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1. Aa IRMA wos WAL Net VA FRA N _ f 6 S aN Gs P D m V ju 204 Marine Transmission Service Manual 1019677 22961014 uoissiusueJ SUNEN 202 5 Description Item Bearing tapered roller primary amp secondary shaft front bearing Bearing needle roller Shaft assembly secondary Ring external retaining primary secondary shaft needle bearing Ring internal retaining pinion needle bearing Pinion assembly primary amp secondary Tube lube Bearing tapered roller primary amp secondary pinion rear bearing Backplate clutch Retainer spring primary amp secondary shaft Ring external retaining primary amp secondary shaft O spring retainer Spring compression clutch release Gear transfer secondary shaft LH helix Piston clutch Ring piston clutch piston inner Ring assembly piston clutch piston outer Housing lube relief valve Spring compression lube relief valve Ball steel lube relief valve Screw hex head lube relief valve Washer lube relief valve Bearing tapered roller primary amp secondary shaft rear bearing Qty Description Spacer bearing Plug pipe temperature sensor port Ring piston primary and secondary s
2. PRIMARY SECONDARY CLUTCH CLUTCH 4 SPRING RELEASED CLUTCHES CUSTOMER INSTALL r PRESSURE GAUGE LINE HERE PRESSURE GAUGE BE MOUNTED IN PILOT HOUSE SEE MARINE TRANSMISSION INSTALLATION DRAWING LUBE TUBE GEAR LUBE CLUTCH ZA PRIMARY amp SECONDARY 4272 SHAFT LUBE NC C XC CN 4 SS BEARING s Uy 422 2 NN 1 1 1 gt i Zee d 477 A DINE ase 472227702 N MARINE TRANSMISSIUN Et Eo 5 CONTROL VALVE 2 zz 5 85 Xi SEE CHART 5 QE Mtm REFERENCE A7119W ELECTRIC B amp TD EN EN d qui war SWITH MECHANICAL BACK UP HYDRAULIC dou JI 1 lice n ISM gt A SS MARINE J TRANSMISSION val 2 2 2222 Y 17272 044 jm SS gt i i 1 1 A CONTROL VALVE 222787 CUSTOMER zzz PORTION ENCLOSED WITHIN LINE IS REMOVED IF MANUAL j INSTAL eT 9 SS WN THESE LINES IS REQ D FOR OPTIONAL HYDRAULIC 0 5 PRESSURE D 7 OPTIONAL HYD P T D ONLY IS SUP
3. 183 T 18050 713 Output seal 184 T 18050 714 Shaft lifting fixture output shaft 185 T 18050 715 Shaft lifting fixture primary and secondary 11 7 MT L 186 18050 723 Bearing cone and transfer gear driver primary and secondary Shalls Up eI RPM EPFL MEE 187 T 18050 771 Front output bearing cup driver 188 T 18050 784 Input hub advancement tool 189 T 18614 6 Adapter used with SKF pump 190 T 19330 Spring retainer compressor coil spring units 191 T 20023 3 Output gear installing fixture sheet 1 of 3 192 T 20023 3 Output gear installing fixture sheet 2 of 3 193 T 20023 3 Output gear installing fixture sheet 3 of 3 194 T 21433 Output flange installing fixture sheet 1 of 3 195 T 21433 Output flange installing fixture sheet 2 of 3 196 T 21433 Output flange installing fixture sheet 3 of 3 197 21506 Output shaft bearing driver sheet 1 of 2 198 21528 Gear assembly rail 199 T 21566 2 Output bearing driver 200 T 21566 3 Output bearing cup dr
4. 116 Assembly and Installation of Primary and Secondary Shafts 117 Installation of Exterior Components 131 Installation of Output Flange eres 133 Installation of Top Cover Assembly Heat Exchanger and Oil cj 138 Installation of Input Oil Seal Front Housing and Input rs Ds E EET 140 Assembly and Installation of Control Valve 144 Installation of Electric Control Valve 153 8 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Table of Contents e 155 Prior to 155 Alignment also reference SAE J 1033 and 617 156 igiiur 160 TOOS MUT 175 Special ou 175 Recommended Pump Set and Fluids 177 18050 705 Bearing driver for pinion needle roller bearings 179 T 18050 706 Input seal driver and protection sleeve 180 T 18050 708 Bearing cup 181 T 18050 711 Bearing cone driver primary and secondary EDI ue 182 T 18050 712 Seal protector plug driver
5. H 1 4 T Dowel Return spring 4 m po t Figure 10 Neutral Solenoid Engaged Marine Transmission Service Manual 1019677 41 Operation Twin Disc Incorporated Manual Override Operation The control valve has a manual override feature which is a lever operated selector When the manual override lever is rotated counterclockwise and pulled outwards the upper portion of the valve is disabled because the connecting slots in the manual override stem are no longer aligned with the oil passages in the valve body Oil pressure from the solenoid operated pilot valve controlled spools cannot reach the clutch pressure passages in the transmission The main oil pressure regulator shuttle ball neutral pressure regulator and rate of rise functions remain exactly the same as when the valve is in the electric mode In the manual override position shifting is controlled by rotating the lever on the manual override stem In the Neutral position both clutches are vented to sump by two pockets in the stem Figure 11 Stem Pocket or Passage Main pressure oil can flow through the hole in the end of the stem to a narrow slot between the two pockets This slot does not connect to any other passages when the stem is in the Neutral position When the lever and stem are rotated to engage either the primary or secondary clutch main pressure oil flows through the slot in the stem t
6. DR DTHERS CONTRACT Engineering Drawings Twin Disc Incorporated Notes 232 Marine Transmission Service Manual 1019677 11019677 12 01 AR Disc 2 POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
7. 63 Prepare Transmission for Disassembly 64 Remove Transmission External Components and m1 p 65 Hemove Output Flange 68 Remove and Disassemble Manifold and Bearing Carrier 70 Remove Primary and Secondary Clutch Shaft Assemblies 72 Remove Output Gear and 73 Disassembly of Trailing Pump Drive Components 76 Disassembly of Primary and Secondary Clutch Shafts 78 Disassembly of Selector Valve Electric Valve 83 Disassembly of Upper Valve Body Half electric section 88 1017555 Trolling Valve Optional Equipment 90 Cleaning and Inspection 95 EID E 95 2 97 PG e c 101 Prior to Assembly 102 Preliminary 103 Installation of Trailing Pump Shaft and Driven Gear 105 Installation of Output Shaft and Gear 107 Installation of Output Shaft Bearings 110 Output Shaft Tapered Roller Bearing Adjustment 112 Assembly and Installation of Gear Pan
8. SECONDARY SHA SHOWN DISENGAGED PORT ON LOSED WITHIN ESE 15 REQ D EYD PED ONLY TH I ge REAR P h CLUTCH CLUTCH HYDRAULIC P CONTRO VAL VE Xe A7119Y FOR H DI TAG RAM OF CONTRO g SEE CHART YDRAULIC VALVES CS CO SU MP STRAI NER pe1e10d402u 3510 4 Operation Twin Disc Incorporated Trolling Valve Optional The trolling valve is used to reduce and control propeller speed below that normally attained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure to reduce the propeller speed 44 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation 1017555 Mechanical Trolling Valve This trolling valve is a variable orifice that controls the pressure in the rate of rise chamber The pressure in the rate of rise chamber determines the rate of rise piston position which ultimately controls the main and clutch pressures for the transmission When the trolling valve lever is in the detent non trolling position the orifice in the trolling valve is closed Oil cannot exit from the rate of rise chamber through the trolling valve s orifice and the ra
9. STAMP TOOL NO 18050 708 NOTE UNLESS OTHERWISE SPECIFIED 1017005 SHEET 1 OF 1 PART NO MG 406 4 LIED BREAK ALL SHARP CHRNERS vasso ______ 5 30 57 HHe24346 BRG rrr CAD FILE T 18050 708 dwg MUN 1 4 UN ANGULAR DIMENSIDN 0 13 DRILL 3 8 3752 DIA THRU 4 HOLE USE FOR PICKING BRG DRIVER UP KNURL FULL LENGTH SHAFT 748 SF DIA DRILL 5 16 3125 DIA x 1 00 DP 3 8 16 UNC x 88 DP D REQ D CAD FILE 050 711 1 50 DIA 6 x 45 06 x 30 DRILL 5 16 3125 DIA THRU 3 8 16 UNC 02 REG D STAMP T 18050 711 BEARING DRIVER FOR INSTALLING CUP 1017081 0 750 DIA BEARING DRIVER 15 REQ D MAT CARB amp HDN NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 DF EACH NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS cR a our umcms s i sme soc cae screw a roo Have WA CANCELLED 1 1 MS BEARING DRIVER 875 DIA 138 THK IDETIREG DESCEIPTILN STOCK SIZE ME BEARING DRIVER FOR CUP L MG 5301 1017081 T 18050 TOOL NUMBER 1 18050 742 PART NUMBER M 1945 BY MDDEL NUMBER MG 5301 1 06 x 45 KNURL HANDLE 10 0 TOTAL 100 DIA DRILL ROD OR EGIV 20 00 EEN SE
10. 226 1018085 Control valve assembly with trolling valve 227 1017555 Valve assembly mechanical trolling 228 1017554 Valve assembly electric trolling 229 1018554 Integral trailing pump option 230 1016473 Remote trailing pump assembly 231 10 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for Twin Disc models MG 6690SC and MG 6848SC 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 application of the material in this manual will result in consistent performance from the unit and help reduce downtime Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Inc will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unaccepted maintenance working practices Marine Transmission Service Manual 1019677 11 Introducti
11. ARE NOT POLARITY SENSITIVE SETSCREV 018085 1 1101808 5 ee re E HYDRAULIC LOCK ON PIN A2711AC 2 SPOOL 1017432 2 HYDRAULIC LOCK ONLY HYDRAULIC LOCK ONLY NDTE LEVER MAY BE LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTAL ROTATION amp 114mm AXIAL MOTION REQUIRED FOR CONTROL PLUG MA1038E 2 PISTON SEE CHART SOLENOID ASS Y SEE CHART TORQUE TO 33 9 25 0 2 WASHER 1017522 VALVE BODY ASSY 31017444 BODY 1017 BALL MAGIA 11 BALL M1990Y 6 SPRING 2705 2 PIN A2711R 2 WITH OR WITHOUT HYDRAULIC LOCK SPRING ASSY SEE CHART PISTON B1399H GASKET B1334C PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND HYDRAULIC LOCK lt OPTIONAL CONDITION WIRING DIAGRAM OPTIONAL CONNECTOR MATING WIRING HARNESS 1017501 A SERIES SPECIFY LENGTH PORT SOLENOID D COVER ASSY 1017336 A CARRIER 1017335 BALL M1990Y NEUTRAL SOLENOID BALL 19906 2 BALL M1990L 2 BALL MI990M 7 VALVE GASKET 10171368 SCREEN 221336 M8 X 125 6 TH D 2 HOLES Y CONNECTOR SHROUD 100426 MANUAL DVERRIDE POSITION orate WHITE WIRE WITH PIN 2 PORT CONTROL 2 Z 12 4 ty CONNECTOR LEVER POS
12. MANUAL DVERRIDE NEUTRAL START R AGRAM SWITCH CLOSED ONLY WHEN valve DITCH SOLENOID GLUTCH ORIFICE TROLLING OF E T FIRST No PUATE nol seer wo OTA uae no VANE par Rx or 57 ae PORT SOLENOID 1018085 mre Eam M e e fol d H mesa 40760 merzsss 117179 vod 350 intesa inrsse x erem 4 e wesesev 5 NEUTRAL SOLENOID E 1018085 41079 1017383 1017179 xwe7s9rMa 2655 385 1017129 1017554 7 x 20 6 4 BessiB _ 6449 224414141 See d mee ER LER CONNECTOR 1018085 7 1017383 1017179 N 2 xme7S9FM24 voc aero Revoapu 2450 355 10171290 1017554 7 x 6 4 2451 kep FEMA VALVE ues pess _ nn 2 ae7o7An 2000
13. 1017129 101888 x 2 easing Loo Messe 10180856 41152 1018688 xwezserMe voc B EE EET Ed OPTIONAL 473 1018688 5 4 27072 7072 250 roy 10 7 x 20 6 2 2451 5 wc sizopc 927 MATING WIRING HARNESS 1017502 2 41256 188688 2 jwe7ssrM 24 7072 7072 70 725 eso 1017329 1017554 x 20 60 __4 sees 7879 SERIES SPECIFY LENGTH 255 we7ssFi te 7072 227072 e763T 1725 230 1017129 1017554 x 20 60 4 poesia __ _ 5 1 64 1018085 41266 10171334 1017134 37 1017179 759 24 707 1585 230 1017129 1017554 0 8 6 4 45 1052 2 5 2 544 1018085M 41304 1017179 xwe7s9rMe4 04 a2707ap 2703 1860 270 10171294 1017554 10 x 20 6 4 4518 eeo 5141 10180854
14. 216 Marine Transmission Service Manual 1019677 REMARKS SOCKET HEAD DOG POINT HEAD OME MODELS UTER INNER e 5 Q2 SOME MODELS HEX TROLLING VALVE GROUP SF S N PLATE ORIFICE SEAL VALVE BODY SCREW NUT PIN LEVER BALL RING RING WASHER SPRING SPRING SETSCREW BS lt LONS 27222 Y E 22 7 77 SECTION SECTION Illustrations Twin Disc Incorporated Notes 218 Marine Transmission Service Manual 1019677 Twin Disc Incorporated List of Engineering Drawings Engineering Drawings Engineering Drawings The following pages include the engineering drawings that are specific to these models The engineering drawings included are listed below and continued on the following page Note Any part numbers listed in the following engineering drawings are for reference only Please refer to your bill of material for part numbers specific to your model 1019086 1020350 1019086 1020350 1019086 1020350 1019086 1020350 A7119AA 1018084 1018085 1017555 1017554 1018554 D D D D D O D D UD 1016473 Marine Transmission Service Manual 1019677
15. THREADED HOLE BEHIND PULL TIGHT TRIM END SHORT TOP VIEW STRAP M2942B NOTE DETENT GROOVE UNTIL SNUG BACK OFF 1 2 TURN THESE SOLENOID CONNECTIONS ARE NOT POLARITY SENSITIVE SETSCREW M2038W SPRING A2702BQ 2 HYDRAULIC LOCK ONLY PIN A2711AC 2 SPOOL 1017432 2 HYDRAULIC LOCK ONLY NOTE HYDRAULIC LOCK ONLY LEVER MAY BE LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTAL ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL PLUG MA1038E 2 PISTON SEE CHART WASHER 1017522 THESE SOLENOID CONNECTIONS ARE NOT POLARITY SENSITIVE GASKET 1334 SPRING 2705 2 A2711R 2 OR WITHOUT HYDRAULIC LOCK SPRING ASSY SEE CHART PORT SOLENOID COVER ASSY 1017336 CARRIER 1017335 BALL 1990 NEUTRAL SDCENDID e M8 X 125 6 TH D 2 HOLES 9 MANUAL OVERRIDE POSITION 3 POET ELECTRIC N PISTON B1399H POSITION POSITION ASN PLATE SEE CHART f SEAL MA778 N 4 emm A SHIM 7 NL eae hasan 366 22222 222046240 N Ce a EUH ir N A EA A N amp GASKET 1017334 GASKET 1017130 2 SNAP RING 29155 BALL 1990 SPRING 2702 SHIM 10
16. TWIN Dc 1 L E jin 15 35 TRAILING PUMP INSTALLATION INSTRUCTIONS REMOVE COVER GASKET CAPSCREWS AND WASHERS FROM REAR DF HOUSING TEMPERATURE PICK UP PORT MIB x 15 THREAD METRIC PORT CONFORMS ISO 6149 ASSEMBLE 90 FITTING ONTO THE PUMP DIRECTION SHOWN ALIGN THE TANG OF THE PUMP WITH THE SLOT IN THE PUMP SHAFT IN THE MAIN HDUSING AND ASSEMBLE THE GASKET PUMP AND FITTING SCREEN COVER AND PLATE ONTO THE R DF THE MAIN HOUSING REA USING THE 5 M12 x 75 0 LONG CAPSCREWS AND TORQUE 62 N m gt REMOVE PLUG 8 FROM MANIFOLD AND INSTALL 90 FITTING DIRECTION SHOWN gt ASSEMBLE TUBE TO FITTINGS CAUTION IF OIL TEMPERATURE EXCEEDS 100 C OUTPUT SHAFT SPEED MUST BE REDUCED DIL TEMPERATURE CAN BE MEASURED ANY Q3 PORT LOCATION OF PLUG 9 SEE NOTE 4 FITTING MA1053N TUBE 1018382 FITTING MA1053N RING 916 WASHER MA1039D 4 SCREW 996 5 COVER 2502 PUMP 1018469 STRAINER B2130A GASKET 1018393 PLATE 212754B TEMPERATURE PICK UP PORT 1 4 18 NPTF TAP lt DRYSEAL gt BUM ND 40907 on NOTICE THIS PRINT CONTAINS ee ul PROPRIETARY INFORMATION AND 15 9 3 98 TO USED IN ANY MANER TAIN DIKE 50 100 DISC INCDRPDRATED EA eve DU ENSE p THIS NOTICE 5 INTENDED 1018554 PX LM Ra on eee ome
17. BREAK ALL SHARP CORNERS SQUARE amp CONCENTRIC TO WITHIN B DET 8 ADDED 005 DF EACH CS 2 21 97 MG 5301 SHEET OF 3 DESCRIPTION TWIN DISC INC RACINE VIS 21433 RETRACTED LENGTH OF PRESS RAM x 45 DRILL 5 16 3125 DIA x 125 DP TAP 3 8 16 x 100 DP REQ D 180 USE FOR LIFTING 2 44 MID STRDKE LL eZ __ UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE REWORK DET 5 ALL GRD DIA S amp SURFACES MUST SQUARE amp CONCENTRIC TO WITHIN DIMS SHOWN 005 OF EACH OTHER m ince I 45 49 Rof a 1 MS PUSHER PLATE 57 REWORKED TO THIS DRWG S i ms Puer sase e see 3 1 saon PULLER ROD E eS 1016523 DETRE MAT JESCRIPTION 1 STOCK SIZE 1017009 FLANGE Date 2 21 97 By JPL Scate FULL Hei em e amp DET 8 ADDED ES FLANGE FIXTURE 21 97 J DET 5 REV D PL FOR SHEET 3 DF 3 _ SHT 3 ADDED amp MG 5301 CAD FILE nance ___ av TR DISC Wc meme vis 21433 FLAME 1 74 DRILL 7 8 875 DIA THRU 1 8 15 REQ D DRILL 29 32 906 DIA THRU 5 REQ D FOR CLEARANCE THREADED ROD 1 REQ D MAT DRILL ROD OR THREADED STOCK FLAME HDN AS SHOWN FLAME SQUARE 7 8 8 THREAD DRILL
18. sd Eccentricity 0 48 0 019 0 41 0 016 0 36 0 014 0 30 0 012 0 25 0 010 0 23 0 009 0 20 0 008 0 18 0 007 0 28 0 011 With the indicator mounted as in the previous paragraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing E NELLE Thousanaths Engine DUE 5 uot Flywheel Crankshaft p AL Flywheel Housing Figure 113 Checking Flywheel Housing Bore Eccentricity Marine Transmission Service Manual 1019677 157 Installation 158 Twin Disc Incorporated Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the previous Table for allowable tolerances Bolt a thousandths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the surface to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter Fr Engine Engine Flywheel Housing r Engine Flywheel Thousandths Engine Indicator Crankshaft C Figure 114 Checking Flywheel Face Runout Marine Transmission Service Manual 1019677 Twin Dis
19. 21 COUPLING 1019074 CDUPLING 1019123 PLUG 1016191 pau Lo IN PLUG 1016191 g 9 D g 9 9 g 9 D 9 g HO e 9 555552 FLYWHEEL DUTLINE MUST CONFORM SAE J620 No 460 55 FLYWHEEL DUTLINE MUST CONFORM TD SAE 620 530 4 1 f SERVICE REFERENCE ROLLER MA1116D 102 SERVICE REFERENCE ROLLER MA1116D 10 pcc NN S THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 5574 SERVICE MANUAL VALUES NN THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER 150 898 1 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES SEE SHEET 1 FOR MAXIMUM TRANSMISSION rpm THE WR OF INNER PARTS INCLUDES HUB AND 1 4 SHAFT Ce FOR OTHER TRANSMISSION MASS ELASTIC DATA REFER B35044U FOR OTHER TRANSMISSION INSTALLATION DIMENSIONS REFER 1019086 1020350 SHEET 3 ORNS us DYNAMIC TORSIONAL STIFFNESS JIK 405 Ve espe iac is 929 PARTS INNER PORTS em ws mm n e em ome ww 16 12 mm e
20. RY CLUTCH SHAFT 4 RH ENGINE ROTATION DRIVING THRU PRIMARY CLUTCH 610 00 325 00 9 374 00 REF H C 200 000 0 025 LOCATION FOR OPTIONAL TRAILING PUMP RH ENGINE ROTATION DRIVING THRU SECONDARY CLUTCH TEMPERATURE PICK UP PORT 1 4 18 NPTF DRYSEAL FOR USE WITH OPTIONAL AILING NOTE M33 X ALL POINTS AVAILABLE M33 X 2 0 THREAD METRIC PORT CONFORMS FOR TEST ARE CODED TO 150 6149 EYEBOLTS 2 FOR LIFTING MARINE TRANSMISSION EQUALIZE LOAD ON BOTH EYEBOLTS TO LIFT lo INCORPORATED 53405 USA OR OTHERS BY CONTRACT ELECTRIC CONTROL MODE SWTCH CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE WIRING DIAGRAM CONNECTOR PRIMARY CLUTCH SOLENOID 2 B 7 SECONDARY CLUTCH SOLENOID Pp NEUTRAL SOLENOID MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH CENTER OF GRAVITY M24 X 3 0 THREAD 38 0 DEEP SIDE USE ALL 16 HOLES FOR MOUNTING UNIT USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 5576 OR SERVICE MANUAL VALUES MARINE TRANSMISSION COUPLING A COUPLING HDUSING 1017013 THRU 0 HOLES EQUALLY SPACED USE 88 PROPERTY CLASS QUALITY CAPSCREWS PER 150 898 1 AND TORQUE TD 5574 DR SERVICE MANUAL VALUES J THRU HOLES EQUALLY SPACED USE 88 PROPERTY CLASS QUALITY CAPSCREWS PER 150 898 1 AND TORQUE TO 5574 OR SERVICE MANUAL VALUES SCREW MA996Y 195 996
21. T SS 7 iy BEARING MAS28 2 GOP MASSOAT E co 2 S MAGO 2 PINION ASS Y 1019134 2 PINION 1019137 2 22 A Ope 590 r7 HUB 1017007 o V4 rZ sS PLUG 1945 ES TAPERED EDGE 2 STU AAS toe Z 2 A s T WASHER B1504KY 19 19 SCREW M2020AD 2 HUB 1018361 2 HUB 1018361 2 sl ANS RING A2669EV 4 RING A2669EV SCREW 1055 a eee 22222 US ING 015592 GEAR 1018419 1019084 2 n 0 89 1 RATIO ay 0 d niliil 2222 RING A2916kD HUB 1018361 1018361 2 SEE NOTE 4 SHAFT ASS Y 1019073 4 AA SCREW MA996P 4 RING t RING A2669EV 4 RING A2916HP BALL 2 5 RAT D 4 SS Wy 2 SEAL 1017085 2 b LA 1 ONES 4 2 PLUG 1016191 SHAFT ASS Y 1019954 PLATE 2127548 2 S ZZ 2 lt 2 1020043 BUSHING 1018333 5 SEE NOTE 46 2 diii SCREW MASSEAD 2 v N FLANGE 1018344 Y 22 60 RING 1904 8 2 STRAINER 81479 RING M2693S 2 Mo A ASR PISTON 1019950 2 SEE NOTE 2 Ay m 7m 3777 SL ALIGN RING GAPS RING M2059L 2 SECONDARY SHAFT RING B1048BH 2 APART 4 a 1018472 nag Ed 2 K Ui y epe 22 20325 Ara 2 PLACES BEARING M201159 24 77
22. 1 51 1 RATIO 71T 1 51 1 RATIO 71T CONE AS V 5850 55 585 0 SECTION 4 4 COUPLING INPUTS CUP 590 CUP MASSOCE _ CUSTOMER NOTES GEAR 1018414 GEAR 1019081 SEE SHEET 2 B3504AU MASS ELASTIC CAPACITY OIL CAPACITY 41 6 L 1 19 1 RATIO 741 1 19 1 74T SCREW MA1052B 4 SYSTEM b THIS UNIT CAN NOT BE USED WITH GEAR 1018422 GEAR 1019083 GEAR 1018474 HEAT EXCHANGER A LEFT HAND ENGINE 0 89 1 64T 0 89 1 RATIO 647 EXE RIS B3649M REQUIREMENTS c OPTIONAL EQUIPMENT PAN ASS Y 1018351 GEAR RATIOS _ COMPANION FLANGE ASSEMBLY 1018682 PAN 1018350 7119 HYDRAULIC MANUAL TROLLING VALVE KIT 1017555 NUT 1054 4 DIAGRAM MAX INPUT SPEED 2 47 ELECTRIC TROLLING VALVE KIT 1017554 Ee E HANT d E FLEXIBLE COUPLING INPUTS SEE SHEET 4 _ CONSULT SALES DEPT APPLICATION mma KIT BOM K1195 METRIC TO NPTF ADAPTER KIT INTEGRAL HEAT EXCHANGER ENGINEERS FOR OTHER LIMITING SZ PROJECTION KIT BOM K1254 METRIC TO NPTF ADAPTER KIT REMOTE HEAT EXCHANGER CONDITIONS FRESH WATER OIL COOLER SEE SHEET 2 DITCH_PLATE FOR CUSTOMER SUPPLIED OIL COOLER SEE SHEET 2 MOUNTED TRAILING PUMP KIT 1018554 OIL TEMPERATURE INDICATING SM TCH B3424 FOR INSTALLATION tipos twp Reb ROME TANT ION ARD S 30418 USED IN LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 3 1 30353 10 5 04 1 0 1 PRA Pat
23. 2 ere 2415 350 10171298 7 x 20 6 2451 aeg 9485 eser ams 22222 meee Vic Led i Solaneo x ereden d 4118 1017133 1017134 B1337F 1018688 xwe7s9ri 1e voc 7072 427072 ae7o3 1725 eso 10171298 10 8 7 x 0 451 52 2 marosek 2 52025 559 horsogsac 4163 1017134 1018688 no 759 12 voc eroan eoo ceo 10171298 x _ 41171 1018688 759 24 voci a2703T 1725 250 1017129 7 x 20 6 24518 eea MG si70Dc 442758 101 0 4 4172 1018688 7 9 12 a2703T 1725 250 10171294 x 2451 85 5170 0708 689 41244 1018584 1018594 1174 1018688 759 12 voc 703 1725 lt 250 10171294 x 2451 455 7 2 2 7 2 540 04 118688 75 24 voo 725 50 1017129 x arcel ma
24. 41305 1017179 xwe7seri 1e 2707 2703 1860 270 1017129 1017554 1 2o ee 4 824518 h 51415 Pu 1018312 EESTI EE EU MEM egg a feet 1 1018688 5 707 270 2000 lt 290 10171298 1017554 20 69 4 24518 ELECTRIC CONTROL MODE SWITCH SCREW MA1052P 4 9 1017134 1018688 759 24 7 A2707AD 270 2000 lt 290 1017129 1017554 7 x 20 60 4 824518 CGLGSED WHEN MANUAL VALVE TORQUE TD 542 N n LT AG rx STEM IS LOCKED IN ELECTRIC 40 0 lbf ft NDTE MODE I 20 TOP VIEW _____ SECURE LEVER IN THE DEPRESSED CLIP CONNECTOR 1017322 lt 2 ptr EE dii I ELECTRIC CONTROL MODE POSITION Sed VADE 1 ana CN LEVER amp THREADED CONNECTOR SHROUD 1001825 ASSEMBLY SEE CHART 1018085x HOLE BEHIND PULL TIGHT TRIM CASSEMBLY 1018883 SHOWN END SHORT STRAP M2942B NOTE INSTALL USING MA908 LOCTITE 1018085 1 1 242 THREAD DOG POINT INTO DETENT GROOVE UNTIL SNUG 018085 1 2 TURN 101808540 018085 THESE SOLENOID CONNECTIONS
25. 7070 cleaner is recommended Tapered surface of shaft and matching tapered bore of hub must be completely free of grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance measurement of hub on shaft and adversely effect torque carrying capacity of the assembled joint Both parts must be at the same temperature Marine Transmission Service Manual 1019677 141 Assembly Twin Disc Incorporated 6 Seat hub onto the taper of the shaft using only the weight of the hub 7 Measure the distance from the coupling hub shoulder to the end of the primary shaft This distance is the advance and must be 3 56 mm to 5 64 mm 0 140 to 0 222 inch Note Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance Figure 98 Measuring Hub Advance 8 Install tool T 18050 784 onto the primary shaft to advance the hub onto the shaft Install tool T 18614 6 into the hub if necessary to clear the ram Connect the oil injection equipment to T 18614 6 or to hub 9 Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating surfaces 142 Marine Transmission S
