc Incorporated Remove the input flywheel adapter flange 43 Remove the output end flexible membrane with spacer Item 10 Note spacer should not be removed from the flexible membrane at any time and the bolts that hold the two flexible elements together should not be removed as this would be detrimental to maintaining the proper runout tolerances The intermediate ring Item 46 or safety ring item 48 if so equipped should not be removed Attach the input flywheel adapter flange Item 43 to the engine flywheel and torque the bolts as shown in the torque chart in Description and opecifications These bolts are not supplied with the coupling If
78. front roller bearing into its bore in the front inner face of the housing Use driver T 18050 684 to press drive the bearing to the bottom of its bore Install the output bearing retainer ring into the output bearing bore Figure 56 Front output bearing installation 4 Install the chilled front inner output bearing cup into the transmission housing Use tool T 18050 685 to seat the cup in the housing Figure 57 Inner output bearing cup installation 118 Marine Transmission Service Manual Twin Disc Incorporated Assembly 5 Install the input shaft plate into the housing and secure with capscrews See below Apply proper sealant and torque non lubricated capscrews to 80 Nm 59 Ib ft c ou MIO LO e au Sc W Apply 8908 Loctite 242 to non lubricated thread Input Shaft Centering Plate Figure 58 Input Shaft Centering Plate Marine Transmission Service Manual 119 Assembly Twin Disc Incorporated Output Shaft and Gear Assembly 1 Block the housing in the upright position 2 Clean the tapered surface of the output shaft and the tapered bore of the output gear Use an OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Loctite 7070 cleaner is recommended 3 Check the clearance advance between the output shaft and the output gear outside of the transmission The calculated advance C A B shoul
79. housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will cause loss of press of bearings or races Inspect oil passages for obstructions If you find an obstruction remove it with compressed air or work a wire back and forth through the passage and flush it with solvent Inspect machined surfaces for burrs scratches nicks and foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels This applies where a matched set of parts is not involved Inspect dowel pin holes for wear due to movement between mating parts If a dowel pin hole is worn re bore and sleeve the hole when possible Otherwise replace the parts This applies where a matched set of parts is not involved Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Marine Transmission Service Manual 111 Cleaning and Inspection Bearings Twin Disc Incorporated
80. in actual column Main Pressure at Primary Secondary T em Valve Inlet Clutch Clutch P Range Min Act Min Act Min Act Min Act Max 99 kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa psi psi psi psi psi psi psi psi psi ps F 1830 1690 ET m 245 2 325 2 12 590 280 450 E si i E n 1660 1790 1660 69 Y 240 260 240 10 Secondar 1660 1790 1660 69 Y 240 260 240 10 18 51 0 0 3 20 Input Speed Ranges test speed TN 1690 1830 1690 100 380 Y 245 265 245 15 55 1500 1900 900 1299 1100 1300 1699 rpm 1500 rpm rpm 1900 rpm 1700 2100 CAUTION Do not exceed maximums Note It is required that lube pressure with primary clutch engaged must equal lube pressure with secondary clutch engaged within 21 kPa 3 psi 38 Marine Transmission Service Manual Jenue N UOISSIUISUPEJ 65
81. 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 OUTPUT SHAFT Figure 108 Checking Output Flange Face Runout Marine Transmission Service Manual 177 Installation Twin Disc Incorporated Figure 109 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 178 Marine Transmission Service Manual Twin Disc Incorporated Installation There are many types of flexible couplings in the market today that solve variety of problems Couplings to reduce noise and vibration Couplings to allow permanent angular misalignment Coupling
82. is installed with the small I D of the taper toward the front and seated against the shoulder of the bore in the clutch hub Figure 77 Install Bearing Cup Marine Transmission Service Manual 137 Assembly Twin Disc Incorporated 16 Install the chilled needle roller bearing into the bore at the front of the pinion and install the internal snap ring into the groove in the pinion bore Figure 78 Lower Pinion Assembly left and Install Bearing Retaining Snap Ring right 138 Marine Transmission Service Manual Twin Disc Incorporated Assembly 17 Install the pinion into the clutch drum Rotate both directions to engage the clutch plate teeth onto the clutch hub slight lifting effort while rotating may make the alignment and subsequent engagement easier Continue until all plate teeth are in mesh and the pinion is riding on the tapered roller bearing Install the external snap ring to insure that the pinion cannot accidentally slide off of the shaft Figure 79 Rotate while Lifting to Engage Teeth left and Install Snap Ring to Retain Pinion right 18 Repeat the assembly procedure for remaining clutch shaft assembly 19 If not already done install the front tapered roller bearing cones for the primary and secondary pinions onto the cup previously installed in the bearing bores in the front of the transmission housing inner wall Note Ihe front tapered roller bearing cones in assembly 1015239 with a r
83. is through a torsional coupling mounted on the engine flywheel The coupling is splined to the input shaft and gear assembly causing this to rotate in engine direction Power is transmitted to the transfer gear that is spline connected to the primary clutch shaft causing it to rotate opposite of engine rotation Power is transmitted to the secondary reverse clutch shaft through transfer gear teeth on the outer diameter O D of the primary clutch housing These teeth are in mesh with gear teeth on the O D of the secondary clutch housing causing the secondary shaft to rotate in engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in 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 anti engine direction Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications Construction Features Housings The 5600 series transmission has a one piece main housing The 1015239 assembly has front housings in SAE No 0 and SAE No 00 sizes available top cover bea
84. not already installed the transmission hub must be installed on the transmission input shaft Mount the flexible membrane and spacer Item 10 to the hub with the flexible membrane toward the transmission It may be temporarily held in place with capscrews through the hub Note Alignment marks exist on the flywheel adapter flexible element and spacer on the transmission side Refer to Figure 120 Suspend the flexible elements Item 1 from a hoist and install one capscrew to properly align the flexible element to the flywheel adapter and roll the flexible element into place See Figure Apply Loctite 242 and install the capscrews and washers Item 39 and 44 into the flywheel adapter and torque to 86 Ib ft 116 Nm Hemove the temporary capscrews that were used to hold the flexible membrane rearward on the transmission hub Install the bolts and washers through the flexible elements and the spacer and flexible membrane Install the copper washer hardened washer and nuts Items 16 19 28 39 and 41 Torque to 86 lb ft 116 Nm Insert the split ring between the transmission input flange and the coupling output element and install the capscrews and torque to the value shown in the torque chart in Description and Specifications Marine Transmission Service Manual Twin Disc Incorporated Installation Removal of Vulkan Rato Coupling Reverse the steps for assembly for removal from the installation Assembly Sp
85. of 6 DETJREQ MAT IESCRIPTION STUCK SIZE a zi 0 63 19 4 4140 SPACER 52 59 Rc 2 0 DIA x 112 LLY 11 4 4140 SPACER HDN 52 59 Rod 20 DIA x 112 2 250 3500 10 M S ATE 15 25 DIA x 262 THK Alesis x e HA 4 STK SOC HD CAP SCR GRADE 8 3 8 16 x 10 LG 3 E Me ETAINER 45 49 38 x 175 x 3 75 et 2 2 STK HD CAP SCR GRADE 8 JOS SUD ls TYPO 2 KEY SLOTS 1 1 4140 COLLAR 45 49 Rc 15 25 DIA 2 38 MAT IESCRIPTION STOCK SIZE RETAINER 2 REQ D PL MS CHDN 45 49 230 manne oervice Manual Jenue N 923IAJ9S UOISSIUISUPJ SUNEN LEZ Ml Co we Co 4 50 15 TU x 45 25 R i 8 21 00 DIA 19 080 DIA i 50 x 15 TYPICAL DIA ARK ED 5 1031 DIA 4 HOLES SHOWN 1015 DIA 45 H MARKED AS SHOWN MCTYP UHMW R CD REQ D DEL LYE HYLENE gt NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 DF EACH NOTE UNLESS OTHERWISE SPECIFIED BREAK Al SHARP CORNERS 9
86. opening and the pressure test ports from metric to NPTF threads Mounting Brackets Steel fabricated mounting brackets for rigid mounting are available They are 1016428AA and 1016428AB Torsional Input Coupling Several models of torsional input couplings are available Marine Transmission Service Manual 31 Description and Specifications Twin Disc Incorporated SAE 0 HOUSING 5 1018662 COUPLING 1018663 C UU gpsOLETE SAE 00 HOUSING Figure 3 Close Coupled Centa CF DS Obsolete 32 Marine Transmission Service Manual Twin Disc Incorporated COUPLING 2 3 4 DUSING Description and Specifications HUPLING 1019653 lt 00 HOUSING Figure 4 Close Coupled Centa CF R 510 Marine Transmission Service Manual DUPLING 1019654 L R H ENGINE ENGINE VY ERVICE REFERENCE ROLLER MA1116D 1 ING 1019655 RH ING 1019656 L H 02 ENGINE ENGINE x x 33 Description and Specifications Twin Disc Incorporated UUTPUI FLANGE FACE Ee 11311 CHUPLING 1016681 lt 18 FWL HUB 10166 9
87. passages in the transmission The main oil pressure regulator shuttle ball neutral pressure regulator and rate of rise functions remain exactly the same as when the valve is in the electric mode In the manual override position shifting is controlled by rotating the lever on the manual override stem In the Neutral position both clutches are vented to sump by two pockets in the stem ee a n MANUAL OVE 1 L W 1 mj Figure 25 Stem Pocket Main pressure oil flow through the hole the of the stem narrow slot between the two pockets This slot does not connect to any other passages when the stem is in the Neutral position When the lever and stem are rotated to engage either the primary or secondary clutch main pressure oil flows through the slot in the stem to the appropriate clutch pressure port The opposite clutch port passage remains connected to sump by the same pocket in the stem as when the stem was in the Neutral position When the stem is rotated back to the Neutral position the main pressure oil slot in the stem is no longer aligned with either clutch port Both clutches are again vented to sump by the two pockets in the stem Marine Transmission Service Manual 63 Operation Twin Disc Incorporated
88. rt doc E wt 2 l ia IhIDGATIRS Clit Flee TLE o Anat ma 25 i RELIER 1 I aea I 5 I Sl APE TEZ Y i Ff peter 7l EN ES MEE DD a te L a z m SEE Je PLS H oEFLOADDLI Webs B ue AG ut 2I6aR AV ed AL LLE 5 SU EVI woes FETT IFT 3 La NE oC 5 C3 S h da Al CU T c a j auf amp 1 nn E ce m 2 i Pa EE I gt eo nat Tart eoi MG5602 cem Ee Loon oce TUER TIS IC JI C __ lasa a n s quo TL MEA et T3800 uy BINE 5 I Tei Ell EDFA gm xz BAR n To E 2 r _ a gt _ gt van n Pai TOS ADIRE w1 ls 58 WIE REMAT ca n Das 12 up INTER ILE ub Massi QIUID CHI Poo gees DADEA dv Paks 2 L38137 T 1 eut PRIMARY SECTNLARY
89. the centrifugal protection ring 3 can now be separated Hemove the M16x50 socket head cap screws that secure the fail safe ring 4 rubber element 1 and link flange 5 These components can now be separated Reassembly of Subassemblies 1 Assemble the link flange 5 fail safe ring 4 and the rubber element 1 with the M16x50 socket head capscrews 12 Line up the centering pins 15 with the rubber element 1 flange Assemble the rubber element 1 and the centrifugal protection ring 3 using the supplied screws 14 Assemble the rubber element 1 centrifugal protection ring 3 and the flywheel flange 2 with the M16x50 socket head cap screws 12 Assemble the two rubber elements 1 together using the M16x35 Socket head cap screws 10 M16 nuts 11 and spacers 8 Use care to line up the centering pins 7 Make sure the jaws of the centrifugal protection ring 3 and fail safe ring 4 are oriented 90 apart from each other Make sure all fasteners are properly torqued to specifications Marine Transmission Service Manual 185 Installation Twin Disc Incorporated Centa L Series CX 72 for Free Standing Transmissions gt E A 8 AM TUS Z J MS L ih LL Figure 115 Enlarged Views 196 Marine Transmission Service Manual Twin Disc Incorporated Installation Installation of VULKAN RATO R Coupling with freestanding Transmissions Information extracted
90. the orifice size regulator spring stiffness and the final main pressure after completion of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the rate of rise piston Is against the stop pressure regulating springs are compressed the most the main oil pressure reaches approximately 350 psi When the control valve is shifted to Neutral the clutch that was engaged is vented to sump within the valve As a result the passage behind the ball and spring regulator is vented to sump and induces a high differential pressure between the rate of rise chamber and the passage behind the ball and spring oince the pressure in the rate of rise chamber is much greater than the pressure it is to be regulated at the ball unseats from the orifice plate allowing main oil pressure to return to the neutral pressure level rapidly and again be regulated by the ball and spring regulator The ball returns to the pressure regulating position once the spring force is equal to force induced by the pressure at the rate of rise piston 60 Marine Transmission Service Manual Twin Disc Incorporated Operation Electric Operation The transmission normally operates with the control valve in the electric mode Two spools each controlled by a solenoid operated pilot valve control clutch engagement When a solenoid is energized it opens the pilot valve and allows main pressure oil to flow to the end of the spool he pr
91. to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 2 of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 C Transmission output shaft bearings Push Pull bearing adjustment method Shim thrust bearings per S692 IV A1 using thrust force shown below Hecord endplay S692 THRUST OUTPUT SHAFT 1340 4000 N 300 900 Ibf 7 Retainer Washer Shimming Procedure At output shaft Determine the gap flange face protruding beyond end of shaft Measure gap and use shims 0 08 0 15 mm 003 006 in thinner than gap No record is required 8 Input Hub Coupling Joint Assembly and Input Shaft Centering Plate Screws Apply MA908 to the as received bolts just before assembly and torque per S574 II ASSEMBLY CHECKS General 1 Visually inspect housing and components for imperfections 2 Backlash Roll all gears to insure no binding The expected backlash including housing tolerances is given below Reduction Gear Box Gears 0 15 0 28mm 006 011 in Transfer Driving to Transfer Driven Gear 0 15 0 28mm 006 011 in Transmission Reduction Gea
92. un EM FITTING Pi 7 ul oce E gt ADAPTER 1017205 y mE oco 1 1 2 ADAPTER gt 1 CAPSCREW Me rgAV 54 UU 7 7 E un PLLG Midas RING AEFI i25 iP IEERMDSTAT VALVE PARTS OPTIONAL Loc DUE 5 ATFS TO T _ gr READABLE FREH SUCTION TUBE SEE CHARI I RING BELE BREATHER SIDE UNIT _ 4 gt SLE 707 DN SHEET STRAINER B2469 Puao PUM SEE UHAR LH ENGINE PLATE 201513 ATTACH AS SHOWN ON Mai FHUSING f n ROTATION CNLY SCREW M4gPB a OO FUR LH ESBIME ROTATIZK ONLY I ARROW POINTS TO AASB 3 TAG MAGOT PLATE Beals FING AFSC I EV 449 GAUGE CITTING XMZEA1AV S LINE 7 4264 WASHER 449 FING 29151 1 PLATE FITTING BREA HER 25 RAFIR SPRING AP7067 _ f HOSE CHAIN M1072 C dau el EAD Mou PLUG amp SS Y E E 14 EDE HEAT EXCPANGER 5 h CLIP F1262A 5 FITTING W248 EAL
93. 00 0 0 40 65 1724 1931 1724 0 7 69 RPM 250 280 250 0 1 10 780 j 250 280 250 10 Neutral 255 310 0 1 T remy mpi E Cooling temperature range Delvac 1110 at 30C 35 86 95 F or Mobilkote 501 2 38 C 90 100 F Required Primary lube pressure secondary lube pressure within 21 kPa 3 psi ALL SHIFTS MUST BE DONE OR BELOW 1200 RPM Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 8 of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 VI PRODUCTION TEST SHEET MG 5600DR Assembly 1018100 Ratio Check Observable Drag Limits At 780 rpm Input Speed IN NEUTRAL 1800 rpm Max Pull Tangent at Final Checks 400 mm 15 75 in Dia Output Flange Hole Circle N Ibf Name Plate amp Serial No accepted Range Accepted Range Capscrews torqued W ee Leakage None Permitted Lube Filter Mounting Holes Motor Drag at 1800 rpm Input Speed Ranae Actual g N m Ibf ft e Seen wem 7277 Tester Da
94. 015731 1016702 1016703 PUMP 1016658 1016699 1016700 CADSUECW MAGIA tad CET LING MEE Aw SUCTION 116662 10166684 6166688 WASHER 4 In o da Fc ime LI Z PLAN in amp amp z0 EOE UM 1017609 10176094 10176098 m im e sm ES Le want ero gt SUC TION IFES i 1376094 CIZ609E e TUBE BOSE 4 2 HAGA xeu hoc MELFCTRIT YE LH 12611 7 amp 2 T CAPSC 3F u a L MOST MASA MEZ ING HAZAZA m Us Lv SEXE w LISE CMECKANICAL VALYEs Magg34t 1 m EP 2E m BIHES HISES APE USED WITHOUT THERMOSTAT VALVE WHEN 4 RTL _ HIL TE RRCPEERANICAL WALWEE MASSIA o 2 OPTIDRAL 4 qe h 3 SEE CuapT Q 9o E PIE A XELECTFICAL YET Mase3az AT VA WE 5 USED SEE CAELOLT FITTING MARAL mo MN RT xs Deve m 5 Ul BAL VIEW l RIGHT SEE D AREAS ne ER Ty WISE B ELECTRICAL VALVE MA9z386 THES sg N AL 51 EE OTHER BOXED AREAS P ADAPTER 1017209 y 7 a RIC Fe iy _
95. 1 Ca _ pots i r gt ZELLE a 1 gg 1 Y x 2470 24 22 at 1 4 a 7 e L Pu La lds 1 Mor 4 _ eI NE Dru ma xi D n L _ Lai DL m 2 I b So _ s 1 ho F aa 1 S An LI poiius eg dZ E um ap cb 27 if n r a D ss g EE snn ss si esas a ll ESAE 1 l iie qo wn ria i ENS 1 1 1 MT E UE el E is NIS MN zu Vous TN i TX p fn Bey itf m nn we x s uet 1 mm M E pata Lu hv Dea te eel f 0 b tn a LI E 1 we EP H 4 1207 Y R ERN l t 1 HERE me Nu S Gi h n C oat O C 1 1 rx al mu
96. 1415503 CONE wey BABS m m Pan 1515302 MASSIF erp CAGED NUT MAIUS4B 542 IEEE E ASSEMBLE DIL me RING SEAL AE ING 2916 JN HOUSING 4551 10155523 HOJSING 1615522 SHIM 11559 es BAC MAIC C22 SHIM 1015520 Lang SEE NOTE 6 8 2 CAPSCREw MAYBOL d SHIM 1015521 CAPSCREW MADELA TUBE enn 2 jl D RING 41S04GM lt 2 SEE MOTE Wd WASFER 6e PLUG PLATE 1015455 CLAMP ASSY 1015556 w TEE TO SEAL MEDIS75A CAE TE EM Gn SENE T ASSSHL eu ait fet 2 e iT r JEL n UY H HL E U x UU vM o _ 42 wiew L BC p FUTING M275 e TE LIF f ji ak MEL W i LEBEN UE CDS 1017614 UNIT SEAL 1000013 62 GEAR 1015283 IEE AR 10 7606 1 d _ i TEM i 6 04 14511 52344 RATIO 1417 ASSEMBLE DIL SEALS 1 2 AS SHOWN t utan 1015351 jj CZAR 1017627 i joli Fi gt os _ 4 4tg woe 9 041 RATIO 1437 4030 RATIU 1437 gt MN GEAR 10 528411 GEAR 10 76286 mE C T SES eet BENE 19503 133T j FHL RATITI 1397 i _ vlw C E 7 GEAR 1015354 GEAR 015357 wiew D D 017 b UI
97. 15498 CARRIER 12 X 30 NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 11 17 Bearing Driver T 18050 690 DET REQ MAT Description amp Stock Size 4 1 Flat Washer to suit 3 1 SOC HD CAP SCR 9 8 16 x 1 5 LG 2 1 Handle 1 25 Dia x 7 25 LG 1 1 Driver Base 8 25 Dia x 1 50 THK jenuey UOISSIUISUEJ JULEN pe1e10dJoo2u 5510 UIML Jenue N 923IAJ9S UOISSIUISUPJ SUNEN 1 REQ D ESRB NE iN 1015453 GEAR HELICAL REF 9 101545 RETAINER SPRING 1 REQ D t ar 30 BASE PLATE 9 4 J H I DRILL 1 2 500 DIA REAM THRU 6 4 3 00 4 ME 3 75 DIA 3 88 I CAP 1 REQ D LEG 3 REQ D 0 ___ T 18050 680 DRIVER REF 69 0 081 1 NOTE GROUND SURFACES MUST PARALLEL WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 11 18 Spring Hold Down Retainer T 18050 694 TEMA Description amp Stock Size 6Lc Base Plate carburized and hardened Leg 3 4 Dia x 4 0 LG CAP carburized and hardened Weldment pe1e10dJoo2u 5510 u AL 1001 IeI 5 ds 022 Jenue N 01551 8 1 SUNEN 11 19 Output Flange Fixture 21413 1 of 2
