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1. PROPORTIONAL VALVE N gt x gt an A 4 PROPORTIONAL VALVE Ed S E Q 4 HELENI DENS LI SUMP 9 20 D rate LUBE an UR TEGUL HY DRAUL I AGRAM GRAPHIC SYMBOLS Figure 16 Hydraulic Schematic GP control valve Assembly 1020729 Marine Transmission Service Manual 1021569 53 Operation Twin Disc Incorporated
2. CUSTOMER SUPPLIED O_O SEE MODULE POWER CONNECTION CHART RED 45V TROLL SPEED POTENTIOMETER 1K OHM ORANGE 0 0 TO 0 5 VOLT MINIMUM TROLL GREEN 4 75 TO 5 0 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 SOLENOID B ON s CUSTOMER SUPPLIED RED LED VIOLET TROLL SPEED CURRENT INPUT GREEN 4 20 MA SEE NOTE 1 GREEN TEMPERATURE SENSOR TAN 2 2 TAN Ada TAN ENGINE SPEED SENSOR 2 RED ee AZ POWER OK O BROWN GREEN LED lt PROPELLER SPEED SENSOR GREEN B BLACK E Z A COM NORMALLY CLOSED BLACK SOLENOID NOT IN NEUTRAL RELAY BED XN NM 2 CLOSED IN NEUTRAL aA Ag CUSTOMER SUPPLIED B lt BLUE MP o SOLENOID A ON BLACK 200 mA MAXIMUM ae Nw RED LED e bes D BLACK 7 SOLENOID SWITCH po YELLOW CUSTOMER SUPPLIED TO 87A START m SEE MODULE POWER CIRCUIT 35252 2 TRANSMISSION MANUAL a OVERRIDE SWITCHES O SOLENOID RETURN Figure 178 E Troll Wiring Diagram Marine Transmission Service Manual 1021569 207 Installation Twin Disc Incorporated 208 SOLENOID B ON RED LED WIRING SCHEMATIC GREEN TEMPERATURE SENSOR 212 0H POWER OK GREEN LED BLACK NORMALLY CLOSED BLACK B lt SOLENOID A NOT IN NEUTRAL RELAY RED MP CLOSED IN
3. 65155 5 ANSI Yi 7 PX 11615 A 7 POWER TAKE OFF ASS Y ce e scs ACIO TWIN DISC INCORPORATED RACINE 53403 USA PROPORTIONAL VALVE a MANIFDLD z a a PROPORTIONAL VALVE MANIFOLD 1021000 CSHOWN ol LUBE q PRESSURE REGULATOR HYDRAULIC DIAGRAM GRAPHIC SYMBOLS PLATE 1018175 SCREW 1100 100 7 SEE NOTE NOTES A PROPORTIONAL CONTROL VALVE OPERATION 1 WARNING DO NOT CONNECT VALVE COIL DIRECTLY BATTTERY POWER SUPPLY VOLATAGE 2 OPERATION TO BE PERFORMED WITH ONLY TWIN DISC CONTROL SYSTEMS OR MODULES MANUAL DIRECTIONAL CONTROL VALVE OPERATION 1 WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PUSH TO ENGAGE PORT 2 WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PULL TO ENGAGE PORT B MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH 1 SWITCHES ARE NORMALLY CLOSED WHEN MANUAL DIRECTIONAL CONTROL VALVE IS IN THE CENTERED POSITION AND OPEN WHEN LEVER IS ACTUATED FROM CENTERED POSITION 2 CURRENT 20 AMPS 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE DRAWING PROPORTIONAL VALVE SEE CHART 2 gt TORQUE TO 27 230 1 SEE NOTE SEE NOTE PLUG SEE CHART PLUG MA1038B 25 Z CLUTCH PRESSU
4. CLUTCH CLUTCH 1 PROPORTIONAL VALVE s aps gt _ 4 1 E VY PROPORTIONAL VALVE a gt 172 Al L 4 XI e SUMP EE e FROM PUMP PRESSURE GULATUR mm MANUAL DBIRECTIDNAI CUNTROL VALVE _OPTIONAL TEMPERATURE SEN gt PORT M14 X i IMARY amp SECONDARY LUBE Figure 17 Hydraulic Schematic GP control valve Assy 1021658 54 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Manual Direction Control Valve Operation The manual direction control valve is locked in the Neutral center position during normal operation There are three possible positions of the manual direction control valve stem If a condition occurs where the proportional valve is not operational for any reason the operator can remove the locking pin from the direction control valve and push the stem into the valve for engagement of clutch A or pull it out of the valve for engagement of clutch B The manual direction control valve has an integral switch with contacts that are closed only when the manual direction control valve is in the neutral positi
5. 19 Drecun DIVO 19 Construction 20 Lubrication FedEUT OS used RENE ESL OINRES 21 Heat Exchanger 23 Specifications and Maintenance 25 Oil Pressures ER 27 Optional EQUIPMENT aun 29 Torque Values for Fasteners eese 32 Clutch Plate Wear 36 n 37 e 37 Hydraulic System with PX 9975 Manual Control Valve 38 GP Control Valve with Electronic Interface 47 GP Control Valve Hydraulic Portion 48 GP Control Valve Electronic Control Interface Profile or E Troll MOGUIG cc 50 Trolling Valve Optional eere eeu 56 Power Take Off Optional 59 60 Marine Transmission Service Manual 1021569 7 Table of Contents Twin Disc Incorporated Preventative Mainte
6. N RSS zi SS SIN SNS SALAS n dvo i sale fay itn CLUTCH Pup rite Son NOS D eee Ss RM AD UR CONNECTION MES REFER CUSTOMER SUPPLIED HEAT EXCHANGER INSTALLATION DRAWIN REDUCER BUSHING 3 4 X 1 2 INSTALLATION OF OPTIONAL TEMPERATURE INDICATING SWITCH USING PIPE TEE WITH REDUCER BUSHING 250 P SI XA7371M VALVE CONTROL 3 4 X 3 4 X 3 4 MGS141 HYDRAULIC DIAGRAM PICTORIAL OIL PUMP NOTICE SUMP TD N THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS e STRAINER NUT BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED NULLIFY OR LIMIT RIGHTS GRANTED TO THE 0 5 GOVERNMENT OR OTHERS BY CONTRACT PRIMARY 1 1 RELEASED CLUTCHES a4 NEN A 5 j T In m Oo 14 9 CLUTCH LT PRIMARY amp SECONDARY SHAFT LUBE SPLIND FRONT BRG FRONT amp BRGSO LUBE hao d VALVE PSI CLUTCH PLATE AND BEARING LUBE FOR OPTIONAL MECHANICAL TOP CIF ONE Jl IS DESIGNED PORTION ENCLOSED WITHIN THESE LINES IS REQ D FOR OPTIONAL HYD P T O ONLY IS NOT REQ D W O Lo Pao THIS LINE P T D LUBE 4 REPLACES IT amp COOLING CLUT
7. TWIN DISC INCORPORATED Service Manual arine ransmission Document Number 1021569 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 1021569 October 2004 Marine Transmission Service Manual 3 TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY MARINE PLEASURE CRAFT Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of thirty six 36 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twenty four 24
8. 4 z m d A Ta i i 1 a i x L3 DCP 1006 DCP 1004 Figure 135 Hydraulic Pump Installation PTO Cover and Top Cover 1 Apply MA1015 sealer to the sealing surface of the PTO cover 1 2 Install the PTO cover 3 Torque the four M12 1 75 capscrews to 80 Nem 59 Ib ft 4 Place a new gasket on the sealing surface of the top cover 166 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 5 Install the top cover 2 6 Torque the twelve M12 x 30 capscrews to 80 Nem 59 Ib ft DCP_1001 Figure 136 PTO Cover 1 and Top Cover 2 Installation Input Coupling iP Apply molydisulfide grease to the splines at the input end of the primary shaft Lubricate the lips of the input oil seal 2 Position the input hub on the shaft 3 Temporarily attach the coupling to the input housing for shipping Marine Transmission Service Manual 1021569 167 Assembly Twin Disc Incorporated Control Valve Mechanical Control Valve PX 9975 Install valve onto the transmission and torque the attaching screws to 20 Nem 27 Ib ft Figure 137 Installing Selector Valve Assembly Electronic Control Valve PX 10225 Install gasket and valve onto the transmission and torque the attaching screws to 20 Nem 27 Ib ft Install the solenoid coils onto the spools and torque the retaining nuts to 6 8 Nem 5 Ibeft Solenoid Spool Solenoid Figure 138 Solenoi
9. Marine Transmission Service Manual 1021569 219 Special Tools Twin Disc Incorporated TD 300498 Outer Bearing Race Installation MA590CS 1 50 45 2 PLACES 950 00 652 10 00 110 00 O 3 2 S 2170 00 2176 00 9 00 2188 00 Break shorp corners Moteriol 40 40 50 HRe All dimensions ore in mm Tolerance 0 1 mm Not al Scale 220 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Engineering Drawings Engineering Drawings List of Engineering Drawings The following pages include the engineering drawings that are specific to this model The engineering drawings included are listed below and continued on the following page Note Any part numbers listed in the following engineering drawings are for reference only Please refer to your bill of material for part numbers specific to your model 10830 MG 5145A Marine Transmission Sectional View sheet 1 of 7 10830 MG 5145A Marine Transmission General View sheet 2 of 7 10830 MG 5145A Marine Transmission General View sheet 3 of 7 10830 MG 5145A Marine Transmission General View sheet 4 of 7 10830 MG 5145A Marine Transmission General View sheet 5 of 7 10830 MG 5145A Marine Transmission General View sheet 6 of 7 10830 MG 5145A Marine Transmission General View sheet 7 of 7 A7119M MG 5145A Hydraulic Diagram 1161
10. gt 3 1 1061 Co rine 6 1 11253 T mu TH AA E RARA o pomum nde gjs S 9 SIS 5 V M S 3 7 I e N D 7 2 N gt 1 11789 S S 1 M 2052 AJ 2 12 2057 516 3 20 33 152 4 6 00 300 0 11 81 300 0 11 81 392 4 15 45 e ER E 449 6 17 72 450 0 17 72 O 20 40 60 METRIC PROJECTION DIMENSIONS SHOWN IN 0 1 0 2 0 3 0 BRACKETS ARE IN INCH NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER IER E pem TAUN ES LBs LBS IN INCORPORATED FOR OTHERS INSTALLATION DIMENSIONS TWIN DISC INCORBORATEE HEAT TREAT RT USE RACINE WI 53403 USA SEE DRAWING PX 10830 SHEET 2 RACINE WI 53403 USA PX 1 0830 THIS NOTICE IS NOT INTENDED NAME TO OTTO THe US GONCENUENT MG5145 A MARINE TRANSMISSION OR OTHERS BY CONTRACT REF PX 10830 gt 5 4 4 REV T e B da a nae _ ___ GN BREN on GME NS YIS Be USES Aibo He a a N TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO 2 eee REFER TO B3649 FOR HEAT EXCHANGER REQUIREMENTS e MAY RESULT IN DAMAGE TRANSMISSION SEE BELOW 91 0 3 58 18 0 71 THE 10830 CONFIGURATION IS NOT SUITABLE FOR REMOTE MOUNTING 6 RECOMMENDED ACCEPTED 417 0 DRILL THRU ON PADS 4PLACES AN NZ