26. Conditions where backdriving may occur The vessel is being towed One more of the engines on a multiple transmission vessel are shut down while under way Sailboat under sail with auxiliary engine is shut down The vessel is tied up or docked a heavy current The following solutions are applicable for all MG 6690SC and MG 6848SC series transmissions without the optional integral trailing pump if any of the above conditions are present Lock the propeller shaft to prevent rotation Install an electrically driven auxiliary oil lubrication pump into the transmission lubrication circuit Refer to the hydraulic system diagrams for details on auxiliary lube pump specifications for the specific transmission or contact a Twin Disc Authorized Distributor Marine Transmission Service Manual 1019677 Twin Disc Incorporated Introduction Ordering Parts and Obtaining Services replacement parts or products including hoses and fittings must be of Twin Disc origin or equal quality and otherwise identical with the components originally installed on the equipment Use of any other parts or products will void the warranty and may result in equipment malfunction or an accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distrib
27. KEEL COOLER WATER 46 C 60 C 115 F 140 F gt ENGINE JACKET WATER 74 C 85 C 165 F 185 F gt STATE MIN ALSO L min DF WATER F INSTALLATIUN amp SERVICE REQUIREMENTS OW NU DIL LINES TRANSMISSION TD AND RETURN 1 VELOCITY IN FITTINGS PIPE HOSE AND TUBES 7 6m s 5 2 BURST PRESSURE MIN 10 x PEAK DIL PRESSURE AT 3 HOSE SAE J517 100R1 MEETING USCG 46CFR 56 60 25 135 275 F TEMP RATING 4 PROTECT ES FROM MECHANICAL DAMAGE ZINC ANODES PROTEC LE RAW WATER PASSAGES FROM CORROSION CHECK amp REPLACE THEM FREQUENTLY CLOSED ENGINE JACKET WATER MAY IMPUSSIBI IMPRACTICAL TU HAVE HEAT EXCHANGER SUITABLE FUR MAINTAINING 85 183 F MPERATUR Figure 2 Heat Exchanger Specification Information 22 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Specifications Maximum operating speed Maximum oil sump temperature Description and Specifications 2500 rpm with ratios 3 21 1 through 2 47 1 2300 rpm with ratios 2 03 1 and less 85 C 185 F when using SAE 40 oil 93 C 200 F when using SAE 50 oil Oil type and viscosity See data plate below Oil capacity 41 6 liters 11 0 gal Approximate Dry weight 970 kg 2140 Ibs Oil pressur
28. MALIU HM ee d Marine Transmission Service Manual 1019677 Twin Disc Incorporated Trailing Pump Shaft Group N Qty Description Gear trailing pump driven Ring external retaining Key Bearing ball Ring internal retaining Gasket cover plate Bearing ball Shaft trailing pump drive Plate cover Washer flat Screw hex head cap cover plate Marine Transmission Service Manual 1019677 Illustrations 213 Illustrations Twin Disc Incorporated Trailing Pump optional equipment QU OQO AEN x DV NI NGA NIA KG 9 NOD mb fe SA ERN 6 Fitting elbow adapter Tube lubrication Fitting elbow adapter Screw hex head cap trailing pump Washer flat Pump trailing O ring suction strainer cover Cover suction strainer Strainer suction Plate clamp suction strainer cover Gasket trailing pump 214 Marine Transmission Service Manual 1019677 Illustrations Twin Disc Incorporated Notes
29. PICK UP PLATE 362 DIA x 88 THK DESCRIPTION STOCK SIZE 1016987 CLUTCH SHAFT mas es DETI UD 3 5 MOD 25 DETI NAME CLUTCH PICK UP FIXTURE stamp Too 18050 715 PART 01 121 530 SHEET 1 G 53 BREAK ALL SHARP CDRNERS 1016987 SHAFT T 18050 715 TOLERANCE UNLESS OTHERWISE SPECIFIED DN ACTIONAL AND PLACE 1 CAD FILE 18050 715 1 4 UN ANGULAR DIMENSION MARK 7 18050 723 FOR PART 38 DIA gt REQ D MA 628 BEARING SHAFT 1016987 UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP 1016987 SHAFT 2 GROUND SURFACES MUST 1017010 SHAFT PARALLEL WITHIN 0005 EACH WELDMENT 5 REQ D 1016993 GEAR SEE DEES us LL CARB amp HDN caps 4 75 THK 19944 GEAR amp an BODY 475 rem CAR 1016987 BEARING GENE DRIVER Lucem 11 8 oss 0 6980 loro 1016394 UDE TV BSc ING RACINE 18030 7 3 92 50 6 HOLES THRU EQUALLY SPACED LOCATION NOT CRITICAL 1 50 31 4 DRILL 5 16 THRU TAP 3 8 16 X 100 THD HOLES FOR LIFTING 42 191 212 INDUCTIUN FLAME RADIUS MAS90CD BEARING Pu MEM s 1 pur Teco 54973 TAPER IND
30. _ pert 6 45 SHCS X 1 2 THD LGTH 12 X 2 1 2 BALL BEARING PARALLEL 18 X 2 1 2 BALL BEARING PARALLEL SPACER PAD 7 32 X 1 X 1 2 55 BRACE X 1 2 X ve 48 x 2 1 2 x 1 8 we GEAR ASSY RAIL FUR SHEET 1 OF 1i 1018375 1 21528 DISC INC RACINE VIS 7 08 7 68 1 STAMP TOOL NUMBER ON TOOL 02 USE WITH T 18050 772 OR SIMILAR TOOL TERCER m sez pET REG DESCRIPTION STOCK SIZE senem y RR rene sene rt TL 14 BEARING DRIVER MG6650 MG6848 MG6690 vs NOUS wom bel www 1 2166 2 TWIN DISC INC BEARING DRIVER 7 T 21566 3 pET REG MAT DESCRIPTIUN STUCK SIZE 11 08 01 RTR FPN FULL LII __ LII __ _ __ Se LII __ ES LII LJ EE CERE 11 L t Bre xxxxx bp x bs 611 95 115 918 DESCRIPTIUN 0 06 X 45 9 50 MIN 60 THRU SIDE DNLY 2 00 THREAD LENGTH IN ZZZ 2222224 571555555 e ZZ Z ZZ 717777777 1 2 13 UNC SECTION A A 9 69 48 502 mn AUTOCAD FILE T 506000 DWG KNURL H
31. engaged within 21 kPa 3 psi 24 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Description and Specifications Optional Equipment The following optional equipment for use with the models MG 6690SC and MG 6848SC are available through the nearest authorized Twin Disc distributor Optional Trailing Pump An optional integral trailing pump is available It is identified as Twin Disc part number 1018554 An optional 115 vac electric powered remote trailing pump system is also available Twin Disc part number 1016473 Drawings are included in the Engineering Drawings Section of this manual Power Take off A live power take off pump mount is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 A hydraulically clutchable PTO is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 Metric to NPTF Adapter Kit Adapter kits are available to convert the oil drain plug opening the pressure test ports and the heat exchanger connections from metric to NPTF threads Kit K1195 is for units with an integral heat exchanger and kit K1254 is for units with a remote heat exchanger Torsional Input Coupling The CF R torsional input coupling is available in both SAE 0 and SAE 00 sizes Marine Transmission Service Manual 1019677 25 26 Description and Specifications Twin Disc Incorporated Trolling Valve Two types of trolling valves are available an electrically actuated tro
32. in Neutral and to main pressure when either clutch is engaged A shuttle ball connected to both clutch pressure ports permits pressurizing this passage with oil from the engaged clutch without allowing oil to flow to the disengaged clutch Figure 4 Location of Shuttle Ball The electric control valve can be used in a manual override mode in the event of an electrical power failure When the control valve is energized or shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively increases the clutch 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 1019677 35 Operation 36 Twin Disc Incorporated Control Valve Assembly in Neutral Some of the main pressure oil from the oil inlet chamber flows through a passage to the orifice in the orifice plate The small flow of oil through this orifice fills and begins to pressurize the rate of rise chamber Both clutches are connected to sump when the control valve is in Neutral Since there is no pressure acting
33. 1 1 8 1 125 DIA THRU 5 REQ D FOR ROD CLEARANCE DRILL 2 00 DIA 8 REG D EASIER LIFTING M12 x 175 THREAD 3 ROD 5 REG D MAT FIRM X FLAME AS SHOWN NOTE GROUND SURFACES MUST BE PARALLEL 1018363 WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BEARING ASS Y BREAK ALL SHARP CORNERS 2950 4 ___ ______ BEARING ASS Y E x 30 s stk Ro 1 8 THREAD x 525 16 s FLANGE NUT 776 6 THREAD s s Fre f 10 825 16 1 s soo 125 LII D 111 puare 70 x75 THK 1 WELDMENT ASS Y 1 REQ D e Date 10 22 98 1018372 SHAFT WELD NORMALIZE amp HARDEN BEARING DRIVER r CAD FILE 21506 Ss __ me 1721506 ND WELD FLASH ABOVE RAIL SURFACE MOUNT CROSS RAILS FLUSH WITH BOTTOM FOR WELDING WELD THESE TWO SIDES ONLY 2 00 MOUNT DET 5 AND 1 DET 6 EVENLY SPACED ON EACH DET 1 RAIL WELD ON INSIDE CORNERS ONLY 16 PLACES MOUNT PADS EVENLY SPACED EXACT LOCATION NOT CRITICAL BUT MUST NOT INTERFERE WITH BALLS DETS 5 amp 6 THICKNESS COMPENSATES FOR SLDP IN BALL BEARINGS MOUNTING DET S 45 amp 6 ON DET S 1 DET 5 amp 6 DETS 5 amp S jcHance
34. 1990 6 THESE SOLENOID CONNECTIONS A iW a 7 ARE POLARITY SENSITIVE WI 5 A 3 22702209 A VALVE GASKET 10171368 M N SS Ne RSI CONNECTOR SHROUD 1001434 D e NN DITCH PLATE GASKET p INN INN SEE CHART ie na RN AMY TRANSMISSION GASKET RING A2916FT 1 WL 7 LAN PLUG 1017389 x BALL MI990E SETSCREW 2870 0 RING A2916DK VALVE BODY ASSY 1018095 PIN 927 BALL 1034 SEAT 1017524 BALL MA1034D 2 e SPOOL 1017433 2 HYDRAULIC DIAGRAM A7119W SHEET 1 OF e THIRD ANGLE PROJECTION TE FOR PRODUCTION RVICE THESE PARTS ARE TO BE PACKAGED SEPARATELY AND SHIPPED WITH UNIT UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mn MACHINED DIMENSIONS Pese TUIN DISC INCORPORATED DETRIMENTAL TD THE INTERESTS OF 29694 1 22 99 x 23 30462 1 16 00 50 100 RACINE VI 53403 USA 5515 TWIN DISC INCORPORATED os 29515 302 RACINE 53403 USA GEDMETRIC TDLERANCING 1 0 1 8 0 8 4 THIS NOTICE IS INTENDED MIEL He 52 PER ANSI Y14 5M 1982 TO NULLIFY DR LIMIT RIGHTS RW SERIES GRANTED TD THE U S GOVERNMENT OR OTHERS BY CONTRACT ISURFACE TREATMENT VALVE CONTROL WITHOUT TROLLING VALVE APPD lol PLUG M2051K 2
35. 28585 6 3 98 10 eU EE FIRST USE 35 RACINE VI 53403 USA 2455255 sre cipes VIN DISC 4 menn P 29863 1 31 o0 B a 4 28315 1 21 98 THIS NOTICE 15 NOT INTENDED VARIOUS PER ANS vis 1982 1 1 7 5 E E e7 293s0 s 2 se A ALL 28208 11 26 97 pe VALVE ASS Y TROLLING ess cw ame ame cs wo pore OR OTHERS CONTRACT CONNECTOR SHROUD 1001426 CLIP CONNECTOR 1017322 FEMA VALVE 1017170 TORQUE TO 33 9 WHITE WIRE BLACK WIRE lt gt SECTION GASKET 1017334 VALVE CDVER ASSY 1017185 COVER 1017184 PLATE x BALL 1034 BOM NO 40537 GASKET 1017130 Mp TR THIRD ANGLE PLATE IS NOT INCLUDED IN PROJECTION ASSEMBLY USE PLATE FROM CONTROL VALVE PX 8671 Z NOT SERVICEABLE SEPARATELY Ae NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED DATE oe TIONS 1 29503 RACINE VI 53403 USA assy 1015207 52020 PER ANSI Y14 5M 1982 2 EAE 4 T 29350 6 24 99 novice 15 NOT INTENDED e 1 4 ez 28585 3 95 gR LIT RIGHTS pe VALVE ASS Y TROLLING zme cu wr awe zone pare OTHERS BY CONTRACT 1
36. CAD FILE 050 713 DRILL 21 32 66563 DIA THRU TOOL NUMBER T 1805 714 SHAFT NUMBER 1017000 374 10 UNC 0 REQ D MODEL NUMBER MG 5301 fase REWDRK NOTE SPOT WELD amp LOCATE SHLD ER EYE BOLT AS SHOWN DRILL 1 28 5002 DIA THRU 552 REQ D AS DIMENSIONED V UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF EACH OTHER ICE PLATE Cl dS ES REWORK JERGENS 18506 OR EQUIV 2 1 PUR JERGENS SHD ER EYE BOLT 3 4 10 unc MS amp HDN2 CARB amp HIND Sta Tm T 18050 714 SHAFT PICK UP FIXTURE 01 SHEET 1 1 MG 53 BREAK ALL SHARP CORNERS TOLERANCE UNLESS OTHERWISE SPECIFIED SORS rr el CAD FILE 050 714 CHANGE DESCRIPTION DATE TWIN DISC INC RACINE WIS 1 4 UN ANGULAR DIMENSION NOTE SPHT WELD amp LOCATE SHD ER EYE BOLT DRILL 27 64 4219 THRU TAP 172 13 UNC 12 REQ D WELD ROD TD DRILL 172 5002 DIA THRU PLATE AS SHOWN REQ D AS SHOWN STAMP EDGE ONLY DR BOTTOM STAMP TOOL NUMBER 18050 715 SHAFT NUMBER 1016987 MODEL NUMBER MG 5301 PUNE ESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS CLUTCH PLATE SEQ GROUND SURFACES MUST BEPARALLEL MAT M S CCAR BE amp HDN WITHIN 005 OF EACH OTHER BS a Re es JERGENS 18504 OR EQUIV 2 1 extension 50 x 425 LG 1 1 1 Ms
37. CRUISE MODE AT DETENT MIN TROLLING PRESSURE SECTION MAX TROLLING CAPSCREW M2000H 70 75 NUT M2027C TROLLING RANGE LEVER B2103 TROLLING PRESSURE TROLLING SETSCREW 2041 ADJUST SETSCREW SO THAT THE TORQUE REQUIRED ON STEM TO OVERCOME DETENT 15 1 1 1 7 10 15 Ibf in SPRING 10504 BALL M1990U e 0 RING A2916DD RING 29168 SHIM 2057 5 REQ D PIN PM 3036 M INSERT SPRING A2701BN OVER ROLLPIN PM 3036 M UNTIL FIRST SPRING REMAINS LOCATED AGAINST STEM FACE pi M p A ANS 4 277 in A T 67 1 S SPRING A2701BM 0 SPRING A2701BN 5 SECTION B B BOM NO 40588 M8 X 1 25 TH D 19 1 DEEP GASKET 1017553 2 HOLES METRIC PLATE 9 GREASE APPLICATION PROCEEDURE E THIRD ANGLE BEFORE INSTALLING VALVE STEM INTO BODY GASKET 1017130 PLATE IS NOT INCLUDED IN ASSEMBLY CONSISENG TO SIMILAR TD 6 USE EXISTING PLATE FROM CONTROL VALVE THE VALVE STEM FROM THE O RING GROOVE PX 8671 TO NECKED DOWN DIAMETER AT LEVER END bo dE 29117 2 4 99 NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT wee UNLESS OTHERWISE SPECIFIED TIN DISE __ _____ 4129015 12 17 98 USED IN ANY MANNER went MACHINED DIMENSIONS 2
38. Engaged 52 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance Lubrication Grease the oil seals on the output end of the output shaft through the grease fitting with water pump lithium soap based NLGI No 2 grease Apply grease every 100 hours or when the boat is docked No other lubrication is required beyond the daily oil check Oil System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil init 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 filter element after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the
39. F TWN DISC INCORPORATED NOT SERVICEABLE SEPERATELY J 30221 18 14 00 DOTENA RACINE W 53403 USA e 0 5 30202 7 10 00 1 1 29712 11 4 99 4 REMOVE BEFORE OPERATING 2 PLACES CLOSURES 6 20 01 3069 6 15 00 1 loal 29643 Leas sev zo oae OUS OTHERS BY CONTRACT MARINE TRANSMISSION 00 ON 056555 2272227227 4 2 5954 GASKET 81974 UM LN o OS x WASHER MA1039D 45 5 x e 9 5 NN SPRING A2706Z H 4 PLUG ASS Y 2080 PLUG RING 42916 FILTER HEAD 9892 RING 42916 SCREW MA960D WASHER M2081D ANODE 1017049 EXCHANGER 1017051 CLOSURE 2067 A GASKET 1017047 PLATE 2415 SCREW M422B 8 PLATE 204098C S LINK A2007 CHAIN 1072 CLIP M1763A FILL ENTIRE HDLE Q x 56 SCREW 9962 42 1019905 250506 5050505 255 555 ettet OS 55050 5050505 KAA 5 SRY 950505050606 505005050505 555525 LRN D 5 1 e eX OIL FILTER SCREW 996 14 HOUSING 1017125 PLATE 1017127 GASKET 1019905 PLUG MA1038A SCREW 1062 125 ELEMENT GROUP XM2934 POPPET 204
40. O ring M18x1 5 pressure test ports Manifold O ring primary shaft end cover Cover primary shaft end Screw hex head cap primary shaft end cover Plug O ring flange removal oil injection port Flange output Screw hex head cap output flange Washer retaining output flange Shim retaining washer 0 005 0 007 0 020 Seal output oil Shim bearing 0 005 0 007 0 020 Fitting grease Carrier output oil seal Screw hex head cap output seal carrier Washer flat O ring output s eal carrier Bearing tapered roller output shaft rear Plug O ring M33x2 oil drain Bearing tapered roller 211 Illustrations Torsional Input Coupling COUPLING SAE 0 Korres WML N R 4 RH Emin SERVICE REFERENCE 212 e SS mcs ZZZzzz pere S AED N Qty Description Coupling assembly SAE 0 Plug O ring coupling removal oil injection port Washer retaining Screw hex head cap coupling hub Element to service item 154 Coupling assembly SAE 0 Plug O ring coupling removal oil injection port Washer retaining Screw hex head cap coupling hub Element to service item 154 Twin Disc Incorporated CUUPLING 5 SAE 00 5 N
41. OR OTHERS bY CONTRACT TRAILING PUMP o gt pas ser A ev CENTER LABEL 1018729 100 REDUCE SHAFT SPEED IF EXCEEDED 100 C SINGLE PHASE CAPACITOR TYPE C THERMALLY PROTECTED DUAL VOLTAGE DUAL ROTATION 8 LEAD T Zu Te E DR REDUCE PROPELLER SHAFT RPM 222222222222222222222222222222222222224222222222222222222222222222222222222224 Zz HEAT EXCH FAN MAXIMUM TEMP SSSSSSSSSSSSSSSSSSSSS PART 1016473 ON RED PILOT LIGHT MOTOR NAMEPLATE LIT WHEN MOTOR IS OPERATING GAUGE REMOVE PLUG TO INSTALL 9379 Wee USTOMER SUPPLED PRESSURE ALARM SWITCI 13 8 41 4 kPa SETTING SEE TOP VIEW FOR LOCATION OL AIR HEAT EXCHANGER OIL OUT 1 2 14 N P T THREAD INSTALL PLUGS FOR SHIPPING FILTER REPLACEMENT ELEMENT FILTER PRODUCTS CORPORATION FPE 30 25N PARKER 925023 CROSS 119023 n IN LAR 3 4 NPT QUICK DISCONNECT INSTALL PLUGS FOR SHPPING OIL IN 3 4 14 N P T THREAD FEMALE PIPE SWIVEL PUMP FLOW RATE IS 110 l min 102 C 100 MESH INLET STRAINER REMOVABLE SCREEN M 1 R I C ANGLE O C mas REMOVE THIS ENDCAP TO EXTRACT SCREEN FOR CLEANING UG REMOVE TO CLEAN 65 POWER COR E S PRONG GROUNDING PLUG TWIN 1 DISC INCORPORATED 115 V 9 WRAPI THIS NOTICE IS NOT INTENDED FOR SHIPMENTS PED LIMIT RIGHTS rev 20
42. PRESSURE PICKUP PORT BALL M1990H 1 4 18 NP T F CDRYSEAL TH D PIN 1927 1017524 PASA ANS NS SPRING 42705 SPOOL 1017433 2 BALL M1990Y 5 SWITCH MA866A 2 APPLY MA895 SPREAD SEALANT NOTE INSTALL USING MA908 LOCTITE WITH TEFLON 95 THREADS TORQUE TO 30 0 lbf ft NUT M2027C SCREW MA1042A FLUSH WITH SURFACE HYDRAULIC DIAGRAM 7119 SHEET 1 DF e 40 7 N m SCREW M2000L SEE CHART FOR QUANTITY 1018883 TROLLING VALVE IS REQUIRED TO PROVIDE CLEARANCE ETRIC FROM THE HYDRAULIC PTO THIRD ANGLE PROJECTION A ATMOSPHERIC PRESSURE A NOT SERVICEABLE SEPARATELY TE PRESSURE LP INTERMEDIATE PRESSURE THESE PARTS ARE BE PACKAGED LEVER B2103A CLUTCH PRESSURE SEPARATELY AND SHIPPED WITH UNIT m UNLESS DTHERVISE SPECIFIED X s TH D 0 RING 1506149 MAIN PRESSURE DIL INLET WHEN INTERNALLY SUPPLIED THREAD SIZE AT PDRT o 1 4 18 N P T F WHEN 2052 REDUCER BUSHING IS SPECIFIED VIEW 4 8 1 5 3 30568 2 06 01 LR 5 30462 11 16 06 T Q 8 30 00 LP 3 30277 8 30 00 465 10 26 01 LN 6 6 30015 4 1e 00 0 7 49 6 20 01 zone zone 5 PRI
43. REEN Ly RANSMISSION IS LUBRICATED AND MAINTAINED AS N rue SERV MAN H Aat UN REQUEST REFER TU MARINE TRANSMISSION LATE SI WITH UNIT a BILL OF MATERIAL NO MUST BE GIVEN WHEN ORDERING PARTS VIN p usa Se Figure 1 Nameplate MG 6690SC MG 6848SC Marine Transmission Marine Transmission Service Manual 1019677 17 Description and Specifications Twin Disc Incorporated Power Ratings The MG 6690SC and MG 6848SC transmissions can be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation when viewing rear of engine This series of marine transmission cannot be driven by a left hand rotation engine Contact an authorized Twin Disc distributor for more information Transmission clutches are hydraulically applied using main oil pressure All bearings clutches and gears are lubricated and cooled with low pressure oil Always reference the Bill of Materials BOM or Specification number when ordering service parts 18 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Description and Specifications Construction Features Housings The MG 6690SC and MG 6848SC series transmissions have a one piece main housing Front housings in sizes SAE No 0 and SAE No 00 sizes are available A top cover bearing carri
44. Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Connect the oil injector to the output shaft Install tool T 20023 3 onto output shaft and gear Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating surfaces Advance gear to shaft shoulder stop with the portable press Figure 63 Advancing Output Gear 10 Release injection oil pressure between the mating surfaces and wait five minutes before lowering the press force and removing the assembly tool Remove the assembly tools from the output shaft and gear Confirm that the output gear has been advanced completely such that there is no gap between the shaft shoulder and the gear hub Marine Transmission Service Manual 1019677 109 Assembly Twin Disc Incorporated Installation of Output Shaft Bearings 1 Install the chilled output shaft front tapered roller bearing cup into the output bore of the transmission housing Seat bearing with tool T 21566 3 Figure 64 Output Bearing Cup Installed 110 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly 2 Install the two heated rear output shaft tapered roller bearing cones Install the large bearing first with the large O D of bearing to the rear Install the small bearing second with the small O D of bearing to the rear Press drive bearing cones to shaft shoulder using
45. arrangements must be made to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine can be raised by screwing down or lowered by backing off on the jacking screws to obtain the desired adjustment Steel plates must be inserted under the jacking screws so that the bolts will not damage the engine bed Lifting can also be accomplished by the use of chain hoists or properly placed jacks Adjustable shims also are available and can simplify the alignment process particularly for future realignment It may also be necessary to move the engine and transmission to one side or the other on the engine bed to obtain horizontal alignment This can be done with a jack placed horizontally between the engine and the foundation Atthe same time a straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE MALE FEMALE STRAIGHT EDGE Figure 118 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1019677 163 Installation Twin Disc Incorporated As the engine and marine transmission come into their aligned position it will be possible to mate the output flange and propeller coupling and prepare for bolting together Care should be taken not to burr or mar this connection because the fit is very cr
46. 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 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 98 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Cleaning and Inspection Gears Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the defect with a soft stone replace the gear Inspect gear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear Inspect thrust faces of gears for scores scratches and burrs you cannot remove these defects with a soft stone replace the gear Splined Parts Inspect splined parts for stripped twisted chip
47. cover and gasket and torque the attaching screws to 112 Nm 83 ft Ib Install protective plugs into cover to prevent the entrance of contaminants into the transmission s water circuit Install the M10x1 O ring water drain plug and torque to 25 Nm 18 ft Ib Units with Integral Raw Water Heat Exchanger Install stiffener plate and gasket Install two O rings into counterbores of stiffener plate Install heat exchanger element and cover gasket over adapter plate and O rings Install anode into cover with gasket screw and sealing washer torquing screw to 18 Nm 13 ft lb Fill the remaining threads in the anode below the screw with RTV silicone sealer Be sure sealer has proper curing time before exposing it to water Install heat exchanger cover and torque the attaching screws to 80 Nm 59 ft Ib Install protective plugs into cover to prevent the entrance of contaminants into the transmission s water circuit Install the M10x1 O ring water drain plug and torque to 25 Nm 18 ft lb Marine Transmission Service Manual 1019677 139 Assembly Twin Disc Incorporated Installation of Input Oil Seal Front Housing and Input Coupling 1 Apply a thin coat of M2828 anaerobic sealer to the OD of the oil seal and also to the housing input oil seal bore Install the input oil seal with the driver of tool T 18050 706 detail 2 Be sure to use the seal sleeve detail 1 to protect the input oil seal from being damaged by the primary shaft Remove any