98. 215 w MH2O001P Biz 8B PTS TOM ALISA OA3KET ESA Joye BOD ASS Y XATOS Was BUDY BALL MiSo0C lt 2 STEM BALL aA TUBA VALVE ASSEMBLY TAPSTRE w ods LM MECHANICAL i G MEAN FITTING MAdDdH 77 NE 077 a w us PLUG MA 3BE s X ey Cc n PLUG MAIQ38A m E _ _ ME MEN MN al T CM n e 12 7 ELECTRIC CINTRO YALYE OPTIONAL 3 Z y LC CaPsCREV 14000 07 4777 GASKET 1017613 TERING AR FDL ate CAPSCREW MA996D 4 DLTuH PLATE 1017583 eun PLUG sc 1 7 DITCH PLATE IN 2 32 FLUG 25 PLUG V ID3BC qe 2 Jg BALL MAIET B RINT a SAGEN sil M TOU i Bidpg A _ T dc um ma VA DASKET 207599 SQ Pi LOCATION FOS Dit TEMPERATURE 77 07 Q 4 3 son NTICATING SWITCH CONNEC cM x QS V CAPSCREWw amp 2 im TE va INDICATING SWITCH UN MM e Th une 99 Ir t 1 M P Ww MAJ GZER 23 d Um Lu 2 i FILTEP HEAD 892 IET ah LAY EFT EL974 FE
99. 47 DASkET pease SPRING 927062 FITTING NG GAUGE B363 7 LE KT BREATHER PSIA FUSE MASZ3AE 7 CHAIN Sl am A 4 PLUG AEST 080 P B E INS NEDIR HEAT EXCHANGER 195 2 CLIP ML783A t vss TaN FITTING MP483 amp i EYEBDLT Mz Os 7B 2a Th AF STARE 43 4 l k FILTER HEAD 9392 E Fel SCREW MAZZE cm 1 Mu BK a WASHER 1039 42 CAPSCREW MADE 4302 GASKET 274 ipli 7 RING Ud z Ma aH TAU WASHER 4 i E da Oy y TN 4 HOSE CaF SCRE MASSES 14 5 SLE CHART E ep CLEMEN GROUP xMeo34 TURE ASEUL XBDODIP Ud ns PUPPET 274367 FITTING Fegan Beanie Di qo By ADAPTER ug BOLT 204365 PLUR A AD C oo E ELEMENT H2725 FIRING PAHS 2 24 DAHER ATES et LAPSURE WV 243 MM s MASISE B FITTING Madde _ PUG T PLUG ELECTS CONTROL STANDARD 1917614 UNIT OPTIONAL FOF 1615001 UNIT 1
100. 5 x LI u r D J 1 Tl wal al a at rm LI i m I E D 22 gt 2 z i 2 i tea 7 I r T L T _ UC 278 s E Ms L t uc e T 5 ae l eee L P 7 RP D r l et E L 1 L Lad T oam at 5 3 ZH s 1 Ll HE L1 b 1 tl r vi n d Ul 1 7 1 1 LI J 7 of LI E bh a ya 21 st t PITTING PACZCE FIrTIMD Meas3 L ESIE 1 FITTING MEBEL eM aa HESE WASESAK PUMP bie fuz 22 FRA EXCHANGER M95900 ui 1215500 FITTING ASS Y XMgE4iAV _ 4 E SC JEN 101761 oda z FAA ALAY W L ING AP2916LJ ELECTRIC VALVES 1017609 u WASHES MAOIST c4 VN 7 MEN u a 05 0 Memes d f v THE3MDSTAT 147035 lc 1 r a gt n 7 rl 9 C CAPSZREW MI732R 64 ua e 7 Co oT HAF MASP aan 7 0 0 tu ER S 7 i 3 3
101. 5310 DIA 1 DETI REQ DESCRIPTION amp STUCK SIZE C i 20 PUR ENERPAC HYD CYLINDER RR 1502 19 4 4140 SPACER 52 59 Rc 2 0 DIA x 112 18 4 PUR JERGENS FLANGE NUT 19910 148 i 7 4 PUR ROD 45 49 Rc 1 000 DIA x 360 LG 16 PUR JERGENS SHOULDER EYE BOLT 18506 15 8 STK HEX HD JAM NUT 1 2 13 14 4 STK THREADED ROD 1 2 13 x 11 25 LG PA 225 13 4 PUR ROD 1 000 DIA x 36 0 LG m 12 4 PUR JERGENS FLANGE NUT 19909 7 8 9 11 4 4140 SPACER 52 59 Rc 2 0 DIA x 112 THK 10 1 MS TOP PLATE 15 25 DIA x 2 62 9 1 MS SUPPORT CYLINDER 10 5 DIA x 75 THK 8 M S SPACER SHAFT 8 25 DIA x40 S 7 STUD LOCATOR POLY 21 00 DIA x 5 75 6 4 SIK SOC HD CAP SCR 3 8 16 x 10 LG Y Y 3 2 MS RETAINER 45 49 RO 38 x 175 x 375 9 SUPPORT CYLINDER lt 12 REQ D 2 2 STK JERGENS SHOULDER SCR 441717 499 D x 778 d 1 1 4140 COLLAR HDN 45 49 Rc 1525 DIA x 2 38 THK 228 Marine Transmission Service Manual Twin Disc Incorporated T 20023 1 3 of 6 2 638 TYPO Special Tools
102. 6001 amp 1017614 Checked DAS Approved TBC Original Issue Date 04 10 95 PROCEDURE Latest Issue Date 09 26 00 ECN 30339 II ASSEMBLY CHECKS General 1 Visually inspect housing and components for imperfections 2 Backlash Roll all gears to insure no binding The expected backlash including housing tolerances is given below Transfer Driving to Transfer Driven Gear 0 15 0 28 mm 006 011 in Reduction Gears 0 15 0 28 mm 006 011 in 3 Record total indicator runout of the following items specified in section V 4 Recheck dipstick I NAMEPLATE DATA 1 Oil Capacity 110 L 29 gallons 2 Minimum oil pressure lt lt when cruising non trolling mode 1520 kPa 220 psi 1725 kPa 250 psi Control Valve 1800 kPa 260 psi 2000 kPa 290 psi Control Valve 3 oee shop order for bill of material and model numbers Also apply serial number ratio and customer number when applicable IV PRODUCTION TESTING Before approval for shipment assembled units are to pass production tests Limits for the production tests are provided in section VI Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 3 of 8 S570AH ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS
103. 8 Place the housing gasket over the housing face using the dowel pins to locate the gasket 9 Lower the input housing onto the gasket engaging the dowel pins Into the appropriate holes 10 Install twenty eight capscsrews M12 1 75 x 40 torque to 130 Nm 96 Ib ft 11 Install the two bearing cups into the bores of the housing These loose fit in the bore 12 Install the two bearing retainers on the housing and retain with at least three capscrews finger tight Marine Transmission Service Manual 161 Assembly 162 13 14 15 16 17 18 19 20 Twin Disc Incorporated Using a feeler gauge measure gap between the retainer flange and the housing and assemble shim packs that are between 0 05 and 0 15 mm 0 002 to 0 006 in thicker than the measured gaps Press the input seal into the input bearing retainer so that it is flush with the front of the retainer Install with the lip opening toward the transmission Install the o rings on the o d of the pilot diameter of the bearing retainers and install with the shim packs in place Assemble with eight capscrews M12 1 75 x 40 in each retainer and torque to 130 Nm 96 Ib ft Rotate gears through at least three revolutions and install dial indicator from the housing with the finger resting on the face of the gear or shaft Mark location with a felt tip pen and zero the dial indicator Apply a lifting force equal to at least tw
104. 90 and torque 10 112 Nm 83 Ib ft 5 Install the suction screen into the suction tube inlet and install an ring onto both ends of the suction tube Insert the suction tube into the housing and secure the suction tube to the oil pump with four capscrews 1 2 13 NC 1 25 in and torque to 88 Nm 65 Ib ft 6 Attach the oil filter head assembly and gasket to the housing with four capscews M12 1 75 x 40 with washers and torque to 112 Nm 83 Ib ft Apply a film of oil to the o ring in the housing and to the threads of the canister bolt Insert a filter element and tighten the canister bolt to 81 Nm 60 Ib ft Install the filter bypass valve consists of poppet spring and plug with o ring into the filter head assembly and torque to 108 Nm 80 Ib ft Marine Transmission Service Manual 149 Assembly Twin Disc Incorporated Installation of Output Flange Use of an SKE THAP 300 Oil Injection Kit or similar is required for tapered output shaft 1 Clean the tapered surface of the output shaft and the tapered bore of the output gear Use an OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Loctite 7070 cleaner is recommended The tapered surface of the shaft and the matching tapered bore of the gear must be completely free of grease oil dirt or solvent residue Failure to properly clean the mating parts could prevent the proper advance of the gear on the shaft and adversely effect the torqu
105. 987 detail 4 left and Aligning plate T 19987 Detail 5 right 122 Marine Transmission Service Manual Twin Disc Incorporated Assembly 8 Place and block the transmission housing with the output side facing up Block in a manner that the input shaft will have clearance when it is installed and such that the four holes near the output shaft in the front of the housing are accessible for the installation of capscrews Remove output shaft alignment tools T 19987 9 Install the heated output bearing inner race onto the front of the output shaft with special tool 18050 687 and install the bearing retainer snap ring onto the output shaft Figure 64 Bearing Inner Race left and Lower Shaft Into Gear left 10 Lower the output shaft into the output gear in the transmission housing Seat the shaft onto the taper of the gear using only the weight of the shaft Marine Transmission Service Manual 123 Assembly 11 12 Twin Disc Incorporated Connect the oil injector to the output shaft Install fixture T 20023 Details 2 through 20 onto the output gear and shaft Figure 65 Fixtures in Place and Injection Lines in Place 13 14 15 16 17 124 Inject oil with a viscosity of 300 mm S 300 cSt at room temperature into the shaft until it leaks out of both ends of the mating surfaces Advance the output gear to the shaft shoulder stop using a 100 ton 889 6 kN ram load Helease the injectio
106. AT Description amp Stock Size 2 1 PUR Liner UHMW PE Poly Kitco 6 50 Dia x 7 8 THK 1 1 Mild Bearing Driver carburized and hardened Steel 8 00 Dia x 1 75 THK J9UU 10 Buue g 99 06091 1 pe1e10dJoo2u 5510 UIML 1001 Jenue N 3IA419S UOISSIUISUEJ SUNEN 1015522 HOUSING 1015423 CLUTCH SHAFT 1 WELDMENT ASS Y 1 REQ D DRILL 27 64 422 DIA N N 201576 OIL SEAL NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE GROUND SURFACES MUST BE PARALLEL 11 13 Driver Seal T 18050 693 sn EM PRIME E ric iar Description amp Stock Size Base Plate carburized and hardened 3 00 Dia x 38 THK Cap carburized and hardened 4 50 Dia x 1 0 THK Tube Body carburized and hardened 4 50 O D x 1 00 WALL x 8 5 LG Weldment Ass y THRU TAP 1 2 13 1 REQ D 29 69 06081 1 1001 219 4 5510 UIML Jenue N 923IAJ9S UOISSIUISUPJ SUNEN GL 1015560 BEARING 585 ASS Y 1015453 GEAR TUR 3 25 1 00 aoe MIN U CUT 1015423 SHAFT 06 X 45 2 50 0 38 X 15 2 4 12 4 33 DIA 4 41 P F DIA JTO DET 1A 5 00 DIA A O KNURL 3 50 MARK T 18050 681 FOR PART s 1015560 BEARING CONE NOTE GROUND SURFACES MUST PARA
107. BS TES E 37 YD TI 3 Pb s fuam j ID AVIS r UM Riu 42 66 e ADT UU pono 0 Apoc oC MEDHANTCA a i i DC ALWE 71 toa tg 7 E oS u Wa T L 2 04 F p J TOL 475 2 LETO RT Da gk lal 1a amp ert Vb Da oth Tet Ee U Lia GIU r 1 IN mos TU 4 1 1 II on vum 0 ts Sof o E ouv Ll Len que aed ns 7 fo J aes IDD o 5 CAPSCREW 25 2 7 xBEYE DaT aT 2 220202008004 DOGO 5 2022 7 BENE ele COUPLINGS ASSY DRIVE xB2335 w 4 7 cco lft les s or x FR Br375 5 SALVE PIN MIO27CZ L C ADARE eii EAE Vulg unn Lia o ADAFTER 10 7647 P por es i J CE 1 127 DUE ei 3 eun VP il pU 5 ici D luar al __ r _ 1 n 7 To DE uoa v N
108. Control Valve Neutral Cutaway View Marine Transmission Service Manual 51 Operation Twin Disc Incorporated Manual Control Valve Primary When a shift to the primary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 14 and 15 he pressurized oil in chamber B is directed through ports G and K to passages D and J Passage D is aligned with a passage directing main pressure oilto the primary clutch Pressurized oil from port K travels through passage J and enters chamber L through orifice in the orifice plate The orifice in this plate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against the springs until the piston is stopped by a shoulder in the valve body This causes the pressure in chamber B to rise to clutch engaging pressure When in primary passage E remains at atmospheric pressure because slot F remains open to sump When a shift is made from primary to neutral the valve stem is rotated to the position illustrated by Figures 12 and 13 Under these conditions passage D is connected to sump by slot F Passage J also is connected to sump by port H in the valve stem Because passage D is connected to slot F oil drains rapidly from the primary clutch to sump Because passage J is now at atmospheric pressure the oil pressure in chamber L
109. D I 227 20023 1 2 of 6 228 e 229 T 20023 1 4 of 6 J 230 T 231 T 20023 1 6 of 6 232 10 Marine Transmission Service Manual Twin Disc Incorporated Table of Contents Engineering Drawings 233 1016473 Electric Trailing Pump 235 MODI 236 1015239 2 MG5600 237 238 1015239 4 MG5600 T 239 ODES c 240 1015239 6 5600 2 2 22 12 241 1152397 ito 242 1016001 1 MG5600 243 Michi u 244 1016001 3 MG5600 245 I 246 1016001 5 5600 2 2 2 247 1015650010 248 1016001 7 MG5600
110. ER FLUSH WITH DRIVER FLANGE SHOWN IN THE AS SHOWN F UP POSITION w 4 m zs a L b FLANGE DOWN FLANGE 4 PRESS IN FIRST SEAL PRESS IN SECOND SEAL oo 1015301 CARRIER 1015479 BEARING MA 590 FC CUP NOTE GROUND SURFACES MUST BE PARALLEL 11 21 Seal Driver T 18050 692 WITHIN 0005 OF EACH OTHER Description amp Stock Size NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS Mild Driver Seal carburized and hardened Steel 13 0 O D x 1 0 WALL x 2 00 THK 5 669 04081 1 1001 219 4 5510 UIML Jenue N 923IAJ9S UOISSIUISUPJ SUNEN SCC STAMP 18050 683 BEARING DRIVER FOR 1015434 BEARING QUOD 10 Duueeg 89 06081 1 9 25 12 7 50 DIA 12 X 45 1015434 GEAR 1 BEARING DRIVER 1 REQ D MAT M S C X H 1015477 BEARING MA 585 HK 11 22 Bearing Driver for Cone T 18050 683 NOTE GROUND SURFACES MUST BE PARALLEL REQ MAT Description amp Stock Size WITHIN 0005 OF EACH OTHER 1 1 Mild Bearing Driver carburized and hardened NOTE UNLESS OTHERWISE SPECIFIED Steel 7 5 D x 1 62 THK BREAK ALL SHARP CORNERS 5 560 DIA p l1ei1odiooul 5510 u AL 1001 IeI 5 ds Special Tools Twin Disc Incorporated T 05600 Lifting Tool for Clutch Removal in Boat
111. ER T P E e _ _ 25 MICRON VAS Me INSTALLATION 97 DPTIZN FULL FLOW f m TEMPERA INDICATING CN TUTE SWITCH USING SIPE TEE WITH lt lt 2 OPTIGNAL REDUCER PUSHIN ELECTRIC OTOR FEF ASSEMBLY 1016035 DRIVE PUM i 422 650 rr FEAT EXCHANGER en seg 2 amp 4 en Li H3SE m RPE BES _ J 2 STSAINER i J i7TALL OF LETICIA S TEMPERS TLRT ous Vo d Mem i BUSHING ZEN TEE __ Lc MA13403 DRAM PI LG LJZATIDSs TR OR BiP X une i 433 x Talal SYS MARINE TRANSMIS SLUM A MG S600DR INSTALLATION AND ASSEMB_ Y SIL HYDRAULIC DIAGRAM EAM IND C 26 nw GRAPHICAL SYMBOLS m Y pu i i EN Ich ers DATE 307 UL O MG 956900RE ACE eT IR EL t JN BOND LIE wi 124041 uia FICTORIAL UI 83203 USA MG 00 fe ANYS TEM pas 1 1 7 X nue rire wr ha 171 SC JED Ih JETR MERTAL TC THE IM TESTS 6 046 HYDRAULIC DIAGRAM DN E E ce E REL ES i 2 422 17 Engineering Drawings Twin Disc Incorporated Notes 256 Marine Transm
112. GRANTED THE U S GOWERNHENT OFRERS EY CONTRACT SURFACE TREATMENT MASS ELASTIC SYSTEM PRIMARY NEUTRAL SECONDARY FLY WHEEL WR m Ve 2 HG TORSIONAL RIGIDITY MASS 1019100 RATIOS zot S ajeo2a o J o k ka LLL cbe FLEXIBLE CHUPLING DUTER PARTS je FUR ALL RATIDS FLEXIBLE COUPLING INNER PARTS 3 8 SHAFT amp GEAR Cz ABAPTER HUB le FOR ALL RATIOS GEAR BEARINGS 1 4 PRIMARY SHAFT 4 115 pet DRIVING TRANSFER GEAR REAR BEARING 11 FOR ALL RATIOS mes 419 X D 107 x 10 357 X 10 40 1 X 10 MIN D D OF TT 42049 RUUT DIA imm 35 Ben geo T 44 4 X 107 138 0 e8g3 x107 gr 1150 X10 7 m 3 4 PRIMARY SHAFT PISTON x BACKPLATE DRIVING PLATES PRIMARY PINION CLUTCH HUB NEEDLE BEARING PINIUN BEARINGS DRIVING PLATES J 37 FOR ALL RATIOS DRIVEN TRANSFER GEAR REAR BEARING SECONDARY SHAFT PISTON BACKPLATE 11 FOR ALL RATIOS DRIVING PLATES OUTPUT GEAR BEARING amp DUDU SHAFT faz ror ratios SECONDARY CLUTCH HUB NEEDLE BEARING GUTPUT FLANGE OUTPUT SHAFT C mun 2 59 FOR ALL RATIOS 1 COMPANION FLANGE WITHOUT BRAKE DISC 52 FOR ALL RATIOS PR 2 loi4mm BRAKE DISC DIA USE WITH Le mv 6 9 FDR ALL RATIDS amp REFER 1018100 FOR WR AND TORSIONAL RIGIDITY STIFFNESS DATA ALL APPLY DIRECTLY TO NAMED MASS
113. HDN 45 49 1 000 DIA 36 0 LG E 5 B X SEAGERCSCSBAFT 825 DIA x40 THK 7 i PUR RUD LOCATOR POLY 28500 DIA e SS THAS 9 V T 5 27 g 0 b gt d 1001 219 4 9 JO 9 L Z007 L pe1e10dJoo2u 5510 UIML Twin Disc Incorporated 1016473 1015239 1016001 1018100 71195 A7119X 5570 5570 B3504AH D D U UD O D UD UD B3504A1 Marine Transmission Service Manual Engineering Drawings Engineering Drawings Electric Trailing Pump MG5600 7 sheets MG5600 7 sheets MG5600DR 4 sheets Hydraulic Schematic Mechanical Valve Hydraulic Schematic Electric Valve MG5600 Assembly Instructions MG5600DR Assembly Instructions Mass Elastic System MG5600 Mass Elastic System MG5600DR Engineering Drawings Twin Disc Incorporated 234 Marine Transmission Service Manual a4 4 1 qd 1 T LI LI re ee ee ee r f AE 2 x x x x x x x x x x x x x degit NE S8 9 4 ha MECH vaL vct d aaa iL LIU A
114. I 1 Moll ae Fal 1 E 7 I 1 1 I 11 n 1 L 11 1 _ I T no pois n M i E 7 Tee T T zal 1 Li L i I i e UM Ce 7 M Eb 05 64 lu F IM G ni 1 LLL r n a Tt ad n dh 2 ue E lt P Ek a ee 1 1 1 i 1 r Lon i k s l Uu x SOON ZEE TEN MERI 4 t IS a L s i t L a i m 8 E a EAD PL me vc m W n Pu Lu T LL 2 5y ya T i 2 2 4 a re 1 moi ue uu Son T z a 4E 4 t T F z 3 7 T kama r T n a T _ I 7 DT Sacs 2 S e UT vit TU 11 1 2 P LU E s vr Uh L 2jUc LU i SA Ta E l 000 M 2o ov VOTA je CH pi 1 T RE we Di n A c npe M SU 1 t r T m UG ME DEDE Y 1 _ 1 2 m T Tn ye 1 eu T Lan r uu fre _ uL 15 2 a lic on gt 7 UA wo uM uh 5 a i f 1 r
115. ICK UP PLATE 1 REQ D MAT M S CARB amp HDN 11 07 Clutch Pickup Fixture Secondary 1T 18050 727 Ac Description amp Stock Size Shoulder eye bolt 1 2 13 UNC Extension 50 Dia x 4 25 LG i Pick Up Plate 3 62 Dia X 88 THK 1001 219 4 5510 UIML Jenue N 3IA49S UOISSIUISUPJ SUNEN MA 217 J BEARING 1015434 GEAR HELICAL CAGED ROLLER NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 60c jo 0 50 1 69 12 15 25X15 4 L T 56 12 WIDE 06 DP U CUT 12 TYP f 06 X30 E275 DIA 1 HOLE N 2 PLACES KNURL MARK 18050 682 BEARING DRIVER 1 FOR 217 J BRG CAGED ROLLER 1 BEARING DRIVER CAGED ROLLER 1 REQD 5 CARB amp 11 08 Bearing Driver Caged Roller T 18050 682 REQ MAT Description amp Stock Size 1 1 Mild Bearing Driver carburized and Steel hardened 4 75 D x 2 75 THK Duueeg 89 0 081 1 p l1ei1odiooul 5510 u AL 1001 IeI 5 ds Ole Jenue N 923IAJ9S UOISSIUISUPJ SUNEN 13 50 DIA TYP 4 HOLES EQUALLY SPACED FOR ra HOLD DOWN DOG Y i DRILL THRU 66 DIA 1 REQ D EE sm 1015522 HOUSING 1 z l
116. INCORPORATED Racine WI Page 6 of 8 S570AH ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION 5 5 MARINE TRANSMISSION MG 5600 Drawn ALC BJE _ ASSEMBLIES 1015239 1016001 amp 1017614 Checked DAS Approved TBC Original Issue Date 04 10 95 PROCEDURE Latest Issue Date 09 26 00 VI CONTINUED PRODUCTION TEST SHEET MG 5600 Input Speed Range Limits for Marine Transmission Equipped with Control Valve with 2000 kPa 290 psi Spring CIRCLE UNITS IN ACTUAL COLUMN rpm Range l Min Act Max Min Act Min Act Min Act Max kPa kPa kPa kPa kPa kPa kPa kPa kPa ps psi psi psi psi psi psi Primary 1960 2137 1960 _ e ees C ee el 0 285 310 0 Neutral 280 689 0 Lao o ies es al d 250 280 250 1 10 C es es 0 n 250 280 0 250 1 10 Len ela NEN 37 45 0 0 3 20 5 Input Speed Ranges Test speed 900 1299 rpm 1100 rpm 1300 1699 rpm 1500 rpm 1700 2100 rpm 1900 rpm Do not exceed maximums ui Cooling temperature range Delvac 1110 Oil at 30 35 C 86 95 F or Mobilkote 501 at 32 38 C 90 100 F Required Primary lube pressure z secondary lube pressure within 21 kPa 3 psi ALL SHIFTS MUST BE DONE AT OR BELOW 900 RPM A reading outside the limiting range could mean oValve Inlet Pressure faulty valve springs sticky valve pump flow too low or high wrong valve spring shims or quanti
117. IZE BREAK ALL SHARP CORNERS STK THREADED RUD 1 8 THREAD x 80 LG 4 3 STK FLANGE NUT 7 8 8 THREAD 3 FIRM X RUD 10 DIA x 11 25 LG 2 1 MS PLATE C x H 7 0 DIA x 150 THK 1B 1 MS PLATE 10 0 DIA x 1 25 THK 1A 1 TUB TUBE DRIVER 95 x 10 WALL x 12 0 LG 1 1 WELDMENT ASS Y 226 Marine Transmission Service Manual Twin Disc Incorporated Special Tools T 20023 1 1 of 6 1 2 13 THREADED DET 14 42 REQ D 10 88 4 1424344456 Marine Transmission Service Manual 227 Special Tools Twin Disc Incorporated T 20023 1 2 of 6 NE wp 0 750 utput Gear to Shaft Puller lt 20023 1 1 amp 2 of 6 DRILL 17 32 6