11. Check Ball and spring Ball seat Plate 1 MG 238 Figure 85 Rate of Rise Components 9 Remove the plug and spacers and the shuttle ball seat and ball Make sure the O ring is removed from the bore if it does not remain on the ball seat Ball Seal Shuttle am Washer Seat Ball P 4 O ring Spacers 239 Figure 86 Shuttle Ball Components Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Disassembly of GP Control Valve with Electronic Interface The GP Valve is made up of a non serviceable electronic interface and two valve bodies with plugs and cartridges O ring kits are available for servicing the plugs and cartridges however none of the cartridges are field serviceable beyond replacement of the o rings The later version Assembly 1021658 of the hydraulic pressure regulator valve is serviceable and contains an orifice filter plug and a ball check valve assembly that are replaceable i E i Figure 87 GP Valve Assembly mounted Marine Transmission Marine Transmission Service Manual 1021569 123 Disassembly Twin Disc Incorporated Disassembly 1 Disconnect the connectors at the proportional valves the neutral switch and the temperature sensor if equipped and loosen the four M6 1 0 capscrews that retain the Electronic Interface Module to the Hydraulic portion of the valve assembly If th
12. Hsia Lez D S 2 o Levis TH 72 P 7H P1036 1 p cil INN sere 4 NER EMEN ER 222 2 572 15 a lea Purok 4 A 22 ETE o wes 1 1996 9 Sz ee A NITE 27 1 20572 12 iB Lee f 199 _ 4_ 22 2 1002498 1 MA1038A 2 1016215 1 1 i Leser LT T 1018048 1018254 1 ieee Ces pr af Pose 1 AD _ 2018 __ 3 EE 7 Pie e 1 9 PM2009AC 1 1 841 E 2 NE MA 72 2 iy j WV 1190 1 11909 2 OPTIONAL EXTRA SUPPLIED 3 tes 1018272 INSTALLATION L eese T Taser 1046 H __ P 9926 MA1048A 8 12 2127548 1 9 0 VIEW T HA EF 1 Pes lt Tees str Ti sl giela lglg 7 7 SS ASSEMBLY INSTRUCTIONS 5 ELASTIC SHEET alg j ASSEMBLE TEST PER S570AL M 5 amp 7 MTU MOUNTING PADS Bess 8 i 55 2 ats amp a CUSTOMER NOTES NOTE 8 CONTROL VALVE BOLTS ONLY ARE TO HYDRAULIC PES EU T Sr BE TORQUED DRY TO 53 0 61 0 N m 12236 HYDRAULIC CAPACITY 15 2
13. ia Figure 155 Assemble Top Valve Body Components Install a new gasket and the main regulator valve assembly to the transmission or ditch plate using the four twelve point capscrews Torque the capscrews to the level specified for the appropriate sized capscrew into aluminum threads See the torque specifications in Description and Specifications 180 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Figure 156 Install Regulator Valve Body to Transmission 4 Install a new gasket and the top valve body assembly on the main regulator valve assembly using six M10 1 50 x 70 hex head capscrews and torque to 46 Nem 34 Ib ft Figure 157 Install Top Valve Body onto Regulator Valve Assembly Marine Transmission Service Manual 1021569 181 Assembly Twin Disc Incorporated D Install the Electronic Profile or E Troll Module on the top valve body and torque the four M6 1 0 capscrews to 9 5 Nem 7 lbeft Figure 158 Place Profile or E Troll Module onto Valve and tighten screws 6 Connect the electrical wires to the proportional valves and connect any other wires that were removed during disassembly 182 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Adjustment of Main Pressure Valve Assembly 1020729 It is recommended that following the servicing of the GP valve assembly off of the transmission that a procedure be followed to ensure the
14. 5 lt 2 5 5 TE A 28 e Tm T HH 617 0 24 29 E 1 m LIVE PTO 4 BOLTS O 14 el 1 ELECTRIC SELECTOR 30 PRESSURE ANGLE AND ELECTRIC TROLLING 4 197 0 7 76 205 0 8 07 154 0 6 06 WATER IN fa a 1 WATER OUT THREAD 1 1 2 1194S 1 11710 12 3570 S 1 11710 3 M 235 0 8 4885 gs DA 2 d ARP SS 5 S 38 Art 2 gt K 2n S NT 5 o 2 12 2057 516 3 20 33 300 0 11 81 300 0 11 81 THIRD ANGLE e PROJECTION 0 20 40 60 450 0 17 72 450 0 17 72 mae gt A DIMENSIONS SHOWN IN BRACKETS ARE INCH NOTICE THIS PRINT CONTAINS WEIGHT PROPRIETARY INFORMATION AND 15 ae 14 0 01 TUN 20156 1 D NOT TO BE USED IN ANY INCORPORATE FOR OTHERS INSTALLATION DIMENSIONS DEIRIMENIA TO INIERESTS EAT TREAT FRST USE P25 1 00 RACINE 53403 USA SEE DRAWING PX 10830 SHEET 2 to sc E 10856 THIS NOTICE 15 INTENDED 5 857 ELECTRIC AND MECHANICAL VALVES SHOWN GRANTED TO THE U S GOVERNMENT 65145 MARINE TRANSMISSION peso BY REF 10830 COWPLING 2 COUPLING 56 15 70 15 0 74 00 dm SAE 0 n m ar
15. ET 18 00 ISSUES 550 5 SP N 22222 22222 2 1 H A NO O CA O ALL 4026 gt M 25552 Je 00 260606 0 D H SSSI 50000006 XXX T XXX XX OD KKK QKK KO E CX XD 2 E 521 2 AK LLR gt al t 525555 SN ALSI AIA IN xx IN eig m d 255 ese 5225 y Boss 000 6 SOM H 942 90 0 2 6 HOLES 17 0 0407 7 5 55 Gos 4 2 2 9 7 THES 5 SIS 2407 0 gt 171 al WW IIMS ANS 77 D SAKIN lt lt 571 40 466 60 6 6 438 20 1 2 HOLES 135 571 50 2 466 70 lt lt INNS D COUPLING CENTA NOMINAL DYNAMIC TORSIONAL STIFFNESS CTdyn KNm rad amp Lbsin rad o O WR DUPINE DRAWING TORQUE 0 05 T kN 0 25 T kN 0 50 T kN 0 75 T kN 1 00 T kN OUTER PARTS INNER PARTS SPEED CENTA TYPE R 6300 74 115 6 Kgm 0 165 Px 11518 GENUS DEO 95686 bsin 53023 203256 653953 1016278 1573022 704 Lbs 564 Lbsim 3000 RPM CENTA TYPE R 6300 Nm 0 290 Kgm 0 165 Kgm PX 11536 DEN DEL OO 55686 Lbs in 53023 203256 653953 1016278 1573022 992 Lbsim 564 Lbsi 2800 RPM mm WEIGHT UNLESS OTHERWISE DIMENSIONS ARE kg MACHINED DIMENSIONS 0 75 FIRST USE xx 2025 ASSEMBLY ALL ANGULAR TOLERANCES 2 GEOMETRIC TOLERANCI MUR S 2 MG 9145 A PER ANSI Y1
16. M422 2 20572 12 SEE NOTE b e Ss 1 PX11570 1 5967 2 J A i j 1016217 e EN Pw AN SAA T Leer P n T 12 2 j 10791 2 d e Sy 7 O mE Ly MA656B 1 10797 1 H 4 H 195 RATO 26 25 2073 HAY 2 2073 E 7 T T T Vy Px10801 K LL a 244 UN 4 Zs INC NI D lt lt qo N VY CLOG AY ES fe SAFARI 27 VAT a AW ZZ ZA AE 2 ha 14st RAO N S SS A2916K8 1 L PM20577 3 BUSHING N NS BABAR SSS 1 AM EET MN C maosa 1 J GCG 3 T r N SS REN F 1018234 M2073 wa AUY NY 22 MSS 1018234 1 823018 1 P 12220 1 D Lf 227 SS kp a 5 A2916BE 2 5 B2301B 1j VA set VA
17. 280 Connection Part J Oil Pressure Passage K Oil Directional Port 1 08 Pressure Chamber Control Valve Lever Control a J Atmosphere Pressure L Engaging Pressure Figure 4 Mechanical Control Valve Neutral Cutaway View CONTROL VALVE BODY TO FORWARD CLUTCH A be TO REVERSE ELENG CONTROL VALVE STEM ATMOSPHERIC PRESSURE 1 ENGAGING PRESSURE Figure 5 Mechanical Control Valve Neutral Sectional View 42 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Manual Control Valve Primary When a shift to the primary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 6 and 7 The pressurized oil in chamber is directed through ports G and K to passages D and J Passage D is aligned with a passage directing main pressure oil to the primary clutch Pressurized oil from port K travels through passage J and seats the ball against its seat thus preventing oil from exiting chamber L to sump Oil also travels from chamber A through an orifice into chamber L This orifice meters the oil for a steady smooth pressure rise from the neutral regulated pressure in chamber L As chamber L fills with oil the pressure rate control piston moves against the springs until the piston is stopped by a shoulder in the valve body This causes the pressure in chambe
18. 144 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 8 Lubricate the area of the clutch shaft that will contact the pinion assembly Install the pinion assembly Gently rotate the pinion as it is lowered into the clutch plates until the splines are fully engaged in all the clutch plates DCP_1046 Figure 109 Pinion Assembly Installation 9 Install the larger diameter thrust race into the pinion bore 10 Install the front needle bearing and remaining rear thrust race Note This thrust race pivots on the shaft DCP 1045 Figure 110 Front Thrust Races and Needle Bearing Installation Marine Transmission Service Manual 1021569 145 Assembly Twin Disc Incorporated 11 Install the snap ring to retain the front thrust races needle bearing and pinion DCP_1043 Figure 111 Snap Ring Installation 146 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Secondary Shaft Assembly 1 If removed install a new rear taper bearing cone on the output end of the shaft a Heat the bearing cone to 120 C 250 F Handle the bearing cone with care The bearing cone is HOT b Place the bearing cone on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing cone against the clutch housing as the bearing cools 2 Install the clutch piston into the clutch housing a Lubricate and install a new piston