48. cup driver Bearing cone driver primary and secondary shafts Seal protector plug driver Output seal driver Shaft lifting fixture output shaft Shaft lifting fixture primary and secondary shafts Bearing cone and transfer gear driver primary and secondary shafts Front output bearing cup driver Input hub advancement tool Adapter used with SKF pump Spring retainer compressor coil spring units Output gear installing fixture sheet 1 of 3 Output gear installing fixture sheet 2 of 3 175 Special Tools 20023 3 21433 21433 21433 21506 21528 21566 2 21566 3 T 506000 D D D D D D Twin Disc Incorporated Output gear installing fixture sheet 3 of 3 Output flange installing fixture sheet 1 of 3 Output flange installing fixture sheet 2 of 3 Output flange installing fixture sheet 3 of 3 Output shaft bearing driver sheet 1 of 2 only Gear assembly rail Output bearing driver Output bearing cup driver Lifting bracket for clutch removal in boat SPX Power Team RD1006 100 ton x 6 375 inch stroke double acting ram no drawing SPX Power Team RT1004 100 ton x 4 88 inch stroke ram or equivalent no drawing SPX Power Team RT172 17 5ton x 2 inch stroke ram or equivalent drawing SPX Power Team 554 electric over hydraulic pump no drawing Two SPX 9764 hoses no drawing Two SPX 9795 couplers no drawing 17
49. engagement Marine Transmission Service Manual 1019677 33 Operation Twin Disc Incorporated Hydraulic System with Electric Control Valve 34 The oil pump draws oil through the strainer from the oil sump and discharges it through the oil filter Filtered oil enters the control valve through the inlet port The incoming oil forces the pressure regulator piston against the springs to open the path to the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the heat exchanger to the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings There is a lubrication oil pressure relief valve to limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation The pressure in the rate of rise chamber is controlled by a ball that is spring loaded against the orifice plate The passage behind the ball and spring is connected to the sump atmosphere
50. is the front and the output side is the rear Left and right sides are determined by facing the output side of the transmission from the rear Identify and place the following bearing components in an oven at 120 C 250 F for 30 minutes output shaft tapered roller bearing cones output shaft front bearing inner race and the rear bearing cones for both clutch shafts Submerge all new friction clutch plates in transmission oil for a minimum of one hour prior to installation Identify and place the following bearing components in a deep freeze 51 C 60 F for at least two hours prior to assembly output shaft front bearing output shaft center tapered roller bearing cup all pinion bearing cups and both pinion inner needle roller bearings Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Preliminary Assembly 1 Lay the transmission on blocking with the rear side up 2 Install the seal protector into input shaft front bearing area using tool T 18050 712 Figure 54 Seal Protector Installation 3 Install the chilled cups for the primary and secondary front tapered roller bearings into their respective bores in the front inner face of the housing Use driver T 18050 711 to press drive cups to the bottom of the bore It is important to maintain downward force as temperatures equalize to ensure that cup is at bottom of bore Figure 55 Front Pinion Bearing Cup Installation Marine Transmis
51. lines and heat exchanger for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required 58 Marine Transmission Service Manual 1019677 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 The troubleshooting chart begins on the following page Marine Transmission Service Manual 1019677 59 Troubleshooting Table 9 Troubleshooting Chart Twin Disc Incorporated Symptom Cause o Remely 2 60 Low main oil pressure No oil pressure or erratic low pressure at control valve tap Partially clogged oil strainer Stuck pressure regulation piston Broken piston rings on clutch 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 p
52. of the bearing cup with an electric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced 11 Remove input oil seal Remove input oil seal protector plug only if replacement is necessary Marine Transmission Service Manual 1019677 75 Disassembly Twin Disc Incorporated Disassembly of Trailing Pump Drive Components 1 From inside the transmission remove the retaining ring from the gear end of the trailing pump shaft Figure 29 Removing External Retaining Ring 2 Remove the trailing pump driven gear and key from the trailing pump shaft Remove the trailing pump trailing pump cover if equipped and gasket from the transmission housing 4 Remove the internal retaining ring from the bore of the transmission housing Figure 30 Removing Internal Retaining Ring 76 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 5 Remove the trailing pump shaft assembly Figure 31 Removing Shaft Assembly 6 Press the bearings off of the trailing pump shaft only if replacement of parts is necessary Marine Transmission Service Manual 1019677 77 Disassembly Twin Disc Incorporated Disassembly of Primary and Secondary Clutch Shafts 1 Remove two piston rings from rear end of shaft Figure 32 Removing Piston Rings From Shaft 2 If rear bearing must be removed remove bearing retaining ring from rear end of shaft Remove
53. on the shuttle ball from either clutch the passage behind the ball and spring regulator is also connected to sump This allows the oil pressure in the rate of rise chamber to be regulated by the ball and spring since the overage oil can flow to sump The oil pressure in the rate of rise chamber acting on the rate of rise piston causes it to stroke over partially which compresses the pressure regulating springs additionally This additional spring compression further resists the movement of the pressure regulating piston resulting in a force balance between the area at the pressure regulator the springs and the area behind the rate of rise piston Neutral main pressure of approximately 40 psi is maintained by relieving excess oil behind the rate of rise piston through the ball and spring regulator T Ball and Spring Regulator Figure 5 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation Control Valve Assembly in Primary or Secondary Pressurized oil is directed to one of the transmission s clutches to engage it The pressurized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the passage to the opposite clutch The pressurized oil also forces the ball of the ball and spring regulator against its seat on the orifice plate stopping the flow of oil from the rate of rise chamber to sump Since oil continues to flow into the rate o
54. or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment Only a Twin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer a
55. shaft New screws must be installed if the old Screws were over torqued during the advancing process 12 Measure the distance from the output flange shoulder to the end of the output shaft Record this as dimension D Dimension D must be the same as dimension B minus dimension A within 0 05 mm 0 002 inch 13 Create a shim pack that is 0 05 mm to 0 15 mm 0 002 to 0 006 inch less than dimension D Install the shim pack and retainer washer onto the output shaft Install the screws and torque them to 112 Nm 83 ft lb Figure 94 Installing Output Flange Retainer Washer and Shims 136 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Attach dial indicator to housing with probe resting on face of output flange Locate indicator probe as close to O D of flange as possible Check flange face runout by rotating flange Total indicated runout must not exceed 0 10 mm 0 004 in Attach dial indicator to housing with probe resting on O D of output flange pilot Check pilot runout by rotating output flange Total indicated runout must not exceed 0 10 mm 0 004 in Note Should total dial indicator runout exceed 0 10 mm 0 004 in the flange must be removed and reinstalled on the shaft taper Install the O ring plug into the oil injection port of the output flange and torque to 16 Nm 12 ft lb Marine Transmission Service Manual 1019677 137 Assembly Twin Disc Incorporated Insta
56. sheet 1 of 4 Marine transmission sheet 2 of 4 Marine transmission sheet 3 of 4 Marine transmission sheet 4 of 4 Marine transmission Hydraulic diagram Control valve assembly without trolling valve Control valve assembly with trolling valve Valve assembly mechanical trolling Valve assembly electric trolling Integral trailing pump option Remote trailing pump assembly 219 Engineering Drawings Twin Disc Incorporated 220 Marine Transmission Service Manual 1019677 ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 5570 BREATHER B1251A NOTES 1 THRU 10 ARE IN S570AR SCREEN MA993 RING AZ916W THESE STANDARDS APPLY _ 5574 FASTENER TORQUE REQUIREMENTS SCREW MA960D 3 PLATE 2060676 20 S692 BEARING SHIMMING WASHER 20810 3 S765 TAPERED JOINT ASSEMBLY E E 9 PLATE 206063 18 5774 ANAEROBIC SEALANT APPLICATION 22 3 SCREW MA996Z 4 9 RING M2078CE 2 RETAINER 1019951 2 lt PLUG MA1038C PLATE 1017026 BACKPLATE 1020371 2 SPRING A2704CN 32 SEE NOTE 47 GASKET 1017035 BEARING 1019971 USED FOR 1020350 ASS Y USED FOR 1019086 ASS Y GASKET 1017028 cor asada nce USED FOR 1020350 ASS Y USED FOR 1019086 ASS Y GEAR 1016994 GEAR 1010085 COVER 1018598 GEAR 1016993 GEAR 1019104 RING M2693T 2 ADAPTER B1966A SPRING A2706AC SCREW MA996P 24 SEE NOTE 2 USED FOR 1020350 ASS Y USED FOR 1019086 ASS Y HOUSING 929 WASHER MA1039D 24
57. 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 1019677 Twin Disc Incorporated Preventative Maintenance Torsional Coupling Do not obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling The ambient temperature of the air around the coupling should be between 6 C 22 F and 80 C 176 F Assure baffles are installed properly so hot air is ported out of the housing Visually inspect the element after the first 100 hours of operation 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 Cracks in the surface of the rubber be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate or deterioration of the rubber to metal bond See above Deterioration of the rubber element as evidence
58. 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 bogy Marine Transmission Service Manual 1019677 145 Assembly Twin Disc Incorporated 6 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn Figure 102 Installing Dogpoint Setscrew 7 Install the steel detent ball into the valve 8 Install the detent spring over the detent ball 9 Apply 908 threadlocker to the threads of the hollow setscrew and install into the threaded hole A stepped Allen wrench or one wrapped with tape will ease the installation of the hollow setscrew Tighten the setscrew until itis flush with the gasket surface of the valve body Check the stem rotation and detent action Figure 103 Installing Detent Ball Setscrew 146 Marine Transmission Service Manual 1019677 Twin Disc Incorporated 10 11 12 13 14 Assembly Install the thrust washer over the end of the stem Press the oil seal into the cover assembly until flush with the adjacent cover surface Install the O ring into the counterbore in the cover assembly Apply grease to the stem O ring and oil seal lip Install cover assembly and gasket onto valve body Be sure to align the oil drain hole in the gas
59. with compressed air Do not spin unlubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently it is important to keep bearings clean Do not remove grease from new bearings Keep the wrapper on new bearings until they are installed Do not expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Sealed Joints For previously sealed joints scrape surfaces to remove old gasket material or silicone Clean surfaces with solvent to remove oil and grease residue Test clean surfaces by applying 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 1019677 Twin Disc Incorporated Inspection Cleaning and Inspection Housings Cast Parts and Machined Surfaces Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will cause loss of press of bearings or races Inspect oil passages fo
60. 0 124 in to 0 164 in for the primary shaft transfer gear and 2 67 mm to 3 71 mm 0 105 in to 0 146 in for the secondary shaft transfer gear If calculated advance is not within the range recheck all measurements and calculations for errors If no errors found contact the Product Service Department at Twin Disc Incorporated for information 3 Set transfer gear on fixture T 18050 723 with large diameter of tapered bore up Move fixture and transfer gear to a press with at least 667 kN 75 tons capacity 4 Install shaft front end up into tapered bore of transfer gear Seat shaft in tapered bore of gear by applying 445 N to 890 100 Ibs to 200 Ibs downward force on shaft Marine Transmission Service Manual 1019677 117 Assembly Twin Disc Incorporated 5 Center fixture gear and shaft under ram of press and apply approximately 391 kN to 596 kN 44 tons to 67 tons of force on front end of shaft Release pressure and turn fixture shaft and gear 180 Reapply pressure to complete advance 1 Figure 72 Pressing Clutch Shaft Into Transfer Gear 6 Using a depth micrometer measure distance from rear end of shaft to face of transfer gear Record as dimension C Transfer gear face should be within 0 05 mm 002 in of the shaft shoulder at the small diameter end of the taper Note Actual advance C B must be 3 15 mmto 4 17 mm 0 124 in to 0 164 in for the primary shaft transfer gear and 2 67 mm to 3 7
61. 00 10171294 x eo em 2451 ERE ME 46764 017363 wo 2 RWE7SFH 24 vac pm 8 EE aeo Dose Ars vx 096 1 18084 40817 1018688 no 759 24 7 7 ae707ap A2703AB 2000 lt 290 10171298 7 20 6 2451 wesesesc mer 69 1180840 40842 1017133 1017134 1337 1018688 kMe759rMe4 voc 7072 27072 703 1725 eso 10171298 7 20 2451 re HOMI OE Usa ims Imre 10779 vir AEN Aem men pasar crie amp Meessz 55 een 10180845 40954 1018584 1018594 3117 1018688 5 vnc xae7o7z 427072 7 725 eso torztea 2451 2 7 2 540 pere peor vod 2702 Bess peunsocoer x 206 sessi 8 we e ss eg oer vc fana Em pae nee a soane EE e eo 5 e 1 o 018084 40967 1017383 1017179 5 3 2759 24 voci ieee 3 e
62. 1 FILTER ee NE CIRCUI SHOWN DISENGAGED s a OC MM 5 aH VALVE 15 8 DIA MIN d REMDVE 1038 10 1 ree a 10 HOSE bg PLUG FROM MANIFOLD 25 MICRON EEN A A A ANA nS e cf aet AND INSTALL OPTIONAL 1 FULL FLOW TEMPERATURE INDICATING FILTER PLA RARE ETE 7 Er SWITCH HERE we E ls PORTION ENCLOSED WITHIN THESE LINES IS REQ D FOR FIETER gt PLECTRIS MOTER 2 OPTIONAL HYD P T O ONLY 25 41 L min ge ee s 19 0 DIA MIN Li I D HOSE Bae aise ede ae m Qo STRAINER 4 MA1040A DRAIN PLUG LOCATION M33 X 2 THREAD PER MARINE TRANSMISSION INSTALLATION AND ASSEMBLY DRAWING MG 6650 00 SC MG 6848 00 SC HYDRAULIC DIAGRAM GRAPHICAL J LC SYMBOLS 5 mew ANGLE 5 mew f L HYDRAULIC MARINE X CONTROL VALVE STRAINER PTD CONRTOL VALVE TRANSMISSION REGULATOR PRESSURE REGULATOR PRESSURE MG 6650 00 SC 2000 kPa 2000 kPa SUMP MG 6848 00 SC 2415 kPa 8415 kPo L uA PLUG FROM MANIFOLD i AND INSTALL OPTIONAL TEMPERATURE INDICATING 8 E SWITCH HERE DIL PUMP nx UNLESS DTHERWISE SPECIFIED DAT
63. 1 mm 0 105 in to 0 146 in for the secondary shaft transfer gear If transfer gear has not been advanced as specified above contact the Product Service Department at Twin Disc Incorporated for information 118 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly 7 Install heated tapered roller bearing cone onto shaft against clutch housing Install bearing with large O D toward transfer gear Use driver 18050 723 and hydraulic press to ensure bearing is fully seated against transfer gear 8 Install the external retaining ring onto the shaft with the tapered edge side away from the bearing Figure 73 Installing External Retaining Ring Marine Transmission Service Manual 1019677 119 Assembly 120 Assembly of Clutch Twin Disc Incorporated 1 Install clutch piston inner seal ring into groove in secondary shaft Apply a coat of assembly grease or oil to seal ring Install multi piece seal ring in groove in O D of clutch apply piston as follows A B Install the expander into the piston seal ring groove Install the first seal ring section into the groove over the expander ring Install the second seal ring section into the groove over the expander ring with the ends rotated 180 from the ends of the first seal ring Install the third seal ring section into the groove over the expander ring with the ends rotated 90 from the ends of the first seal ring Install the
64. 1019677 29 Description and Specifications Twin Disc Incorporated Table 8 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal men mm Diameter FOES porem Diameter or 5 or 5 Thread 11 5 8 5 3 8 M12X1 5 37 27 7 16 M14X1 5 47 35 1 2 M16X1 5 58 43 9 16 M18X1 5 74 55 5 8 M22X1 5 105 77 11 16 SON 179 132 3 4 M27X2 0 IN 85 63 718 M33X2 0 326 240 1 1 16 75 55 M42X2 0 347 256 1 3 16 88 65 M48X2 0 441 325 11A 88 65 15 16 108 80 1 3 8 108 80 1 5 8 135 100 178 162 120 2 1 2 312 230 30 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Clutch Plate Wear Limits Clutch steel plates Maximum cone 0 20 mm 0 008 inch Clutch friction plates Maximum cone 0 25 mm 0 010 inch Minimum thickness 3 48 mm 0 137 inch Marine Transmission Service Manual 1019677 Description and Specifications 31 Description and Specifications Twin Disc Incorporated 32 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation Operation General The control valve obtains primary neutral and secondary positions When these positions are selected the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate control piston within the control valve assembly provides a rapid smooth oil pressure increase in the hydraulic system during clutch
65. 20005 AS REQ D gt DITCH PLATE SEE CHART SCREW SEE CHART PORT LEVER PDSITION SCREW 1042 4 RING 2916 WASHER A2782AS senn SPRING 2705 MAIN PRESSURE PICKUP PORT 1 4 18 NP T F CDRYSEAL TH D SWITCH 866 2 APPLY 895 THREAD SEALANT WITH TEFLON 9 TO THREADS oe TU 300 lbf Ft NUT M2027C SCREW 1042 4 n SCREW M2000L 6 LEVER B2103A X STR TH D RING 1506149 MAIN PRESSURE DIL INLET WHEN NDT INTERNALLY SUPPLIED THREAD SIZE AT PDRT o 1 4 18 WHEN M20S2AA REDUCER BUSHING IS SPECIFIED VIEW CDNNECTDR SHRDUD 1001825 CLIP CONNECTOR 1017322 INSTALL USING MA908 LOCTITE 242 THREAD DOG POINT INTO 7 DITCH PLATE GASKET SOLENOID t ANSMISSION PISTON B1337F aces fest BOM DITCH ASS Y No No PLATE Ur ios iras 017179 e vi pem BALL M1990H BALL 1990 52 NOTE INSTALL USING 908 LOCTITE 242 gt DF SCREW MUST FLUSH WITH SURFACE ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE INTERMEDIATE PRESSURE CLUTCH PRESSURE 63 OOBSOLE AND SE ___ 54 5 9 76 3 3 00 LS 0 4 29757 12 1 99 Y 3 30568 2 06 01 NOTICE THIS PRINT CONTAINS PRO
66. 367 ING 204369 WASHER 2888 CLOSURE M2067 D A EXCHANGER 1017121 GASKET 1017126 GASKET 1017124 OPTIONAL FRESH WATER HEAT EXCHANGER SCREW 1062 12 PLATE 1017127 GASKET 1019905 CLOSURE M2067T 2 OPTIONAL DITCH PLATE FOR CUSTOMER SUPPLIED HEAT EXCHANGER WITH SILICON SEALANT ALLOW PROPER CURE TIME GASKET 1017050 A GAUGE B1703D SCREW 996 12 HDUSING 1017037 PLUG 1038 RING A2916W PLATE 1019906 1017569 PLATE 1017583 GASKET 1017613 SCREW 1062 2 SCREW 1062 22 VALVE ASS Y 1018084AD 350 psi 12 VDC VALVE ASS Y 1018084AE 350 psd 24 VDC SCREW 996 185 WASHER MA1039D 19 PLUG M2051FL NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 15 mE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA 25 SE P MODEL 6 a TS a ec MG 6690SC MG 6848SC CONTRACT MARINE TRANSMISSION pas GAUGE B3631AK EYEBOLT 1047 2 TAG 656 TUBE ASS Y XB2301D ADAPTER B2300 TUBE B2301D PLUG MA1038C 1035 PLUG MA1038C PLUG M20SIFL METRIC AN THIRD ANGLE PROJECTION 53 99 pe Az WATER OUT FROM HEAT EXCHANGER M42x2 0 THREAD METRIC PORT CONFORMS TO ISO 6149 REDUCTION GEAR SPEED PICK UP PORT M16 X 1 5 THREAD METRIC PORT CONFORMS WATER IN HEA
67. 6 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Special Tools Recommended Pump Set and Fluids Twin Disc recommends the 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 126 THAP 300 Air driven Pump Set Marine Transmission Service Manual 1019677 177 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 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 127 SKF LHMF 300 and LHDF 900 Note Order Through Your Local Authorized SKF Distributor 178 Marine Transmission Service Manual 1019677 2 940 3 720 DIA DIA MARK T 18050 705 BRG DRIVER 217 CAGED ROLLER F
68. 60606 255505505 77075767 52 592 5 5 z 2 50 50 50650 00 5 5 5 50 5 500 255 252505 Y RRR B RRS SSSR KEKE NBR SIA Mes DS 210 NO 5 J NU NG J MO Ww 6 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Item Qty Description Item 5 a Gear output Bearing roller output shaft front Shaft output Plug expansion Housing front Shaft assembly primary Seal input oil Plug seal protector Housing assembly Screw hex head cap SAE 0 front housing Screw hex head cap SAE 00 front housing Washer flat Screw hex head cap top cover Cover assembly top Gasket top cover Baffle assembly Nut caged Screw hex head cap baffle Washer sealing O ring breather cap Screen oil filler Plate cover PTO vale location Screw hex head cap PTO valve cover Gasket PTO valve cover Marine Transmission Service Manual 1019677 Qty gt 20 20 gt gt Illustrations Description Gear transfer primary shaft RH helix Plug