118. LLEL TO SHAFT 1015423 VIEW OF DRIVER SHOWING WITHIN 0005 OF EACH OTHER DET 2 DELIN SLEEVE FOR NOTE UNLESS OTHERWISE SPECIFIED SHAFT PROTECTION BREAK ALL SHARP CORNERS WHEN PRESSING BEARING CONE ON SHAFI 11 14 Bearing Cone Driver T 18050 681 REQ MAT Description amp Stock Size 2 1 PUR Sleeve Delrin or Equiv 4 50 Dia x 2 75 LG Cap carburized amp hardened 5 0 Dia x 1 25 LG Body Tube carburized amp hardened 5 0 OD x 4 12 ID x 3 5 LG Weldment euo Duueeg 189 0 081 1 pe1e10dJoo2u 5510 u AL 1001 IeI 5 ds 91 Jenue N 3IA419S 01551 8 1 SUNEN DRILL 5 16 312 DIA THRU 18 00 DIA Lo 3 8 16 4 HOLES EQUALLY STAMP 18050 680 SPACED ON 13 25 B C 1015301 CARRIER 13 25 DIA lt 1015479 BRG MA 590 FC CUP 1001 219 4 12 25 DIA 12 X 45 15 000 e5R sasa 4 12 TYPE 5 1 cRoss SECTION BRG DRIVER MAT M S 1 REQ D CARB amp 699 09081 1 gt 14 99 DIA D F 12 00DIA X Wo 1402DA a O Y ak 4 4 26 LL s i 1015301 CARRIER 1015479 BEARING 590 FC CUP NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED B
119. Min Act Min Act Max kPa kPa kPa kPa kPa kPa kPa kPa kPa psi psi psi ps ps psi psi Primary 1690 1830 1690 o pem eem _ o ew 245 265 0 Neutral 280 590 0 S pes e pee eem _ ol 240 260 240 1 10 Secondary 1660 1790 0 1660 7 69 T en e o eges toa lol 18 51 0 0 3 20 Input Speed Ranges Test speed 900 1299 rpm 1100 rpm 1300 1699 rpm 1500 rpm 1700 2100 rpm 1900 rpm Do not exceed maximums 7 Cooling temperature range Delvac 1110 Oil at 30 35 C 86 95 F or Mobilkote 501 at 32 38 C 90 100 F Required Primary lube pressure z secondary lube pressure within 21 kPa 3 psi ALL SHIFTS MUST BE DONE AT OR BELOW 900 RPM A reading outside the limiting range could mean oValve Inlet Pressure faulty valve springs sticky valve pump flow too low or high wrong valve spring shims or quantity of shims wrong pump installed leakage broken forgotten or cut seal rings amp Secondary Pressure broken seal ring at collectors or piston oeLube Pressure out of tolerance or missing orifices broken rear seal ring faulty lube relief valve Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC
120. N e ALIM i Ul 1 n WASHER PS13398 43 n B I CAPSCREW MASSA a gt ELEMENT XMAS 264367 7 HODY BJI33 ra WALWE 120849 iaw DL BOLT 56 CONTROL Val YE 1018084 J L2 v DC NEM Wal YE DROW iho I ASHER _ PARTS 5 3 P m MM v n 31534 cbe cos ZAPSCREV N4995 711 ots TE to du 5PAL R 10261 ee Lette 222224 D c 10152839 L __ RASKET _ Be cop O Lll 5 ut mafi TEAHZHMISSIDM au F MECHANICA valve qur t I DAPSURE W Masse __ PETTING MESEJAK T CaPLCREW MIT3PAA lt 42 SLUG MAMSSD tat WASTER AIOSIC 449 I I I I CAPESCREwW Cim 522 MRE ASE TUBE B2a0 M ADAPTER 32390 3 LI Cad 1 7 _ _ ta m uo I _ I _ _ 1 _ gt is _ _ _ 1 1 mo 1 1 1 1 1 1 L _ 2 _
121. NCORPORATED Racine WI Page of 8 S570AH ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600 Drawn ALC BJE ASSEMBLIES 1015239 1016001 amp 1017614 Checked DAS Approved TBC Original Issue Date 04 10 95 PROCEDURE Latest Issue Date 09 26 00 ECN 30339 4 Output Flange Taper Assembly Joint surfaces to be in condition described 1 1 Coat the tapered surfaces with thin oil Measure distance from output shaft end to taper roller bearing cone assembly face Measure length of output flange hub taper Note With the output flange fully assembled the difference between these two measurements must equal the space available for shaft end shims within 0 05 mm 002 in Install output flange onto output shaft along with retainer washer and screws Connect oil injection equipment to output flange hub Seat hub using 1340 N 300 Ibf load Inject oil with a viscosity of 300 mnf s 300 cSt at the operating temperature into the hub until it leaks out between the hub and shaft Continue injecting oil while using retainer washer screws to advance flange to bearing stop Release injection oil pressure between the mating surfaces and wait 5 minutes before removing screws and retainer washer Record actual advance 5 Splines The input spline for the close coupled model assembly 1015239 is a loose fit and should assemble without need to heat the internal spline Press the input spline pa
122. P 2 25 DIA 45 1015512 BEARING 1 13 BEARING DRIVER 1 REQ D OUTER RACE M 5230 E MAT M S C X H 1015522 HOUSING Duueeg 789 06081 1 UNLESS OTHERWISE SPECIFIED f YN BREAK ALL SHARP CORNERS NOTE GROUND SURFACES MUST PARALLEL WITHIN 0005 OTHER 11 11 Bearing Driver for Outer Race 18050 684 REQ MAT Description amp Stock Size Locator Guide 7 0 Dia x 1 75 THK SOC HD CAP Scr 3 8 16 x 1 25 LG Washer 1 12 Dia x 401 0 x 18 Handle 1 25 Dia x 20 5 LG Bearing Driver carburized and hardened 10 5 Dia x 1 50 THK 1001 219 4 5510 UIML Jenue N 923IAJ9S UOISSIUISUPJ SUNEN ELZ STAMP T 18050 687 BEARING DRIVER 1015285 SHAFT amp 1015512 BEARING BEARING INNER RACE 1015512 MA 5230 1015285 SHAFT OUTPUT 8 00 DIA O2 w 475DIA 2 25 E VA 5 Vr 6 00 DIA S42 6 375 DIA _ _ 7 25 DIA 1 BEARING DRIVER 1 REQ D i i c 62 KNURL i 2 LINER UHMW PE 1 REQ D 4 1 NOTE GROUND SURFACES MUST PARALLEL 7 WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 11 12 Bearing Driver Inner Race 18050 687 DET REQ M
123. R RING BALL M amp l 34L 2 LT a i un i SUME Ww MA996C lt 23 0 Fir ADJI Kd c EN WASHER RLIS AHBX COVER 1015518 i utm _ RETAINER ASSY 1018467 lt 2 a i SHAFT ASZZ Y 1015424 RETAINER 1015466 i w 1615423 1 xP HALL L i T E RING Meets rg _ RING EB1D34BHEL 422 PLUG 1015722 x eee 6 RING THES WIEW SHOWS THE PUMP AS SEMELE FTIGE SPACER AS USED WITH SIDE FROM BEARING ELECTRIC VALVE JSED WITH ASSEMBLY 1217614 STANDARD ANE WITH ASSEMBLY 0180521 OPTIONAL SFEE x amp Pun ANDE 7 101545 23 SRP T ASST LOSI SHAFT 1015230 BALL PISTON 1015368 te GbARING ANNY 1215427 e gt CONE MA A3BH SFK CUF SHIM 101551 3 SHIM uu AS REC D NOTE 47 1615285 SHIM 1015514 PLATE 206200 4262 2 SING AZSISCL PLATE PC623PB 245 RETAINER 1015454 P gt BEARING 1015512 WASHER 150460 _ SPRING AP70SAU 28 RING LAPZCREW CH RING MARAE 2 CAPSCREW MAIGIC 4 FL 1017727 WASHER MZ0F1E CARRIER 191530 Tu E MODUM BEARING ASS Y 1015479 Aiii PAM AES YT
124. REAK ALL SHARP CORNERS 11 15 Bearing Driver T 18050 689 REQ MAT Description amp Stock Size 3 4 SOC HD CAP SCR 3 8 16 x 1 5 LG 2 1 PUR Brg Driver Locator Kitco Poly 15 25 Dia x 1 25 THK 1 1 Mild Bearing Driver carburized and hardened Steel 19 0 Dia x 1 25 THK pe1e10dJoo2u 5510 UIML Jenue N 923IAJ9S UOISSIUISUPJ SUNEN 216 3 50 I 1 00 75 5 50 DIA 6 31 DIA 6 00 DIA 7 25 DIA 19 X 15 TYP 12 X 45 69 06081 1 STAMP 18050 691 amp 25 PART 1015435 THRU 1015445 pO NIE M 2983 BEARING MA 590 A CUP 590 CU 1 BEARING DRIVER 1 REQ D MERI E ICE M S CARB amp NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 OF EACH OTHER 11 16 Bearing Driver T 18050 691 NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS Bearing Driver 7 25 Dia x 1 0 WALL x 4 Steel pe1e10dJoo2u 5510 u AL 1001 219 4 gt o k e o 1 25 L 12 X 45 e D KNURL FULL LENGTH D DRILL 5 16 312 DIA X 1 38 DP 700 TAP 3 8 16 X 1 25 DP 1 REQ D O 200 p A STAMP 18050 690 g 06 J PART 1015301 CARRIER 2 U CUT V 12 X 30 lt 62 75 0 750 DIA 8 350 DIA mm pr 9 00 DIA MA 590 AT CUP A 10
125. Se Ls k 2 II unl 1317 2 981 RATIO 1 51 pH i oct 0 Sort i i MEN Dd o SU i 10 5357 GEAR 1215362 i eU D tadas e Pto oco a GEAR RATIOS M TERN BIS a7 298 1207 2 53 RATIO UST j HE dU S fore e UO Ro e v dee GEAR 10 52362 ET _ Eus 062 048 n _ LEIJ FATIG LEST BEEN DES D Cou ka 1 L i tf ost s wer 1 um 10 40 o 4 1 Po ta L Ue nt BEEN 12 5 m _ E _ Eh Uu p 1016001 vo 2522512 Diis Wu 017514 _ IN 2n Glance LEEREN 2600 TONS 415504 l FUR 1015001 UNIT MGIME FULL LDAD 1017614 CNIT ELLING x FITTING FITTING ME4S IML HOSE Ma323AE VALVE THERMOS TAT c4 ENG3NE GOVERNED SPEED R P M T ENGINE FULL CDAJ m6 4f i POT AT LOH RPM r Pu 4 La 1302 1699 i700 2100 HFAT HIRYA Pia HOSE nn 1299 L200 1599 Poo rpg k Pi PUNE 166838 HIE t LYLE U 5 _ LH 1
126. a _ T en 17 E AL Us u E I T T tx i A x 5 i wm wan c rama war al i u r MT D iit ree Far 17 t L 2 uU 3 oot gt cy 1 n 1 t tog a 7 E EM E 1 i oe fe _ L w m DI a ZUM gn E 1 4 1 4 a _ _ r 4 1 T AEN D d e TU E luco a ai a jd air mta a o E r pod SE lS 4 1 ag 7 1 _ A 1 1 D D I x Aa Le lt L 1 1 c n macer F n 1 m D m t FQ D _ i I n T s 4i I _ t n 1 Tr it I mo l SA DU M L 401 1 07 274 I 1 _ T oa rn a Li E l i Li n ik _ E sq 1 E i X 2 1 wl _ L 1 I 2 ole i i
127. ace the external snap ring on the shaft and move the shaft assembly to a press and install special tool 18050 694 over the shaft Compress the spring retainer and springs to expose the snap ring groove in the shaft Install the snap ring into the exposed groove on shaft Slowly release the pressure on the springs assuring that the spring retainer counterbore covers the snap ring and prevents the snap ring from coming out of the groove Remove special tool T 18050 694 Figure 75 Compress Spring Retainer and Springs left and Insert Snap Ring Into Groove right Marine Transmission Service Manual 135 Assembly Twin Disc Incorporated 12 Beginning with a friction plate alternately install 13 oil soaked friction plates and 12 steel plates into the clutch drum and against the clutch apply piston 13 Install the clutch backplate and internal snap ring Figure 76 Alternately Install Clutch Plates left and Install Backing Plate right 14 Install the pinion tapered roller bearing cone assembly onto the clutch shaft Install with the large diameter of the bearing seating against the shoulder on the shaft This bearing is a slip fit and will not require special tools for installation 136 Marine Transmission Service Manual Twin Disc Incorporated Assembly 15 Use special tool driver 18050 691 and install the chilled cup for the tapered roller bearing into rear of the clutch shaft pinion as seen below The bearing cup
128. al 109 Cleaning and Inspection Twin Disc Incorporated 110 Cleaning Bearings Do not remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease Never dry bearings with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently It is important to keep bearings clean Do not remove grease from new bearings Keep the wrapper on new bearings until they are installed Do not expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Sealed Joints For previously sealed joints scrape surfaces to remove old gasket material or silicone Clean surfaces with solvent to remove oil and grease residue Test for clean surfaces by applying a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface in a film If the water puddles or forms beads use fresh solvent and reclean Marine Transmission Service Manual Twin Disc Incorporated Inspection Cleaning and Inspection Housings Cast Parts and Machined Surfaces d d Valve Seats Replace cast parts or
129. anual Twin Disc Incorporated Disassembly 6 Remove the filter screen from the valve body Figure 54 Remove Filter Screen using Allen Wrench 7 Remove the two socket head O ring plugs from the bores in the end of the valve body 8 Remove the two spools from the valve body 9 Remove the spool return spring and dowel pin from the bottom of each of the spool bores in the valve body Marine Transmission Service Manual 107 Disassembly Twin Disc Incorporated 108 Marine Transmission Service Manual 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 he dried and oiled immediately Examine all parts carefully for grit dirt and abrasives and reclean them if necessary Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent to flush oil pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher screw locations Marine Transmission Service Manu
130. aper bores and their mating shaft seats per 5765 Assembly Instructions before assembly B All bolts screws and nuts are to be as received from bins with only light rust preventative oil on them and torqued per 5574 C The main housing should be oriented with input end up during installation of input reduction gear box and down during installation of transmission shaft assemblies 2 Transfer Driving and Driven Gears Taper Joint Assembly Joint surfaces be in condition described in 1 1 Place gears on shafts using 445 890 100 200 Ibf max force to seat them on their tapers Advance each gear A static pressure of approximately 569 738 kN 64 83 tons will be required For primary and secondary shaft assemblies advance gear within 0 00 0 05 mm 000 002 in of the shaft shoulder at the small diameter end of the taper andecord advance 3 Output Gear Taper Assembly Joint surfaces to be in condition described 1 1 Coat the tapered surfaces with thin oil Install cylindrical roller bearing outer race roller assembly along with snap ring into main housing Use suitable C type lift fixture to position gear into correct position Install cylindrical roller bearing inner race and snap ring onto output shaft Install the output shaft assembly thru the gear bore and into the cylindrical roller bearing outer race roller assembly Connect oil injection equipment assembly tool Use portable press 890 kN 100
131. arranty 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 18 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications General Description and Specifications There are four distinct assemblies in the MG 5600 marine transmission family and all are included in this manual They are identified by different drawings Assembly drawing 1015239 identifies an engine mounted unit that attaches directly with a flywheel housing This unit has a mechanical control valve standard with an electric control valve option Assembly drawing 1016001 is identical with the exception that it is a freestanding version Assembly drawing 1017614 is a freestanding unit with a higher power rating for right hand engine use only This unit requires an electric control valve Assembly drawing 1018100 identifies a double reduction unit designated as MG 5600DR This unit for service requirements is essentially the same as assembly drawing 1017614 in a 5 04 1 reduction ratio with an additional reduction section in front of the input section This assembly requires an electric control valve Marine Transmission Service Manual 19 Description and Specifications Twin Disc Incorporated Nameplate The namepla
132. ary and secondary clutch plates Further disassembly reassembly of the primary or secondary shafts will require use of tools and equipment normally not available on board the vessel Marine Transmission Service Manual 73 Preventative Maintenance Twin Disc Incorporated General Maintenance 74 Lubrication Grease the oil seals on the output end of the output shaft through the grease fitting with water pump lithium soap based No 2 grease Apply grease every 100 hours or when the boat is docked No other lubrication is required beyond the daily oil check Oil System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil in it With the engine running at low idle and the transmission in Neutral check the oil again The oil level should be near the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval With a new transmission change the oil and filter element within the first 50 hours of operation Change oil and filter element after each 1000 hours thereafter or more often if conditions warrant For a rebuilt transmission check the filter element after eight hours of operation If the filter is clean install a new filter element and then change the oil and filt
133. at 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 175 Installation 176 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
134. be required For primary and secondary shaft assemblies advance gear within 0 00 0 05 mm 000 002 in of the shaft shoulder at the small diameter end of the taper andecord advance 3 Output Gear Taper Assembly Joint surfaces to be in condition described 1 1 Coat the tapered surfaces with thin oil Install cylindrical roller bearing outer race roller assembly along with snap ring into main housing Use suitable C type lift fixture to position gear into correct position Install cylindrical roller bearing inner race and snap ring onto output shaft Install the output shaft assembly thru the gear bore and into the cylindrical roller bearing outer race roller assembly Connect oil injection equipment assembly tool Use portable press 890 kN 100 ton capacity and fixture to seat gear using 1340 N 300 lof load Inject oil with a viscosity of 300 mn s 300 cSt at the operating temperature into the shaft until it leaks out of both ends of the mating surfaces Advance gear to shaft shoulder stop Release injection oil pressure between the mating surfaces and wait 5 minutes before lowering the pull on force and removing the assembly tool Record actual advance Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC I
135. cator finger on the original mark and read the shaft endplay on the dial indicator Figure 70 Read Endplay with Indicator Finger on Mark Adjust the shim pack thickness from step 1 above to obtain an endplay of 0 05 mm to 0 15 mm 0 002 in to 0 006 in Install the new shim pack between the seal carrier and the housing Hepeat steps 2 through 5 until the endplay is between 0 05 mm to 0 15 mm 0 002 in to 0 006 in Hemove the lifting fixture Remove the capscrews and remove the output seal carrier Install the o ring in the groove in the O D of the output seal carrier pilot Marine Transmission Service Manual 129 Assembly Twin Disc Incorporated 9 Coat the O D of the oil seals with M2828 anaerobic sealant and install the oil seals into the output seal carrier using driver T 18050 692 Remove any excess sealant that is wiped off as the seals are pressed into position Install the forward seal seal closest to bearing cup with the open lip toward the inside of the transmission and install it lush with the inner face of the seal carrier Install the rear seal with open lip of the seal toward the rear of the transmission and install it flush with outer rear face of the seal carrier 10 Pack the area between the seals with water pump grease Figure 71 Fill Cavity between Seals with Grease 11 Install the grease fitting zerk fitting if not previously installed 12 Install the final shim pack established above
136. cessary Filter Assembly A canister style filter is located between the heat exchanger inlet and the selector valve in the hydraulic circuit The replacement element is Twin Disc part number M2725 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 The input reduction gears of the MG 5600DR are one piece and mounted on tapered roller bearings Marine Transmission Service Manual 25 Description and Specifications Twin Disc Incorporated 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 da Dampen torsional vibrations Change the natural frequencies of 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 and on engine rotation Care must be tak
137. clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation When the control valve is shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively increases the clutch engaging pressure causing the clutches to engage at a controlled rate The control valve allows only one clutch to be engaged at a time and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag General The control valve assembly contains passages and ports to direct pressurized oil within the transmission s hydraulic system The pressure rate control piston within the control valve assembly provides a rapid smooth oil pressure increase in the hydraulic system during clutch engagement Marine Transmission Service Manual Jenue N 2I A19S UOISSIUSUEJ 1 6t pe1e10dJoo2u OSIA UIML
138. completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of the engine flywheel housing secure the mounting brackets to the engine bed rails Before securing the mounting brackets to the engine bed rails the propeller shaft should be checked for alignment Note The transmission output flange and companion flange bolts must be torqued to the proper value as identified in Description and Specifications Torsional Input Coupling Alignment Free Standing Units 174 Alignment of freestanding transmissions must begin by aligning the transmission output flange to the propeller shaft The engine must then be moved to properly align the engine flywheel to the transmission input hub Marine Transmission Service Manual Twin Disc Incorporated Installation Engine and Marine Transmission Alignment When mounting the engine and transmission in the boat all of the mounting pads on both the engine and transmission must be used Failure to do so may result in damage to the transmission or the engine flywheel housing Hecormrmmndecd Figure 106 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 bo
139. creases the clutch engaging pressure causing the clutches to engage at a controlled rate The control valve allows only one clutch to be engaged at a time and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Marine Transmission Service Manual Twin Disc Incorporated Operation Figure 19 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 57
140. ctual Maximum 0 05 mm 0 15 mm 002 in 006 in Transmission Output Shaft Bearing Endplay Minimum Actual Maximum 0 05 mm 0 15 mm 002 in 006 in Record total indicator runout of the following max allowable shown 0 10mm 004 in face of propeller flange near O D from main housing 0 10mm 004 in pilot of propeller flange from main housing Tester Date Inspector Date Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 7 of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION 5 5 MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 VI PRODUCTION TEST SHEET MG 5600DR Assembly 1018100 Limits for Marine Transmission Equipped with Control Valve with 2000 kPa 290 psi Spring CIRCLE UNIT IN ACTUAL COLUMN Valve Inlet Primary oecondary Lube Ratio Range or Max rpm Min Act Max Min Act Min Act Min Act kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa psi Primary 1960 2137 1960 0 100 380 285 310 285 0 15 55 Secondary 1960 2137 1960 100 380 285 310 285 15 55 Neutral yn 689 0 280 450 40 1
141. d be 11 86 mm 0 467 in to 13 54 mm 0 533 in See Figure 59 and 60 ADVANCE A B 11 25 mm OG 12 54 mm 0 467 in ta D Sir Figure 60 Note Gap Between Shoulder and Gear 120 Marine Transmission Service Manual Twin Disc Incorporated Assembly Should the calculated advance fall outside the range given check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it willbe necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance The tapered surface of the shaft and the matching tapered bore of the gear must be completely free of grease oil dirt or solvent residue Failure to properly clean the mating parts could prevent the proper advance of the gear on the shaft and adversely effect the torque carrying capacity of the assembled joint 4 Coat the tapered surfaces of the output shaft and gear with thin oil 9 Install tools T 20023 1 and T 19987 onto the output gear Figure 61 Tool T 20023 1 Collar and T 19987 lift adapter Marine Transmission Service Manual 121 Assembly Twin Disc Incorporated 6 Use special tool T 19987 to lift the output gear and lower into the transmission housing Figure 62 Lowering Gear Into Housing T Use the shaft locator tools T 19987 Details 4 through 6 to position and hold the output gear in the housing Figure 63 Aligning shaft T 19
142. d into manifold at plug MA1038D at the primary shaft D Zo oecondary Clutch actuated Pressuregauge connected into manifold at plug MA1038D at secondary shaft 2 Run at 780 rom Make a few shifts to primary secondary and neutral If unit performs and sounds satisfactory accelerate to rpm shown IV 3 until oil temperature is at a minimum temperature in IV 1 All shifting must be done at or below 900 rpm 3 Limits for Marine Transmission Equipped with Control Valve After unit is up to required temperature at rpm shown below check andecord pressure as charted in section Then reduce speed to 780 rpm and check and record pressures as charted in section VI The unit should not be run at speeds in excess of the specified speed The rpm for test is dependent on overall ratio shown in the Remarks column of the bill of material Use rpm test speeds as shown below Bill of Material Input test Speed Overall rpm Hatio Hequired 7 01 1 2100 6 56 1 1950 6 02 1 1800 reading outside the limiting range as charted section could mean Valve Inlet Pressure Faulty valve springs sticky valve pump flow too low or high wrong valve spring shims or quantity of shims wrong pump installed Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Gov
143. d screen Remove the pump from the transmission Remove the pump drive coupling assembly Remove the oil filter element and remove the filter head from the transmission Remove the selector valve and gasket Set it aside for further disassembly Remove the oil level dipstick and tube from the top cover Hemove the top cover and gasket Loosen but do not remove the four capscrews from the front of the transmission near the output shaft that retain the output gear pan assembly Marine Transmission Service Manual 85 Disassembly Twin Disc Incorporated Assembly 1016001 or 1017614 Model MG 5600 free standing Remove the three M12 1 75x25 capscrews washer and coupling hub if not already removed The hub is a press fit onto the shaft and will require the use of a puller to remove It should not be necessary to place the transmission on rear side 86 Marine Transmission Service Manual Twin Disc Incorporated Disassembly Assembly 1015239 Model MG 5600 close coupled Note It may be advantageous to use wood blocks to support the transmission with the input side facing up to remove the input elements due to their weight and size 1 Hemove the input coupling if applicable This coupling is a slip fit on the input shaft and should easily slide off 2 Hemove 18 or 26 depending on housing size of M16 2 00x45 capscrews and remove the engine flywheel housing cover Marine Transmission Service Manual 87 Disassemb
144. dy half 156 Selector Valve Installation sse 160 Input Reduction Components for Model MG 5600DR 161 Installation of Remaining Transmission External Components all models unless noted 163 Installation 167 Prior to Installation 167 Alignment also reference SAE J 1033 and J 617 168 Installation 173 Marine Transmission Service Manual 9 Table of Contents Twin Disc Incorporated Special Tools 199 Recommended Pump Set and Fluids 201 T 19987 Gear Lifting Fixture 203 T 19987 detail 1 2 and 3 Gear Lifting Fixture 204 T 19987 detail 4 Gear Assembly Fixture 205 T 19987 detail 5 and 6 Gear Assembly Fixture 206 T 18050 726 Clutch Pickup Fixture Primary 207 T 18050 727 Clutch Pickup Fixture Secondary 208 T 18050 682 Bearing Driver Caged Rolle
145. e Transmission Primary Transfer Gear Advance Minimum Actual Maximum 3 33 mm 4 29 mm 131 in 169 in Transmission Secondary Transfer Gear Advance Minimum Maximum 3 33 MM 4 29 mm 131 in 169 in Transmission Output Gear Advance Minimum Maximum 11 86 mm 13 54mm 467 in 533 in Transmission Output Flange Advance Minimum Maximum 10 16mm 12 35 400 in 486 in Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 6 of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION 5 5 MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 V continued ASSEMBLY CHECK SHEET MG 5600DR Assembly 1018100 Reduction Gear Input Shaft Tapered Roller Bearing Endplay Minimum Actual Maximum 0 05 mm 0 15 mm 002 in 006 in Reduction Gear Output Shaft Tapered Roller Bearing Endplay Minimum Actual Maximum 0 05 mm 0 15 mm 002 in 006 in Transmission Primary Shaft Tapered Roller Bearing Endplay Minimum Actual Maximum 0 05 mm 0 15 mm 002 in 006 in Transmission Secondary Shaft Tapered Roller Bearing Endplay Minimum A
146. e 12 months of service whichever occurs first This isthe only warranty made by T win Disc Incorporated and is in lieu of any and all other warranti ress or implied or intended to be given by Twin Disc Incorporated The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering Incorporated be either the repair or replacement of any T win Disc Incorporated part or product found by T win Disc Incorporated to be defective and the labor to perform that work and to remove and reinstall or equivalent credit In this context labor is defined as the flat rate labor hours established by T win Disc Incorporated in the blished T win Disc Flat Rate Schedule required to remove disassemble i repair reassemble reinstall and test the T win Disc Incorporated product only Authorized reasonable travel and living expenses will be considered for ent Under no circumstances including a failure of the exclusive rem shall T win Disc Incorporated be liable for economic loss consequential incidental or punitive damages he above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair 2 Thewarranty is void if in the
147. e 5 centering pin 7 spacer 8 M16x35 socket head capscrew 10 M16 nut 11 M16x50 socket head capscsrew 12 screw 14 centering pin 15 and snap ring 16 3 Lower the subassembly into position and secure to the engine flywheel These bolts are not supplied and must be torqued to specifications shown in Description and Specifications section 4 Mount the links 6 so that the pilot on the sleeves fits into the recess in the link flange 5 and the output flange 9 Tighten the M27 bolts to 1400 Nm 5 The coupling must be shielded to meet safety regulations while providing adequate ventilation 184 Marine Transmission Service Manual Twin Disc Incorporated Installation Complete Disassembly 1 Remove the axial bolts 27 100 and the radial bolts 27 120 Remove the links 6 Support the subassembly and remove the bolts that secure the coupling to the engine flywheel Subassembly Disassembly 1 Remove the M16x50 socket head cap screws 12 which secure the flywheel flange 2 to the rubber element 1 and centrifugal protection ring 3 The flywheel flange can now be removed Hemove the M16x35 socket head cap screws 10 M16 nuts 11 and spacers 8 Use care to not lose the centering pins 7 and snap rings 16 the two rubber elements 1 can now be separated Hemove the screws 14 which secure the centrifugal protection ring to the rubber element 1 the rubber element 1 and
148. e bearing to seat against the transfer gear Install the retaining snap ring with the tapered side of the snap ring away from the bearing Figure 73 Pressing Bearing Onto Shaft left and Install Retaining Snap Ring right 6 Install the two seal rings into the grooves on the shaft Turn the shaft over and support the assembly on the rear face of the transfer gear with clearance to avoid damage to the bearing and shaft end Marine Transmission Service Manual Assembly Twin Disc Incorporated 8 Install the piston seal ring in the groove in the clutch shaft to seal the I D of the clutch apply piston and apply a coat of light grease or oil to the piston seal ring 9 Install the piston seal ring in the groove in the O D of the clutch apply piston and apply a coat of light grease or oil to the piston seal ring 10 Install the clutch apply piston into the piston bore in the transfer gear Figure 74 Install Piston Into Gear left and Install Springs Into Pockets right 134 Marine Transmission Service Manual Twin Disc Incorporated 11 12 Assembly Install 14 clutch return springs into the pockets in the face of the clutch apply piston and install the spring retainer over the springs with the open end toward the springs Working through the holes in the retainer use a small punch or probe to assure that all the springs are in the pockets in the face of the piston and that the springs stand straight Pl
149. e eccentricity of the engine flywheel should not exceed 0 13 mm 0 005 In maximum total indicator reading Thrust the flywheel should be in one direction at all times to obtain a correct reading mM Engine i Flywheel isse Thousandths Indicator Engine T Crankshaft ia Flywheel ns Engine Figure 103 Checking the Flywheel Pilot Ring Bore Eccentricity Marine Transmission Service Manual 171 Installation 172 Twin Disc Incorporated 7 Readjust the indicator so that the tip will ride on the pilot bearing bore of the flywheel Rotate the flywheel The eccentricity of the pilot bearing bore should not exceed 0 13 mm 0 005 in maximum total indicator reading Eccentricity between the driving ring pilot bore and pilot bearing bore should not exceed 0 20 mm 0 008 in total indicator reading _ ENGINE FLYWHEEL HOUSING ENGINE ENGINE CRANKSHAF T THOUSANDTHS INDICATOR MM ENGINE FLYWHEEL Figure 104 Checking the Flywheel Pilot Bore Eccentricity Marine Transmission Service Manual Twin Disc Incorporated Installation Installation Alignment Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boat to change its form with various loads and with age Engine and shaft alignment can also change on a boat due to varying l
150. e Transmission Service Manual Twin Disc Incorporated Assembly Remove the retainer washer and capscrews Install pusher tool 21413 and portable press onto the output shaft Inject oil with a viscosity of 300 mm S 300 Cst at room temperature into the hub until it leaks out between hub and shaft Continue injecting oil while using the portable press to push the output flange tight to the bearing face Figure 89 Install Tool T 21413 left and Inject Oil while Pressing Flange right Release the injection oil pressure and wait five minutes before removing the pressure from the portable press Check the actual advance Measure the distance from the end of the output shaft to the flange hub retainer shoulder This distance subtracted from the measurement from step 5 is the actual advance Make a shim pack that will leave a clearance of 0 08 0 015 mm 0 002 0 006 in between the retainer and the shaft Install the retainer washer shims and three capscrews M24 3 x 65 Torque the capscrews to 912 Nm 673 lb ft Marine Transmission Service Manual 151 Assembly Twin Disc Incorporated 9 Attach a dial indicator to the housing with the probe resting on the face of the output flange Locate the indicator probe as close to the O D ofthe flange as possible Check the flange face runout by rotating the flange Total indicated runout must not exceed 0 10 mm 0 004 In Figure 90 Check Face Runout of Flange 10
151. e carrying capacity of the assembled joint 2 Verify that when fully assembled there will be a minimum of 0 05 mm 0 002 in clearance between the output flange hub retainer shoulder and the end of the output shaft Measure the length of the output flange and the distance from the end of the output to the shaft bearing face This difference is the minimum clearance between the flange hub retainer and the end of the output shaft If the clearance is out of tolerance it is necessary to change parts Contact the Product Service Department at Twin Disc Inc for assistance 3 Coat the tapered surfaces of the output flange and shaft taper with thin oil 4 Install the output flange onto the shaft with a retainer washer and three capscrews M24 3 x 65 Connect the oil injection equipment to the output flange hub Seat the flange onto the shaft taper using 1340 N 300 load D Using a depth micrometer measure the distance from the output flange retainer shoulder to the end of the output shaft This distance will be the maximum available advance The advance should be 10 16 mm to 12 35 mm 0 400 in to 0 486 in Should the measured advance fall outside of the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Inc for assistance 150 Marin
152. e determined by facing the output side of the transmission from the rear Identify and place the following bearing components in an oven at 250 F 120 C for 30 minutes Front output bearing inner race both rear output bearing cones both rear clutch shaft bearing cones and all bearing cones for the input reduction gears of the MG 5600DR 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 for at least two hours prior to assembly Front output bearing roller and outer race assembly both rear output bearing cups both rear pinion bearing cups both front pinion bearing cups both pinion inner needle bearings and rear cups for the input reduction gears of the MG 5600DR Marine Transmission Service Manual Twin Disc Incorporated Assembly Preliminary Assembly 1 Lay the transmission on blocking with the rear side up 2 Install the chilled cups for the primary and secondary front tapered roller bearings into their respective bores in the front inner face of the housing Use driver T 18050 686 to press drive cups to the bottom of the bore It is important to maintain downward force as temperatures equalize to insure that cup is at bottom of bore Figure 55 Front pinion bearing cup installation Marine Transmission Service Manual 117 Assembly Twin Disc Incorporated 3 Install the chilled output shaft
153. e removed screws into the threaded pusher screw holes in the manifold Use the screws to separate the manifold from bearing carrier Remove the manifold and gasket Remove the lube tube and then remove the bearing retainers and shims from the bearing bores in the bearing carrier for the primary and secondary shafts Note that the shims are contained between the bearing and the bearing retainer on the MG 5600DR and not on the MG 5600 The lube oil pressure relief valve on the MG5600 is attached to the bearing retainer by two capscrews Remove these two capscrews M8 1 25x16 and remove the valve housing ball and spring The lube oil relief valve on the MG 5600DR is non serviceable and is a slip fit into a cavity in the bearing retainer and will easily slip out The bearing cups are a loose fit in the bearing retainer and may fall out or remain on the bearing cone Figure 34 Lube tube Location in Bearing Carrier Marine Transmission Service Manual Twin Disc Incorporated Disassembly HUUSINI E ING BALL LAPSUREW WASHER BEARING CARRIER Figure 35 MG 5600 Lube Relief Valve LUBE VALVE BEARING CARRIER MAN
154. e the bearing cage and rollers Use a split type bearing puller cheese cutter to grip the flange at the small end of the tapered inner race and using a hydraulic jack or puller pull on the bearing inner race while pushing on the rear end of the shaft to remove the bearing inner race from the shaft Marine Transmission Service Manual 95 Disassembly 96 Twin Disc Incorporated Support the shaft assembly solidly on the rear face of the transfer gear with the input end up Remove the round retaining ring from the input end of the shaft and remove the pinion from the shaft Figure 39 Remove Round Retaining Ring The straight roller bearing in the bore of the input end of the pinion is a tight fit and will likely be destroyed during removal Remove the internal snap ring from the input end of the pinion and remove the straight roller bearing with the use of a puller behind the roller ends Do not remove the rear tapered roller bearing outer race from the bore at the rear of the pinion unless the bearing must be replaced This bearing is an interference fit with the pinion and will be destroyed during removal If it must be replaced use an electric welder to weld a light bead around the 0 of the bearing race This will shrink the race for easier removal Remove the tapered roller bearing inner race from the shaft bearing supports rear of pinion This bearing is a slip fit and should be removed easily Marine Transmission