19. DCP_1031 Figure 125 Securing Output Gear Pan Output Shaft Front Bearing Carrier 1 Heat the bearing inner race to 120 C 250 F for 30 minutes before installing it Install the bearing inner race on the output shaft A CAUTION Handle the bearing with care The bearing is HOT 2 Deep freeze bearing outer race and rollers to 51 C 60 for at least two hours Handle the bearing outer race with care The bearing outer race is extremely COLD 3 Lubricate the bore of the main housing Install the outer race and rollers into the main housing 158 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Front Output Cover 1 Lubricate a new O ring with grease 2 Install the O ring onto the cover 3 Press the cover 1 into bore of the main housing DCP 1031 1 Figure 126 Front Output Cover 1 Installation Input Housing 1 Position the input housing on the main housing 2 secure the input housing with twelve M12 1 75 capscrews and washers Torque the capscrews to 80 Nem 59 Ib ft DCP_1030 DCP_1029 Figure 127 Input Housing Installation Marine Transmission Service Manual 1021569 159 Assembly Twin Disc Incorporated Front Bearing Carriers Note Position the main housing with input end down Be sure the main housing is securely supported 1 lf necessary assemble the primary clutch shaft and secondary cltuch shaft front bearing carriers a Heat a bearing co
20. 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 E Change the natural frequencies of a system to move critical frequencies out of the operating speed range Accommodate a certain amount of misalignment Absorb shock reduce noise Minimize gear rattle oeveral 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 22 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing coolant from the engine through the heat exchanger The heat exchanger is mounted on a special bracket bolted on the live PTO face The special brackets allow either live PTO connection or clutchable PTO and no PTO as well In case of remote mounting the heat exchanger should be installed in a location convenient to both engine coolant and marine transmission oil Marine
21. NOTES 64 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance In boat Maintenance and Repair Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures n D D D O Note Marine Transmission Service Manual 1021569 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 Further disassembly reassembly of the primary or secondary shafts will require removal from the engine and the use of tools and equipment normally not available on board the vessel 65 Preventative Maintenance Twin Disc Incorporated General Maintenance 66 Overhaul Interval A complete overhaul and thorough inspection of the unit should be made at the same time as the scheduled engine overhaul Refer to Cleaning and Inspection for more detailed inspection instructions Oil System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil in it With the engine running at low idle and the transmission in Neutral check the oil again The oil level should be near the oil level mark Transmission oil temperature should be in the normal operati
22. RH ENGINE PRIMARY CLUTCH LUBE PRESSURE CHECK CONTROL VALVE PRIMARY CLUTCH PRESSURE CHECK BREATHER OIL FILL PLUG LUBE PRESSURE OIL PUMP 4 Q CI 27 ALL ma i TT A ess d OIL LEVEL GAUGE INPUT SHAFT ROTATION RH ENGINE OIL GAUGE TUBE ASSEMBLY SECONDARY i CLUTCH LUBE PRESSURE CHECK PTO COVER SECONDARY CLUTCH PRESSURE CHECK RH PROPELLER ROTATION RH ENGINE PRIMARY CLUTCH 8 1 25 PUMP SUCTION STRAINER LH PROPELLER ROTATION RH ENGINE SECONDARY CLUTCH MANIFOLD OIL DRAIN PLUG MG_300 Figure 24 MG 5145A with Mechanical or Electrical Control Valve 82 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly INPUT SHAFT ROTATION RH ENGINE PRIMARY CLUTCH LUBE PRESSURE CHECK CONTROL VALVE P lt KX PRIMARY CLUTCH PRESSURE CHECK BREATHER BEES 1D OIL FILL PLUG LUBE PRESSURE er Ex ALLU gt 122 INPUT SPEED SENSOR m OIL LEVEL GAUGE fT OIL GAUGE SECONDARY TUBE ASSEMBLY CLUTCH LUBE PRESSURE CHECK tay eh i E 9 cd PIEVE eid LM n RH PROPELLER ROTATION RH ENGINE PRIMARY CLUTCH SECONDARY CLUTCH PRESSURE CHECK 8 1 25 PUMP SUCTION STRAINER LH PROPELLER ROTATION RH ENGINE SECONDARY CLUTCH OIL DRAIN PLUG OUTPUT SPEED SENSOR MANIFOLD MG_302 Figure 25 MG 5145A with GP Control Valve with Elec
23. 68 General Check the mountings for tightness or damage such as cracks Tighten loose mountings and replace damaged parts Check pressure and temperature gauge where applicable Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required E Inspect unit nameplates for looseness and corrosion Tighten mounting screws that are loose and replace nameplates that are corroded Inspect and oil the exposed stem of the Manual Direction Control Valve for corrosion protection Torsional Coupling DO NOT obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling The ambient temperature of the air around the coupling should be between 6 C 22 F and 80 C 176 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 Perform a complete inspection whenever the transmission is removed from the engine for any reason When inspecting the flexible coupling look for evidence or conditions identified in th
24. CS 11 NZ 7 CONN LINE BETWEEN AND CONTROL VALVE FACE USED FOR CONTROL MOUNTING BRACKET IL IN FROM HEAT ER EM ALUMINUM PROTECTOR BEFORE OPERATING UNIT M10X1 THREAD ISO 61 49 OIL OUT TO HEAT THO REMOVE ALUMINUM THREAD PROTECTOR BEFORE OPERATING UNIT TJ A 264 1 10 40 395 0 15 55 MAX BORES vy COMPANION FLANGE BB8 9 50 DIA 5 106 4 4 19 DIA AT HUB END OF 3 175 m 1 1 2 A TAPER WITH 25 4 1 X 15 NOTE WHEN MOUNTING ENGINE TRANSMISSION IN BOAT ALL THE MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW THE PX 10830 CONFIGURATION IS NOT SUITABLE FOR REMOTE MOUNTING RECOMMENDED HOLES MAY BE USED FOR LIFTING MARINE TRANSMISSION ONLY UBE P S I 10x1 149 SUPPLY INLET IS DIAGRAM TO HYDRAULIC 17 87 X 15 9 5 87 KEY HEAT EXCHANGER REQUIREME REFER TO B3649H FOR HEAT EXCHANGER DATA CONTROL VALVE 44 4 155 10 30 LBS AT THE peo 220 LOCATION OF THE 6 35 5 DIA HOLE IS REQUIRED TO OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE FULL PRIMARY CLUTCH FULL SECONDARY CLUTCH AND NEUTRAL LEVER POSITIONS THE DETENI SPRING G THE TROLLING LEVER ANGULAR LOCATION MAY
25. RING FITTING TO DELIVER AND DS 1 49 CAE HOLD 89 6 KPA 13 PSI MINIMUM TO CLUTCH DURING ASSEMBLY Pulisis p Zar LA ES D Wp Si Y 22 Foshan ED I 4 t peu rot 2 A 24 NI NW 10 5 7 y N 2 19 NCE ee NIC m SS SS Bil SSA a m Ne WY 777 A 2 7 12 7 95 2 KEY gt BASS 6 5080x375 gt mST END 2 NA Elo 0 72 1945 WN NY NIE er N 2 mys ole 818 226 1 _ 2 78 1 NIE IHE 1 2271 VAN mit Ox 2031 0 1 SECTION B E mer To 2 Yi OUTLET TO VALVE 2 GLU SS 259 HYDRAULIC P T O IP 11612 110 SHAFT DRIVE B3628 110 pa T DIA A Pan pit 1 sane B2506 2 CONTROL VALVE 201411 1 E E E E E nau EET SZ SEL Tres NIT E OIG 224 FLAT ROOT _ P meon MBs aul ff me 1167 PRCHDIA SI Nid SS TAMU A2711AU 2 Th UNS PM 4049A 2 NNS DOWEL PIN pee SA 7 HYDRAULIC P T O BUMP DRIVE 11615 ASSEMBLY_INSTRUCTIONS 77 IMPORTANT UNMARKED PARTS COMMON TO BOTH DRIVE TYPE P T 0 S DENOTES PARTS FOR SHAFT DRIVE HYDRAULIC P T O ONLY 11615 DENOTES PARTS FOR PUMP DRIVE HYDRAULIC P T O CONLY 11615 jeste
26. O ring Spacers Figure 149 Shuttle Ball and Components Marine Transmission Service Manual 1021569 175 Assembly Twin Disc Incorporated 2 Install the rate of rise orificed plug if it was removed Torque it to 8 5 Nem 11 5 Ibeft 3 Install the inner cup followed by the spring set Insert shims if necessary into the rate of rise piston and insert it into the bore of the valve body and over the springs 4 Insert the check ball spring and ball into the proper cavity and install the gasket ball seat plate gasket and end cover Install four screws and torque to 28 Nem 20 7 Ib ft Orificed Plug in here Rate of Rise Si Rate of Rise End Plate Inner Cup Check Ball and spring Ball seat Plate 3 MG 238 Figure 150 Rate of Rise Components D Lubricate the O rings and install the override cartridge into its housing if it was removed 176 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 6 Install the override valve assembly over the rollpin install retaining screw and torque to 12 Nem 8 9 Ibeft Figure 151 Override Valve Cartridge Assembly MG_237 7 Lubricate the O rings and install the solenoid spools into the bores and torque to 33 9 Nem 25 Ib ft 8 Install gasket and valve onto the transmission and torque the attaching screws to 20 Nem 27 Ib ft 9 Install the solenoid coils onto the spools and to