69. 77 Twin Disc Incorporated Disassembly 6 Remove the detent setscrew spring and detent ball Figure 48 Removing Detent Setscrew left and Detent Spring and Ball right ra Remove the dog point setscrew from the valve bogy Figure 49 Removing Dogpoint Setscrew Marine Transmission Service Manual 1019677 91 Disassembly Twin Disc Incorporated 8 Slide the stem and adapter out of the valve body together as one piece Push the stem out of the adapter such that the spring end of the stem exits the adapter first Note that the inner spring will come out with the stem Figure 50 Removing Stem and Adapter from Valve Body left and Removing Stem from Adapter right 9 Remove the O ring from the groove in the end of the stem Figure 51 Removing O ring from Stem 92 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 10 Remove the inner spring and roll pin from the stem only if replacement of parts is necessary 11 Remove the washer from the bore of the valve body some models Note the washer may have been removed with the stem 12 Removethe outer spring and piston from the bore of the valve Note that there may be washer s in the bore of the piston some models Figure 52 Removing Spring and Piston from Valve Body Marine Transmission Service Manual 1019677 93 Disassembly Twin Disc Incorporated 13 Remove the O ring from the groove and the
70. AD FILE 1 19550 A 5 375 X WAS 525 9882 A2708AM SPRING 2 POSITION DESCRIPTION DATE TWIN DISC INC RACINE WIS 19550 TOP HYD HOSE LOCATION LN PARTIAL VEIW 1 KA SPACER SHAFT 15 REQ D MS HDN 45 49 Rod LA AZ ZZ P LE 42 f OUTPUT SHAFT 101 000 EARN TEAM DOUBLE ACTING RAM 100 TONS 6 625 STROKE MODEL RD 1006 13 782 LONG SSS See GEAR SHAFT PULLER NOTE REF THIS DRWG FROM 20023 MG 5301 wc 6650 amp 13 14 apo 77 8 e FIRST USED UN 62516 bme xm 1 20023 3 Wie Jalal ei s DRILL 7 2010 DIA x 1 00 DP DRILL THRU amp C BDRE FDR 1 4 80 UNC x 88 DP 162 REQ D DRILL 49 64 7656 DIA x 175 DEEP LOCATED AS SHOWN FOR TAP 7 8 9 UNC x 147 DEEP DET 12 GRD 8 2 000 DIA 8 REQ D FOR RODS 5 amp amp 4 906 DIA DRILL 27 64 4219 DIA 2 138 1 1 2313 UNC x 125 DEEP i TYPICAL KEY SLOT 8 REQ D RADIAL LOCATION 180 USED FOR LIFTING SPLIT CENTERED 1 38 TYPO STAMP T 20023 3 DET 1 DRILL 27 64 4019 DIA THRU TAP 1 2 13 UNC 1 R
71. ANDLE 913 mm 2 NOTE HOLD DRILLED C BORED AND OR TAPPED HOLES 005 NOTE LIFTING CAPACITY 325 POUNDS L3 1 fixem mensem 4 Ls xim 5 jeesxzsvuixus 1 ve mewe Ls smxes es 5 Jeexesx oom ma x esm oom ma ____ 25 Scole 1 1 mps P amp S SHAFT LIFTING DEVICE DO IN BDAT CLUTCH REPAIR rem bist ane 11 206000 Twin Disc Incorporated Illustrations Illustrations List of Illustrations The following pages include illustrations that are specific to these models The illustrations included are listed below Note Any part numbers listed in the following illustrations are for reference only Please refer to your bill of material for part numbers specific to your model Clutch Group Oil Filter Optional Heat Exchangers Transmission Rear View Transmission Section View Torsional Input Coupling Trailing Pump Shaft Group Trailing Pump optional equipment Electric Control Valve BB OC B Trolling Valve optional equipment Marine Transmission Service Manual 1019677 203 Illustrations Twin Disc Incorporated Clutch Group rm tr
72. Clean tapered surface of output shaft and tapered bore of output flange Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Do not touch cleaned surfaces Loctite amp 7070 cleaner is recommended CAUTION Tapered surface of shaft and matching tapered bore of flange must completely free of grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance measurement of flange on shaft and adversely effect torque carrying capacity of the assembled joint Both parts must be at the same temperature 2 Measure the length of the tapered bore of the output flange using a depth micrometer The flange must be placed on a flat surface and the length being measured is to the inner shoulder of output flange Record this distance as dimension A Figure 90 Measuring Output Flange Bore Length Marine Transmission Service Manual 1019677 133 Assembly Twin Disc Incorporated 3 With a depth micrometer measure the output shaft height This is the distance from the end of the output shaft down to the rear tapered roller bearing cone Record this distance as dimension B Figure 91 Measuring From Output Shaft Height 4 Seat flange onto the taper of the shaft using only the weight of the flange 5 With depth micrometer measure distance from inner shoulder of output flange to end of output shaft Record this distance as dimension Figure 92 M
73. D 57 Ww amp OPTIONAL DITC PLA lt CUSTOMER SUPPLIED Gasket adapter plate mounting Screw socket head cap Plate adapter Closure oil ports 2 Screw socket head cap Plug O ring water drain Gasket adapter plate mounting Housing heat exchanger Plate adapter Screw hex head cap Closure water ports Exchanger heat exchanger element Gasket heat exchanger housing Gasket heat exchanger element 1 1 1 1 1 14 2 1 1 1 Marine Transmission Service Manual 1019677 Illustrations 207 Illustrations Transmission Rear View D gt D P ND M WE t 4 4 y A Twin Disc Incorporated 208 Marine Transmission Service Manual 1019677 2296101 uoissiusueJ SUMEN 605 Item Description Item Description Capscrew hex head manifold Pin dowel manifold amp bearing carrier Plug O ring M16x1 5 speed ports Washer flat Control valve assembly Adapter plate gaskets and screws electric control val
74. E E cde fee 1 TT T _ TJIN 5086 REP FOR HYDRAULIC EE SELLOS i Rr pe DIAGRAM DF CONTROL VALVE Lb o Fc esespea39 TIN isc 97744 kssr 1016375 t ie s E un E y RACINE WI 53403 USA t 9500 7119 MG 6650 00 SC MG 6848 00 SC 29090 eso THIS NOTICE IS INTENDED NAME HYDRAULIC DIAGRAM 2 3 28871 10 13 98 TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT PICTORIAL GRANTED THE US GOVERNMENT DIAGRAM HYDRAULIC APPD ev zme cu zoe cu no mare OR OTHERS BY CONTRACT L m i kv B WIRING DIAGRAM CONNECTOR MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL 0 A PORT SOLENOID PORT SOLENOID PLUG M2051K 2 NEUTRAL SOLENOID gt OPTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH ELECTRIC CONTROL MODE SWITCH lt CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE I 20 SCREW MA1052P 4 TORQUE 54 2 N m 400 lbf Ft NOTE SECURE LEVER IN THE DEPRESSED ELECTRIC CONTROL MODE POSITION BY LOOPING PLASTIC STRAP THRU 1 4 HOLE IN LEVER amp
75. EQ D DRILL THRU amp C BORE FOR 3 4 SOC HD CAP SCREW 4 REG D TO MOUNT TOP PLATE TO RAM 1 COLLAR 45 REQ D STAMP 20023 3 4140 45 49 Rc DET 8 TOP PLATE D REQ D MS 45 49 Rod STAMP 20023 3 BOTH DET S 3 amp 4 U CUT TYP BOTH DETS 3 amp 4 ROD 42 REQ D MAT 4140 45 49 STAMP 20023 3 DET 3 7 8 9 UNC TYP BOTH RODS DIM 35 81 FOR 5301 ENDS AS SHDVN 29 00 FOR 5301 DRILL THRU LA BORE AS SHOWN A 37 02 FOR MG 6650 SC 960 DI S SPACER 8 REG D BY 30 21 FOR MG 6650 SC MAT 4140 52 59 o 2 e 4 4140 ROD 45 49 RO 100 DIA x 37 25 LG 4 a140 op 45 49 Ro 100 x 3725 LG sm soc wm cap screw s 9 16 x 250 460 COLLAR HDN 45 49 Rc 1804 x 325 THK RUD 4 REQ D STAMP T 20023 3 DET 4 He PLATE HON 45 49 MAT 4140 HDN 45 49 Rc so RID 45 49 RO x 3600 LG 4140 HDN 45 49 RO 14 HDN 45 49 RO 104 DIA x 3600 LG 2 DIM 3581 MG 5301 EE 1 17 e L L 1 DUTPUT GEAR SHAFT PULLER Seer 2 3 O DIM 37 02 FOR MG 6650 SC NOTE GROUND SURFACE
76. ES WERE M 1945 BY WITH PLUG DRIVER our GROUND SURFACES MUST BE PARALLEL WITHIN 005 EACH UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CDRNERS 2 1 RoD HANDLE __________ 100 DIA x 2025 LG a 1 MS PLATE CARB amp HDN 625 DIA x 75 THK DESCRIPTIDN STOCK SIZE a Eee NAME C E 06 DRIVER TOLERANCE UNLESS OTHERWISE SPECIFIED 5301 JM DM FRACTIONAL AND TWO PLACE SE CORE PLUG M 1945BY ME a CAD FILE T 18050 712 dwg 06 45 2 0 31 105 REF 2 U CUT DIA 9 990 12 x 15 d SEAL DRIVER D DUTY DRIVER MAT MS CARB amp PRESS SEAL INTO CARRIER WITH SEAL DRIVER FLANGE DOWN INSERT THIS SEAL FIRST AS SHOWN 1017019 CARRIER 1 7 DITE TOOL NUMBER 1518050713 CARRIER NUMBER 107019 SEAL NUMBER 1017085 MODEL NUMBER MG 5301 ge N a 1 FLANGE UP PRESS 1017085 SEAL 111 i FLANGE DOWN PRESS IN FIRST SEAL IN SECOND SEAL UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF EACH OTHER ibt ans i m 188 VAL ETE BSCHPTUN sac 3 1017019 CARRIER DRIVER ws eene DISC INC RACINE VIS T 18050 713
77. EX BUSHING 1 bur i e THREADED INSER s 1 1 x 16 3 4 mock exexe DETIREQI DESCRIPTION 512 fieteszass pem ME BEARING DRIVER FOR CUP Jm ser 1 w MG 930l O O re WE MG 5301 T 18050 771 rev marc sv TWIN DISC ING RACINE 172 Dx22mmIDx25THK 85 30 SE SPARE B1504KY M20x2 5 SP Smm 50 CAN AL 2 50 WASHER 8 MG6848 amp MG669 4 1 5 17 5t RAM THAN 20 IONS HUB ONIO PRIMARY SHAFT DO APPLY ADVANC CAN USE T TO614 0 LO HELP NOTE SKF INJECTOR CLEAR HYD RAM B1504KY WASHER N B T em sr cil pd AUTOCAD FILE T 18050 784 DRILL 2 75MM 0 108 THRU DRILL 11 445MM 60 451 HOLE X 19 0 05 0 95 0 10 gt DEEP TAP 1 4 19 BSPP TAP X 17MM 0 67 MIN DEEP 0 88 NOTE TAP TO BOTTOM BY HAND FOR BALL TO SEAT PROPERLY R0 06 FOR BALL THD RELIEF 1 4 19 BSPP THD SECTIUN STAMP 18614 6 516 4140 amp DRAW 102 4140 Pressure Extension Tube 1 125 DIA x 5 5 MAX MATERIAL Date 10 29 99 By AF Scale FULL Sue TOL
78. GASKET 1018387 PINION ASS Y 1018420 2 PINION ASSY 10 1019107 2 CARRIER 1018386 1017007 28T 3 21 1 RATIO 28T GASKET 1018388 PINION ASS Y 1018403 2 PINION ASS Y 1019077 2 1018402 GEAR 1019076 MANIFOLD ASS Y 1018396A GEAR 1018 222222222 MANIFOLD 1018395 2 HUB 1017007 2 1017007 SCREW M2020AD 2 INSERT MA1064C 4 2 93 1 RATIO 50 GASKET 1017589A f Ko PLUG MA1038D 4 PINION ASS Y 1018416 2 PINON 557 1019102 2 GASKET 101 508 PART NUMBERS FOR 017007 1017007 PILOT 1020007 INPUT OPTIONS SHIM 1017041 As Rego 2 47 1 2 47 1 RATIO 34T L 7 4 SEE NOTE 4 L YY lt b PUMP 1017584 SHIM 1017043 PINION ASSY 1018417 2 PINION ASS Y 1019080 2 S 2 NS d Qe 1 GEAR 1018412 7 NN VLDE SPACER 1017046 2 gt HUB 1017007 1017007 BEARING 1017081 2 2 03 2 05 1 RATIO 39T b BALL MA1034C SCREW MA960E 2 WASHER MA1039A 2 SF ASSEMBLE INION_ASS Y 1018418 2 lt SIDE AWAY FROM BEARING ASS 19 Coe Z HUB HUB 1017007 t PLATE 1015518 51 51 1 RATIO 47T Ve aw Z N 2 7 A RING M1904L 4 GEAR 1018415 2 GEAR 1019082 2 RATIO BS 1 19 1 RATIO 249 2 4 SCREW 996 4 AA SEAL MA297 zi
79. Heavy Strap Restraining Output Shaft Always use retainer bolts or a safety strap to hold parts being separated with oil pressure Oil pressure applied between the two parts for disassembly can reach 300Mpa 43500psi The use of proper safety equipment is mandatory when working with high pressure hydraulic tools The parts may separate with extreme force 6 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature dismounting fluid into the output shaft until the shaft and gear separate Note Use caution to prevent damaging the taper of the output gear or shaft as the torque capacity can be reduced Lift the output shaft out of the transmission using tool T 18050 714 Remove the inner race of the front output shaft bearing and tapered roller bearing cones from the output shaft only if replacement is required Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 8 Remove output gear assembly from transmission housing Tool T 21528 can be used to ease removal of gear from housing Figure 28 Removing Output Gear Assembly 9 Remove the trailing pump drive gear from the output gear 10 Tapered roller bearing cups for front bearings on primary pinion secondary pinion and output shaft are an interference fit in their respective bearing bores of the transmission housing Remove these parts only if replacement is required To remove these bearing cups weld a light bead around the 1 0
80. ITION 44 5 5 PA POSITION 1 AA 54 lt oo VALVE THESE SOLENOID CONNECTIONS SEAL MA778 4 ARE NOT POLARITY SENSITIVE SS BLACK WIRE zm N ibo 6 SNK ZZ 07 6 X 2 LA V c 24 VAN 27 ZZA amp A 7 7 2 SEES 2 2 70 72 N TROLLING VALVE ASSEMBLY SEE CHART CASSEMBLY 1017554 SHOWN L Ix 17 ZZ e AZ V ERE ZZ ZZ 5 WLLL 2729 72 SS STEM 10191638 SS 7 D RING MA379CP 9 cil tJ 737 D RING 2916 774 m SNAP RING 29155 m 7 0 PLUG 1017389 PORT SCREW 1042 4 lt i SHIM SEE CHART C C PDSITION TRANSMISSIUN GASKET PLATE SEE CHART SPRING 1801 SEE CHART D BALL MI990H SETSCREW A2870K 0 RING A2916DK DITCH PEATE GASKET SEE CHAR RING A2916AT WASHER A2782AS SPRING 2702 SHIM 1020005 5 VALVE BODY ASSY 1018095 DITCH PLATE SEE CHART A BODY 2 1018094 SEE CHART BALL 1034 BALL MA1034D 2 MAIN
81. LIUTPUT FLANGE FIXTURE CHANGE DET 5 REWORKED 2 21 97 JPL FOR SHEET 1 F 3 SHT 3 ADDED 5301 DESCRIPTION TWIN DISC INC RACINE WIS 1433 CAD FILE 2 495 DIA 1740 1 1016523 HSG 1017000 SHAFT DUTPUT 1017009 FLANGE 0 926 2 1 498 6 63 2 010 DIA 2 503 DIA 2 508 DIA S PULLER BASE 1 FILE MAT 21433 1 M S HDN 45 49 2 00 4 1 2 UNC 2A THREADS TO BE GROUND AFTER HEAT TREAT 1250 HEX FLATS CENTERED BELL CENTER ENDS PULLER ROD 1D REQ D SAE 4340 H AIRCRAFT QUILITY HEAT TREATMENT HARDEN amp TEMPER Rc 44 48 CHECK HARDNESS DN 2 000 DIA ONLY DO NOT TOUCH THREADS INSPECTION CHECK ALL SURFACES WITH MAGNIFLO EQUIPMENT DRILL 5 16 63185 DIA x Leo DEEP 3 8 16 x 1 00 DEEP REQ D DRILL 31 64 64844 DIA THRU 23 32 7187 DIA x 94 DP 552 REQ D FOR 175 BOLTS DRILL 5 16 63125 DIA x 125 DEEP 1 PUSHER PLATE lt 1 378 16 100 DEEP 2 REQ D MS 45 49 o hasson Porce RO 25 LG EM DETIREQ DESCRIPTIDN STOCK SIZE NOTE UNLESS OTHERWISE SPECIFIED ALL GRD DIA S amp SURFACES MUST
82. NT CDNTAINS NOT USED IN NNER DETRIMENTAL TD THE INTERESTS TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT WEIGHT ko FIRST USE 55 1015207 MG S202DC VALVE ASS Y DIMENSIONS ARI MACHINED DIMENSIONS ALL ANGULAR TOLERANCES 21 GEDMETRIC TOLERANCING PER ANSI Y14 5M 1982 CONTROL WITH TROLLING VALVE APPD SHEET 1 OF A TUIN DIS INCORPORATE RACINE WI 53403 USA 1018085 SERIES INSTALLATION NOTE 0 6 0 9N 5 5 8 3 Ib AT THE 46 0 1 81 LOCATION OF THE 6 4 1 4 DIA HOLE IS REQUIRED CAPSCREW 10428 2 TO OVERCOME DETENT REMOTE CONTROL ACTUATOR MUST PROVIDE 65 0 mm 2 56 TOTAL LINEAR TRAVEL AT THE 6 4 1 4 DIA HOLE LOCATION 9 STEM 1017901 SEAL 5591 ADAPTER 1017530 F d 22 SETSCREW MA1037D SCREW IN UNTIL POINT 5 THEN LOOSEN E 1 2 TURN BALL STOP IN NO TROLL POSITION PISTON P 10491 THE 90 LEVER ROTATION REQUIRED FOR CONTROL MAY FALL ANYWHERE WITHIN THE 360 IN WHICH THE LEVER MAY BE CLAMPED PROVIDED CLEARANCE EXISTS FOR FULL 90 OF TRAVEL NNN CA S A i 2 WN VALVE BODY 1017529 VA LLL 6 4 9 THRU ONE HOLE 2 INSTALL USING MA908 LOCTITE 242
83. Nor T 186146 PARALLELISM TION s T RFS REGARDLESS o PERPENDICULARITY REGARDLESS OF BREAK ALL SHARP CORNERS CONCENTRICITY NAME Adapter OTHERWISE SPECIFIED SYMBOL ME Used w SKF Pump i CIRCULAR RUNOUT DATUM FEATURE AUTOCAD FILE 1 18614 6 3 010 ON FRACTIONAL J AND TWO 27 TOTAL RUNOUT aoe on M MG516 SHEET 1 OF 1 4 001 ON THREE PLACE DECIMAL DIMENSION Various 1 4 by ANGULAR DIMENSION POSITION 9 DIAMETER Fe 18614 6 STAMP 19330 MG 540 X 9882 A SPRING A2708AM STAMP T 19330 DET X 9882 A 20 27 THRU MG 540 SPRING A2708 AM 0 58 C SINK 82 3 PLCS 20 27 THRU 1156 2 58 BC SINK 82 3 PLCS e71 871 1 8 CLEAN UP CLEAN UP RING PLATE 1 4 80 THD X 8 DEEP 02 PLCS 4 6 stk FLAT SCR ____ 1 4 20 THD 1 C 3 3 Ms SUPPORT BARS 93 4 X 20 1 PLCS SOLID END PLATE 975 X 5 SYMBOL CHARACTERISTIC SYMBOL MODIFIER 1 1 RING PLATE 75 5 PLATE 97 5 X 5 7 MO OBE SHES 0 b W SCHEEL Scole HALF PARALLELISM CONDITION SPRING DE COMPRESSER e elisa d UPDATED PRINT TOOL ADD 3 amp 4 CORNERS SYMBOL NAME 20 SE SP B DRAWING RTR FOR SHEET OF 1 0 FOUR JENSI CIRCULAR RUNOUT t ier PAGE DENA DATUM FEATURE AUTOC
84. OR 217 BEARING CAGED ROLLER 1017005 GEAR 1 BEARING DRIVER D MS CARB UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS P GROUND SURFACES MUST BE PARALLEL Li r ws sewuws peiver se 275 A BEARING DRIVER CAGED ROLLER TOLERANCE UNLESS DTHERWISE SPECIFIED 06 217 BRG 718050705 001 DN THREE PLACE DECIMAL DIMENSION va CAD FILE T 18050 705 dwg GRIND 62 FLATS UP WIDE TO INSTALL i DIA THRU SEAL EASIER WITH OIL CDREQ D DRILL 5716 3125 DIA THRU D REQ D TAP 3 8 16 UNC USE FOR PULLING KNURL SEAL MA 297 DIA SHAFT 1016987 SHAFT 25577 3 004 DIA 3 002 Epp p Exi 3 064 DIA 3 062 NYL Date 11 18 96 JPL FPN Scoate FULL sue mo T 18050 706 _ scu 0 SEAL DRIVER amp SLEEVE dede OC o T T aeae C 001 DN THREE PLACE DECIMAL DIMENSION 010 ON FRACTIONAL AND TWO PLACE 297 A BIER DATE Twin BC ence wi 0090 706 T 18050 708BRG DRIVER STAMP T FOR 1017005 PINION BEARING CUP 590 CUST 47679 4e X 15 456 DIA e BEARING DRIVER 1 PEO D MAT x HD x NOTE GROUND SURFACES MUST BE PARALLEL E seems eem SEGA 1a MAT DESCRIPTION STOCK SIZE
85. PLIED GAUGE AND EE SHAFT LLLA gt LINE HERE SUUM ENGAGED A E ny MAPA RARE L Om Gi S 2 BON AZ TROLLING VALVE 7 lz B OPTIONAL TROLLING VALVE 22 WS P T O LUBE KKK 2 EX ee QY EP E OPTIONAL AUXILIARY LUBE SYSTEM USER SS ONERE CERERI Ere SUPPLY COMPONENTS AND INSTALL SS i LUBE HDSES MEET REQUIREMENTS 1 1 SAE J517 FOR 10081 HOSE SELF lt lt lt RKQQ yy l EXTINGUISHING FIRE RESISTANT REQUIREMENTS ALSO IDENTIFICATION Y REQUIRED BY THE US COAST GUARD DIS ENG AS SPECIFIED CODE OF FEDERAL S pn 4 DISENGAGED REGULATIONS 46 CFR 56 60 25 lt RE LLL SESS SSS qu li AUAM emm m ZAI H UB REMOVE MAI038C 6 X 15 a o d BER NE V LUBE mi VALVE West INSTALLATION DRAWING AND 22 620 NS INSTALL LUBE LINE DIRECT LUBE FLOW INTO TRANSMISSION HYDRAULIC SHAFT
86. PRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER AME SPRINGS ER _ CONSISTS A NOT SERVICEABLE SEPARATELY me 2 27 S202DC ______ BUTCH ORIFICE T 1725 eso 10171298 1038 927 x 20 oe 2415 350 MA1038E Me7 X 2 0 6H B2451B 1 Moos 1 eoesr 3 3575 en ne eer t venesr eoesac e 707 2 707 27 1380 200 1017129 1535 45 lt 1 Meosor 3 6 4 2 2 ma su el e 2 we sm A2703T 2000 290 10171298 7 824518 0 Ma1062B 2 1062 we sem pmrsss ives ines a APR v panen cwm 40762 10171334 1017134 1337 1017179 759 24 voc 87070 1585 230 10171294 1038 2 x 20 69 24518 mas eh 40763 1017133 1017134 B1337F 1017179 No e _ ___ 2707 0 585 lt 3
87. Piston d Remove piston ring from ring groove in shaft seals of clutch piston and multi piece piston ring from ring groove in O D of clutch piston Note Do not separate clutch housing transfer gear from the secondary shaft unless the shaft or the clutch housing must be replaced and the mating part remains serviceable Use the following procedure to separate the housing transfer gear from the primary or secondary shaft 9 To remove clutch housing place shaft and clutch housing on a press front end of shaft down Place a sleeve over input front end of shaft with an 1 0 only slightly larger than the O D of the shaft taper large end 101 6mm 4 00 in Rest one end of sleeve on a heavy wood block while the other end supports the inner face of the clutch housing Apply press force to rear end of shaft to separate shaft from clutch housing The shaft must be protected and restrained to prevent damage as the tapered joint separates 82 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly Disassembly of Selector Valve Electric Valve CAUTION Steel ball is under pressure from the spring Care must 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 37 Removing Orifice Plate Cover Gasket 2 Remove orifice plate 3 Remove steel ball and neutral
88. S MUST PARALLEL NOTE UNLESS OTHERWISE SPECIFIED 960 WAS 100 DIA 7 3 98 5301 amp MG 6650 SEET 8 OF 3 WITHIN 0005 OF EACH OTHER BREAK ALL SHARP CORNERS sca 7 5 5301 66 T 2000353 AUTOCAD FILE T20023 3A SS 100 TONS 6 625 STROKE WH MODEL RD 1006 13 782 LONG PUWER TEAM DOUBLE ACTING RETRACTED LENGTH PRESS RAM DRILL 5 16 3125 DIA 125 DP 3 8 16 x 100 DP REQ D 180 USE FOR LIFTING 2 44 MID STROKE NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE ALL GRD DIA S amp SURFACES MUST SQUARE amp CONCENTRIC TO WITHIN 005 OF EACH OTHER 06 TYP SEE SHI 3 LATEST REVISION O 3 8 1 5 Pusher J ______ 7 1 ms WASHER cams 488 56 THICK ee reali pur wut 44 6 s o Es us NUT WELDMENT 5 stk soc screw x 175 80 LG NUT WITH HANDLES see a 1 PULLER RP 1016529 HSG THREAD SIZE 2 4 172 UNC GRADE 8 1017009 FLANGE 194 GRADE 2H HEAVY HEX FULL NUT rc ee ee D ES DET REPACES DET 1 amp amp 2
89. SCREW 996 5 10488 FITTING M1275 WASHER B1504GF BEARING MA217K 2 u N 00 SHAFT 1018372 SCREW MA996Y 6 SM 1018384 AS SHIM 10185848 SEE NOTE 5 S BEARING 1018453 GASKET 1018393 SHIM 1018379 AS REQ D BEARING 143 fs SHIM 1018379A SHAFT 1018473 SCREW MAQ6OL 4 ere 74122 10183798 4 USED FOR USED FOR V washer PLATE 1018331 1020350 ASS Y 1019086 ASS Y WASHER M2081D 4 1018348 GEAR 1019105 CARRIER 1018374 WASHER 10590 5 SEE NOTE 10 3 21 1 RATIO 90T 3 21 1 RATIO 90T Y SCREW MA996Y 5 RING A2916DA HOUSING ASS Y 1018335 GEAR 1018401 GEAR 1019075 1 HOUSING 1018334 2 93 1 RATIO 88T 2 93 1 RATIO 88T PLUG MA1040A 2 CROSS SECTION N 1 4 AND PART NUMBERS 722222222 5 INSERT MA1064A 2 GEAR 1018408 GEAR 1019100 INSERT 10648 at 1019100 BAT USED FOR 1020350 FOR 1019086 ASS Y 1017931 1019078 GONE ASSI ASS MASBSJE PET GROSS SECTION 1 4 4 AND PART NUM SHEET INSTALLATION GEAR 1019133 GEAR 1019135 DRAWN 1 88 1 771 1 88 1 RATIO 77T USED FOR 1020250 ASS Y USED FOR 1019086 ASS Y 1018181 1018181 BEARING M BEARING 1019090 SHEET FLEXIBLE
90. T EXCHANGER TO ISO 6149 M42x2 0 THREAD METRIC PORT CONFORMS TO ISO 6149 CONNECT OIL PRESSURE GAGE LINE HERE M27 X 2 0 THREAD METRIC PORT CONFORMS TO ISO 6149 MOUNT GAGE IN PILOT HOUSE WATER DRAIN M10 X 1 0 THREAD METRIC PORT CONFORMS TO ISO 6149 LUBE PRESSURE M18 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 AUXILIARY LUBE SUPPLY SECONDARY CLUTCH ACTUATING PRESSURE M18 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 TEMPERATURE PICK UP PORT 1 4 18 NPTF DRYSEAL SECONDARY CLUTCH SHAFT 4 CENTER GRAMTY olL OUTPUT STRAINER SHAFT d L M12 X 1 75 THREAD 33 0 DEEP 24 5 THRU 8 HOLES 4 EACH SIDE 12 HOLES SPACED AS SHOWN H IN FROM HEAT EXCHANGER M33x2 0 METRIC PORT CONFORMS TO ISO 6149 MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL OPTIONAL DITCH PLATE FOR CUSTOMER SUPPLIED HEAT EXCHANGER PORT SURFACE TO GEAR O D GEAR GEAR 145 08 3454 nemi 126 3454 fist 96 40 3454 79 79 ses JAIN PRESSURE PICKUP PORTS 1 4 18 DRYSEAL THREAD PRIMARY CLUTCH ACTUATING PRESSURE M18 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 LUBE PRESSURE M18 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 AUXILIARY LUBE SUPPLY INLET SEE HYDRAULIC DIAGRAM VALVE LEVER CENTERLINE FRAHING PUMP INLET M16 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149
91. TWIN DISC INCORPORATED Service WELL ual Marine Transmission Components MG 6690SC MG 6848SC Document Number 1019677 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 1019677 December 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 partson which written warranties issued by the respective manufacturers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of shipment by Twin Disc Incorporated to original customer but not to exceed twelve 12 months of service whichever occurs first This i
92. YWHER ON ITS SHAFT THAT PERMITS FREI MOVEMENT WITHIN THE 50 lt TOTALD ROTATION amp 11 4mm AXIAL MOTION MANUAL OVERRIDE NEUTRAL STARI REQUIRED FUR CONTR SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp 6 4 THRU TRANSMISSION IS IN NEUTRAL ENGAGES PRIMARY SHAFT CLUTCH MANUAL o E VERRIDE 36 1 X 25 6H IREAD POSITION BH FOR REMOTE CONTR ELECTRIC BRACKET CONTROL POSITION fea jH 40 ELECTRIC CONTROL CLOSED WHEN STEM IS LDCKED uonejeisu 25 0 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 Power Controls Selector valve positioning devices must be installed so that full travel of the actuating cylinder places the transmission selector valve in the detent position for forward or reverse as selected without exerting pressure on the rotational stop on the selector valve stem Selecting neutral must place the selector val