155. e with an I D only slightly larger than the O D of the shaft over the input front end of shaft Rest one end of the sleeve on a heavy wood block while the other end supports the inner face of the clutch housing Apply a press force to the rear end of the shaft to separate the shaft from the clutch housing The shaft must be protected and restrained to prevent damage from falling as the joint separates Marine Transmission Service Manual Twin Disc Incorporated Disassembly Selector Valve Assembly Mechanical Valve 2B 27 2 26 21 55_ 22 i 23 24 3 L a UO UAR HS Bs e CN 16 19 ys 17 11 L Flug Rate Rise Piston Lavar Bushing shim Pin Valve Body Outer Spring Valve Stem Spring Inner Spring Piston Check Ball Bearing Detent Lrapserew O Ring spring Drifface Gover Cover O Ring Gasket Capscrew Flug Oriface Plate collar Gasket Capscrew 2 3 4 5 7 3 n Figure 42 Mechanical Selector Valve Exploded View Marine Transmission Service Manual L oo m 99 Disassembly Twin Disc Incorporated Steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Hemove four of 5 16 18 x 1 25 inch capscrews and remove the orifice cover orifice plate gaskets check ball and spring Figure 43 Cover Gaskets Orifice Plate Check Ball and Spring
156. eat toward the check ball Install the cover gasket cover and four of 5 16 18 x 1 00 inch capscrews and torque to 20 Nm 15 Ib ft Marine Transmission Service Manual Twin Disc Incorporated Assembly Assembly of Electrical Control Valve upperbody half 1 Install one dowel pin large diameter into each of the two bores of the valve body 2 Install one spring into each of the two bores of the valve body Figure 93 Dowel Spring Spool and Plug 3 Install one spool into each of the two bores of the valve body 4 Install the two o ring plugs into the valve body and tighten to 85 Nm 63 Ib ft 5 Apply lubricant such as Dow Corning 2000 30 000cSt fluid to the o rings of the solenoids and plug Install solenoids and plug into the valve body and torque them to 34 Nm 25 Ib ft 6 Insert the wires pins into the Weatherpak connector according to the location markings made at disassembly Close the end of the Weatherpak connector to lock the wires in position 7 Install the Weatherpak connector onto its retaining clip on the top of the valve body Marine Transmission Service Manual 155 Assembly Twin Disc Incorporated Assembly of Electrical Control Valve lower body half 1 Install the steel shuttle ball into its bore in the valve body Figure 94 Shuttle Ball Shuttle Seat and Roll Pin 2 Install the o ring onto the shuttle ball seat 3 Apply lubricant such as Dow Corning 200 30 000cSt fluid to
157. ecifications The following notes are referenced in Figures 117 and 118 Refer to Installation for proper installation procedures The hardware is secured with Loctite 242 at final installation The axial spacing dimension must be corrected for the thermal expansion of the system The hardware is supplied untorqued Removal of indicated bolt will alter coupling runount tolerance JU 900 Table 18 Bolt Torques based on unlubricated conditions Marine Transmission Service Manual 189 Installation Twin Disc Incorporated Figure 117 Vulkan Rato R with Mechanical Stop 190 Marine Transmission Service Manual Twin Disc Incorporated Installation QUANTITY OF ITEM Figure 118 Vulkan Rato R without Mechanical Stop Marine Transmission Service Manual 191 Installation Twin Disc Incorporated Figure 120 Alignment Marks 192 Marine Transmission Service Manual Twin Disc Incorporated Installation split Figure 121 Split Ring Marine Transmission Service Manual 193 Installation Twin Disc Incorporated 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
158. ecrew O Ring Spring Oritace Gover Cover O Ring Gasket Lapscrew Flug Oriface Plate collar Gasket Capscrew 1 2 3 4 5 7 3 B Figure 92 Selector Valve Exploded View Marine Transmission Service Manual 153 Assembly Twin Disc Incorporated Assembly of Mechanical Control Valve 154 J 2 Install the bearing onto the valve stem Install the o ring into the counterbore in the valve cover Coat the o ring and the stem with light assembly grease Install the valve stem into the valve cover Use caution to prevent damage to the o ring and bearing Install the cover gasket and valve stem and cover assembly onto the valve body Installthe four of 5 16 18 x 1 25 capscrews and torque to 20 Nm 15 Ib ft Install the stop and rollpin lining up the marks made at disassembly Use small punch to line up the rollpin hole in the stop with the corresponding hole in the stem Continue to hold the holes in alignment as the rollpin is driven into place Support the stop while driving in the roll pin to prevent damage to the stem and valve Install the shift lever onto the stem lining up the marks made at disassembly Torque the screw to 15 Nm 11 Ib ft Install the pressure regulator piston regulating springs shims and rate of rise piston into the bore in the valve body Install the spring and check ball orifice plate gasket Install the orifice plate with the chamfered side of the hole check ball s
159. eduction ratio of 6 04 1 has a spacer between the pinion gear teeth and the rear of the bearing cone on both clutch shafts Marine Transmission Service Manual 139 Assembly Twin Disc Incorporated 20 If equipped with a bearing spacer lay the bearing spacer on top of tapered roller bearings installed above Position the spacer with the chamfer on the O D of the spacer facing up Use grease to hold the spacer in position as the primary and secondary shafts are installed 21 Install the primary and secondary shaft assemblies into the main transmission housing using tool T 18050 726 Figure 80 Lower Clutch Shafts Into Housing 140 Marine Transmission Service Manual Twin Disc Incorporated Assembly Installation of the Bearing Carrier and Manifold 1 Install the bearing carrier gasket over the dowels onto the rear of face of the housing Install with the silicone bead up No additional sealant should be used Note Ihe rear bearing cups are a slip fit into the bore of the bearing retainer The rear bearing cup retaining method is different for the MG 5600 and the MG 5600DR models and the lube relief valve arrangement is also different between the two models Figure 81 Gasket with Silicone Bead up left and Lower Assembled Bearing Carrier right Marine Transmission Service Manual 141 Assembly Twin Disc Incorporated Model MG 5600 2 Assemble the lube relief valve spring and lube relief valve steel ball into
160. en when servicing that replacement couplings are matched to this criteria 26 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications 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 cooler is selected for a water temperature of 130 F max The heat exchanger is located on the top of the marine transmission Marine Transmission Service Manual 27 Description and Specifications Twin Disc Incorporated Specifications Maximum operating speed 2100 rpm Maximum oil sump temperature 200 F Oil type and viscosity See data plate below Oil capacity 110 liters 29 gal Approximate Dry weight MG 5600 6770 16 MG 5600DR 7100 lbs Oil pressure See Tables 4 and 5 Oil temperature to be in normal operating range I I E E AJ ib d JF x aga
161. er element after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the filter is clean and then change the oil and filter after 1000 hours of service or more often if conditions warrant Marine Transmission Service Manual 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 oil suction tube below the pump See Engineering Drawings for suction strainer location Type Oil Hecommended oee Description and Specifications Filling 1 2 Remove the filler breather in the top cover of the transmission Fill the transmission s sump with 110 liters 29 U S gal of the proper weight and type oil See Description and Specifications for oil recommendations otart the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the oil level to FULL mark on the oil gauge Allo
162. ernment or others by contract TWIN DISC INCORPORATED Racine WI Page 4 of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 leakage broken forgotten or cut seal ring Primary amp Secondary Pressures Broken seal ring at collectors or piston Lube Pressure Out of tolerance or missing orifices broken rear seal ring faulty lube relief valve 4 Drag Check The unit is acceptable if after shifting the transmission control valve to neutral the output shaft remains at rest or can be held at rest with force charted in section when using 780 rpm input speed Record if okay Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 5 of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 V ASSEMBLY CHECK SHEET MG 5600DR 1018100 Model BOM Number Serial Number Ratio Assembly Dat
163. essure acting on the end of the spool overcomes the return spring at the opposite end causing the spool to stroke over and connect the clutch passage with main pressure passage Figure 22 Pilot Spool Passages Marine Transmission Service Manual 61 Operation Twin Disc Incorporated Main pressure oil flows from the spools above to the clutch passages of the transmission below via connecting slots in the manual override stem These connecting slots are aligned with passages in the valve body when the valve is in the electric mode Figure 23 Flow Path in Override Spool Main pressure from the energized solenoid operated pilot valve also acts on a pin on the return spring side of the opposite spool to ensure the opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Return spring Figure 24 Pin to Prevent Simultaneous Engagement of Clutches 62 Marine Transmission Service Manual Twin Disc Incorporated Operation Manual Override Operation The control valve has a manual override feature which is a lever operated selector When the manual override lever is rotated counterclockwise and pulled outwards the upper portion of the valve is disabled because the connecting slots in the manual override stem are no longer aligned with the oil passages in the valve body Oil pressure from the solenoid operated pilot valve controlled spools cannot reach the clutch pressure
164. ews that were previously loosened are accessible for removal at a later time The MG 5600 and MG 5600DR requires the use of a SKF THAP 300 oil Injection Kit see Special Tools or similar device to remove the output flange and output shaft 1 Loosen the three output flange capscrews M24 3 00x65 approximately 5 turns each The capscrews and washer will retain the output flange when it separates from the output shaft 2 Install the oil injector into the output flange Note that these are special 1 4 19 BSP threads Figure 33 Output Flange Injection Location WARNING Always use retainer bolts or a safety strap to hold parts being separated with oil pressure The parts may separate with extreme force 3 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature into the hub until it lifts the output flange off the output shaft taper Hemove the three capscrews and washer and remove the output flange Marine Transmission Service Manual 89 Disassembly 90 Twin Disc Incorporated Remove twenty two of M12 1 75 capscrews securing the manifold to the bearing carrier and housing Note that on the MG 5600 there are fourteen screws 50 mm long and eight screws 70 mm long and on the MG 5600DhR there are fourteen screws 70 mm long and eight screws 90 mm long The rear bearings on the clutch shafts and the bearing retainer and shim packs are different between the MG 5600 and MG 5600DR units Install two of th
165. ft causes the control valve stem to rotate and assume the position indicated in Figures 12 and 13 The pressurized oil in chamber B is directed through ports G and K to passages E and J Passage E is aligned with a passage directing main pressure to the secondary clutch Pressurized oil from port G travels through passage J and enters chamber L through an orifice in the orifice plate The orifice in the plate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against springs until the piston is stopped by a shoulder in the valve bogy The causes the pressure in chamber B to rise to clutch engaging pressure When in secondary passage D remains at atmospheric pressure because slot F remains open to sump When a shift is made from secondary to neutral the valve stem is rotated to the position illustrated by Figures 16 and 17 Under these conditions passage E is connected to the sump by slot F Passage J is also connected to sump by port H in the valve stem Because passage E is connected to slot F oil drains rapidly from the secondary clutch to sump Because passage J is now at atmospheric pressure the oil pressure in chamber L unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The secondary clutch is now disengaged and main system p
166. g 16 Remove the dog point setscrew Note that the setscrew is retained with 908 threadlocker Figure 50 Dogpoint Setscrew 104 Marine Transmission Service Manual Twin Disc Incorporated Disassembly 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 51 Thrustwasher 19 Remove the stem from the valve body 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 52 Roll Pin Retaining Shuttle Seat 21 Thread a M8x1 25 screw one of the cover screws works well into the seat and remove it from the valve body 22 Remove the shuttle ball from the valve body Marine Transmission Service Manual 105 Disassembly Twin Disc Incorporated Disassembly of Upper Valve Body Hall electric section 1 Remove the Weatherpak connector from the valve body by sliding it In the direction of the opening in the shroud 2 Mark the wires with the location letters that are on the Weatherpak connector Open the end of the Weatherpak connector to allow removal of the pins and wires 3 Remove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool Tool is Packard Electric P N 12014012 Figure 53 Remove Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them 5 Remove the plug No hydraulic lock on MG5600 106 Marine Transmission Service M
167. hapa Input Shift Inlet Clutch Min Clutch Min Speed Position a we sm s pol vt pal Newal we o o o 2 1724 250 7 69 1960 2137 285 310 1960 100 380 15 55 1960 2137 285 310 0 o 1960 100 380 15 55 Marine Transmission Service Manual 29 Description and Specifications Twin Disc Incorporated Optional Equipment The following optional equipment for use with the model MG 5600 and MG 5600DR is available through the nearest authorized Twin Disc distributor Optional Trailing Pump A 115 vac electric powered trailing pump system is available It is identified as part number 1016473 A drawing is included in the Engineering Drawings Power Take off A live power take off pump mount size C 2 bolt or 4 bolt is available It is identified as BOM 40106 Electric Control Valve An electric control valve is available with either 12 vdc or 24 vdc actuating solenoids These are identified as 1018084J 12 vdc and 1018084H 24 vdc Coupling Flange for Shaft Brake A coupling flange for disc type propeller shaft brake applications is available It is 1018651 Oil Bypass Thermostatic Valve Kit A thermostatic oil bypass valve arrangement is available 30 Marine Transmission Service Manual Twin Disc Incorporated Description and Specifications Metric to NP TF Adapter Kit An adapter kit K1232 is available to convert the oil drain plug
168. he gear Rotate gear to aid in aligning holes Install four capscrews M10 1 5 x 45 and sealing washers Torque the capscrews to 64 Nm 47 Ib ft Marine Transmission Service Manual 127 Assembly Twin Disc Incorporated Output Shaft Tapered Roller Bearing Adjustment 1 Install the seal carrier without the o ring Secure the seal carrier with eight capscrews M16 2 00 x 45 torqued evenly to 10 Nm 7 lb ft Use a taper gauge or feeler gauge to measure the gap between the rear housing face and the flange of the output seal carrier Build a trial shim pack with a thickness equal to the gap plus 0 50 mm 0 020 in Install the shim pack and torque the eight capscrews to 275 Nm 203 lb ft Figure 69 Lower Cover Over Output Shaft left and Measure Gap for Shims right 2 Seat the front tapered roller bearing by rotating the shaft several times 128 Marine Transmission Service Manual Twin Disc Incorporated Assembly Install a dial indicator onto the housing with the finger resting on the rear of the output shaft or on the lifting fixture Zero the dial indicator and mark the spot where the reading was taken To lift the output shaft install eyebolts and strap to the rear of the output shaft Using a hoist apply a lifting force of 1340 N to 4000 N 300 16 to 900 16 greater than the weight of the shaft and gear assembly Rotate the shaft several times with the lifting force applied otop the shaft rotation with dial indi
169. ication 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 13 Introduction Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure sale 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 disconnect the battery cables fro
170. ice Plate and Gasket 2 3 Remove orifice plate Remove steel ball and neutral pressure regulating spring Remove orifice plate gasket Remove rate of rise piston Note that shims are located between the piston and springs Figure 46 Rate of Rise Piston left and Regulator Springs right 6 Remove pressure regulating springs Marine Transmission Service Manual Twin Disc Incorporated Disassembly 7 Remove pressure regulating piston with external retaining ring pliers Figure 47 Removing Regulating Piston with Pliers 8 Remove external retaining ring from the lever end of the stem 9 Loosen the clamping nut and remove the control lever from the stem It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 10 Remove the washer and spring from the stem 11 Remove four of M8 x 25 socket head capscrews 12 Remove the cover assembly with gasket from the valve body 13 Remove the O ring and oil seal from the cover assembly Figure 48 O ring in Cover Marine Transmission Service Manual 103 Disassembly Twin Disc Incorporated 14 Remove the two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body 15 Remove the detent setscrew spring and steel ball from the valve body Figure 49 Detent Setscrew and Sprin
171. ice the weight of the gear and rotate through three revolutions stopping with the dial indicator finger resting on the previously applied felt tip pen mark Read the end play on the dial indicator The proper end play for the reduction gears is 0 05 to 0 15 mm 0 002 to 0 006 in Adjust shim pack and recheck if necessary Hemove the capscrews from the upper retainer and install the o ring in the groove Install the cover using the eight capscrews M12 1 75 40 and torque to 130 Nm 96 Ib ft The input hub is a tight fit on the shaft spline and should be heated for installation Install the washer and retaining snap ring into the input end of the flange Lower the heated flange assembly over the shaft and install three capscrews M12 1 75 x 25 and torque to 130 Nm 96 Ib ft Install fittings and front housing drain hose Marine Transmission Service Manual Twin Disc Incorporated Assembly Installation of Remaining Transmission External Components all models unless noted 1 es Turn the transmission and block securely in an upright position Install the input shaft oil seal for the MG 5600 into the housing bore using protector driver T 18050 693 Coat the housing input shaft bore with M2828 anaerobic sealant Install the oil seal with the open lip of the seal toward the inside of the housing Press the seal into the bore flush with the inside face of the housing Install the top cover gasket Use the four dowel