27. To ISO 6149 VALVE BODY 1020519 4 SEE NOTE VALVE SEE CHART TORQUE TO 36 N m SEE NOTE 0 3 Sati id AU SEE CHART STAMP VALVE ASSEMBLY IDENTIFIER HERE 2 F APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS AROUND CORE PLUG JUST BEFORE FINAL ASSEMBLY REFER TO 5774 FOR FURTHER INFORMATION THIRD ANGLE PROJECTION SIMILAR TO REVISED AND REDRAWN SUPERSEDES 1020729 DATED 8 9 02 1020525 LET Be ECNI1978 1 18 03 NOTICE THIS PRINT CONTAINS MATERIAE bcd UNESIMENSINS ARE n 8 9 02 1 a enee e PRAE ari Jee A Es TWIN DUSS k 413 7 4 D 703 DISC INCUREDESIER HEAT TREAT FIRST USE EMEN 51 111 RACINE 53403 USA H 058 8 03 8 68 4 08 0 NOTICE IS NOT INTENDED TREATMENT NAHE SERIES X NOT SERVICEABLE SEPARATELY G 4 0 5 2 03 03 A 21 1 30 03 GRANTED THE US GOVERNMENT VALVE ASSEMBLY APPD E REV smeer zone cH NO pare smeer zwe ce we UR OTHERS BY CONTRACT SHEET 1 nr 1 E D A SCREW 961 6 PLUG MATOGBB MAIN PRESSURE CHECK M12x1 5 THD CONFORMS PORT oN TO 150 4149 a 2 BODY 1020519 UL x VALVE SEE CHART TORQUE TO 36 ou 10210004 SHOWN T a SEE NOTE E Ti m 8 rmx SEE NOTE NES i
28. When one of the clutches is commanded to engage the proportional valve directs main pressure to engage the selected clutch pack The rate of rise is controlled electronically and prefills the engaging clutch at a predetermined level and then increases to full pressure following a predetermined timing sequence The initial prefill level is factory adjustable by means of an adjustment screw embedded in the bottom surface of the electronic interface Field adjustment of this feature should never be attempted without special equipment and knowledge of its use to prevent serious mechanical damage to the marine transmission or vessel The electronic interface portion of the control valve allows only one proportional valve to be energized at a time thus only one clutch can 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 Note Installations with this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 2 75 or better Besides the valve s requirement on filtration the filter must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation
29. ground point used by the gear controller or the engine control Connect to the output in the gear controller that is used to energize Solenoid A Connect to the same point as the control s power ground signal Connect to the control s Solenoid B postive driver output Connect to the control s solenoid negative output circuit Connect to the control s Solenoid A positive driver output used to energize Solenoid A The customer supplied normally closed not in neutral relay must be located in a position to not be affected by vibration The coil must have a 200 maximum current draw The coil must be connected to the two not in neutral wires of the Profile Generator The contacts of the manual direction control switch closed in neutral must be wired in series with the energizing coil of the not in neutral relay E Plug the appropriate connectors from the Profile Generator into the appropriate Proportional Valves Plug the appropriate connectors from the Profile Generator into the Engine Speed sensor and the Propeller speed sensor if equipped When the not in neutral circuit is not used Insulate and secure the blue and black wires 206 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation WIRING SCHEMATIC TROLL ENABLE SWITCH CLOSED TROLL MODE OPEN CRUISE MODE
30. is not a cartridge assembly but is comprised of a spring and spool with an adjustment cover The regulating valve body contains a ball check valve assembly in parallel with an orifice with a filter that provides rapid fill and damping for the rear cavity of the regulator valve Akit is available to upgrade the earlier version to the later version A temperature sensor is housed in the main regulator valve body on some applications The manual direction control cartridge valve contains a switch that is closed when the valve is in the neutral position Separate identical proportional cartridges are used for primary and secondary clutch actuation When the primary or secondary clutch is selected by the operator the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate of rise profile is controlled electronically by the GP Control Valve Electronic Interface Profile or E Troll Module to provide a rapid smooth oil pressure increase in the clutch hydraulic passages during engagement A CAUTION The proportional valve coils are low resistance devices that are current driven The use of an uncontrolled power source may supply too much current and damage the proportional valve Note Installations with this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 75 or better The filter mu
31. making the connector the highest point of the wire If not possible install wire or harness with drip loop 4 Protect wire or harness with grommet loom or flex guard at rub point particularly when passing a sheet metal hole 5 Locate wire or harness away from potential hazards For example screw cuiting through the jacket and shorting a conductor to the chassis welding drilling etc 6 Prevent the wire from becoming a step or hand rail When mating connectors make sure they will mate properly Coat pins and sockets only with dielectric compound to seal out moisture and corrosive substances Twin Disc part number MA890 or Dow 4 Compound Locate and use the connecior orientation key 8 Circular connectors must be hand tightened Wire or harness bend radius must not be less than twenty times the wire or harness diameter 10 Avoid twisting or winding the wire or harness along its axis during installation or removal 11 Whenever mating connectors always inspect each for damage or defects For example bent pins pushed back sockets broken keys etc Marine Transmission Service Manual 1021569 203 Installation 204 12 13 14 Twin Disc Incorporated Check that sure seal connectors have clip clamps in place Check the wire or harness tie downs Keep wires securely fastened to vessel frame Check the condition of the wire or harness at any rub point and wherever the w
32. months of service whichever occurs first This is the only warranty ied including the given by T win Disc Incorporated This warranty applies only to private non commercial non revenue earning marine pleasure craft applications delivered by Twin Disc Incorporated to the original customer on or after May 1 1995 The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering Twin Disc Incorporated is not responsible for any specific application installation of performance standard Any analysis program by Twin Disc Incorporated based upon customer supplied information is done solely as an accommodation to the customer and is not to be interpreted or construed as an approval for specific application or a guarantee of performance Twin Disc Incorporated cannot be held liable or responsible for incorrect information supplied or deviations from specifications provided by customer T he exclusive rem ovided T win Disc Incorporated whether arising out of warra within the applicable be either the repair or replacement of any T win Disc Incorporated part or product found by T win Disc Incorporated to be defective For all models except MG340 and MG360 this include the labor to perform that work and to remove and reinstall or equivalent credit or punitive damages The above warranty and remedy are subject to the following terms and condi
33. 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 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 through an orifice at all times The pressure in the rate of rise cavity increases until it reaches the neutral regulated pressure as determined by the neutral regulator spring behind the ball The passage behind the spring is connected to sump in neutral When the control valve is shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to the neutral regulator spring cavity seating the ball preventing the flow of oil from the rate of rise cavity Oil flows through the orifice compressing the 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 e
34. 15 55 14 0 551 DRILL THRU 8 SPACED 297 0 11 69 EYEBOLT USE 8 8 PROPERTY CLASS QUALITY OER Sie GRADE x LIT CAP 285 0 111 141 OIL FILLER HOLE SAE J429 AND TORQUE 574 OR SERVICE MANUAL VALUES 2580 1016 OLGAEQ FLYWHEEL OUTUNE MUST CONFORM TO SAE J620 NO 355 14 CN XK V BEN ER ae 9 NN Bl el E SIS 2 d SIS E 5 i 2 a 8 T UNE l eae y REMOV NT TWIN NR DISC 488 0 19 21 IN g N 5 NE S N Ad HA aye g V e 6 S 8 cL g 38 gt Sig 8 gl ah amp 9 o is 6 0 24 FLYWHEEL OUTLINE MUST 127 0 15 00 CONFORM SAE J620 NO 457 18 M20x2 5_TH D 32 5 1 28 DEEP 12 HOLES 6 EACH USE ALL 12 HO FOR MOUNTING UNIT USE ERTY QUALITY 14 0 551 THRU 17 0 670 DRILL THRU USE PROPERTY GLASS QUALITY HOLE SP 6 00 PER ISO 898 1 ACED USE 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 ER SAE A29 AND TORQUE TO AF 5574 OR MANUAL VALUES GRADE 5 Q REWS SAE J429 AND TORQUE TO 574 OR MANUAL VALUES 395 0 15 55 516 3 20 33 529 5 20 85 1 4 19 BSP TAP 18 0 71 MIN DEEP 40 0 1 60 STOCK BORE SIZE TO FINISH BORE LT SEE NOTE Lj 9140 0 5 51 9165 0 6 50 9245 0 9 64 274 5 10 81 SAE 1 2 36 STRAIGHT SIDED SERRATION