93. ach of the spools 5 Install the two O ring plugs into the valve body and tighten to 85 Nm 63 Ib ft 6 Apply lubricant such as Dow Corning 2008 30 000cSt fluid to the O rings of the solenoids and plug plug used on units without hydraulic lock Install solenoids and plug if equipped into the valve body and torque them to 34 Nm 25 Ib ft 7 Insert the wires pins into the Weatherpak connector according to the location markings made at disassembly Close the end of the Weatherpak connector to lock the wires in position 8 Install the Weatherpak connector onto its retaining clip on the top of the valve 144 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Assembly of Electrical Control Valve lower body half 1 Install the steel shuttle ball into its bore in the valve body 2 Install the O ring onto the shuttle ball seat 3 Apply lubricant such as Dow Corning 200 30 000cSt fluid to the O ring and install the seat into the valve body Be sure to align the roll pin holes in the seat with the holes in the valve body One of the valve s M8x1 25 cover screws threaded into the seat can be used to adjust the seat location in the valve body 4 Install the roll pin to retain the shuttle ball seat Drive the roll pin in until it is flush with the gasket surface of the valve body Figure 101 Installing Shuttle Ball Seat Roll Pin 5 Install the stem into the valve body aligning
94. aring carrier Mark the shims and spacers for location identification 5 Remove the lubrication tube from the bearing carrier Figure 21 Lube Tube in Bearing Carrier 70 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 6 Install two of the removed screws into the threaded pusher screw holes ofthe bearing carrier near the dowel pins Tighten the screws alternately and evenly to push the bearing carrier off of the housing and dowel pins Remove the bearing carrier and prevent the bearing cups from falling out of the bores Figure 22 Pusher Screw Installed in Bearing Carrier 7 Remove the bearing cups from the bearing carrier Mark the bearing cups for location identification 8 Remove the lubrication oil pressure relief valve from the bearing carrier Figure 23 Lubrication Oil Pressure Relief Valve Marine Transmission Service Manual 1019677 71 Disassembly Twin Disc Incorporated Remove Primary and Secondary Clutch Shaft Assemblies 1 Lift out primary and secondary shafts 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 Figure 24 Lift
95. asin 6 GOR 41251 1018688 759 12 voc 27072 703 1725 lt 250 10171294 7 20 6 24518 kh 5 0 mensa herso vnd cevo itiiese x er adean msc 2 4 ETT MEE EE 1017179 xwe7ssri 1e 82707 703 1860 1017129A 7 x 0 5 6 51415 250 ae OT s 75 4 voc py 2450 355 1017129 103 20 6 24518 __ esas fee user BALL MI9906 2 SOLENOID ASS CHART PARTS PR UNITS WITHDUT NEUTRAL SOLENOID AND BALL 19901 2 25 0 lbf Ft HYDRAULIC LOCK OPTIONAL CONDITION 9 RINI AM OPTIONAL BALL M1990M SCREEN 221336 MATIS AT SS 1017 emer snp SERIES SPECIFY 74 VALVE BODY ASS Y 1017444 PO Ag 7 7 A BODY 1017443 PORT SDLENDID BAN GG 44 BALL MA1034A 11 40 RY 2 BALL
96. ates in clutch pack Assure that clutch hub is in mesh with all clutch plates Marine Transmission Service Manual 1019677 125 Assembly Twin Disc Incorporated E Install external retaining ring to retain pinion on shaft Figure 81 Installing External Retaining Ring Onto Clutch Shaft 9 Assemble primary shaft Repeat previous procedure steps as assembly procedure for primary shaft is exactly the same as for the secondary shaft 126 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Installation of Clutch Shafts Bearing Carrier and Manifold 1 Install clutch shaft assemblies into transmission housing Use caution to prevent damaging the shafts gears and bearings Use tool T 18050 715for lifting the primary and secondary shafts Figure 82 Installing Clutch Shaft Assembly 2 Install bearing carrier gasket over dowels onto rear face of housing 3 Assemble lube relief valve spring and lube relief valve steel ball into lube relief valve housing Attach assembled lube relief valve to inner face of bearing carrier with the screws and washers Torque the screws to 23 Nm 17 ft Ib Figure 83 Lubrication Oil Pressure Relief Valve Installed Marine Transmission Service Manual 1019677 127 Assembly Twin Disc Incorporated Install two alignment studs into face of transmission housing Install bearing carrier over studs and onto dowels in housing face Use a soft hammer near the dow
97. c Incorporated Installation With the indicator mounted as in the paragraph above adjust the indicator tip so that it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot bore eccentricity of the engine flywheel should not exceed 0 13 mm 0 005 in maximum total indicator reading Thrust on the flywheel should be in one direction at all times to obtain a correct reading gt Engine Flywheel Engine Housing 4 E lU m A S 1 i Thousandths A Indicator Engine vl Crankshaft Engine r v Flywheel gt TN Figure 115 Checking the Flywheel Pilot Ring Bore Eccentricity Marine Transmission Service Manual 1019677 159 Installation Twin Disc Incorporated Installation Alignment Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is 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 loads and the boats age The following steps may be taken to secure proper marine transmission alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure Install the m
98. d by sponginess or by black carbon like dust on rubber surface May be caused by contaminants or excessive heat either external or internal to the coupling Cracked bent or otherwise damaged flex plate or coupling plate Bolt holes in flex plate 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 1019677 55 Preventative Maintenance Twin Disc Incorporated Inspect the hub looking for the following Damaged or worn splines Cracked parts Oil seal surface for wear damage Replace any defective parts including defective fasteners that are found Heat Exchanger Check Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days If over 5096 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist it is evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush 56 Marine Trans
99. e See Table 1 Oil temperature to be in normal operating range MARIN KANSMISSIUN LUBRICANI OIL SERVICE CLASS USE SAE API SERVICE ASS CD ENGINE UIL CERTIFIED VENDOR TO PASS ALSO APPROVED IS SERVICE CLASS CC ENGINE DIL 2104B VISCUSITY BASE SELECTION ON SUMP EMP CUNDITIDNS TABULATED BELUW START UP STEADY ION VISCOSITY SOF MIN 50 lt NO 40 2 C MIN 65 RR SAE NUSO STEADY OPERATION BELOW 1507 65 C ABOVE 200 93 C IS NOT RECOMMENDED Wi IN D p INCORPORAT RACINE WI 5340 2415 J Marine Transmission Service Manual 1019677 Figure 3 Oil Specification Plate Example 23 Description and Specifications Twin Disc Incorporated Table 1 Transmission Oil Pressure Specifications Electrical Valve 350 psi Springs Main Pressure at Valve Primary Secondary Input Shift Inlet Clutch Min Clutch Min Speed Position YT Primary 2275 2480 330 360 2275 330 7 69 Secondary 2275 2480 330 360 2275 7 69 Neutral 689 1034 100 150 280 450 Primary 2380 2550 345 370 100 380 Secondary 2380 2550 345 370 100 380 Note It is required that lube pressure with primary clutch engaged must equal lube pressure with secondary clutch
100. e O ring plug location Note that the threads are 1 4 19 Figure 19 Output Flange Oil Injection Plug Location 68 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 3 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature into the flange hub until the flange separates from the output shaft Remove the oil injection equipment Remove the capscrews washer shims and output flange Note Use caution to prevent damaging the taper of the output flange or shaft as the torque capacity can be reduced 4 Remove the output seal carrier 5 Press the oil seals out of the seal carrier and remove the O ring from the seal carrier 6 Remove the output bearing cup and adjustment shims from the seal carrier Marine Transmission Service Manual 1019677 69 Disassembly Twin Disc Incorporated Remove and Disassemble Manifold and Bearing Carrier 1 Remove the primary shaft end cover plate and O ring 2 Remove manifold attaching screws Install two of the removed screws into the threaded pusher screw holes of the manifold near the dowel pins Tighten the screws alternately and evenly to push the manifold off ofthe bearing carrier and dowel pins Remove the manifold and gasket Figure 20 Pusher Screws Installed in Manifold 3 Remove the bushings from the bores of the manifold only if replacement is necessary 4 Remove the shims and bearing spacers from the bearing bores of the be
101. e and steel ball against spring onto valve body Install orifice plate cover and gasket onto valve body Install cover 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 valve attaching screws through valve body halves to keep parts in alignment until installation onto the transmission When installing the valve onto the transmission torque the screws to 54 Nm 40 Ib ft Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Assembly of Trolling Valve optional equipment 1 Press a new oil seal into the counterbore in the end of the adapter Install a new O ring into the groove of the adapter Figure 106 Installing O ring onto Adapter 2 Install a new O ring into the groove of the stem 3 Install the roll pin into the end of the stem if removed 4 Install the inner spring onto the roll pin in the stem end with a counterclockwise twisting motion The spring is to be installed onto the roll pin such that the first coil contacts the end of the stem 5 Apply assembly grease to the stem from the O ring to the reduced diameter end Install the stem into the adapter with the reduced diameter end entering the adapter first Adjust the position of the stem if necessary to bring the helical slot into alignment with the dog point setscrew hole 6 Install the large diameter washer used on some models in
102. eads of the screws and torque them to 130 Nm 96 ft Ib Install the pump spacer pilot onto the manifold Figure 89 Pump Drive Adapter and Spacer Pilot Installed Install the pump spacer and its gasket onto the manifold Install the oil pump gasket and oil pump onto the pump spacer Mesh drive tang on pump shaft with drive slot in secondary shaft or drive adapter Install attaching screws and torque to 80 Nm 59 ft lb Assemble oil filter differential bypass valve parts into oil filter head and torque the O ring plug to 108 Nm 80 ft lb Install the oil filter head onto transmission and torque the attaching screws to 80 Nm 59 ft lb Install O ring filter element and filter housing onto filter head and torque the bolt to 81 Nm 60 ft lb with its threads and washer oiled Install the trailing pump cover if not equipped with optional trailing pump Install the five attaching screws and washers and torque them to 80 Nm 59 ft lb If the transmission is equipped with the optional trailing pump install the trailing pump tube and elbow fittings Install the trailing pump suction strainer and cover with its O ring Install the five attaching screws and washers and torque them in an alternating pattern to 62 Nm 46 ft lb Tighten tubing fittings to 41 Nm 30 ft lb and the elbow fitting jam nuts to 47 Nm 35 ft lb Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Installation of Output Flange 1
103. easuring Output Step Height 134 Marine Transmission Service Manual 1019677 Twin Disc Incorporated 10 Assembly Calculate the output flange advance which is dimension B plus dimension C minus dimension A This is advance must be 4 85 mm to 7 04 mm 0 191 in to 0 277 in Note Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance Connect the oil injector to the output flange Install tool T 21433 onto the output shaft to advance the flange onto the shaft Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating surfaces Advance flange onto shaft with the portable press Figure 93 Advancing Output Flange Onto Output Shaft Marine Transmission Service Manual 1019677 135 Assembly Twin Disc Incorporated 11 Release injection oil pressure between the mating surfaces and wait five minutes Remove 21433 from the transmission Note is possible to advance the flange using the retainer washer and its five retaining screws The screws must be tightened evenly in small increments and in an alternating star pattern to advance the flange squarely onto the
104. ectly over the bearing cup The thinnest of the shims should be in the center of the pack and the thickest shim should be against the bearing cup Repeat this process for the other shaft Install the shaft seal rings into the grooves of the clutch shafts Apply a coat of assembly grease or oil to the seal rings of both clutch shafts Center the seal rings in the shaft grooves to prevent seal ring damage during manifold installation Install the manifold over the bearing carrier and gasket Use a soft hammer near the dowels to seat manifold against gasket and over dowels Install the manifold attaching screws and torque to 80 Nm 59 ft lb Marine Transmission Service Manual 1019677 129 Assembly Twin Disc Incorporated 16 Confirm shaft endplay A With a felt tip pen make a mark across the rear end of the secondary shaft Install a dial indicator on a machined surface on the manifold with the probe resting on the mark made on the secondary shaft Figure 86 Confirming Secondary Shaft Bearing Adjustment B Install an eyebolt into the end of the shaft and exert 890 N 200 lbs downward force while rotating the shaft several revolutions in each direction Stop so that the dial indicator probe is resting on the mark C Zero the dial indicator D Remove downward pressure and exert 1334 N to 1557 N 300 lbs to 350 Ibs lifting force on the shaft Rotate the shaft several revolutions in each direction stopping with the dial i
105. els to seat carrier against gasket and over dowels Install lube tube through keyed hole in bearing carrier and into machined pocket in front inner face of housing Rotate tube so elongated key of tube fits into corresponding key in bearing carrier Properly installed lube tube will be flush with rear face of bearing carrier Figure 84 Key Orientation of Installed Lube Tube 128 Install cups for rear tapered roller bearings on primary and secondary shafts into bores in bearing carrier Tap cups down gently with soft hammer or brass drift to seat against bearing cones on shafts Install manifold gasket over alignment studs and against bearing carrier Install the bearing spacers over the bearing cups Rotate the shafts at lease three revolutions to seat the bearing rollers while pressing down on both bearing spacers Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Push tapered roller bearing cups with bearing spacers firmly against roller bearing cones on rear of primary and secondary shafts Use a depth micrometer to measure from top of manifold gasket down to shim retainers Measured distance is shaft endplay Use necessary shims to develop a shim pack for each shaft to reduce shaft endplay to 0 013 mm to 0 063 mm 0 0005 in to 0 0025 in Figure 85 Measuring to Determine Shim Pack Thickness 11 Remove one bearing spacer and install the shim pack for that shaft dir
106. er and manifold sealed with gaskets complete the housing enclosure Bearings The primary and secondary clutch shafts and pinions are supported and located by a combination of straight and tapered roller bearings Bearing clearances for each clutch shaft and pinion assembly are set by use of a single shim pack atthe rear tapered roller bearing on each shaft A combination of straight and tapered roller bearings support the output shaft and have bearing clearance adjusted by use of shims in the rear bearing carrier Oil Pump and Drive The oil pump is driven by the secondary clutch shaft Marine Transmission Service Manual 1019677 19 Description and Specifications Twin Disc Incorporated Lubrication Features The MG 6690SC and MG 6848SC series transmissions have a lubrication tube located inside the main housing The tube extends from the front to the rear of the inside of the housing The lubrication tube has drilled holes in the tube that spray oil on the transfer gears and the primary and secondary pinions Bearings and clutches on the primary and secondary shafts are lubricated through drilled passages in the shafts Output shaft bearings are gravity and splash lubricated Suction Screen The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and oil pump in the hydraulic circuit The strainer can be replaced if necessary Filter Assembly A caniste
107. er only slightly larger than the shaft diameter to push bearings on until they are stopped by the shaft shoulder Figure 57 Installing Trailing Pump Shaft Bearings 2 Install the trailing pump shaft and bearings into the transmission housing using a soft hammer if necessary Figure 58 Installing Trailing Pump Shaft Marine Transmission Service Manual 1019677 105 Assembly Twin Disc Incorporated 3 Install internal retaining ring into housing over bearing Figure 59 Installing Internal Retaining Ring 4 Install key and trailing pump driven gear onto trailing pump shaft b Install external retaining ring onto trailing pump shaft to retain driven gear 84 Figure 60 Installing External Retaining Ring 106 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Installation of Output Shaft and Gear 1 Install trailing pump drive gear onto output gear using guide studs to help align the screw holes Apply 908 threadlocker to the threads of the four sockethead capscrews and torque them to 75 Nm 55 ft lb 2 Clean tapered surface of output shaft and tapered bore of output gear Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Do not touch cleaned surfaces Loctite amp 7070 cleaner is recommended CAUTION Tapered surface of shaft and matching tapered bore of gear must be completely free of grease oil dirt or solvent residue Failure to proper
108. ervice Manual 1019677 Twin Disc Incorporated Assembly 10 Advance hub onto shaft with the portable press Do not apply more than 20 tons of force as the tool s threads may be damaged Figure 99 Advancing Input Coupling Hub 11 Release injection oil pressure between the mating surfaces and wait five minutes Remove T 18050 784 from the transmission Note It is possible to advance the flange using the retainer washer and its attaching screw The screw must be tightened carefully while advancing the hub onto the shaft A new screw must be installed if the old screw was over torqued during the advancing process 12 Usingadepth micrometer measure distance from the hub shoulder to the end of the primary shaft Hub must be advanced to within 0 05 mm 002 in of the shaft end 13 Install the retainer washer and torque the screw to 530 Nm 391 ft lb Marine Transmission Service Manual 1019677 143 Assembly Twin Disc Incorporated Assembly and Installation of Control Valve Assembly of Electrical Control Valve upperbody half 1 Install one dowel pin large diameter into each of the two bores of the valve 2 Install one spring into each of the two bores of the valve body Figure 100 Dowel Return Spring Spool and Plug 3 Install one spool into each of the two bores of the valve body 4 On units equipped with the hydraulic lock feature install one spring followed by one pin small diameter into e
109. etaining ring from coming out of the groove Remove tool T 19330 5 Install the pinion rear tapered roller bearing cone onto the shaft Note This bearing is a slip fit and will not require special tools for installation 6 Beginning with a friction plate alternately install 10 friction plates and 9 steel plates into clutch housing transfer gear against clutch apply piston Marine Transmission Service Manual 1019677 123 Assembly Twin Disc Incorporated 7 Install clutch backplate and internal retaining ring Figure 77 Installing Clutch Backplate 8 Assemble pinion A Use tool T 18050 708 to install chilled tapered roller bearing cup into rear of pinion for secondary shaft Bearing cup is installed with small 1 0 of taper toward the front and seated against shoulder of bore in clutch hub of pinion Figure 78 Installing Tapered Roller Bearing Cup Into Pinion 124 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly B Use tool T 18050 705 to install chilled needle roller bearing into bore at front of pinion with the radius edge of the outer race entering the pinion first Figure 79 Needle Roller Bearing Installed C Install internal retaining ring into groove in pinion bore Figure 80 Installing Internal Retaining Ring Into Pinion D Align plates in clutch pack and install pinion on secondary shaft so that external teeth on clutch hub mesh with internal teeth of steel pl
110. excess M2828 sealant from the seal Figure 96 Installing Input Oil Seal 2 If the expansion plug has been removed from the output shaft bore of the housing apply a thin coat of M2828 anaerobic sealer to the OD of the new expansion plug and also to the housing bore Drive the plug in until the flange is flush with the machined surface of the housing 3 Install the front housing onto the transmission Torque the attaching screws to 80 Nm 59 ft Ib 140 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly 4 Check front housing runout A Mount a dial indicator on the input shaft 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 97 Measuring Front Housing Face Runout B Move the dial indicator s probe so it measures the O D of the front housing pilot diameter Rotate the input shaft and note the total indicator runout The 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 5 Clean tapered surface of primary shaft and tapered bore of input hub Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Do not touch cleaned surfaces Loctite amp
111. f 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 compressing the pressure regulating springs even further yet Figure 6 Rate of Rise Piston in Neutral left and Rate of Rise Piston with Clutch Engaged right The travel rate of the rate of rise piston and resulting pressure rate of rise is controlled by the orifice size regulator spring stiffness and the final main pressure after completion of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the 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 Since the pressure in the rate of rise chamber is much greater than the pressure itis to be regulated at the ball unseats from the orifice plate allowing main oil pressure to return to the neutral pressure level rapidly and again be regulated by the ball and spring regulator The ball returns to the pressure regulating position once the spring force i