172. input reduction ratio of the transmission and in the opposite direction Because the primary input pinion Is in mesh with the output gear the output gear and shaft will rotate in the engine direction The secondary input pinion will be backdriven opposite engine direction when the unit is in the primary position Figure 30 MG5600DR Power Flow with Primary Clutch Engaged Marine Transmission Service Manual 69 Operation Twin Disc Incorporated Secondary In secondary the same parts are turning that were turning in neutral When the secondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates together The secondary input pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when the unit is in the secondary position secondary Clutch Engaged Figure 31 MG5600 Power Flow with Secondary Clutch Engaged 70 Marine Transmission Service Manual Twin Disc Incorporated Operation Model MG5600DR 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 cl
173. irect coupling the accessory is driven when the engine is running Trailing Pump Optional The trailing pump supplies oil flow to the transmission lubrication circuit when the output shaft is rotating This lubrication oil is required when the transmission is in a backdriving condition Backdriving sometimes referred to windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller When the engine is running and the output shaft is rotating oil flow from the trailing pump supplements the oil flow supplied to the lubrication circuit by the main oil pump The trailing pump is driven by an electric motor and oil flow from the trailing pump flows through a check valve into the oil inlet of the heat exchanger and into the transmission lubrication circuit Marine Transmission Service Manual 65 Operation Twin Disc Incorporated Power Flow Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Other parts including the output shaft do not turn Driving Gear f Primary Shaft secondary Shatt 7 Driven Gear NEUTRAL Output Gear Figure 27 MG5600 Power Flow in Neutral 66 Marine Transmission Service Manual Twin Disc Incorporated Operation Model MG5600DR The input gear reduction set is driven by the engine and in turn rotates the same compo
174. ission Service Manual ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600 Drawn ALC BJE ASSEMBLIES 1015239 1016001 amp 1017614 Checked DAS Approved TBC Original Issue Date 04 10 95 PROCEDURE Latest Issue Date 09 26 00 ECN 30339 The unit is to pass all these checks and tests before being approved for shipment Please follow your routing instructions carefully The routing contains additional information to assist you in determining when it is best to apply each check and test it also offers additional guiding instructions l ASSEMBLY INSTRUCTIONS Assembly check limits are given in section V 1 Unless otherwise specified A Degrease surfaces of taper bores and their mating shaft seats per 5765 Assembly Instructions before assembly B All bolts screws and nuts are to be as received from bins with only light rust preventative oil on them and torqued per 5574 C The main housing should be oriented with the SAE flywheel housing down during the installation of the shaft assemblies D oplines only may be lubricated with white lead or molydisulphide treated lubricants 2 Transfer Driving and Driven Gears Taper Joint Assembly Joint surfaces to be in condition described 1 1 Place gears on shafts using 445 890 100 200 Ibf max force to seat them on their tapers Advance each gear A static pressure of approximately 569 738 kN 64 83 tons will
175. l the lubrication tube through the keyed hole in the bearing carrier The tube fits into a machined pocket in the front inner face of the housing Turn the tube so the elongated key of the tube fits into the corresponding key in the bearing carrier The properly installed the lubrication tube should be flush with the rear face of the bearing carrier Install the manifold gasket over the guide studs and against the bearing carrier Install with the silicone bead up No additional sealant should be used Marine Transmission Service Manual Twin Disc Incorporated Models Assembly 9 10 Install the manifold over the guide studs and dowel pins On the Model MG 5600 assure that the shim retainer anti rotation pins fit into the pockets in the inner face of the manifold Secure with twenty two of M12 1 75 capscrews Note that on the MG 5600 there are fourteen screws 50 mm long and eight screws 70 mm long and on the MG 5600DR there are fourteen screws 70 mm long and eight screws 90 mm long Torque the capscrews to 112 Nm 83 Ib ft With a felt tip pen make a radial mark on the rear end of each of the clutch shafts Install a dial indicator on a machined surface on the manifold with the probe resting on the mark made on the clutch shaft Note that the procedure for checking and setting the clutch shaft end play is the same for each shaft and must be done on each shaft Figure 88 Measuring Shaft End Play 11
176. lated advance is not within the specified range recheck all measurements and calculations for errors If no errors are found contact the Product Service Department at Twin Disc Incorporated for assistance Marine Transmission Service Manual 131 Assembly Twin Disc Incorporated 3 Move the shaft and transfer gear to a press with at least 445 kN 100 tons capacity Install special tool over the shaft and center the gear and shaft under the ram of the press and apply approximately 569 kN to 890 kN 64 tons to 83 tons of force on the special tool Figure 72 Pressing Shaft Into Gear 4 Remove the special tool and measure the distance from rear end of shaft to the face of transfer gear using a depth micrometer record as Actual advance should be 3 33 mm to 4 29 mm 0 131 in to 0 169 in If the transfer gear has not been advanced as specified above contact the Product Service Department at Twin Disc Incorporated for information and assistance The transfer gear face should be within 0 05 mm 002 in of the shaft shoulder at the small diameter end of the taper 132 Marine Transmission Service Manual Twin Disc Incorporated Assembly 5 Install the heated tapered roller bearing cone assembly over the shaft or use special tool driver T 18050 681 and an hydraulic press to press the rear tapered roller bearing cone onto the clutch shaft Install the bearing with the large O D toward the transfer gear and press th
177. llation of Manifold Exterior Components 1 Install the M10x1 o ring plug into the recessed hole the manifold near the primary clutch shaft and torque to 26 Nm 19 Ib ft Install the M27 x 20 ring plug in the rear center of the manifold and torque to 179 Nm 131 Ib ft Install the two M18 x 15 o ring plugs into the rear of the manifold and torque to 74 Nm 55 Ib ft 2 Install an o ring into the groove in the face of the manifold at the primary shaft location apply a bead of anaerobic sealant to the face of the primary shaft cover and install the primary shaft cover to the manifold Secure with four capscrews M12 1 75 x 30 and torque to 112 Nm 83 Ib ft 3 Insert the splined pump drive adapter into the drive coupling assembly and insert the retaining snap ring Install this assembly over the oil pump shaft spline 4 For units with manual control valve install the oil pump gasket and oil pump onto the manifold with the slotted mount hole toward the flange Grease the splines on the pump shaft and the splines in the adapter Secure the pump with four capscrews M12 1 75 x 40 with washers and torque to 112 Nm 83 Ib ft For units with electric control valve install the gasket and spacer followed by the oil pump gasket and oil pump onto the manifold with the slotted mount hole toward the flange Grease the splines on the pump shaft and the splines in the adapter Secure the pump with four capscrews with washers M12 1 75 x
178. long enough that it is hanging outside the flange Turn the two couplings halves in a position that the arrows of both halves are just opposite See Figure 111 View X tape or cord D p kE E M NE UM ET 2 Figure 112 Coupling into Flywheel Flange Marine Transmission Service Manual 181 Installation Twin Disc Incorporated 4 Then push the output side of the coupling with the gear into the outer flange If necessary apply some lubricant on the outer flange Suitable lubricants are soap water detergents etc but no oil or grease In case a tape or cord had to be used push the coupling only half way together and then take the long end of the tape or cord and pull it away hen grease or oil the gear shaft and plug it into the coupling spline remove tape or cord IEEE 12 shaft Figure 113 Final Assembly 5 Bolt the gear flange to the flywheel housing Note When bolting the gear flange to the flywheel housing make sure that no axial thrust is exerted to the coupling by tightening of the bolts Before the engine is started the first time check that the crankshaft has endplay otherwise serious damage may occur to the engine 182 Marine Transmission Service Manual Twin Disc Incorporated Installation Assembly Instructions for CENTA L Series CX 72 Torsional Couplings used with
179. ly Twin Disc Incorporated Assembly 1018100 Model MG 5600DR free standing 88 Note It is necessary to use wood blocks to support the transmission with the input side facing up Use caution to avoid damaging the output flange Hemove three M12 1 75x25 capscrews washer and coupling hub The hub is a press fit onto the shaft and will require the use of a puller to remove Hemove 16 of M12 1 75x40 capscrews and remove the seal carrier with shims from the input location and the cover plate retainer and shims from the upper location Hemove 28 of M12 1 75x40 capscrews and insert two of them into threaded holes to use as jacking screws These threaded holes are located near the top and bottom of the housing near the aligning dowel pins Remove the housing taking care that the two bearing cups do not become damaged from falling out They are a loose fit in the bore of the housing Remove the drain hose from the input reduction housing to the main housing Hemove both gears from the reduction housing Remove eight of M16 2 00x60 and nine of M16 2 00x110 capscrews with washers and remove rear reduction housing Marine Transmission Service Manual Twin Disc Incorporated Disassembly All Assembly Models Note It is necessary to block and support the transmission with the output side facing up Use caution to avoid damaging the spline on the shaft It will be advantageous to block in such a manner that the four capscr
180. m 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 Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Transmission Service Manual Twin Disc Incorporated Introduction Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Operators Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment WARNING Under the conditions described below the prop shaft must locked in place to prevent backdriving Failure to do this can damage the marine transmission due to the lack of component lubrication Backdriving also called windmilling occurs when an engine is shut down and the propeller shaft is being driven by the flow of water across the propeller which in turn rotates the components in the marine transmission During backdriving conditions
181. material like nitrile rubber Buna N Perbunan chrome leather PTFE etc SKF LHMF 300 and LHDF 900 are available in 5 liter 5 3 qt cans Designation LHMF 300 5 and LHDF 900 6 Figure 125 SKF LHMF 300 and LHDF 900 Note Order Through Your Local Authorized SKF Distributor 202 Marine Transmission Service Manual Twin Disc Incorporated Special Tools T 19987 Gear Lifting Fixture 11 02 Gear Lifting Fixture T 19987 REQ MAT Description amp Stock Size 6 2 Drawing 11 05 Drawing 11 05 Drawing 11 04 Drawing 11 03 Drawing 11 03 Drawing 11 03 Marine Transmission Service Manual 203 Special Tools Twin Disc Incorporated T 19987 detail 1 2 and 3 Gear Lifting Fixture DET 3 M30 3 5 X 76 GRADE 8 BOLT is J A DRILL amp CTRS K FOR M30 3 5 X 76 GRADE 8 BOLT DRILL ALLEN DET 2 1 01 WRENCH CLEARANCE JERGEN S 423425 CENTER PULL 13 06 0 99 AS SHOWN AT TOP HOIST RING RATED AT 10000 LBS 45 X 25 TYP pare 03192 1 52 1 48 302 2 31 wl 1 227 don 3 i 3 81 6 51 iL 6 49 1 4 1 1 219 2 26 5 39 2 24 5 35 152 L R 2 02 1 48 TAP 1 8 1 98 DER THRU RADII TO BE SMOOTH WITH NO DEEP TOOLING MARKS 11 03 Gear Lifting Fixture T 19987 DET REQ MAT Description amp Stock Size 3 1 PUR 30 3 5 X 76 Grade 8 socket head bolt 2 1 PUR Jergen s 23425 Lifting Ring 1 1 4140 Block 32 36 an
182. n oil pressure between the mating surfaces and wait five minutes before releasing the pull on force Hemove the assembly tools from the output shaft and gear Determine and record the actual advance by measuring any gap between shaft shoulder and gear face Marine Transmission Service Manual Twin Disc Incorporated Assembly 18 Install the front bearing cone assemblies for the primary and secondary clutch shafts Figure 66 Raise Output Shaft and Gear if Necessary to Install Bearing Cones Marine Transmission Service Manual 125 Assembly Twin Disc Incorporated Rear Output Shatt Bearing 1 Install the heated inside rear output shaft tapered roller bearing cone onto the output shaft with the small O D of bearing to the front Figure 67 Install Forward Rear Bearing Cone left and Install Rear Bearing Cone right 126 Marine Transmission Service Manual Twin Disc Incorporated Assembly 2 Install the heated outside rear tapered roller bearing cone onto the output shaft with the small O D to the rear 3 Using specialtool 18050 688 press and retain the bearings against the shaft shoulder Figure 68 Clamp Bearings until Cool left and Install Cup Into Retainer right 4 After the bearing cools remove tool 18050 688 5 Install chilled outside bearing into output seal carrier using special tool T 18050 689 6 Install the gear pan assembly into the housing and over t
183. nents as in the MG5600 but in the opposite direction if used with the same engine type The rotational speed of these components will be either 72 77 or 8496 of engine rpm dependent on the input reduction ratio of the transmission Figure 28 MG5600DR Power Flow in Neutral Marine Transmission Service Manual 67 Operation Twin Disc Incorporated Primary When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel plates are spline connected through the clutch hub assembly to the pinion Because the primary input pinion is in mesh with the output gear the output gear and shaft will rotate anti engine direction The secondary input pinion will be backdriven engine direction when the unit is in the primary position Primary Clutch Engaged Figure 29 MG5600 Power Flow with Primary Clutch Engaged 68 Marine Transmission Service Manual Twin Disc Incorporated Operation Model MG5600DR When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The steel clutch plates are spline connected through the clutch hub assembly to the so the primary input pinion will rotate at either 72 77 or 84 of engine rpm dependent on the
184. nt I ES I I me I xL Ej I 1 I YALYE IO BUE4M ceras mz lx CONTROL WALYE 10 aevpo t SEE WAWE ASS Y i FOR COYSONENT 2 To i VIE Ww ABDWE J 1 MENU MEE CAPZCHE MASSUSJ 4 m oT i Mum l WASHER FER VIEW BOWE Tu PE od ir um clc SPACER 1012605 US ua lu CNIS So 027 GASKET 2258 ci 1018100 o Ee adr M SeO00FI TRAH HIRSI en n r b 2 r an I E an ue JN i al 1 l _ gt UT E 2 7 7 EA T m D i bFoa 4 4 loy LN 1 T c 1 ria jpn 1 r Ln a LU i L L 7 1 r f SOBIQUAM Lu _ griep I Js a S Cr oo c I eel v PO OD cle m gt L SA ever e l 5 1 m 7 u gh _ a eod TE On DEUS Iz i Witt 1 l i iris A 4 T 2 c i Ci r l i il e 1 I 1 7 r i i 7 7 7
185. oads and the boats age The following steps be taken to secure proper marine transmission alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure Install the mounting brackets on the side mounting pads of the marine gear Install the driving ring on the engine flywheel Bolt an indicator to the engine block and set the indicator stem on the engine flywheel housing INDICATOR INDICATOR STEM MARINE GEAR SUPPORT BRACKET ENGINE SHIM HERE Figure 105 Marine Gear Alignment Marine Transmission Service Manual 173 Installation Twin Disc Incorporated Setthe 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
186. ontinued No neutral Harsh engagement Low lube oil pressure Oil spilling out of breather Clutch plates warped Control valve incorrectly indexed Solenoid malfunction units equipped with electric selector valve Hydraulic lock piston stuck units equipped with electric selector valve and hydraulic lock Regulating piston or rate of rise piston stuck Orifice plate ball in control valve not seating properly Blown gasket on either side of orifice plate Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Remove clutch plates O verhaul unit Check and adjust control linkage Replace defective solenoid Inspect repair or replace hydraulic lock spool Disassemble control valve Clean parts Replace parts if necessary Remove orifice plate cover Clean parts Replace parts if necessary Replace gasket Replace pump Remove clean inspect and install the suction Screen Inspect and correct cause of suction leaks Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil Marine Transmission Service Manual Twin Disc Incorporated Disassembly Disassembly The following procedure is for complete disassembly of the unit Prior to thi
187. 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 part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated 6 Thewarranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated 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 main
188. or external grounded electric current If these conditions do not exist itis evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush Overhaul Interval A complete overhaul of the unit should be made at the same time that the engine is overhauled Periodic Visual Inspection Check the mountings for tightness or damage such as cracks Tighten loose mountings and replace damaged parts Check pressure and temperature gauge where applicable Inspect the oil lines and heat exchanger for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required 78 Marine Transmission Service Manual Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting Chart The following chart is intended as a guide for determining the cause of problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Tables begin on the next page Marine Transmission Service Manual 79 Troubleshooting Table 14 Troubleshoo
189. orporated Description and Specifications Wear Limits Clutch Plates Steel separator plates cone Minimum 0 012 in Maximum 0 022 in Friction clutch plates cone Maximum 0 010 in Friction clutch plates minimum thickness 0 137 in Marine Transmission Service Manual 45 Description and Specifications Twin Disc Incorporated 46 Marine Transmission Service Manual Twin Disc Incorporated Operation Operation General The control valve obtains primary neutral and secondary positions When these positions are selected the control valve directs high pressure oil through internal passages to operate the clutches Marine Transmission Service Manual 47 Operation Twin Disc Incorporated Hydraulic System with Manual Control Valve 48 The oil pump draws oilthrough the strainer from the oil sump and discharges It through the heat exchanger and filter to the combination control and pressure regulating valve The oil enters the pressure regulating area of the valve where main pressure is regulated by cascading excess oil into the lubrication oil circuit Lubrication oil is distributed through fixed controlled orifices to lubricate and cool the clutches and bearings There is a lubrication oil relief valve to limit the maximum lubrication oil pressure This pressure is regulated to approximately 690 kPa 100 psi on the MG 5600 and approximately 827 kPa 120 psi on the MG 5600DR In Neutral the inlet port of both