35. 2oreso3 2 A 657 j swAw2 SYM cH No Dare svM cH No DATE ecn e 11581 1 M1841AK 1 e PM 11261A 1 kx B PM 2057 AJ 4 2805 1 11607 1 IPM4330U 2 e O 11608 1 IM1945T 1 PUMP_SPLINE DATA 1369 4 2 1599 4 SECONDARY CLUTCH SHAFT Q IM 2031 L 1 M 2052 AJ 1 M 2988 J 1 PTO OIL DRAIN TO MARINE TRANSMISSION SUMP REPLACE IT AND SERVICE CLUTCH AS REQUIRED TO FOR INSTALLATIONS DRAWING WITH ELIMINATE TURNING IN NEUTRAL BEFORE FURTHER OPERATION HEAT EXCHANGER SEE PX 11380 SHEET 2 AND FOR OTHER DIMENSIONS SEE PX 11380 SHEET 2 NOTE ALL POINTS AVAILAB TESTING ARE CODED FOR OPTION WITH HEAT EXCHANGER ON UNIT OPTION LESS HEAT EXCHANGER ON UNIT 7 STAND ON ITS FACE E OUTPUT END LOOKING DOWN INTO CLUTCH PACK ALIGN TEETH OF DRIVING PLATES BY EYE AND CAREFULLY SLIDE P 11601 DRIVING RING INTO P T O HOUSING SO THAT IT ENGAGES THE TEETH OF ALL DRIVING PLATES AND BOTTOMS AGAINST THE INSIDE OF THE HOUSING 8 APPLY AIR PRESSURE 89 6 KPACLZPSI MIN CLUTCH HOUSING PX 11611 AND MAINTAIN PRESSURE THIS LOCKS PLATES IN PROPER ALIGNMENT FOR ASSEMBLY SLIDE DRIVING RING OUT OF P T O HOUSING 9 ASSEMBLE M1904AQ PISTON RING INTO GROOVE OF DRIVING IF NOT ALREADY DONE 10 ASSEMBLE DRIVING RING TO REAR E
36. Assembly 1020729 1 Install a main pressure gauge into the port on top of the top valve body 2 Remove protective cover cap located at the end of the adjusting stem This will expose a slotted adjustment stem Loosen the jam nut on the stem Figure 160 Main Pressure Regulating Valve Assembly 1021658 57 Start engine with controls in neutral Note This must be done with the transmission in Neutral 4 Turn the slotted adjustment stem clockwise to achieve the main pressure setting See the specifications in Description and Specifications 5 Tighten the jam nut to a torque of 20 Nem 15 Ib ft install the protective and torque it to 14 Nem 10 Ib ft 184 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Trolling Valve Assembly Optional Equipment 1 Press a new oil seal into the counterbore in the end of the valve body 2 Install the roll pin into the end of the stem if removed 1388 Figure 161 Trolling Valve parts 3 Install the inner spring onto the roll pin in the stem end with a counterclockwise twisting motion The spring will be installed onto the roll pin so that the first coil contacts the end of the stem 4 Install a new O ring into the groove of the stem Marine Transmission Service Manual 1021569 185 Assembly Twin Disc Incorporated 5 Apply grease to the stem from the O ring to the reduced diameter end Install the stem into the valve body with the reduced
37. BE rcc EUR E AND PIN MAY BE OMITTED WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY N LEVER ROTATION REQUIRED FOR AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS RANGE IN ERE LEM FORCE AT THE LEVER HOLE TO OPERATE THE VALVE THEN REDUCES TO 13 31 3 7 LBS THE NTROL VALVE ACTUATOR MUST PROVIDE 35 8 1 d LINEAR 1 4 DIA HOLE LOCATION ROTATIONAL STOPS AT THE REMOTE CO LEVER MAY BE LOCATED FROM NEUTRAL AT THE 6 35 STATED VALVE TRAVEL LIMITS HAVE A MAXIMUM CAPACITY OF 445N 100 LBS AT THE 6 55 1 4 DIA HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES SO CAPACITY OF THE VALVE ROTATIONAL STOPS IS NOT EXCEEDED EXCEEDING THE CAPACITY OF THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS OF CONTROL 300 0 111 81 635 4 OIL DRAN amp OIL IN FROM HEAT EXCHANGER Nes 262 0 10 31 292 0 111 50 RESSURE ND 135 0 5 32 DISTANCE REQUIRED 104 0 4 09 TROLLING GAGE IS FLEXIBLE AND OIL OUT LEVER Dii on P DIES FOR MEN F ENGAGES CLUTCH ON Si oo WATER SHAFT E THREAD 1 1 2 11GAS need sf 2 2 1 87 CALLED PRIMARY 6 35 rn 2 14 1 5 eee AN dL uM OIL IN ST 2 BREATHER lt 4 917 5 11 16 DRILL THRU 3 HOLES x PI FOr Z PRESSURE 6140 OUT FOR M16 STANDARD IR
38. Disc Incorporated Assembly 4 Install the stop collar onto the stem so that the roll pin holes are aligned as well as the marks made at disassembly Drive the roll pin into the collar and stem while supporting the stem to prevent damage to the parts 3 MG 233 MG 232 Figure 141 Installing Stop Collar left and Roll Pin right Place the cover gasket over the stem assembly against the cover Install the assembly into the valve body and torque the attaching screws to 33 Nem 24 Ib ft Figure 142 Installing Stem Assembly into Valve Body Marine Transmission Service Manual 1021569 171 Assembly Twin Disc Incorporated 6 Install the detent ball spring and O ring plug Torque the plug to 37 Nem 27 Ibeft MG_230 Figure 143 Installing Detent Ball Spring and O ring Plug 7 Install the valve lever aligning the marks made at disassembly Torque the screw to 15 Nem 11 Ibeft 8 Install the pressure regulator piston and springs into the valve body MG_228 MG_227 Figure 144 Installing Regulator Piston left and Springs right 172 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Install the pressure regulator adjustment shims into the rate of rise piston MG 226 Figure 145 Pressure Regulator Adjustment Shims 10 Install the rate of rise piston with shims into the valve body 11 Install the check ball spring shim s and spring into the valve bod
39. Incorporated 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 227957A Figure 180 THAP 300 Air driven Pump Set 210 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Special Tools 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 Perbunan chrome leather PTFE etc SKF LHMF 300 and 900 are available in 5 liter 5 3 qt cans Designation 300 5 and LHDF 900 6 Figure 181 SKF LHMF 300 and LHDF 900 Note Order Through Your Local Authorized SKF Distributor Marine Transmission Service Manual 1021569 211 Special Tools Twin Disc Incorporated T 18502 Release Spring Compressor eal T rz Vo T
40. Manifold 1 Place the manifold gasket on the rear bearing carrier 2 Position the manifold on its gasket Align roll pin and shim pack with clearance cavity in manifold Torque the capscrews to 46 Nem 34 Ib ft DCP 1017 DCP 1014 Figure 133 Manfold Installation Hydraulic Oil Filter Install filter bypass valve cover and install a new hydraulic oil cover Oil Level Gauge Install the oil level gauge to the main housing 164 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Suction Strainer 1 Place the suction strainer in the manifold 2 Secure the suction strainer with the clamp plate and capscrew 3 Torque the M12 capscrew to 80 Nem 59 Ib ft DCP_1008 DCP_1007 Figure 134 Suction Strainer Installation Marine Transmission Service Manual 1021569 165 Assembly Twin Disc Incorporated Install External Parts Hydraulic Pump 1 Verify that the pump drive tang engeages correctly in the slot at the end of the secondary clutch shaft 2 Observe the index marks on the pump and the manifold made during disassembly Install the pump following the index marks Note Verify that the pump is installed in the correct position The position can vary following the engine direction of rotation If necessary refer to the Engineering Drawings at the end of this manual 3 Torque the four 10 1 5 capscrews to 46 Nem 34 Ibeft a 1 c Ta pE 2 _
41. NS oe THREAD 1 1 2 116 TS WITH NUTS THESE Atl 2 C aas EMIS ale A gt EN Da i d Cee gt A zo M wa n NV A TIL eir HA J 3 331 8 13 06 I 191 2 7 53 162 7 6 40 140 0 5 51 133 0 5 24 160 3 6 31 OIL FILLER HOLE 228 0 8 98 SECONDARY CLUTCH ACTUATING PRESSURE M14x1 5 ISO 6149 fer ae 420 0 16 53 LYBE BS Q M14x1 5 TH D ISO 6149 LANZ O 5_ THREAD 7 6 30 DEEP SUCTION SCREEN LH PROPELLER ROTATION DRIVING THRU SECONDARY CLUTCH FOR AHEAD PROPULSION j 5 8 KEY 305 0 12 01 212 3 8 36 OPTIONAL TEMPERATURE INDICATING SWITCH CUSTOMER TO INSTALL IN A 3 4 X 3 4 X ed PIPE TEE IN THE HYDRAULIC LINE LEADING FROM THE IN TRANSMISSION PUMP TO THE HEAT EXCHANGER INLET REFER TO HYDRAULIC DIAGRAM METRIC EXCEPT FOR INCH DIMENSIONS AND POUNDS SHOWN IN BRACKETS NOTE ALL POINTS AVAILABLE FOR TESTING ARE CODED Q a THIRD ANGLE PROJECTION SMLAR TO 1003728 MAX INPUT SPEED 2500 R P M CONSULT SALES DEPT APPLICATION ENGINEERS FOR OTHER LIMITING CONDITIONS 1 26 1 1 48 1 1 75 1 2 50 1 DRN RZ _ CO O LB FT TORQUE AND GALLONS SHOWN IN BRACKETS TWIN DISC INCORPORATED RACINE W
42. Remove the O ring from the stem MG 234 Figure 81 Removing O ring from Stem Marine Transmission Service Manual 1021569 119 Disassembly Twin Disc Incorporated 12 Remove the thrust bearing and races from the stem MG 235 Figure 82 Removing Thrust Bearing and Races from Stem 13 Remove the remaining plugs from the valve body 120 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Electric Control Valve Disassembly PX 10225 1 Remove the solenoid retaining nuts and remove the solenoids from the spools 2 Remove the solenoid spools Solenoid Soleneid Clamp A Hut if MG_236 Figure 83 Solenoid Components 3 Remove the capscrew that retains the override valve assembly to the valve body Slide assembly off rollpin 4 Remove the override valve cartridge from the body if necessary Figure 84 Override Valve Cartridge Assembly MG_237 Marine Transmission Service Manual 1021569 121 Disassembly 122 Twin Disc Incorporated 5 Remove the four screws that retain the end plate and ball seat plate to the valve body 6 Remove the check ball and spring 7 Remove the rate of rise piston springs with any shims that may be included in the rate of rise piston and inner cup 8 Remove the rate of rise orificed plug if necessary Orificed Plug in here Rate of Rise Springs Rate of Rise Cup End Plate Inner