112. filter is clean and then change the oil and filter after 1000 hours of service or more often if conditions warrant Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Marine Transmission Service Manual 1019677 53 Preventative Maintenance Twin Disc Incorporated 54 Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located in the manifold below the pump See Engineering Drawings for suction strainer location Type Oil Recommended See Description and Specifications Filling 1 2 Remove the filler breather in the top cover of the transmission Fill the transmission s sump with 41 6 liters 11 0 U S gal of the proper weight and type oil See Description and Specifications for oil recommendations Start the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the oil level to FULL mark on the oil gauge Allow the oil temperature to cool to normal cold oil conditions perhaps overnight Check the oil level while cold at low idle engine speed while in neutral Make note of
113. fourth seal ring section into the groove over the expander ring with the ends rotated 270 from the ends of the first seal ring Apply a coat of assembly grease or oil to the seal ring Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly 3 Install clutch apply piston into piston bore in transfer gear Figure 74 Installing Clutch Piston Marine Transmission Service Manual 1019677 121 Assembly Twin Disc Incorporated 4 Installation of clutch return springs A Install 16 clutch return spring into pockets in face of clutch apply piston B Install spring retainer over springs with groove toward springs Working through holes in retainer use a small punch or probe to assure that all springs are in pockets in face of piston and that springs are aligned correctly stand straight up Figure 75 Return Springs and Spring Retainer Ready for Installation 122 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly C Install external retaining ring over shaft to rest against spring retainer Move shaft assembly to press and install tool T 19330 Press down tool T 19330 to compress springs and expose retaining ring groove of shaft Keep force on springs and install retaining ring into exposed groove of shaft Figure 76 Installing Spring Retainer Retaining Ring D Slowly release force on springs assuring that spring retainer counterbore covers retaining ring and prevents r
114. haft Manifold Spacer oil pump Pilot spacer Adapter pump drive Pump oil Screw hex head cap oil pump Gasket oil pump Screw socket head cap pump drive adapter Gasket oil pump spacer Screw hex head cap suction strainer cover Plate clamp suction strainer cover O ring suction strainer cover Cover suction strainer Strainer suction Gasket manifold Carrier bearing Gasket bearing carrier R Shim bearing 005 007 020 primary amp secondary shaft bearing adjustment gt 2 Ring external retaining primary amp secondary shaft rear bearing 20 Plate clutch friction 18 Plate clutch steel 2 Ring internal retaining clutch backplate pe1e10djo2u 26 UIML suoneusnyl Illustrations Oil Filter 206 Item 49 50 51 52 53 54 55 56 57 58 59 60 61 62 2 ZZZZZZ Twin Disc Incorporated Description Screw hex head cap Washer flat Gasket filter head mounting Spring compression filter differential pressure bypass Plug assembly includes O ring Filter head O ring filter body to filter head Element group consists of items 57 through 62 Spring compression Washer sealing Marine Transmission Service Manual 1019677 Twin Disc Incorporated Optional Heat Exchangers 71 mcn E mn FE 6 72 E
115. housing face 0 41 mm 016 in SAE 0 and SAE 00 front housing pilot diameter 0 30 mm 012 in Output flange face near O D 0 10 mm 004 in Output flange pilot diameter 0 10 mm 004 in This note applies to a continous 270 arc if the balance of the pilot is negative in readings otherwise it means all 360 Marine Transmission Service Manual 1019677 27 Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Note All threads and bearing face to be lubricated with light oil film prior to assembly Table 5 U S Standard Fine and Coarse Thread Capscrews Bolts and Nuts Thread SAE Grade 5 SAE Grade 8 Diameter Nm 1 4 6 8 10 12 14 16 5 16 13 17 20 24 27 32 r Dens 5 8 163 190 165 195 224 264 11 4 850 1000 1163 1355 1375 1625 1865 2203 28 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Description and Specifications Table 6 Metric Coarse Thread Capscrews Bolts and Nuts Thread Property Class 8 8 Property Class 10 9 Property Class 12 9 Sue bn gf m m 65 75 0 0 ww Table 7 Pipe Plugs with thread lubricant 73 54 46 34 3 4 14 1 11 1 2 108 80 68 50 11 4 11 1 2 115 85 75 55 11 2 11 1 2 115 85 75 55 Marine Transmission Service Manual
116. ing Out Primary or Secondary Clutch Shaft Assembly 2 Remove front pinion tapered roller bearing cones that were pulled off by output gear as primary and secondary shafts were removed Note Tapered roller bearing cups of front bearings on the primary and secondary shafts are an interference fit in the housing Removal of these bearing cups should not be attempted unless replacement of the bearing is necessary 72 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly Remove Output Gear and Shaft 1 Remove the four screws and sealing washers that retain the output gear pan Rotate the gear pan around the output gear and remove it from the transmission housing 2 Use a hoist to lift output shaft and gear assembly until gear contacts housing Place blocks under gear to support the gear and shaft assembly in position Figure 25 Supported Gear and Shaft Assembly 3 Connect oil injection equipment to the 1 4 19 BSP threaded port on the rear end of the output shaft Figure 26 Oil Injection Equipment Connected to Output Shaft Marine Transmission Service Manual 1019677 73 Disassembly 74 Twin Disc Incorporated 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 restrain the output shaft during disassembly Figure 27
117. is directed to the PTO control valve with the overage oil flowing to the transmission s control valve Marine Transmission Service Manual 1019677 47 Operation Twin Disc Incorporated Trailing Pump Optional 48 The trailing pump is used to supply oil flow to the transmission lubrication circuit when the transmission is in a backdriving condition Backdriving sometimes referred to windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller The integral trailing pump option can be added to any MG 6690SC and MG 6848SC transmission The trailing pump is driven by a gear connected to the output shaft of the transmission The trailing pump pulls oil through a dedicated suction strainer The oil is then discharged through a check valve and into the transmission s lubrication oil circuit The remote trailing pump option is driven by an electric motor This trailing pump pulls oil through its suction strainer and discharges it through a filter to a check valve The oil then flows through an oil to air heat exchanger and into the transmission s lubrication circuit via one of the lubrication oil pressure test ports Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation Power Flow Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is splined to the forward end of the primary f
118. iston 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 Check oil le vel and correct Correct cause of air leak Disassemble and repair as required Remove disassemble clean and repair the regulating valve Replace oil pump Replace heat exchanger Marine Transmission Service Manual 1019677 Twin Disc Incorporated Troubleshooting Table 9 Troubleshooting Chart continued Symptom High main oil pressure High temperature Excessive Noise Regulating valve stuck Improperly shimmed Lube relief valve malfunction Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure or damaged input coupling Excessive torsional vibration Worn or da
119. itical Place a 0 05 mm 0 002 in feeler gauge between the flanges of the coupling Move slide the feeler gauge completely around the coupling Rotate the marine transmission flange coupling in 90 degree increments and move the feeler gauge around the flange in each successive position The feeler gauge will fit snugly with the same tension all around the flange coupling in all four positions if the alignment is correct If the alignment varies during rotation additional alignment is necessary or the marine transmission and shaft couplings should be checked for proper face runout Runout must not exceed 0 10 mm 0 004 in Excessive face runout on the marine transmission output flange can usually be corrected by repositioning the coupling on its spline or taper Excessive shaft coupling runout is usually due to inaccuracy of the taper fit or key to keyway interference The optimum relative mating location will be where the measured runout dimensions of the transmission flange and the shaft coupling flange compliment each other to result in the least relative out of true parallel measurement Figure 119 Checking Output Flange Face Runout Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation PROPELLER FLANGE Figure 120 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
120. iver 201 T 506000 Lifting bracket for clutch removal in boat 202 Marine Transmission Service Manual 1019677 9 Table of Contents Twin Disc Incorporated M 203 mI agli 9 A 203 dii M 204 slug 206 Optional Heat Exchangers 207 Transmission Rear VIGW 208 Transmission Section View nnmn nnna 210 Torsional input COUDIIB 212 Trailing Pump Shaft Group 213 Trailing Pump optional equipment 214 Electric Control 215 Trolling Valve optional equipment 217 Engineering Drawings 219 List of Engineering Drawings 219 1019086 1020350 sheet 1 of 4 Marine transmission 221 1019086 1020350 sheet 2 of 4 Marine transmission 222 1019086 1020350 sheet of 4 Marine transmission 223 1019086 1020350 sheet 4 of 4 Marine transmission 224 A7119AA Hydraulic diagram 225 1018084 Control valve assembly without trolling valve
121. ked for alignment Note The transmission output flange and companion flange bolts must be torqued to the proper value as identified in Description and Specifications Marine Transmission Service Manual 1019677 161 Installation Twin Disc Incorporated Engine and Marine Transmission Alignment CAUTION When mounting engine and transmission in boat all of the mounting pads on both the engine and transmission must be used Failure to do so may result in damage to the transmission or the engine flywheel housing Recommended Figure 117 Transmission Mounting Configurations When mounting the engine and transmission in the boat all of the mounting pads on both the engine and the transmission must be used Failure to do so may result in damage to the transmission It is important to align the engine and transmission only when the boat is afloat and NOT in dry dock During this alignment period it is also advisable to fill the fuel tanks and load the boat in the typical manner that itis to be used Some boats are built with flexibility and may change shape as the loading varies 162 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation When a heavy boat is dry docked it naturally undergoes some bending Therefore it is always good practice to the marine transmission coupling to prevent bending of the shaft With the engine and transmission in position on the engine bed
122. ket with the hole in the valve Figure 104 Holes in Gasket and Cover Must be Aligned 15 16 17 18 19 20 21 Install cover capscrews and 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 7 Ib ft Install external retaining ring onto stem Install the steel balls and electrical switches into the bores in the sides of the valve if equipped Note that the small diameter ball is inboard of the large diameter ball at each switch location Install the pressure regulating piston into valve body with spring pocket out Marine Transmission Service Manual 1019677 147 Assembly 22 2 24 Twin Disc Incorporated Install pressure regulating springs into valve body and into piston spring pocket Install the shims that were removed into the bore of the rate of rise piston Install the rate of rise piston over the springs and into valve Install neutral pressure regulating spring into the pocket of valve body Figure 105 Neutral Pressure Regulating Spring Location 25 26 2f 28 29 148 Install orifice plate gasket onto valve body Install orifice plat
123. l was written has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual For details of the warranty contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Inc Racine Wisconsin U S A 16 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Description and Specifications Description and Specifications General The 1020350 series assembly drawing number identifies the MG 6690SC transmission The 1019086 series assembly drawing number identifies the MG 6848SC transmission Nameplate The nameplate identifies the model bill of material BOM and the serial number of the unit These numbers are necessary to identify the correct parts for your transmission f 5 gt ND RATIU ud BUM SERTAI NO JIL CAPACITY ONDES USTOMER GAL MARINE XA MISSI I ND LU BRICATION MIN GIL PRESSURE WHEN CRUISING PSI EVERY 10 SERVICE HOURS DR DAILY CHECK DIL LEVEL WITH ENGINE RUNNING AND MARINE TRANSMISSI UN lt NEUTRAL ERY 100 HOURS WHERE A GREASE FITTING IS PROVIDED UBRICATE SHA SEALS WITH WATER PUMP GREASE TO PREVENT BILGE WATER ENTERING HOUSING EVERY 1000 SERVICE HOURS OR 6 MONTHS WHICHEVER COMES FIRST RAIN AND REFILL HOUSING WITH CLEAN REMOVE AND RE PLA ACE FILTER ELE WHERE APPLICABLE CLEAN SUCTIUN SC
124. lifting force Read shaft endplay on dial indicator Figure 66 Measuring Output Shaft Endplay Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly 7 Add or remove shims as necessary to achieve the correct bearing adjustment Arrange the shims such that the thinnest shims are in the center of the shim pack and the thickest shim is against the bearing cup Onunits with 1 51 1 and numerically lower gear ratios the output bearings are to have 0 08 mm 0 003 in of preload On units with 1 88 1 and numerically higher ratios i e 1 88 1 2 03 1 2 47 1 2 93 1 3 21 1 the output bearings are to have 0 05 to 0 15 mm 0 002 to 0 006 inch of clearance 8 Remove dial indicator Remove output seal carrier using caution to prevent loss of tapered roller bearing cup and shims 9 Install O ring in groove in O D of output seal carrier Figure 67 O ring Installed onto Output Seal Carrier Marine Transmission Service Manual 1019677 113 Assembly Twin Disc Incorporated 10 Installoil seals into output seal carrier using driver T 18050 713 per the following description A Install forward seal with spring loaded lip toward the inside of the transmission Start inner seal with flanged side of driver T 18050 713facing down and complete its installation with tool inverted as shown below in Figure 68 B Install rear seal with spring loaded lip of seal toward rear of the transmission Install flush with
125. light bead around the I D of the bearing race This will shrink the bearing cup to facilitate removal Bearings removed with this method must be replaced Marine Transmission Service Manual 1019677 79 Disassembly Twin Disc Incorporated 5 Remove internal retaining ring at front of clutch housing and remove clutch backing plate Figure 34 Clutch Backing Plate and Retaining Ring Removed 6 Remove clutch plates 9 steel 10 friction maintaining the respective order for inspection purposes 7 Remove tapered roller bearing cone from shaft Bearing supports rear of pinion This bearing is a slip fit and should remove easily 80 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 8 Remove clutch apply piston a Place clutch in a press input side up Use special tool T 19330 to compress clutch release springs and expose round retaining ring Figure 35 Removing Spring Retainer Retaining Ring b Remove retaining ring Slowly release pressure on press and remove shaft from press Remove special tool T 19330 and spring retainer Remove clutch release springs form pockets in face of piston Marine Transmission Service Manual 1019677 81 Disassembly Twin Disc Incorporated Remove the clutch piston by applying air to the hydraulic pressure port between the seal ring grooves to force the piston from the bore Use caution to avoid damaging the piston Figure 36 Removing Clutch
126. llation of Top Cover Assembly Heat Exchanger and Gauge 1 2 Turn transmission over and block securely in upright position Attach oil baffle to top cover if removed Install the sealing washers onto the screws apply MA908 threadlocker to the screw threads and grease to the sealing washers and torque the screws to 18 Nm 13 ft Ib Install top cover assembly with its gasket Install attaching screws and torque to 80 Nm 59 ft lb Install the two lifting eyebolts Figure 95 Installing Top Cover 138 Install breather filler cap Install oil gauge tube assembly and oil level gauge Be sure the oil gauge tube did not enter the gear pan Install PTO valve cover plate onto the top of the transmission housing and torque the screws to 80 Nm 59 ft lb Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Install the heat exchanger The use of M12x1 75 guide studs will ease the installation of the heat exchanger Units with Remote Heat Exchanger Install the adapter plate and gasket Torque the attaching sockethead capscrews to 80 Nm 59 ft Ib Install protective plugs to prevent the entrance of contaminants into the transmission s lubrication oil circuit Units with Integral Fresh Water Heat Exchanger Install the adapter plate and gasket Torque the attaching sockethead capscrews to 80 Nm 59 ft Ib Install heat exchanger element and gasket over adapter plate Install heat exchanger
127. lling valve and a mechanically actuated trolling valve The electric trolling valve is Twin Disc part number 1017554 and the mechanical trolling valve is Twin Disc part number 1017555 Companion Flange The companion flange assembly is Twin Disc part number 1018682 Table 2 Advance Specifications Transmission Input Coupling Hub Advance Minimum Maximum 3 56mm 140 in 5 64mm 222 in Transmission Primary Transfer Gear Advance Minimum Maximum 3 15mm 124 in 4 17mm 164 in Transmission Secondary Transfer Gear Advance Minimum Maximum 2 67mm 105 in 3 71mm 146 in Transmission Output Gear Advance Minimum Maximum 9 45mm 372 in 11 00mm 433 in Transmission Output Flange Advance Minimum Maximum 4 85mm 191 in 7 04mm 277 in Marine Transmission Service Manual 1019677 Twin Disc Incorporated Description and Specifications Table 3 Bearing End Play Specifications Transmission Primary and Secondary Shaft Tapered Roller Bearing Endplay Minimum 0 013 mm 0005 in Maximum 0 063 mm 0025 in Transmission Output Shaft Bearing Endplay Minimum Maximum 1 88 1 and numerically higher 0 05mm 002 in 0 15mm 006 in 1 51 1 and numerically lower 0 08mm 003 in 0 08mm 003 in Table 4 Front housing and Output Flange Runout Limits Feature Maximum allow able total indicator reading SAE 0 and SAE 00 front
128. loading and unloading Where this condition exists it important to apply common sense alignment techniques to minimize the potential damage to any of the components During the process of securing final alignment it may be necessary to shift the engine many times When the final alignment is accomplished mark and drill the holes for the lag studs or locating dowel pins Then with final alignment secured make up the necessary poured steel or hardwood shims and fasten the engine and transmission in place Then recheck the alignment and if satisfactory bolt the coupling together Marine Transmission Service Manual 1019677 165 Installation Twin Disc Incorporated 166 There are many types of flexible couplings in the market today that solve a variety of problems Couplings to reduce noise and vibration Couplings to allow a permanent angular misalignment Couplings that allow engines to be flexibly mounted and take out the momentary misalignment In some cases the proper alignment of these couplings requires an accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation Torsional Input Couplings Installation For Models Provided by Twin Disc CAUTION Be sure the internal retaining ring is properly installed inside the torsional input coupling hub See Engineering D
129. ly clean mating parts could prevent proper advance measurement of gear on shaft and adversely effect torque carrying capacity of the assembled joint Both parts must be at the same temperature 3 Place output gear into transmission housing using special tool T 21528 to ease positioning of gear into correct location Visually center the gear on the output shaft bore Figure 61 Placing Output Gear into Housing with T 21528 Marine Transmission Service Manual 1019677 107 Assembly Twin Disc Incorporated 4 Install the output shaft assembly into the output gear in the transmission housing using T 18050 714 Use caution to prevent damaging the taper of the gear or shaft Align the shaft and gear such that the oil injection hole of the shaft is centered between two of the gear s threaded puller holes Seat shaft onto the taper of the gear using only the weight of the shaft 5 Use gauge blocks and a feeler gauge to measure between the output gear and shaft shoulder This is the potential advance and it must be 9 45 mm to 11 00 mm 0 372 in to 0 433 in Figure 62 Measuring Output Gear Advance Note Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance 108 Marine
130. mage to the machine or personal injury CAUTION Select lifting eyebolts to obtain maximum thread engagement with the bolt shoulder fastened tightly against the housing Bolts should be near but should not contact bottom of bolt hole Marine Transmission Service Manual 1019677 Twin Disc Incorporated Introduction Preventative Maintenance Frequent reference to the information provided in the Marine Transmission Operator s Manual document number 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 Marine Transmission Service Manual 1019677 13 Introduction Towing Twin Disc Incorporated The MG 6690SC and MG 6848SC series marine transmissions have an integral trailing pump option The following applies only to units not equipped with the optional integral trailing pump Under the conditions described below the prop shaft must be locked in place to prevent backdriving Failure to do this can damage the marine transmission due to the lack of component lubrication Backdriving of the drive shaft also called trailing or windmilling occurs when an engine is shut down and the propeller shaft is being driven by the flow of water across the propeller This action rotates the components in the marine transmission During backdriving conditions the transmission does not receive proper lubrication