190. paration of rubber from flex plate on coupling plate or deterioration of the rubber to metal bond See above Q Deterioration of the rubber element as evidenced by sponginess or by black carbon like dust on rubber surface May be caused by contaminants or excessive heat either external or internal to the coupling Cracked bent or otherwise damaged flex plate or coupling plate a Bolt holes in flex plate or coupling plate elongated oval shaped not round This could be caused by improperly assembled parts loose parts vibration or improperly torqued parts Bolts nuts bent worn or stripped threads Marine Transmission Service Manual Twin Disc Incorporated Preventative Maintenance Inspect the hub looking for the following Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found Marine Transmission Service Manual 77 Preventative Maintenance Twin Disc Incorporated Heat Exchanger Check Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days 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
191. pins to locate the gasket Assemble the baffle to the cover using three capscrews M8 1 25 x 30 with washers and torque to 33 Nm 24 lb ft if it had been disassembled Install the top cover over the dowel pins and secure with thirty capscrews M12 1 75 x 35 with washers and torque to 130 Nm 96 Install the screen into the breather opening in the top cover and install the breather assembly Insert the appropriate capscrew through the clip prior to torquing Install the two eyebolts and tighten Apply suitable pipe sealant such as teflon paste on the o d of the threads of the oil gauge tube assembly and install the oil gauge tube assembly and oil level gauge Use care that the tube goes straight down and not forward to avoid it being trapped in the output gear pan Install the heat exchanger using four capscrews M10 1 5 x 25 and torque to 64 Nm 47 lb ft Install the fittings into the heat exchanger if they have been removed and connect heat exchanger hoses Marine Transmission Service Manual 163 Assembly Twin Disc Incorporated Model MG 5600 Remote Mounted Units Note It may be easier to install the input hub with the transmission assembly supported on the rear with the input end up It is not necessary however The input hub is a tight fit on the shaft spline and should be heated to 250 F for installation Install the washer and retaining snap ring into the input end of the flange Lower the heated flange a
192. ponents and 85 Disassemble Components and Sub Assemblies 95 Disassembly of Upper Valve Body Half electric section 106 Cleaning and Inspection 109 Cleaning J J J Q Q UU EE J J 109 111 8 Marine Transmission Service Manual Twin Disc Incorporated Table of Contents Assembly 115 Prior to Assembly 116 Preliminary 117 Output Shaft and Gear Assembly 120 Hear Output Shaft Bearing 126 Output Shaft Tapered Roller Bearing Adjustment 128 Assembly and Installation of the Primary and Secondary Shafts 131 Installation of the Bearing Carrier and Manifold 141 Installation of Manifold Exterior Components 149 Installation of Output Flange 150 Assembly of Mechanical Control Valve 154 Assembly of Electrical Control Valve upperbody half 155 Assembly of Electrical Control Valve lower bo
193. pring pocket Install the shims that were removed into the bore of the rate of rise piston Install the rate of rise piston over the springs and into valve body Install neutral pressure regulating spring into the pocket of valve body Figure 98 Location for Neutral Pressure Regulating Spring 25 26 27 28 29 Install orifice plate gasket onto valve body Install orifice plate and steel ball against spring onto valve body Install orifice plate cover and gasket onto valve body Install four of M8 x 25 socket head capscrews and torque to 23 Nm 17 lb ft Install gasket over lower valve body half Set upper valve body half over lower valve body half Insert the M10 x 150 attaching screws through valve body halves to keep parts in alignment until installation onto the transmission When installing the valve onto the transmission torque the screws to 54 Nm 40 Ib ft Marine Transmission Service Manual 159 Assembly Twin Disc Incorporated Selector Valve Installation Manual Control Valve Install the selector valve and gasket to the manifold and secure with four capscrews two of M12 1 75 x 180 one of M12 1 75 x 90 and one of M12 1 75 x 45 and torque to 112 Nm 83 Ib ft Electric Control Valve 1 Install gasket and ditch plate onto manifold using four socket head capscrews M12 1 75 and torque to 130 Nm 96 Ib ft Model MG 5600 has two capscrews 35 mm long and two capscrews 120 mm long
194. put Bearing Endplay Minimum Actual Maximum 0 05 mm 0 15 mm 002 in 006 in Record total indicator runout of the following max allowable shown 0 41mm 016 in face of SAE 0 amp SAE 00 front housing from input spline 0 30mm 012in pilot of SAE 0 amp SAE 00 front housing from input spline oo 0 10mm 004 in face of propeller flange near O D from main housing 0 10mm 004 in pilot of propeller flange from main housing This note applies to continuous 270 arc if the balance of the pilot is negative readings otherwise it means all 360 Assembler Date Inspector Date Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 5 of 8 S570AH ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION 5 5 MARINE TRANSMISSION MG 5600 Drawn ALC BJE _ ASSEMBLIES 1015239 1016001 amp 1017614 Checked DAS Approved TBC Original Issue Date 04 10 95 PROCEDURE Latest Issue Date 09 26 00 VI PRODUCTION TEST SHEET 5600 Serial BOM Order Customer Input Speed Range Number Number Number Limits for Marine Transmission Equipped with Control Valve with 1725 kPa 250 psi Spring CIRCLE UNITS IN ACTUAL COLUMN rpm Range Act Max Min Act
195. put shaft has loose fit splines If the input coupling is going to be slipped onto the input shaft for shipment it must be attached to prevent it sliding off and causing damage Marine Transmission Service Manual Twin Disc Incorporated Installation Installation Prior to Installation Most Twin Disc products mount directly onto the flywheel ofthe 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
196. put shaft is clear of the front output shaft bearing Remove the front pinion bearings if they were not previously removed Connect the oil injection equipment to the 1 4 19 BSP threaded port on the rear end of the output shaft Install eyebolts into the end of the output shaft and into the main housing mounting pads Thread a heavy strap through the eyebolts in the output shaft and the strap to the eyebolts in the main housing The strap will retain the output shaft during disassembly WARNING Always use a safety strap to hold parts being separated with oil pressure Parts may separate with extreme force 15 16 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature into the output shaft until the shaft and gear separate Note prevent damage to the housing shaft and bearings the output gear should be supported with blocks Remove the output shaft and set aside for further disassembly Marine Transmission Service Manual 93 Disassembly Twin Disc Incorporated 17 Install special tool T 19987 1 through 6 to hold the output gear in position 18 Stand the transmission upright and remove the output gear through the top opening Figure 38 Special Tool T 19987 left and Lift Gear from Housing right 19 Lay the transmission on blocks with the output side up The outer races for the front bearings on the primary pinion and the secondary pinion are an interference fit in their respec
197. r 209 T 18050 685 Bearing Pick Up and Driver 210 T 18050 686 Bearing Driver for Cup 211 T 18050 684 Bearing Driver for Outer Race 212 T 18050 687 Bearing Driver for Inner 213 T 18050 693 Driver Seal 214 T 18050 681 Bearing Cone Driver 215 T 18050 689 Bearing Driver 216 T 18050 691 Bearing Driver 217 T 18050 690 Bearing Driver s 218 T 18050 694 Spring Hold Down Retainer 219 21413 1 of 2 Output Flange Fixture 220 21413 2 of 2 Output Flange Fixture 221 18050 692 Seal Driver 222 T 18050 683 Bearing Driver for Cone 223 T 05600 Lifting Tool for Clutch Removal in Boat 224 AI OT Z 225 T 18050 688 2 Of 2 226 T OT
198. r washer and screws Connect oil injection equipment to output flange hub Seat hub using 1340 N 300 Ibf load Inject oil with a viscosity of 300 mnf s 300 cSt at the operating temperature into the hub until it leaks out between the hub and shaft Continue injecting oil while using retainer washer screws to advance flange to bearing stop Release injection oil pressure between the mating surfaces and wait 5 minutes before removing screws and retainer washer Record actual advance o oplines The reduction gear box input hub to input shaft spline may be pressed together cold or with internal spline heated to 149 C 300 F The reduction gear box output spline to transmission input spline is a loose fit and shaft must assemble without need to heat the internal spline 6 Taper Roller Bearing Adjustment A Reduction gear box input and output shaft bearings Push Pull bearing adjustment method Shim tapered roller bearings per S692 IV A1 to the specified dial indicator endplay with all cover bolts fully torqued Record endplay B Transmission primary and secondary shaft bearings Shim bearings with spacers and shim assemblies Push Pull bearing adjustment method Shim tapered roller bearings per S692 IV A1 to the specified dial indicator endplay with all cover bolts fully torqued Shims are to be assembled with the thickest shim against the bearing cup Record endplay Notice This print contains proprietary information and is not
199. rated Troubleshooting Table 14 Troubleshooting Chart continued High main oilpressure High temperature Excessive Noise Marine Transmission Service Manual Regulating valve stuck Improperly shimmed Lube relief valve malfunction Im proper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure W orn or damaged input coupling Excessive torsional vibration W orn or damaged gears Improper alignment Damaged propeller Misfiring engine Remove and clean regulating valve Shim as required Inspect repair or replace parts as necessary Check and fill or drain with proper oil to the correct le vel Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch O verhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve O verhaul marine transmission Remove marine transmission Replace a worn or damaged coupling Select proper torsional coupling O verhaul marine transmission Check alignment of engine and transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine 81 Troubleshooting 6 82 Twin Disc Incorporated Table 14 Troubleshooting Chart c
200. rconnected by slot F in the control valve stem when in the neutral position The slot is aligned with a drilled hole and cored cavity in the face of the valve body The drilled hole and cored cavity are aligned and drilled holes that pass through the main housing to sump Therefore passages D and E are at atmospheric pressure at this time Also passage J is at atmospheric pressure because port H interconnects with slot F This area between pistons and around springs is vented to the sump of the transmission This area is at atmospheric pressure at all times permitting the return to sump of any leakage oil past the pistons Marine Transmission Service Manual Twin Disc Incorporated Operation B Oll eu lur REGULATOR PISTON C Oll Pressure Overflow Part D Oil Engaging Passage E Engaging Passage F Oll interconnection Slot Oil Directional Part H Oil Connection Fort 4 Oll Pressure Passage OI Directional Pert L Oli Pressure Chamber RATE OF RISE PISTON CONTROL VALVE LEVER 11 CONTROL Log SPRINGS VALVE STEM EE CONTROL H VALVE BODY 1 ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 12 Manual Control Valve Neutral Sectional View NEUTRAL CONTROL VALVE BODY TO FORWARD CLUTCH O E SEE TO SUMP T E TO REVERSE CLUTCH CONTROL VALVE STEM ATMOSPHERIC PRESSURE gt PRESSURE Figure 13 Manual
201. ressure reduced to neutral pressure Marine Transmission Service Manual Twin Disc Incorporated A Entry Passage B Oll Pressure Chamber D HIGH PRESSURE C Pressure Overflow Port REGULATOR D Oil Engaging Passage E Oll Engaging Passage F Oil interconnection Slat Oll Directional Port H Oll Connection Port J Oll Pressure Passage Oll Directional Port L Oll Pressure Chamber CONTROL VALVE LEVER US PISTON SPRINGS CONTROL VALVE BODY CONTROL VALVE STEM 2 Figure 16 Control Valve Secondary Sectional View SECONDARY CONTROL f VALVE BODY PRIMARY CLUTCH SECONDARY CLUTCH CONTROL VALVE STEM ArwosPHERIC pressure B pressure Figure 17 Control Valve Secondary Cutaway View Marine Transmission Service Manual Operation RATE OF RISE PISTON BE ATMOSPHERIC PRESSURE ENGAGING PRESSURE 55 Operation Twin Disc Incorporated Hydraulic System with Electric Control Valve 56 The oil pump draws oilthrough the strainer from the oil sump and discharges It through the heat exchanger and filter to the combination control and pressure regulating valve The oil enters the pressure regulating area of the valve where main pressure is regulated by cascading excess oil into the lubrication oil circuit Lubrication oil is distributed through fixed controlled
202. ring carrier rear manifold sealed with gaskets complete the housing enclosure Additionally the MG 5600DR transmission has a two piece front reduction housing with bearing carriers Bearings The primary and secondary clutch shafts and pinions are supported and located by a combination of straight and tapered roller bearings Bearing clearances for each clutch shaft and pinion assembly are set by use of a single shim pack at the rear tapered roller bearing on each shaft Tapered and straight roller bearings also support the output shaft and have bearing clearance adjusted by use of shims at the rear bearing carrier The MG 5600DR also has tapered roller bearings supporting the front reduction gear set with clearance adjusted at the front bearing retainers Oil Pump and Drive The oil pump is spline driven by the secondary clutch shaft The model MG 5600 has three different sized pumps depending upon the engine full load governed speed The model MG 5600DR has one pump size for all engine speed applications Different pumps are available for operation on left hand rotation engines See Table 1 for the pump part numbers for the various applications Table 1 is for reference only Verify correct part number on bill of material BOM prior to ordering new parts Marine Transmission Service Manual 23 Description and Specifications Twin Disc Incorporated Table 1 Oil Pump Part Numbers Engine Full Load Governed Speed 900 1299 rpm
203. rs 0 15 0 28mm 006 011 in 3 Record total indicator runout of the following items specified in section V 4 dipstick NAMEPLATE DATA 1 Oil Capacity 110 L 29 gal 2 Minimum oil pressure lt lt when cruising MG 5600DR Assembly 1018100 1800 kPa 260 psi 3 oee shop order for bill of material and model numbers Also apply serial number ratio and customer number when applicable Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 3 of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 IV PRODUCTION TESTING 1 Mount all gauges and add oil closed sump using Delvac 1110 oil at 30 35 C 86 95 F Mobilkote 501 oil at 32 38 C 90 100 F or any comparable rust preventative oil having 20 26mnf s 200 260 SSU at test temperature lt Valve Inlet gauge connected into pressure point at the top of the valve body Lube Pressure gauge connected into manifold at plug 1038 22 Primary Clutch Actuated Pressuregauge connecte
204. rts for the free standing models assemblies 1016001 and 1017614 together when cold or with internal spline part heated to 150C 300 F maximum 6 Taper Roller Bearing Adjustment A Primary and secondary shaft bearings Shim bearings with spacers and shim assemblies Push Pull bearing adjustment method Shim tapered roller bearings per S692 IV A1 to the specified dial indicator endplay with all cover bolts fully torqued Record endplay B Output shaft bearings Push Pull bearing adjustment method Shim thrust bearings per 56921 1 using thrust force shown below 5692 THRUST OUTPUT SHAFT 1340 4000 N 300 900 Ibf 7 Retainer Washer Shimming Procedure At output shaft Determine the gap flange face protruding beyond end of shaft Measure and use shims 0 08 0 15mm 003 006 in thinner than gap No record is required 8 Input Hub Coupling Joint Assembly and Input Shaft Centering Plate Screws Apply MA908 to the as received bolts just before assembly and torque per S574 Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 2 of 8 S570AH ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600 Drawn ALC BJE ASSEMBLIES 1015239 101
205. s procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility Marine Transmission Service Manual 83 Disassembly Twin Disc Incorporated Prepare Transmission for Disassembly 84 Note During service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the old o rings gaskets and seals with the appropriate components being disassembled for future reference during the inspection and assembly process to make sure you don t forget the quantity size etc Drain the oil from the transmission sump by removing the M33x2 hex plug from the bottom of the rear side of the housing Drain the oil from the heat exchanger by removing the pipe plug from the bottom of the heat exchanger shell The physical size and weight of many of the parts for this transmission assembly are such that adequate lifting devices and procedures are necessary for safety considerations This requires that the transmission assembly be adequately supported and properly positioned as identified in the following paragraphs Marine Transmission Service Manual Twin Disc Incorporated Disassembly Remove Transmission External Components and Sub Assemblies All Assembly Models 1 2 Disconnect remove the hoses Identify for ease of reassembly Remove the heat exchanger Remove the suction tube from the pump and remove the suction tube an
206. s Manual Control Linkage Marine Transmission Service Manual Installation Twin Disc Incorporated Power Controls Selector valve positioning devices must be installed so that full travel of the actuating cylinder places the transmission selector valve in the detent position for forward or reverse as selected without exerting pressure on the rotational stop collar on the selector valve stem Selecting neutral must place the selector valve in the neutral detent position Improper installation of power engaging devices could cause failure of the selector valve rotational stop collar permitting improper positioning of the selector valve and resulting in control malfunction 196 Marine Transmission Service Manual Twin Disc Incorporated Installation Electrical Controls All electrical wires and connectors must be adequately supported to prevent rubbing or distress from relative movement WIRING DIAGRAM