43. T 1 T 212 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Special Tools TD 300492 Seal Installation Input 1 1 EN X Marine Transmission Service Manual 1021569 213 Special Tools Twin Disc Incorporated TD 300493 Seal Installation Output 1145 90 2 0065 2100 00 214 2114 00 15 00 17 00 21 52 00 21 5 00 Break sharp corners Material 40 40 50 All dimensions in mm Tolerance 0 1 mm Not ot Scale Marine Transmission Service Manual 1021569 107 00 1 D 300494 930 390 e 30 005 10 p E 54 411 8 5mm DIA DRILL THRU M10x1 5mm THRU 549 e LJ lt m 11mm DIA DRILL THRU 30mm DIA SPOTFACE 10 DEPTH OPPOSITE SIDE 4 HOLES LOCATED AS SHOWN IxITEM 3 155 o F 1 4 1xITEM 5 CxITEM 6 1 5 45 8 5mm DIA DRILL THRU 10 1 5 THRU SCREW 10 40 Twin Disc Incorporated Special Tools TD 300495 Rear Inner Bearing Race Installation Primary and Secondary Shafts Marine Transmission Service Manual 1021569 217 Special Tools Twin Disc Incorporated TD 300496 Output Shaft Inner Bearing Race Installation 218 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Special Tools TD 300497 Outer Bearing Race Installation MA590BF
44. V VALVE 25 MICRON FULL FLOW E FILTER ELECTRIC MOTOR DRIVE PUMP 9 10 GPM 3 4 DIA MIN ID HOSE ES STRAINER c wes ANGLE c wes 8 16 90 TUJIN 9086 SALE NONE INCORPORATED RACINE WI 53403 USA P T O ASSEMBLY TO MARINE TRANSMISSION FACTORY AND FIELD INSTALLATION 1 FOR FACTORY INSTALLATION THE PARTS 2916 RING O 1 PM1996F SCREWS 4 202347 COVER 1 MA1038A 2 ON MANIFOLD MUST BE OMITTED FOR FIELD INSTALLATION THE ABOVE PARTS MUST BE REMOVED OUTLET TO FILTER 1 NOTE 2 CLEAN MATING SURFACE INPUT END OF 11611 P T O HOUSING FROM 2 3 INSTALL 2 PM 4049A DOWEL PINS INTO MANIFOLD AT MATING FACE NEAR REAR END 5 OF PRIMARY SHAFT FW D SHAFT CHAMFERED END PINS SHOULD BOTTOM ETIN sumus EEE Ser 14 5 5145 12 n um al Tit SAS GENE AGANT NE URIOLA Fade OA POMEL PINS AND ENSURE PM 4360AB e 2 vel La S ER ES aa ios S 5 INSTALL 2 A2711AU DOWEL PINS PROVIDED INTO REAR END OF PRIMARY SHAFT EB BE FW D SHAFT CHAMFERED END OF PINS SHOULD BOTTOM IN SHAFT HOLES PM2523 N 2 i Iu LI Iiis 6 ATTACH AN AIR HOSE TO CLUTCH HOUSING PX 11611 S oY FjMA1053 D 2 Z HOLE IS TAPPED FOR M10X1 0 ISO 6149 O
45. diameter end entering the valve body first Adjust the position of the stem if necessary to bring the helical slots into alignment with the dowel pin holes MG_250 1389 Figure 162 Installing O ring and the Trolling Stem Into Trolling Valve Body 6 Install the small washer over the spring The washer must lie flat against the end of the stem Install the lever onto the stem It may be necessary to spray 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 8 Install the screw and nut to clamp the lever to the stem Tighten the screw and nut to 9 5 Nem 7 lbeft Figure 163 Install the Lever onto the Stem 1380 186 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Be sure the helical slots are aligned and press or tap the pins into the holes so that they are into the slots but not bottomed on the slots to prevent the valve from rotating Leave approximately 2 8 mm 0 11 in sticking out beyond the outside of the valve body 1363 Figure 164 Install pins into the holes 10 11 12 Check the action of the stem in the trolling valve If the stem does not rotate 90 smoothly it may be necessary to drive the pins out and reinstall them correctly Install the detent ball and spring into the remaining hole in the valve body Apply MA908 threadlocker to the threads of the detent setscrew and ins
46. encountered Marine Transmission Service Manual 1021569 71 Troubleshooting Twin Disc Incorporated Pressure Test Kit The Digital Pressure Transducer Kit BOM 42168 provides two pressure transducers 0 to 500 psi with hydraulic quick couplings a power supply box for the transducers and cables needed to connect the transducers to the power supply box and the signals out of the power supply box to a customer supplied digital volt meter Contact the Twin Disc Service Department Racine Wisconsin for specific information concerning this test kit One principle of troubleshooting 15 to start with the simple and move to the more difficult Check the simple items first Run the simple test first Then move to the more difficult Figure 23 Test kit 42168 72 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Troubleshooting Table 17 Troubleshooting Chart Mechanical and Electric Control Valves 1 Low main oil pressure 1 1 Partially clogged oil Remove and clean oil 1 2 2 Nooil pressure or erratic low pressure at control valve tap 3 High main oil pressure strainer Stuck pressure regulation piston Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Incorrect linkage adjustment to control valve assembly Clogged or plugged orifice in orifice plate of control valve assembly Shimming required between regulator springs and rate of rise piston En
47. failure at the lift point or points and result in damage or personal injury Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Transmission Service Manual 1021569 Twin Disc Incorporated Introduction Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Owner s Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment WARNING Under the conditiions described below the prop shaft must be locked in place to prevent backdriving Failure to do this can damage the marine transmission due to lack of component lubrication Backdriving also called windmilling occurs when an engine is shut down and the propeller shaft is being driven by the flow of water across the propeller which in turn rotates the components in the marine transmission During backdriving conditions the transmission does not receive proper lubrication Conditions where backdriving may occur Vessel is being towed One or more engines on a multiple transmission vessel are shut down while under way oailboat under sail with auxiliary engine shut down Vessel tied or docked a heavy current Any of the following solutions are a
48. follows the input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing from the rear toward the front Appropriate eye protection must be worn during transmission assembly To avoid personal injury proper safety equipment must be used during installation of any heated bushings bearings and other components Marine Transmission Service Manual 1021590 1 TA Assembly Twin Disc Incorporated Primary Shaft Assembly 1 If removed install a new rear taper bearing cone on the output end of the shaft a Heat the bearing cone to 120 C 250 F Handle the bearing cone with care The bearing cone is HOT b Place the bearing cone on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing cone against the clutch housing as the bearing cools 2 Install the clutch piston into the clutch housing a Lubricate and install a new piston ring on the outside diameter of the clutch piston b Lubricate and install a new O ring in the inside diameter of the clutch piston Thread the two M8 1 25 mm rods into the clutch piston d Lubricate the clutch piston bore with a thin film of grease Install the clutch piston into the clutch housing Note Ifthe clutch piston is difficult to install by hand remove the clutch piston and inspect the piston rings MG 306 DCP 2000 Figure 104 Piston Ring O ring an
49. 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 1021569 57 Operation Twin Disc Incorporated Electric Trolling Valve 1020230 58 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 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 cont
50. is completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of the engine flywheel housing secure the mounting brackets to the engine bed rails Before securing the mounting brackets to the engine bed rails the propeller shaft should be checked for alignment Note The transmission output flange and companion flange bolts must be torqued to the proper value as identified in Description and Specifications Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation Engine and Marine Transmission Alignment A CAUTION When mounting the engine and transmission in the boat all of the mounting pads on both the engine and transmission must be used Failure to do so may result in damage to the transmission or the engine flywheel housing Hecormrnencdserd 1 U m Figure 172 Transmission Mounting Configurations When mounting the engine and transmission in the boat all of the mounting pads on both the engine and the transmission must be used Failure to do so may result in damage to the transmission It is important to align the engine and transmission only when the boat is afloat and NOT in dry dock During this alignment period it is also advisable to fill the fuel tanks and load the boat in the typical manner that it is to be used Some b