131. maged gears Im proper alignment Damaged propeller Misfiring engine Marine Transmission Service Manual 1019677 Remove and clean regulating valve Shim as required Inspect repair or replace parts as necessary Check and 11 or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch 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 61 Troubleshooting 6 7 8 9 62 Twin Disc Incorporated Table 9 Troubleshooting Chart continued Symptom No neutral Harsh engagement Low lube oil pressure 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 p
132. mission Service Manual 1019677 Twin Disc Incorporated In boat Repair Preventative Maintenance Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures are D D D Note Note Overhaul Interval 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 secondary shaft assembly The transmission must be removed from the engine to service the primary clutch shaft as the torsional coupling hub is attached to the primary shaft via a keyless taper See special tools section for lifting bracket to aid in shaft removal or installation Changing secondary clutch plates Further disassembly reassembly of the clutch shafts will require use of tools and equipment normally not available on board the vessel A complete overhaul of the unit should be made at the same time that the engine is overhauled Marine Transmission Service Manual 1019677 57 Preventative Maintenance Twin Disc Incorporated Periodic Visual Inspection Check 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
133. n a 6 mm 0 25 inch gap below the screw head The capscrew and washer will be used to restrain the input hub as it separates from the primary shaft Oil Injection Figure 17 Oil Injection Port and Retaining Capscrew Loosened 6mm Always use retainer bolts or a safety strap to hold parts being separated with oil pressure Oil pressure applied between the two parts for disassembly can reach 300Mpa 43500psi The use of proper safety equipment is mandatory when working with high pressure hydraulic tools The parts may separate with extreme force Marine Transmission Service Manual 1019677 65 Disassembly 66 Twin Disc Incorporated Install the oil injector into the output flange at the O ring plug location Note that the threads are 1 4 19 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature into the input hub until it separates from the primary shaft Remove the oil injection equipment Remove the capscrew and washer and remove the input hub Note Use caution to prevent damaging the taper of the input hub or shaft as the torque capacity can be reduced Remove the front housing from the main housing Remove the oil level gauge and tube assembly from the top cover Remove the top cover and gasket Remove the oil pump and gasket Remove the pump spacer plate and pump drive adapter Remove the heat exchanger housing heat exchanger element and stiffener plate Check the condition of the anode in
134. nd flywheel housing mounting surfaces thoroughly before any measurements are made Note To isolate engine vibration and prevent transferring it to the hull through the propeller shaft the distance from the marine gear output flange to a fixed stuffing box or the first fixed bearing must be a minimum of 20 times the shaft diameter If the distance is less than this a flexible coupling may be necessary to isolate the engine vibration Marine Transmission Service Manual 1019677 155 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 3 2 i 4 S HL _ f Engine Flywheel Engine ANE aes Crankshaft IL Engi Re Housing Figure 112 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 10 156 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation Table 10 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face
135. nd subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit September 4 2001 TDW P2003 TWIN DISC INCORPORATED FLAT RATE HOUR ALLOWANCE Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated COMMERCIAL MARINE TRANSMISSIONS ALL RATIOS MODEL SERIES R amp R UNIT REBUILD CLUTCH REPAIR BOTH PACKS MG 502 MG 5010 MG5011 MG5005A MG5015A 10 0 8 0 MG 506 MG5061 MG 5050 MG5055A MG 507 MG 5081 MG5085 MG5090 MG 5091 MG5112 MG5113 MG 509 MG 5111 MG5114 MG5114A MG5114RV MG 514C MG514M MG5141 MG514CHP MG 516 MG 5161 MG 518 1 MG520 1 MG 5202 MG5203 MG5204 MG5205 MG 530 MG530M MG5301 MG 540 MG5600 MG6000 MGN 80 MGN 232 MGN 233 MGN272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN 472 MGN 493 MGN 650 MGN 800 MGN 1000 MGN 1400 MGN 1600 PUMP ALL MODELS VALVE ALL MODELS September 4 2001 TDW P2003A Twin Disc Incorporated Table of Contents Table of Contents ust TES 11 General uiu mee 11 Safety and General Precautions 11 Preve
136. ndicator probe resting on the mark E Dial indicator reading is secondary shaft endplay Endplay should be between 0 013 mm to 0 063 mm 0 0005 in to 0 0025 in Add or remove shims as necessary to achieve correct endplay Use dial indicator and above procedure to confirm that desired endplay has been attained F Confirm endplay for primary shaft by repeating previous steps on primary shaft 17 Install new O rings onto the M18 O ring plugs used for the clutch and lube pressure test ports Lubricate the O ring and threads and install the plugs torquing them to 74 Nm 55 ft Ib 130 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Installation of Exterior Components 1 Install suction strainer into bore in manifold Figure 87 Installing Suction Strainer 2 Install O ring into groove in suction screen cover Apply assembly grease or oil to the O ring 3 Install suction screen cover and secure with clamp plate and screw Torque attaching screw to 80 Nm 59 ft lb 4 Install O ring into groove in face of manifold at primary shaft Install cover onto manifold at primary shaft Install attaching screws and torque to 80 Nm 59 ft Ib Figure 88 O ring Installed left and Cover Installed right Marine Transmission Service Manual 1019677 131 Assembly 132 Twin Disc Incorporated Install oil pump drive adapter onto the secondary shaft Apply MA908 threadlocker to the cleaned thr
137. ntative Maintenance 2 40 1 7 4 13 ji 14 Ordering Parts and Obtaining Services 15 Source of Service Information eee 16 Warranty Qm 16 Description and Specifications 17 2 f M neers 17 axial iro mee 18 Construction 19 Lubrication 20 le cj jj e 23 Optional Equipment 25 Torque Values for 28 Clutch Plate Wear 22 2 31 33 ci 33 Hydraulic System with Electric Control Valve 34 Trolling Valve Optional saida 44 Power Take off 47 Trailing 48 Power FIOW c 49 Preventative Maintenance 53 Troubleshooting NUM 59 Troubleshooting Chart e 59 Marine Transmission Service Manual 1019677 7 Table of Contents Twin Disc Incorporated Ze
138. o the appropriate clutch pressure port The opposite clutch port passage remains connected to sump by the same pocket in the stem as when the stem was in the Neutral position When the stem is rotated back to the Neutral position the main pressure oil slot in the stem is no longer aligned with either clutch port Both clutches are again vented to sump by the two pockets in the stem 42 Marine Transmission Service Manual 1019677 21961 018 1 51 5 SUNEN ev VV6LLZV 721 1 t 1 t zt 1 UBE TUBE 1 SS ew WK Lee S Curt SSS 9 N MSS p We X T S les AN i f SABE S e ASQ 1 UP TROLLING VALVE TIONAL MANUAL DE i 52 d E
139. oil seal from the end of the adapter Figure 53 Removing O ring from Adapter 94 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Cleaning and Inspection Cleaning and Inspection Cleaning Note Replace all oil seals gaskets O rings piston rings seal rings snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents steam cleaning Parts must be dried and oiled immediately to prevent corrosion Examine all parts carefully for grit dirt and abrasives and them if necessary Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent to flush oil pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher screw locations Marine Transmission Service Manual 1019677 95 Cleaning and Inspection Twin Disc Incorporated 96 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 A CAUTION Never dry bearings
140. on 12 Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance and working practices Inspect the equipment as required to assure safe operation under current operating conditions Proper guards and other safety devices that may be specified in the safety codes should be provided These important safety devices are neither provided by nor are they the responsibility of Twin Disc Inc Selecting NEUTRAL disengages the transmission clutches but does not prevent propeller shaft rotation If you require a positive neutral condition propeller shaft locked a shaft brake or other shaft locking device must be used To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove the ignition key from the key switch Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit engine and transmission Lifting excessive loads from these points could cause failure at the lifting point or points and result in da
141. on The only difference between the electric trolling valve and the previously described mechanical trolling valve is that the electric trolling valve s orifice size is controlled by electrical current instead of a lever When the trolling valve is in the cruise non trolling mode the orifice in the trolling valve is closed Oil cannot exit from the rate of rise chamber through the trolling valve s orifice and the rate of rise chamber is fully pressurized the ball and spring regulator is blocked when either clutch is engaged This full pressure causes the rate of rise piston to remain against its stop in the valve body bore and main oil pressure is not reduced The trolling valve is actuated by sending a controlled amount of current through the valve s coil As the current is increased the orifice progressively opens allowing oil pressure from the rate of rise chamber to escape to sump Since oil is always flowing into the rate of rise chamber through the orifice in the orifice plate the pressure in the rate of rise chamber is controlled by how much oil is allowed to exit through the trolling valve s variable orifice Since the oil pressure in the rate of rise chamber is reduced clutch pressure is reduced which allows the clutch plates to slip The amount of clutch slip is controlled by the current flow amps through the valve s coil Decreasing the current through the valve s coil will increase clutch pressure and therefore reduce clutch sli
142. orward clutch shaft causing the primary shaft to rotate in engine direction during engine operation Power is transmitted to the secondary shaft by means of the transfer gear teeth on the outer diameter of the primary clutch housing These teeth are in constant mesh with gear teeth on the of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their 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 Marine Transmission Service Manual 1019677 49 Operation Twin Disc Incorporated Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Pinians Driving Gear Primary Shaft _ secondary Shaft Gear Output Gear Figure 14 MG 6690SC and MG 6848SC Power Flow in Neutral 50 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation Primary When the primary position is selected h
143. ounting 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 116 Marine Gear Alignment 160 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation Set the indicator gauge at zero 0 Lift the marine gear with a hoist or other suitable means and place the unit in position against the engine flywheel housing Secure the flange of the marine gear main housing to the engine flywheel housing Use a feeler gauge between each mounting bracket and engine bed rail Add shims between the brackets and bed rails to equal the feeler gauge readings Carefully release the lifting force on the marine gear while observing the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading moves from zero lift the marine gear and insert additional shims Continue this procedure until the marine gear is completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of the engine flywheel housing secure the mounting brackets to the engine bed rails Before securing the mounting brackets to the engine bed rails the propeller shaft should be chec
144. outer face of seal carrier with driver T 18050 713 NOTE START FIRST SEAL INTO CARRIER WITH SEAL DRIVER AS SHOWN Tu OILSEAL 2 REQ D AS SHOWN P 1 2 NP PRESS IN FIRST SEAL INVERT SEAL DRIVER AND PRESS IN SECOND SEAL Figure 68 Output Seal Driver 18050 713 114 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly 11 Pack area between the seals with NLGI No 2 grease example Mobilux EP2 Figure 69 Packing Cavity Between Output Seals With Grease 12 Install grease fitting if not previously installed 13 Install assembled output seal carrier onto housing Use caution to avoid damaging the O ring Install attaching screws and washers and torque to 80 Nm 59 ft lb 14 Confirm output shaft endplay is within specification Remove T 18050 714 from output shaft Marine Transmission Service Manual 1019677 115 Assembly Twin Disc Incorporated Assembly and Installation of Gear Pan 1 Assemble four caged nuts into the square openings of the gear pan if not already present The nuts must be placed onto the pan side of the plate and the threads should be free of oil or grease Place the gear pan into the top cover opening of the transmission housing Rotate the pan around the output gear on the side opposite the trailing pump shaft Position the pan so the caged nuts are aligned with the four screw holes in the front of the transmis
145. p Main oil pressure is always the same as the oil pressure in the engaged clutch with this type of trolling valve The 1017170 valve contains no user serviceable parts and is available only as an assembly Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation Power Take off Optional There is a separate manual part number 1020075 which describes the operation installation troubleshooting and service of the optional Power Take off PTO for this marine transmission Live Power Take off The live PTO drives accessories using engine horsepower Since the live PTO connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven when the engine is running Hydraulic Clutched Power Take off The hydraulic clutched PTO also allows accessories to be driven using engine horsepower Since the PTO is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The PTO is engaged by the PTO control valve which is very similar to the valve used to control the transmission clutches The hydraulic clutched PTO operates with an engaged clutch pressure greater than that of the transmission s primary and secondary clutches For this reason the PTO control valve pressure increasing valve is in the transmission s hydraulic circuit before the control valve s inlet and pressure regulator Pressurized oil from the filter
146. ped 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 1019677 99 Cleaning and Inspection Twin Disc Incorporated 100 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Assembly The MG 6690SC and MG 6848SC transmissions require the use of a SKF THAP 300 Oil Injection Kit See Special Tools or similar device to install the output gear and output flange onto the output shaft and also to install the torsional coupling hub onto the primary 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 1019677 101 Assembly Twin Disc Incorporated Prior to Assembly Use the following reference The input side of the transmission
147. pressure regulating spring 4 Remove orifice plate gasket Marine Transmission Service Manual 1019677 83 Disassembly Twin Disc Incorporated 5 Remove rate of rise piston Note that shims are located between the piston and springs Figure 38 Rate of Rise Piston left and Regulator Springs right 6 Remove pressure regulating springs 7 Remove pressure regulating piston with an external retaining ring pliers Figure 39 Removing Regulating Piston with Pliers 8 Remove external retaining ring from the lever end of the stem 9 Loosen the clamping nut and remove the control lever from the stem may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 10 Remove the washer and spring from the stem 84 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 11 Remove four of M8 x 25 socket head capscrews 12 Remove the cover assembly with gasket from the valve body 13 Remove the O ring and oil seal from the cover assembly Figure 40 Removing O ring from Cover 14 Removethe two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body some models 15 Remove the detent setscrew spring and steel ball from the valve body Figure 41 Removing Detent Setscrew and Spring Marine Transmission Service Man
148. ption and Specifications Twin Disc Incorporated Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh water through the heat exchanger HEAT EXCHANGER 2 REQUIREMENTS PERMISSIBLE UI EMPERATURE INTO XCHANGER RATIO OIL VISCOSITY MIN Al RATIOS SAE 40 SCAS FI 65 CX50 F 5 x ALL RATIOS SAE 30 93 CC2 00 F STU MIN RANSFER CAPACITY kWXBtu min PER ENGINE RTD kW Chp APPLY APPROPRIA SERVICE FACTOR CONT amp MED DUTY INT LIGHT amp P C DUTY FRESH AND RAW WATER 035 1 4840 030 412872 APPROX Ul H 2 291 56 PER 100 ENGINE rom PEAK PRESSURE PROOF TEST HE 15 X kPacpsid gt 690 100 psi MAX WABLE OIL PRESSURE DROP ACROSS WITH 207 kPa 66mm s 3002 SUS AT RATED ENGINE rpm 30 psD MAX ALLOWABLE WATER PRESSURE DROP ACROSS HE WATER FLOW HE USE 15 30 TIMES OIL L min WATER PRESSURE RATING MIN 15 X INLET WATER 5 N JATA PURCHASER MUST ALSU TELL VENDUR STATE IF RAW OPEN CHANNEL amp SEA DR FRESH CLOSED ENGINE JACKET AND UR KEEL WATER WILL E TATE MAX WATER IN HE TYPICAL RAW WATER 29 32 85 F 90 F
149. que the ditch plate attaching capscrews to 80 Nm 59 ft lb 2 Install control valve and gasket Torque the valve attaching capscrews to 54 Nm 40 ft lb Marine Transmission Service Manual 1019677 153 Assembly Twin Disc Incorporated 154 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation Installation Prior to Installation A CAUTION Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be made before the driven component is installed After installation of the driven component the crankshaft endplay should be measured again The endplay at the second measurement should be the same as the first A difference in these two endplay measurements could be an indication of interference Consequently the driven component should be 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 a
150. r obstructions If you find an obstruction remove it with compressed air or work a wire back and forth through the passage and flush it with solvent Inspect machined surfaces for burrs scratches nicks and foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part Inspect ground tapers for burrs or nicks If you cannot remove the defect with a soft stone replace the part Inspect ground tapers for scratches galling or scoring damage If any of these the defects replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels This applies where a matched set of parts is not involved Inspect dowel pin holes for wear due to movement between mating parts If a dowel pin hole is worn re bore and sleeve the hole when possible Otherwise replace the parts This applies where a matched set of parts is not involved Marine Transmission Service Manual 1019677 97 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Bearings Inspect bearings for roughness of rotation Replace the
151. r style filter is located between the oil pump outlet 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 20 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Description and Specifications Flexible Torsional Input Coupling The purpose of the torsional coupling is to transmit power from the engine to the marine transmission through a rubber or silicone element that will Dampen torsional vibrations Change the natural frequencies of a system to move critical frequencies out of the operating speed range certain amount of misalignment Absorb shock and reduce noise Minimize gear rattle Several couplings are available from Twin Disc and are selected based on the customer supplied engine information Final coupling selection must be confirmed by the packager based on the torque rpm ratings and the results of the system torsional vibration analysis TVA and on engine rotation Care must be taken when servicing that replacement couplings are matched to this criteria Marine Transmission Service Manual 1019677 21 Descri
152. ragraphs Note The MG 6690SC and MG 6848SC require the use of a SKF 300 Oil Injection Kit as seen in Special Tools or similar device to service the output flange and output gear Use the following reference The input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing the output side of the transmission from the rear Marine Transmission Service Manual 1019677 63 Disassembly Twin Disc Incorporated Prepare Transmission for Disassembly Note During service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the old O rings gaskets and seals with the appropriate components being disassembled for future reference during the inspection and assembly process to make sure you do not forget the quantity size etc Drain the oil from the transmission sump by removing the hex plug from the bottom of the rear side of the housing Drain the water from the heat exchanger by removing the O ring plug from the bottom of the heat exchanger housing units with integral heat exchanger only 64 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly Remove Transmission External Components and Sub Assemblies Note The following steps of disassembly can be accomplished with transmission standing upright 1 Loosen the input coupling hub retaining capscrew approximately three revolutions resulting i
153. rawings section of this manual for correct ring location 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 Y Figure 121 Assemble Flywheel Flange to Flywheel Marine Transmission Service Manual 1019677 167 Installation Twin Disc Incorporated Table 11 Centa Torque Chart htening Torque Bondi lbs ns 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 2 Place rubber rollers in the deepest section of the cam in the output hub Normally they stick there by friction Figure 122 Insert Rollers and Note Alignment 168 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation 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 long enough that 5 hanging outside the flange Turn the two couplings halves in a position that the arrows of both halves are just opposite See Figure 122 View X A ha plined shaft Figure 123 Coupling into Flywheel Flange Marine Transmis