207. s that allow engines to be flexibly mounted and take out the momentary misalignment In some cases the proper alignment of these couplings requires an accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Marine Transmission Service Manual 179 Installation Twin Disc Incorporated Torsional Input Couplings Installation Free Standing Units For Models Provided by Twin Disc Assembly Instructions for CENTAFLEX R on Flange Mounted Gears Information Taken Directly from CENTA Drawing 26 60062 91 3 1 Bolt flywheel flange onto flywheel and tighten bolts as follows Figure 110 Assemble Flywheel Flange to Flywheel Table 16 Centa Torque Chart Tightening Torque inch lbs Tightening torque is for slightly oiled bolts tolerance is or 5 Securing of the bolts by adhesives e g Loctite is possible Assembling of output hub This procedure is for gears with splined shaft where the output hub of the coupling is axially free 180 Marine Transmission Service Manual Twin Disc Incorporated Installation 2 Place rubber rollers the deepest section of the the output hub Normally they stick there by friction View X Figure 111 Insert Rollers and Note Alignment 3 In case that they should not stick place a tape or a cord with a slipknot around all rollers close to the gear side Let the end of the tape or cord
208. sIDH TF j H m _ m 1 _ mma 1 074777 T m 7 a 77 7 _ m 1 m mm 1 D 7 l _ 1 _ I M7 4 I 7 I 2 m r T _ gt m E T l E F _ _ bun FT yi a or 1 521 i 2 7 J r 1 4 v TF too Uk i m m 1 24 2 w 4 Rq z wa red ki C R u cU ot K na a DEM Dios L P 1 1 4 4 H T T i i E 1 I it m 0 vu B lou Le il A TENE TET 2 Spee CH 224 B ALL THE i 1 L 1 ELEC 1 I I 1 1 I 1 7 n v UU I aye Di P an me a 1 a ea i VAR l _ es p vo n wo TI i L 2 1 mee MES NEN 1 L _ i 2 2 Pu r 71 lt Roc PES m soa 5 so l Qo a i TUI uy 4 a 1 weep pe oe A 5 n i PEE 5 1 22a T T f T D Len _ LI r e MN A M gt
209. ssembly over the shaft and install three capscrews M12 1 75 x 25 and torque to 130 Nm 96 Ib ft 164 Marine Transmission Service Manual Twin Disc Incorporated Assembly Model MG 5600 Close Coupled 1 Block and support the transmission assembly with the input end up Use caution to avoid damage to the output flange and other external components Install the front housing to the front of the main housing Secure SAE 0 with eighteen capscrews M16 2 00 x 45 and torque to 275 Nm 203 Ib ft Secure SAE 00 with twenty six capscrews M16 2 00 x 45 and torque to 275 Nm 203 Ib ft Mount a dial indicator on the input shaft spline with the probe on the front housing machined face Rotate the input shaft and note the total indicator runout The face runout must not exceed 0 41 mm 0 016 in for both SAE 0 And 00 housings Figure 99 Measure Flywheel Housing Face Runout Marine Transmission Service Manual 165 Assembly 166 Twin Disc Incorporated Mount a dial indicator on the input shaft spline with the probe on the O D of the front housing pilot diameter Rotate the input shaft and note the total indicator runout he pilot runout must not exceed 0 30 mm 0 012 in for both SAE 0 and 00 housings Should total Indicator runout exceed the allowable limits contact the Product Service Department of Twin Disc Inc for information and recommendations On close coupled models mounted to the engine the in
210. te Inspector Date Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 9 of 9 S570AK Engineering Drawings Twin Disc Incorporated Notes 274 Marine Transmission Service Manual PRIMARY NELTRAL SECONDARY COMPANION FLANGE FLYWHEEL FLYWHEEL FLYWHEEL COMPANION F LANGE PROP SHAFT WRF Kq m 1015239 OR 1016001 RATIOS _ _ TORSIONAL RIGIDITY CNem road gt I y MASS T F EERIE TIENEN EL FLEXIBLE COUPLING OUTER PARTS ME FOR ALL RATIOS W 107 10 x SINTEN a FLEXIBLE COUPLING INNER PARTS 1 4 HUB C 35 7 X 10 Bier shar te apari me e raat ears 44 350 DRIVING TRANSFER GEAR REAR BEARING SHAFT C4 3 4 PRIMARY SHAFT PISTON 11 FOR ALL RATIOS BACKPLATE DRIVING PLATES PRIMARY CLUTCH HUB NEEDLE BEARING PININ BEARINGS DRIVING PLATES pas qve sr je Jo Jo 7 7 727 7 TC C C C F SECONDARY SHAFT PISTON BACKPLATE LI FOR ALL RATIOS DRIVING PLATES HUTFUT GEAR BEARING amp e AO T Q Q v POtTJH A T
211. te identifies the model bill of material BOM and the serial number of the unit nese numbers are necessary to identify the correct parts for your transmission RATIU of _ B POWER 5 E R L 1 DIL CAPACITY CUSTDMER GAL MARINE RAN IN Ne BRICATILN MIN DIL PRESSURE WHEN CRUISING PSI
212. tenance use and operation of said equipment Only a Twin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit July 1 1998 TDW P2003 TWIN DISC INCORPORATED FLAT RATEHOUR ALLOWANCE sy Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated COMMERCIAL MARINE TRANSMISSIONS ALL RATIOS MO DEL SERIES R amp R UNIT REBUILD CLUTCH REPAIR BOTH PACKS MG 502 MG 5010 MG5011 MG5005A MG5015A 10 0 8 0 506 5061 MG 5050 MG5055A 10 0 11 0 MG 507 MG 5081 MG5085 MG5090 10 0 12 0 MG 5091 10 0 12 0 4 0 MG5112 MG5113 10 0 17 0 MG 509 MG 5111 MG5114 10 0 17 0 4 0
213. the lube relief valve housing Attach the assembled lube relief valve on to the inner face of bearing carrier with two capscrews 8 1 25 x 16 and washers Torque the capscrews to 33 Nm 24 lb ft HOUSING NEN 2 2 N 3 BALL CAP SURE w WASHER BEARING N CARRIER Figure 82 MG 5600 Lube Relief Valve HUUSING J RING Figure 83 MG 5600DR Lube Relief Valve 142 Marine Transmission Service Manual Twin Disc Incorporated Assembly Install two guide studs into the face of the housing Install the bearing carrier over the studs and onto the dowels in the housing face Use a soft hammer to seat the carrier if necessary Install the lubrication tube through the keyed hole in the bearing carrier The tube fits into a machined pocket in the front inner face of the housing Turn the tube so the elongated key of the tube fits into the corresponding key in the bearing carrier The properly installed the lubrication tube should be flush with the rear face of the bearing carrier Figure 84 Keyed Lube Tube Installed Flush with Housing Install the cups for the rear tapered roller bearings on the primary and secondary shafts into the bores in the bearing carrier
214. the o ring and install the seat into the valve body Be sure to align the roll pin holes in the seat with the holes in the valve body A M8x1 25 screw threaded into the seat can be used to adjust the seat location in the valve body 4 Install the roll pin to retain the shuttle ball seat Drive the roll pin in until it is flush with the gasket surface of the valve bogy 5 Install the stem into the valve body aligning the slot in the stem with the threaded hole in the valve body for the dog point setscrew Be sure the slot in the stem is aligned with the setscrew hole in the valve body to prevent damage to the stem and valve body 156 Marine Transmission Service Manual Twin Disc Incorporated Assembly 6 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn Figure 95 Dogpoint Setscrew with Threadlocker 7 Install the steel detent ball into the valve body 8 Install the detent spring over the detent ball 9 Apply MA908 threadlocker to the threads of the hollow setscrew and install into the threaded hole stepped Allen wrench or one wrapped with tape will ease the installation of the hollow setscrew Tighten the setscrew until it is flush with the gasket surface of the valve body Check the stem rotation and detent action Figure 96 Detent Ball Spring Hollow Setscrew Marine Transmission Service Manual 157 Assembly 158
215. ting Chart Twin Disc Incorporated 80 2 Low main oil pressure No oil pressure or erratic low pressure at control valve tap Partially clogged oil strainer Stuck pressure regulation piston Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Incorrect linkage adjustment to control valve assembly Clogged or plugged orifice in orifice plate of control valve assembly Shimming required between regulator springs and rate of rise piston Engine idle speed too low Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Regulating valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Remove and clean oil strainer Disassemble the valve and clean the piston Remove the collector and inspect piston rings Replace damaged or worn oil pump assembly pump is not serviceable Adjust linkage so that control valve stem is indexed properly by detent Remove orifice plate cover Clean parts Shim as required Raise engine speed Remove and clean strainer C heck oil le vel and Correct Correct cause of air leak Disassemble and repair as required Remove disassemble clean and repair the regulating valve Replace oil pump Replace heat exchanger Marine Transmission Service Manual Twin Disc Incorpo
216. tive bearing bores If the bearing races must be replaced use an electric welder and weld a light bead around the 1 0 of each bearing race This will shrink the race and destroy the bearing but will facilitate removal 20 Remove the snap ring and remove the front output bearing from the housing Remove the front output end tapered roller bearing cup from the housing Pusher bolt holes are provided in the housing 94 Marine Transmission Service Manual Twin Disc Incorporated Disassembly Disassemble Components and Sub Assemblies Output Shaft Use a hydraulic press to remove the rear output bearings from the output shaft Note In some situations the rear tapered roller bearings on the output shaft can be rebuilt at the time of a regular transmission rebuild Contact a local Timken distributor for bearing rebuild information Primary and Secondary Clutch Shaft Note procedure for both shafts is nearly identical Differences are noted 1 Hemove the two M8 1 25x20 socket head capscrews and remove the oil pump adapter Secondary shaft 2 Hemove the two piston rings from the rear end of the shaft 3 Do not remove the rear bearing unless the bearing must be replaced This bearing is an interference fit with the shaft and will be destroyed during removal If the rear bearing must be replaced remove the bearing retaining snap ring from rear end of shaft Use a hammer and chisel to cut the bearing cage and remov
217. ton capacity and fixture to seat gear using 1340 N 300 lof load Inject oil with a viscosity of 300 mn s 300 cSt at the operating temperature into the shaft until it leaks out of both ends of the mating surfaces Advance gear to shaft shoulder stop Release injection oil pressure between the mating Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page of 9 S570AK ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 surfaces and wait 5 minutes before lowering the pull on force and removing the assembly tool Record actual advance 4 Output Flange Taper Assembly Joint surfaces to be in condition described 1 1 Coat the tapered surfaces with thin oil Measure distance from output shaft end to taper roller bearing cone assembly face Measure length of output flange hub taper Note With the output flange fully assembled the difference between these two measurements must equal the space available for shaft end shims within 0 05mm 002 in Install output flange onto output shaft along with retaine
218. ty of shims wrong pump installed leakage broken forgotten or cut seal rings amp Secondary Pressure broken seal ring at collectors or piston oeLube Pressure out of tolerance or missing orifices broken rear seal ring faulty lube relief valve Notice This print contains proprietary information and is not to be used in any manner detrimental to the interest of TWIN DISC INCORPORATED This notice is not intended to nullify or limit rights granted to the U S Government or others by contract TWIN DISC INCORPORATED Racine WI Page 7 of 8 S570AH Engineering Drawings Twin Disc Incorporated Notes 264 Marine Transmission Service Manual ASSEMBLY INSTRUCTIONS CHECKS AND TESTS AND PRODUCTION TESTS MARINE TRANSMISSION MG 5600DR Drawn ASSEMBLIES 1018100 Checked DAS Approved DAS Original Issue Date 03 18 98 PROCEDURE Latest Issue Date 09 26 00 ECN Number 30339 The unit is to pass all these checks and tests before being approved for shipment Please follow your routing instructions carefully The routing contains additional information to assist you in determining when it is best to apply each check and test and it also offers additional guiding instructions l ASSEMBLY INSTRUCTIONS Assembly check limits are given in section V 1 Unless otherwise specified A Degrease surfaces of t
219. u uu u l llu LIU 25 SDOSDHIO SUOBS 28 pooma 1 9 cent tee teen 30 Torque Values for Fasteners 42 Luci EI Cc T 45 Operation 47 General U 47 Hydraulic System with Manual Control Valve 48 Manual Control Valve Assembly 50 Hydraulic System with Electric Control Valve 56 Live PIO Optiohal I AA 3 SA ii 65 Trailing Pump 65 EET M E 66 Marine Transmission Service Manual 7 Table of Contents Twin Disc Incorporated Preventative Maintenance 73 In boat Maintenance and Repair 73 Generol NIBINISNSIC6 74 Troubleshooting 79 Troubleshooting Chartl 79 Disassembly 83 Prepare Transmission for Disassembly 84 Remove Transmission External Com
220. unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The primary clutch is now disengaged and main system pressure reduced to neutral pressure 52 Marine Transmission Service Manual Twin Disc Incorporated Operation A Oll Entry Passage B Oll Pressure Chamber b HIGH PRESSURE Pressure Overflow Port REGULATOR PISTON D Oil Engaging Passage N E Oll Engaging Passage F interconnection Slot N T RATE OF G Oll Directional Port RISE PISTON H Oil Connection Port eM OF J Oil Pressure Passage Fi MM bow K Oil Directional Port E on L Oll Pressure Chamber a GONTROL WALVE LEVER la PISTON SPRINGS CONTROL VALVE STEM CONTROL 2 VALVE BODY E ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 14 Control Valve Primary Sectional View PRIMARY CONTROL VALVE BODY TQ PRIMARY CLUTCH TO SUMP TO SECONDARY CLUTCH CONTROL VALVE STEM ATMOSPHERIC PRESSURE C ENGAGING PRESSURE Figure 15 Control Valve Primary Cutaway View Marine Transmission Service Manual 53 Operation 54 Twin Disc Incorporated Manual Control Valve Secondary When a shift to the secondary position is desired the control valve lever is moved The shi
221. utch piston clamping the friction and steel plates together The steel clutch plates are spline connected through the clutch hub assembly to the input pinion so the secondary input pinion will rotate at either 72 77 84 of engine rpm dependent on the input reduction ratio of the transmission and in engine direction Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate opposite engine direction The primary input pinion will be backdriven engine direction when the unit is in the secondary position Figure 32 MG5600DR Power Flow with Secondary Clutch Engaged Marine Transmission Service Manual 71 Operation Twin Disc Incorporated 72 Marine Transmission Service Manual Twin Disc Incorporated Preventative Maintenance Preventative Maintenance In boat Maintenance and Repair Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures d U D D L Note Note Removing and installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Removing and installing the control valve Removing and installing the manifold or top cover bearing carrier and lube tube Removing and installing the primary and secondary shaft assemblies oee special tools section for lifting bracket to aid in shaft removal or installation Changing prim
222. w the oil temperature to cool to normal cold oil conditions perhaps overnight Check the oil level while cold at low idle engine speed while in neutral Make note of the oil level in the cold conditions for future reference as it corresponds to the correct oil level at operating temperature Marine Transmission Service Manual 75 76 Preventative Maintenance Twin Disc Incorporated Torsional Coupling Do not obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling The ambient temperature of the air around the coupling should be between 6 C 22 F and 80 C 176 F Assure baffles are installed properly so hot air is ported out of the housing Visually inspect the element after the first 100 hours of operation and every 2000 hours thereafter or every six months whichever comes first Torsional vibration misalignment degradation by contaminants oil heat ultraviolet radiation and excessive system torque can cause cracks or other signs of distress to appear on the surface of the rubber The above described items affect the life of the coupling element When inspecting the flexible coupling look for evidence or conditions identified in the following steps Q Cracks in the surface of the rubber May be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Q Se
223. which compresses the pressure regulating springs additionally This additional spring compression further resists the movement of the pressure regulating piston resulting in a force balance between the area at the pressure regulator the springs and the area behind the rate of rise piston Neutral main pressure of approximately 40 psi is maintained by relieving excess oil behind the rate of rise piston through the ball and spring regulator Marine Transmission Service Manual 59 Operation Twin Disc Incorporated Control Valve Assembly in Primary or Secondary Pressurized oil is directed to one of the transmission s clutches to engage it The pressurized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the passage to the opposite clutch The pressurized oil also forces the ball of the ball and spring regulator against its seat on the orifice plate stopping the flow of oil from the rate of rise chamber to sump Since oil continues to flow into the rate of rise chamber through the orifice the oil pressure in the rate of rise chamber increases This increased oil pressure forces the rate of rise piston to stroke over to its stop in the valve body compressing the pressure regulating springs even further yet Figure 21 Rate of Rise Piston in Neutral left and Rate of Rise Piston with Clutch Engaged right The travel rate of the rate of rise piston and resulting pressure rate of rise Is controlled by
224. y spot 13 5 x 7 0 x 6 5 204 Marine Transmission Service Manual Twin Disc Incorporated Special Tools T 19987 detail 4 Gear Assembly Fixture I 3 75 4 i UR 2 00 KNURLED DIA 2 995 2 990 DIA 1 4 R 30 X 13 i 4 i 4 00 i 1 3 00 12 THD X 3 00 LGTH 5 990 i 8 185 8 1804 nu REF 8 510 DIA 8 490 75R 3 01 2 99 i i m 0 333 1 TAPER METRIC 6 010 5 990 25R DET 4 7 140 7 135 zal DIA 11 04 Gear Assembly Fixture T 19987 30 X 25 REQ MAT Description amp Stock Size UHMW Alligning shaft Pur Comp Kitco Plastics PE Marine Transmission Service Manual 205 Special Tools Twin Disc Incorporated T 19987 detail 5 and 6 Gear Assembly Fixture 10 630 Fr TYP 2 25 i j DRILL 2 75 DIA THRU 8 00 te e DT 3 00 TYP I 2 0 DIA 8 LIGHTENING HOLES MILL OUT MATERIAL BETWEEN HOLES Kas 21 2598 B C 45 X 06 2 DET 6 2 w 24 00 1 00 5 0 DIA 717 0 DIAS 25 R mo 3 005 3 000 19 080 PIA 19 075 DIA DET 5 30 125 11 05 Gear Assembly Fixture T 19987 DET REQ Description amp Stock Size 6 2 PUR Jergens 21906 handle 5 1 4140 Alligning plate Rc 32 36 24 5 x 8 5 x 3 5 206 Marine Transmission Service Manual Jenue N 923IAJ9S UOISSIUISUPJ SUNEN LOC NOTE SPOT

Download Pdf Manuals

Related Search

Related Contents

USB 2.0 Data Link Cable UL  Installation & User Manual Radio Remote RC-12E - Side  パッケージソフトウェア品質認証制度申請者ガイドブック（PDF）  Laufräder - Bike Components  Fio quente CFM / CMM Thermo- Anemómetro  Sony Cyber-shot DSC-T70 User's Manual  CrossWords Administrator`s Guide  

Copyright © All rights reserved. Failed to retrieve file