51. of the valve body and drive it with a drift until it is flush with the face of the body Install the 3 8 nptf pipe plug or optional temperature sensor into the valve body and torque to 23 Nem 17 Ibeft Install the gasket and cover without the adjustment screw to the valve body with four M8 x 20 capscrews and torque to 23 N m 17 Ibeft Install the spool with washer and spring into the bore Install the gasket and cover with the adjustment screw using four M8 x 25 capscrews Evenly tighten the capscrews and torque to 23 Nem 17 Ibeft Install the cap onto the adjusting screw finger tight as the main pressure must be set at the time of installation or testing spring Figure 154 Assemble Main Pressure Regulator Components Marine Transmission Service Manual 1021569 179 Assembly Twin Disc Incorporated 2 Assemble the top valve body Install the two proportional valve assemblies into the valve body install the retaining plate and torque the M6 1 00 x 16 socket head capscrew to 9 5 Nem 7 lbeft Install the manual direction control valve into the valve body and torque to 27 Nem 20 lbeft Install the M12x1 50 O ring plug into the valve body and torque to 16 Nem 12 lbeft Connect the wires for the Neutral switch M12x 1 50 Manual Override Pd o ring plug Valve Proportional Valves Top Valve Body 4 gt By EE Li
52. procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility Prepare Transmission for Disassembly Note During the service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the used components O rings gaskets and seals with the appropriate components for reference during the inspection and assembly process to make sure you don t forget the quantity size etc CAUTION Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Pipe threads called out as PT British Standard Pipe Tapered on drawings and in this text are different from NPT threads PT threads and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Most pusher screws used in the disassembly of this transmission are threaded through aluminum parts ALWAYS LUBRICATE the threads of the pusher screw before threading it into the mating part When installing pusher screws avoid rapid tightening with an impact wrench or similar device If an impact wrench is used with the pusher screws the threads may gall or seize in the aluminum part Tighten pusher screws in an even manner to avoid damaging components Marine Transmission Service Manual 1021569 81 Disassembly Twin Disc Incorporated MG 5145A Component Identification INPUT SHAFT ROTATION
53. suction strainer is located in the manifold below the pump See Engineering Drawings for suction strainer location See discussion under oil change interval Type Oil Recommended oee Description and Specifications Filling Remove the filler breather in the top of the transmission Fill the transmission s sump with the proper weight and type oil See Description and Specifications for oil recommendations otart the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the oil level to FULL mark on the oil gauge Allow the oil temperature to cool to normal cold oil conditions perhaps overnight Check the oil level while cold at low idle engine speed while in neutral This is the proper oil level with cold oil Make note of the oil level in the cold conditions for future reference DO NOT overfill the tranmission The oil level should not be over the full mark at operating temperature A IMPORTANT Liquid sealant must cure for a minimum of 24 hours prior to contact with oil Marine Transmission Service Manual 1021569 67 Preventative Maintenance Twin Disc Incorporated Periodic Visual Inspection
54. 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 Glutsh Engaged Figure 21 Example of Power Flow with Primary Clutch Engaged 62 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Secondary In secondary the same parts are turning that were turning in neutral When the secondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates together The secondary input pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when the unit is in the secondary position Secondary Clutch Engaged Figure 22 Example of Power Flow with Secondary Clutch Engaged Marine Transmission Service Manual 1021569 63 Operation Twin Disc Incorporated
55. 0 002 in Note A negative endplay indicates a pre load condition Table 8 Front housing and Output Flange Runout Limits Feature Maximum allowable total indicator reading SAE 1 front housing face 0 25 mm 010 in SAE 0 front housing face 0 30 mm 012 in SAE 1 front housing pilot diameter 0 30 mm 0 012 in SAE 0 front housing pilot diameter 0 41 mm 0 016 in Output flange face near O D 0 10 mm 0 004 in Output flange pilot diameter 0 10 mm 0 004 in This note applies to a continuous 270 arc if the balance of the pilot is negative in readings otherwise it means all 360 Table 9 Ouput Gear Advance 3 81 mm 0 150 in NEN 5 33 mm 0 210 in Table 10 Transfer Gear Advance Marine Transmission Service Manual 1021569 31 Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Note Lubricate all threads and bearing face with light oil film prior to assembly Note Use grade 5 and Property Class 8 8 specs when threading into aluminum Table 11 Metric Coarse Thread Capscrews Bolts and Nuts Property Class 8 8 Property Class 10 9 Property Class 12 9 Size ee 65 75 12 14 10 12 14 16 8 16 18 21 25 23 26 31 35 25 29 34 40 70 80 121 139 298 342 581 669 1000 1150 2000 2301 Table 12 Metric Stainless Steel Capscrews Bolts and Nuts Note The use of nickel anti seize compound is required to prevent corrosion due to galvanic action Appl
56. 04 10161224 MA 038 NONE 1020520 lt 1420 102125865 43198 gaya 1020542 NONE 20515 1018528 K1419 I021658H 43199 WER mde 1021000 NONF 40518 MATIBSA NONE 1018528 K1418 1021458 J 43200 1020542 M20515 MATOSSQ NONE 1018528 418 TWIN DISC rec ur HIATT aT FILL ar p ARL HAREN O a 1029201 METRIC 1 anl ED T M E MN 2 V 2 ATILI a 021 658 En ra d ss ua m economist 20 82763 ASS Y b E D c B A 1021569 10 04 TW POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
57. 4 5M 1982 TUTIN DISS E PX 10830 APER FLEXIBLE COUPLING 74 Ievsozr ueni MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO 450 0 17 72 2PLACES 500 19 68 2PLACES WHEN MOUNTING ENGINE TRANSMISSION IN BOAT ALL THE MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW THE PX 10830 CONFIGURATION IS NOT SUITABLE FOR REMOTE MOUNTING 6 RECOMMENDED ACCEPTED 25 0 DRILL THRU 2 HOLES ON PADS 2PADS mm 116 je j 5 1 5 AE m MECHANICAL VALVE K bee i 617 0 24 29 LIVE PTO SAE C 4 BOLTS 506 0 19 92 le h 14 TEETH 12 24 DIAMETRAL PITCH SELECTOR VALVE 30 PRESSURE ANGLE LEVER 274 0 10 79 6 4 25 4 OUT o WATER IN THREAD 1 1 2 11GA5 i N WATER OUT THREAD 1 1 2 11GAS 1 12226 12 35570 x gt E 5 1 12226 5 uv o 5 g 2 X X 12 2057 5 516 3 20 33 300 0 11 81 300 0 11 81 326 0 12 83 THIRD ANGLE 450 0 17 72 2PLACES 500 19 68 2PLACES 0 20 40 60 METRIC PROJECTION SCALE SIMILAR TO 532 0 20 94 532 0 20 94 gt DIMENSIONS SHOWN IN 0 1 0 20 30 BRACKETS ARE IN INCH NOTICE THIS PRINT CONTAIN TWIN DISE INCO D MATERIAL FOR OTH
58. 5 11615 1020729 1021658 Marine Transmission Operator s Manual 1021569 221 jijiji P11041 1 D 4 i i a wre800 1 LI A D 28880 9975 SS 7 A2708AC CONTROL VALVE ASSEMBLY B1705D E SS Cr MASS Lese Hm LA 204087B 7 a Ebr US 201341QP 9 H VR A M2067X VWa ree POC SCORNED B1399C 1 LLL TRAN 82334 Lum 1 a aaa Li N 10798 Ay 79 7 b E a 5 mi RES gt Y 7 i HE NS rg aa 77 RN THE BUSHI 7 PX10805 A2704BU B1048H 1003279 1 1003436 1 1003436 E s br 38 e IE M2027F 2 25 N a 10810 Rv 88 eE zv si 59 Sa 2 1904 E Paos i HA y wizsice 1 EE 10818 P10813 1015184 1015185 g L 1015186 22 ZA SA RSS SET SPRING LENGTH TO 30 2mm 1 19 IN FOR CH oO 427021 1 M1990H 1 9 Leto 2 7 1018239 1 L MA10388 1 FILTER BY PASS 201513 1 PMi996F 12 1003738 1
59. 5 Electronic E Troll Module Marine Transmission Service Manual 1021569 51 Operation Twin Disc Incorporated Hydraulic System with GP Control Valve 52 The oil pump draws oil through the strainer from the oil sump and discharges it through the heat exchanger to the oil filter Filtered oil enters the control valve through the inlet port The incoming oil Assembly 1020729 is supplied to the main pressure regulating relief pilot cartridge and the main regulating valve cartridge satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit The incoming oil Assembly 1021658 is supplied to the main pressure regulating valve and is supplied in parallel paths through a ball check valve and an orifice with filter to quickly regulate and dampen pressure oscillations satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings Main pressure is supplied to the inlet of each proportional valve and to the inlet of the manual direction control valve In Neutral the inlet port of both clutches is connected to the sump Since the area behind the clutch pistons is open to sump the clutches are disengaged