154. roperly 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 Cil level too high W rong 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 1019677 Twin Disc Incorporated Disassembly Disassembly The following procedure is for complete disassembly of the unit Prior to this procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility 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 pa
155. s equal to force induced by the pressure at the rate of rise piston Marine Transmission Service Manual 1019677 37 Operation Twin Disc Incorporated Electric Operation The transmission normally operates with the control valve in the electric mode Two spools each controlled by a solenoid operated pilot valve control clutch engagement When a solenoid is energized it opens the pilot valve and allows main pressure oil to flow to the end of the spool The pressure acting on the end of the spool overcomes the return spring at the opposite end causing the spool to stroke over and connect the clutch passage with main pressure passage Figure 7 Pilot Spool Passages 38 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation Main pressure oil flows from the spools above to the clutch passages of the transmission below via connecting slots in the manual override stem These connecting slots are aligned with passages in the valve body when the valve is in the electric mode Figure 8 Flow Path in Override Spool Main pressure from the energized solenoid operated pilot valve also acts on a pin on the return spring side of the opposite spool to ensure the opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Marine Transmission Service Manual 1019677 39 Operation Twin Disc Incorporated Hydraulic Lock Feature some models Some control
156. side the bore of the adapter and over the inner spring until it lays flat on the end of the stem 7 Install the small washer used on some models inside the piston The washer must lie flat at the bottom of the bore in the piston Marine Transmission Service Manual 1019677 149 Assembly Twin Disc Incorporated 8 Apply assembly grease to the adapter where it contacts the trolling valve body and install the adapter into the valve body Be sure to align the setscrew holes in the adapter with those in the valve body Figure 107 Installing Trolling Valve Parts Into Trolling Valve Body 9 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn The end of the setscrew should protrude approximately 3mm from the valve body when the dog point of the setscrew is fully engaged in the helical slot Figure 108 Installing Dogpoint Setscrew 10 Check the action of the stem in the trolling valve If the stem does not rotate 90 smoothly loosen the dog point setscrew 1 8 turn and recheck the action of the stem 150 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly 11 Install the detent ball and spring into the remaining hole in the valve body Apply MA9068 threadlocker to the threads of the detent setscrew and install until flush with the valve Figure 109 Installing Detent Ball Spring and Setscre
157. side the heat exchanger housing units with integral raw water heat exchanger only Remove the oil filter canister housing element and filter head Remove the filter bypass valve parts from the filter head Remove the control valve and set it aside for later disassembly Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 10 Remove capscrew securing clamp plate for suction strainer cover Remove clamp plate suction strainer cover with O ring and suction strainer Figure 18 Removing Suction Strainer Note It is necessary to block and support the transmission with the output side facing up Use caution to avoid damaging the taper on the primary shaft Marine Transmission Service Manual 1019677 67 Disassembly Twin Disc Incorporated Remove Output Flange 1 Loosen each of the output flange retaining washer capscrews approximately six revolutions resulting in a 9 mm 0 35 inch gap below each of the screw head The capscrews and washer will be used to restrain the output flange when it separates from the output shaft Always use retainer bolts or a safety strap to hold parts being separated with oil pressure Oil pressure applied between the two parts for disassembly can reach 300Mpa 43500psi The use of proper safety equipment is mandatory when working with high pressure hydraulic tools The parts may separate with extreme force 2 Install the oil injector into the output flange at th
158. sion Service Manual 1019677 103 Assembly Twin Disc Incorporated 4 Measure and record the distance from the machined surface of the housing to the bottom of the front output bearing bore dimension A Measure and record the width of the bearing dimension B 5 Install chilled front output roller bearing into housing bore Use driver 18050 711 to start bearing in its bore 6 Place T 21566 2 over the bearing Place a suitably sized puller or T 18050 771 inside the housing to push on the steel plate Tighten puller rod to standard torque limit for thread size of puller rod or 275 Nm 200 ft lb whichever is less Maintain this torque until bearing and housing temperatures equalize approx 10 minutes Figure 56 Installing Output Shaft Front Bearing 7 Remove tools Measure and record the distance from the machined surface of the housing to the top of the bearing cup dimension Dimension must equal dimension A minus dimension B within 0 025 mm 0 001 in 8 Install the heated output shaft front bearing inner race onto the output shaft Before the race cools rotate race on shaft to ensure it is fully seated against shaft shoulder 104 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Installation of Trailing Pump Shaft and Driven Gear 1 Press the bearings onto the trailing pump shaft by pushing on the inner race of the bearing Use a driver with an inside diamet
159. sion Service Manual 1019677 169 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 atape 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 Then grease or oil the gear shaft and plug it into the coupling spline remove tape or cord Figure 124 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 otherwise serious damage may occur to the engine 170 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Installation Propeller Shaft Before any attempt to align the engine and gearbox to the propeller shaft proper alignment of the propeller shaft must be determined This includes alignment of the propeller shaft through all struts and intermediate bearings Failure to properly align the propeller shaft may result in premature wear on bearings vibrations or possible damage to other components If the length of the shaft from the last support bearing to the gearbox is excessive or a fle
160. sion housing Figure 70 Installing Output Gear Pan Place a new sealing washer on each of the four hex head capscrews Lubricate the sealing washers Apply MA908 threadlocker to the threads of the screws and install them through the housing and into the gear pan Torque the screws to 18 N m 13 ft lb Figure 71 Installing Output Gear Pan Screws 116 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Assembly and Installation of Primary and Secondary Shafts Assembly of Transfer Gear to Clutch Shaft 1 Clean taper on shaft and tapered bore in transfer gear using OSHA approved cleaner Do not touch cleaned surfaces Loctite 7070 cleaner is recommended 2 Determine if shaft and transfer gear be advanced properly A Hold shaft in a vertical position standing on its front end B Use a depth micrometer and measure distance from the rear end of the shaft to the shaft shoulder at small end of taper Record this distance as dimension A C Install transfer gear on secondary shaft taper small diameter of tapered bore up Seat gear on shaft taper with 445 N to 890 N 100 Ibs to 200 Ibs of force D Use a depth micrometer and measure distance from rear end of shaft to machined face of transfer gear at small diameter of tapered bore Record this distance as dimension Calculate expected advance Expected advance B Calculated advance must be 3 15 mm to 4 17 mm
161. special tool T 21506 Figure 65 Output Bearing Tool T 21506 3 Install the pinion front bearing cones for primary and secondary shafts onto bearing cups previously installed in transmission housing Lift the output shaft and gear with T 18050 714 if necessary Marine Transmission Service Manual 1019677 111 Assembly Twin Disc Incorporated Output Shaft Tapered Roller Bearing Adjustment 112 1 Establish a trial shim pack having a thickness of approximately 1 20 mm 0 047 in Install the shim pack into seal carrier followed by the rear tapered roller bearing cup Install the seal carrier with shims and bearing cup but without output seals or O ring onto the transmission and torque the screws to 80 Nm 59 ft lb Rotate output shaft at least three revolutions to seat bearing rollers of front output tapered roller bearing Install dial indicator onto the housing with finger resting on rear of output shaft or on lifting fixtures Zero the dial indicator and mark the spot where the reading was taken Using a hoist and tool T 18050 714 exert 2225 N to 4000 500 Ibs to 900 105 of lifting force onto the shaft Minimum of 2224 N 500 165 lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 300 Ibs lifting force on bearing Rotate shaft several revolutions with lifting force applied Stop rotation with dial indicator finger on mark previously made continuing to hold
162. sthe 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 The exclusive rem Incorporated be either the repair or replacement of any T win Disc Incorporated part or Disc Incorporated to be defective and the labor to rm that work and to remove and reinstall or equivalent credit In this context labor is defined asthe flat rate labor hours established Twin Disc Incor i Incorporated be liable for economic loss incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product
163. te of rise chamber is fully pressurized the ball and spring regulator is blocked when either clutch is engaged This full pressure causes the rate of rise piston to remain against its stop in the valve body bore and main oil pressure is not reduced Detent position Trolling mode orifice closed orifice opened Figure 13 Mechanical Trolling Valve Rotating the trolling valve lever into the trolling mode opens the variable orifice allowing some of the oil to escape from the rate of rise chamber to sump This reduces the oil pressure in the rate of rise chamber Since oil is always flowing into the rate of rise chamber through the orifice in the orifice plate the pressure in the rate of rise chamber is controlled by how much oil is allowed to exit through the trolling valve s variable orifice The trolling valve lever position determines the pressure in the rate of rise chamber which determines main oil pressure Main oil pressure is always the same as the oil pressure in the engaged clutch with this type of trolling valve Marine Transmission Service Manual 1019677 45 Operation 46 Twin Disc Incorporated 1017554 Electric Trolling Valve This trolling valve is a variable orifice that controls the pressure in the rate of rise chamber The pressure in the rate of rise chamber determines the rate of rise piston position which ultimately controls the main and clutch pressures for the transmissi
164. the bearing as follows Note Do not remove rear bearing unless bearing must be replaced Bearing is an interference fit with shaft and will be destroyed during removal a Remove the external retaining ring from the shaft b With a hammer and chisel cut cage off bearing to remove bearing cage and rollers Use a split type bearing puller cheese cutter to grip flange at small end of tapered inner race d With a hydraulic jack pull on bearing inner race while pushing on rear end of shaft to remove bearing inner race from shaft 3 Set shaft upright with input end up 78 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 4 Remove and disassemble pinion s a Remove round retaining ring from input end of shaft and remove pinion from shaft Figure 33 Removing Round Retaining Ring from Input End of Shaft b Remove internal retaining ring from input end of pinion and remove straight roller bearing Note The straight roller bearing in the bore of the input end of the pinion is an interference fit and will likely be destroyed during removal Remove the straight roller bearing with the use of a puller behind the roller ends e Remove the pinion from the clutch shaft d Remove tapered roller bearing outer race from bore at rear of pinion if bearing requires replacement This bearing race is an interference fit in the pinion bore To remove use an electric welder to weld a
165. tion and remove them 5 Remove the third Neutral solenoid units with hydraulic lock or plug units without hydraulic lock 88 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 6 Remove the filter screen from the valve Figure 46 Removing Filter Screen 7 Remove the two socket head O ring plugs from the bores in end of the valve bogy 8 Remove the two spools from the valve body 9 Remove one dowel pin and spring from each of the spools hydraulic lock units only 10 Remove the spool return spring and dowel pin from the bottom of each of the spool bores in the valve body Marine Transmission Service Manual 1019677 89 Disassembly Twin Disc Incorporated 1017555 Trolling Valve Optional Equipment 1 Remove the trolling valve attaching screws Figure 47 Removing Trolling Valve Attaching Screws Steel ball is under pressure from the spring Care must be taken when removing the trolling valve and orifice plate to prevent loss of steel ball 2 Remove the trolling valve from control valve 3 Remove the gaskets orifice plate and steel ball from control valve 4 Remove the screw and nut clamping the lever to the stem 5 Remove the lever from the stem It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 90 Marine Transmission Service Manual 10196
166. ual 1019677 85 Disassembly Twin Disc Incorporated 16 Remove the dog point setscrew Note that the setscrew is retained with 908 threadlocker MTM Figure 42 Removing Dogpoint Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 43 Removing Thrustwasher 86 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Disassembly 19 Remove the stem from the valve body 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 44 Removing Roll Pin Retaining Shuttle Seat 21 Thread a M8x1 25 screw one of the cover screws works well into the seat and remove it from the valve body 22 Remove the shuttle ball from the valve body Marine Transmission Service Manual 1019677 87 Disassembly Twin Disc Incorporated Disassembly of Upper Valve Body Half electric section 1 Remove the Weatherpak connector from the valve body by sliding it in the direction of the opening in the shroud 2 Mark the wires with the location letters that are on the Weatherpak connector Open the end of the Weatherpak connector to allow removal of the pins and wires 3 Remove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool Tool is Packard Electric P N 12014012 Figure 45 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identifica
167. utor or service dealer Contact Twin Disc Inc for a distributor or service dealer near you Note Do not order parts from the part numbers on the cross sectional diagrams These numbers may be referenced for part identification only All part numbers should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc Inc 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 Inc All returned parts new or old emanating from any of the above stated changes will not be accepted for credit Any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty Marine Transmission Service Manual 1019677 15 Introduction Twin Disc Incorporated 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 necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com Warranty The equipment for which this manua
168. valve models have a hydraulic lock feature and are identifiable by a third solenoid operated pilot valve This feature keeps the engaged clutch pressurized as long as the engine remains running should electrical power fail or malfunction occur while the clutch is engaged The hydraulic lock is accomplished by allowing pressurized oil from the pressurized clutch passage to flow inside the spool Oil pressure inside the spool forces the dowel pin against the O ring plug Neutral solenoid UNITS SE HYDRAULIC LOC Figure 9 Hydraulic Lock Units The resulting reaction is a force on the spool that overcomes the spool s return spring force Should the solenoid become de energized while the spool has its clutch pressurized oil pressure will keep the spool in that position This keeps the transmission in gear as long as the engine is running 40 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Operation The hydraulic lock is disabled when either the engine is stopped or the neutral solenoid is energized When the neutral solenoid is energized it sends pressurized oil to the dowel pins at the return spring end of each spool Since the dowel pin used at the return spring side of the spool is larger in diameter than the dowel pin inside the spool the hydraulic force acting on the larger pin forces the spool to connect the clutch passage to sump with assistance from the return spring
169. ve in the neutral detent position Improper installation of power engaging devices could cause failure of the selector valve stop permitting improper positioning of the selector valve and resulting in control malfunction Electrical Controls All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connections must be tight and free from any corrosion Final Checks Be sure the transmission is filled with oil before starting See Description and Specifications and Preventative Maintenance for proper oil and filling procedure Marine Transmission Service Manual 1019677 173 Installation Twin Disc Incorporated 174 Marine Transmission Service Manual 1019677 Twin Disc Incorporated List of Special Tools Special Tools Special Tools The following pages include the special tool drawings that are specific to these models The special tool drawings included are listed below and continued on the following page D D O O D D D LE BOD O B Marine Transmission Service Manual 1019677 SKF THAP300 T 18050 705 T 18050 706 T 18050 708 T 18050 711 T 18050 712 T 18050 713 T 18050 714 T 18050 715 T 18050 723 T 18050 771 T 18050 784 T 18614 6 119330 T 20023 3 T 20023 3 Pump Set and Fluids Bearing driver for pinion needle roller bearings Input seal driver and protection sleeve Bearing
170. ve models only Plate stiffener O ring Plug O ring raw water drain Eyebolt lifting Housing raw water heat exchanger Capscrew hex head heat exchanger Gasket anode Capscrew hex head anode Washer sealing 1 2 1 2 1 12 1 1 1 Anode heat exchanger Housing lube relief valve Heat exchanger raw water Gasket heat exchanger housing Gasket stiffener plate Plate instruction lube Plate instruction identification Screw drive instruction plate Breather S link Chain Clip Gauge oil level Tag oil gauge Tube assembly oil level gauge pe1e10dj02u UIML suonesnil Illustrations Transmission Section View SNI SN 5 o 2551 55506056 55 25 lt lt lt A 555 555 gt TIRES eae 0 Twin Disc Incorporated B B EON w JI MP NGA NY i ss S b SS LLL ELLE LLL ELLE LLL ELE RRRS 25 554 2554 50626094 500 lt lt lt 55506 255506 555250555 25555505 555500 255552505 25252555506 2555505 55550 60000000060 96402920200 60006060 252552550 060600
171. w 11 Check the torque required to overcome the detent The torque should be 1 1 1 7 Nm 10 15 in Ib Adjust the detent setscrew if necessary to achieve the proper torque to rotate the lever out of the detent position 12 Install the lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 13 Rotate the lever if necessary on the stem to the position shown on the valve installation drawing see Engineering Drawing Section of this manual Install the screw and nut to clamp the lever to the stem Tighten the screw and nut to 9 5 Nm 7 ft lb 14 Install the neutral pressure regulating spring into the bore of the control valve if removed Marine Transmission Service Manual 1019677 151 Assembly Twin Disc Incorporated 15 Install the steel ball onto the neutral pressure regulating spring Figure 110 Installing Neutral Pressure Regulating Spring and Ball 16 Install the orifice plate gasket orifice plate trolling valve gasket and trolling valve onto the control valve Install the attaching screws and torque them to 23 Nm 17ft Ib Figure 111 Installing Orifice Plate left and Trolling Valve Onto Valve Body right 152 Marine Transmission Service Manual 1019677 Twin Disc Incorporated Assembly Installation of Electric Control Valve 1 Install control valve ditch plate and gasket Tor
172. xible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Transmission Controls CAUTION Transmission controls must be checked for proper function and alignment after any transmission selector valve is properly indexed in relation to the operator s control lever Failure to do so could cause control system malfunction resulting in personal injury and or damage to equipment and property See specific marine transmission installation drawings for detail and dimensional information needed for the proper installation of control linkages power engaging devices or electrical connections Marine Transmission Service Manual 1019677 171 2196101 enuen 291139 uoissiusueJ 5 214129 3 SZL WIRING DIAGRAM CONNECTOR SECONDARY CLUTCH SOLENOID SECONDARY CLUTCH SOLENOID Pb 7 PRIMARY CLUTCH SOLENO cP PRIMARY CLUTCH SOLENOID i d 77 NEUTRAL SOLENOID OPTIONAL MATING WIRING HARNESS 1017404 OPTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH NOTE LEVER MAY BE LOCATED AN
173. ydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel plates are spline connected through the clutch hub assembly to the pinion Because the primary input pinion is in mesh with the output gear the output gear and shaft will rotate in anti engine direction The secondary input pinion will be backdriven engine direction when the unit is in the primary position Primary Clutch Engaged Figure 15 MG 6690SC and MG 6848SC Power Flow with Primary Clutch Engaged Marine Transmission Service Manual 1019677 51 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 Secandary Clutch Engaged Figure 16 MG 6690SC and MG 6848SC Power Flow with Secondary Clutch

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