60. 5 L 3 50 GALS LESS 59 45 LB FT OR WELL OILED TO IAG ea b ROTATION ARROW AND PUMP POSITION FOR R H ENGINE IS SHOWN FOR LH ENGINES ROTATION OIL TEMPERATURE INDICATING SWITCH B3424 INSTALL 2067 PLUGS IN MOUNTING CIadip p Por do MES 5 7 THESE STANDARDS AS E mas HESE STANDARDS _ MAX INPUT SPEED 2500 R P M c p Sant ES m A c OPTIONAL EQUIPMENT DIAGRAM AND SHEET 2 0 LB FT TORQUE AND GALLONS S765 TAPERED JOINT ASSEMBLY ENGINEERS FOR OTHER COMPANION FLANGE ASS Y 1018272 Q ANAEROBIC SEALANT LIMITING CONDITIONS NOT SERVICEABLE SEPARATELY CONTROL TROLLING VALVE 10790 0 SHOWN INCEISAEKETS e aid ee LIVE P T O 9768 SHri r 6195 26 00 5 4 M 6581 27FeBo2 T 7187 054 _ Nonce 126 4 1 48 1 1 75 1 DIS REMOVE BEFORE OPERATING 2 PLACES HYDRAULIC CLUTCHED P T O 11615 5 6168 27APROO suri L 5 7153 23aPRo4 Nor ANY GEAR RATIOS 196 1 2 50 1 a ALUMINUM PLUGS ED eon zmows smi x exo 2 DEAL TO TE roar os LLL OPTIONAL FOR SAE 1 WITH MANUAL TROLLING VALVE ASSY PX 10530 c 31711 9039 sees 6376 zzwamor sere a esee osvuneos PX 10830 ELECTRIC TROLLING VALVE 1020230A ez 8 5978 aPRes surs H 65
61. 502 MG5010 MG5011 MG5005A MG5015A 10 0 8 0 MG506 MG5050 MG5061 MG5062 MG5055A 10 0 11 0 MG507 MG5081 MG5085 MG5090 MG5091 10 0 12 0 MG509 MG5111 MG5112 MG5114 10 0 17 0 MG514C MG5141 10 0 25 0 MG5202 MG5203 MG5204 MG5222 10 0 32 0 MG5225 MG6000 10 0 32 0 MGN 80 MGN 232 MGN 233 MGN 272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN 472 MGN 493 10 0 32 0 PUMP ALL MODELS EXCEPT MG340 amp MG360 1 0 VALVE ALL MODELS EXCEPT MG340 amp MG360 1 0 5 January 16 2002 TDW P2004A cu ACS Twin Disc Incorporated Table of Contents Table of Contents Introduction 11 General Information 11 Safety and General Precautions 11 Preventative Maintenance 13 TOWING 13 Ordering Parts and Obtaining Services 14 Source of Service 15 MANY 15 Description and Specifications 17 eee 17 POWER RAUNO S cem sen OPES EEES ES 19 Changing
62. 55 12FeB01 sur2 P 6742 18 2 B smia 9 c e268 14Novoo sus w ees2 s4auco2_ care wo ome OPTIONAL FOR S A E 0 al Meneame wesusson ae jan OPTIONAL TROLLING VALVE INSTALLATION AND OPERATING NOTES 1 REFER TO VALVE ASSEMBLY DRAWING FOR ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TO THE PROPELLER 2 MAXIMUM ENGINE SPEED WHILE TROLLING 1100 RPM OR 60X OF FULL LOAD ENGINE SPEED WHICHEVER IS SMALLER 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUNCTION BY MOVING TROLLING CONTROL LEVER OUT OF LOCKED DETENTED POSITION TO MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION OF TRAVEL BY MOVING CONTROL VALVE LEVER TO THE PRIMARY CLUTCH OR SECONDARY CLUTCH POSITION MOVE TROLLING CONTROL POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED CLOSE TO DETENTED NO TROLL POSITION THE TROLLING CLUTCH MAY ENGAGE FULLY 634 0 24 96 510 0 20 09 5 11 9 15 32 DRILL THRU 0 19 use 2 PROPERTY CLASS QUALITY _ ee fete GRADE 5 QUALITY CAPSCREWS 5 SAE J429 AND TORQUE TO 574 OR SERVICE MANUAL VALUES 395 0
63. 69 131 Disassembly Twin Disc Incorporated 8 Slide the stem out of the valve body Push the stem out of the valve body such that the spring end of the stem exits the valve body first Note that the inner spring will come out with the stem 1389 Figure 101 Removing the Stem from the valve body 9 Remove the O ring from the groove the end of the stem Figure 102 Removing Oring from the valve stem 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 132 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 12 Remove the oil seal from the end of the valve body 1388 Figure 103 Trolling valve parts Marine Transmission Service Manual 1021569 133 Disassembly Twin Disc Incorporated NOTES 134 Marine Transmission Service Manual 1021569 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 or by steam cleaning Parts must be dried and oiled immediately to prevent corrosion Examine all parts carefully for grit dirt and
64. AK OIL PRESSURE AT H E 3 HOSE SAE J517 10081 MEETING USCG 46CER 56 60 25 C 135 C 275 F TEMP RATING 4 PROTECT LINES FROM MECHANICAL DAMAGE ZINC ANODES PROTECT H E RAW WATER PASSAGES FROM CORROSION CHECK amp REPLACE THEM FREQUENTLY B3649H 24 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Specifications and Maintenance Frequent reference to this data and application of the information will result in better service from the transmission Oil Capacity 13 25 Liters 3 50 US Gal less hoses and heat exchanger The transmission should be warmed to operating temperature when oil is checked Oil Pump Capacity 14 1 GPM 1800 RPM Minimum Oil Pressure When Cruising Check your unit s identification plate MG 5145A has a minimum oil pressure at rated engine RPM located on the name plate of 1655kPa 240 psi non trolling mode Maximum Input Speed 2500 RPM Dry Weight Approximately 320 Kg 705 Ibs Type of Oil and Oil Viscosity Note Multi viscosity oils i e 10W 20 etc should not be used in Twin Disc MarineTransmissions The recommended oil is mentioned on the lubricant nameplate located on the housing of your Marine Gear Marine Transmission Service Manual 1021569 25 Description and Specifications Twin Disc Incorporated Table 2 Marine Transmission Lubricant MARINE TRANSMISSION LUBRICANT 2 OIL SERVICE CLAS
65. APS OF PRESE GAGEL imm THD COMETE AL AT ALE i iS eT E Ae TH Th AT VALE pies penal Gm i a PORTION ENCLOSED WITHIN THESE LIES 8 FEED FOE GETE n RTO ahh TH wa NOT REGIO h ETO TRIS ua Gar Br EDS AES jT CHANGER AMD COMET AT DOLEO H OODE FEDTE ii SM ERI LINES Be dis CLERI s Cx PED ORKAN M TE 0 SA THEE ee ERES TALL 2 Sh LIE To CCT LLIURE j ry WTO p orl CHELLMHT jo eS i ATC CHA 1 0 HOSE mum Ed i ed PIE Dmi Polis LO ATO um emori OF i CEN IEEE ise ny Sao Sth Figure 3 Hydraulic Schematic 2 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Manual Control Valve Neutral Refer to Figures 4 and 5 Oil enters the control valve body through passage A and fills chamber B Oil is also supplied to the rate of rise chamber which is pressure regulated by the neutral regulator springs and check ball T
66. CH CUSTOMER SUPPLIED HEAT EXCHANGER AND CONNECTION LINES REFER TO INSTALLATION RAWING PASS S A INSTALLATION OF OPTIONAL 6 TEMPERATURE INDICATING SWITCH USING PIPE TEE WITH REDUCER BUSHING Me080CR DRAIN PLUG LOCATION 1 5 16 12UN 2B THREAD PER MARINE TRANSMISSION INSTALLATION AND ASSEMBLY DRAWING 5141 HYDRAULIC DIAGRAM GRAPHICAL JIC SYMBOLS TD ARA A ALI MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED MACHINED DIMENSIONS LBS LBS IN XX 0 030 XXX 0 010 0 005 FIRST USE ASSY 1003728 ALL ANGULAR TOLERANCES 31 E MODEL MG5141 OME TRIC ERASING PER ANSI Y14 5M SURFACE TREATMENT NAME DIAGRAM HYDRAULIC SECONDARY CLUTCH CUSTOMER TO INSTALL G PRESSURE GAUGE AND LINE HERE XA7371P MARINE TRANSMISSION CONTROL VALVE SHOWN IN NEUTRAL 5 c gt gt I OPTIONAL TROLLING VALVE REF XA7372L OPTIONAL AUXILIARY LUBE SYSTEM USER TO SUPPLY COMPONENTS AND TO INSTALL LUBE HOSES TO MEET REQUIREMENTS OF SAE J517 FOR 100R1 HOSE SELF EXTINGUISHING AND FIRE RESISTANT REQUIREMENTS ALSO IDENTIFICATION REQUIRED BY THE U S COAST GUARD AS SPECIFIED IN CODE OF FEDERAL REGULATIONS 46 CFR 56 60 25 C REMOVE M2051FM 1 2 14 PLUG FROM MANIFOLD PER MARINE TRANSMISSION INSTALLATION DRAWING AND INSTALL LUBE LINE TO DIRECT LUBE FLOW INTO TRANSMISSION HYDRAULIC CIRCUIT CHECK 5 8 DIA MIN LD HOSE
67. DGE Figure 173 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation As the engine and marine transmission come into their aligned position it will be possible to mate the output flange and propeller coupling and prepare for bolting together Care should be taken not to burr or mar this connection because the fit is very critical Place 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 le
68. ERS INSTALLATION DIMENSIONS eo eese R SE mone w sos SEE DRAWING PX 10830 SHEET 2 RAB MODEL zx me 10950 5145 MARINE TRANSMISSION ee 5 PROPRIETARY INFORMATION 15 THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT A LUBE TUBE 022222222277727777 bz y LLL LL Wi WW sR WIS A LUBE O ND OKA SSS EESTI lt lt y oe PRESSURE GAUGE BE MOUNTED IN PILOT HOUSE SEE MARINE TRANSMISSION INSTALLATION DRAWING CUSTOMER TO INSTALL PRESSURE GAUGE LINE HERE TUBE PRIMARY SHAFT SS FRONT amp REAR BEARING PINION EE a amp CLUTCH LUBE SHOWN ENGAGED VS ay WSS i 2 AS NS AAT CTO i gi GK Lt SENE 230 de ISSA SS ASS KG CRG OPTIONAL TROLLING VALVE REF XA7372L SKS QS E WAY CONTROL VALVE AND XA7373K I IKELUL ERAN A 22 JE SECONDARY SHAFT G 8 7371P MARINE TRANSMISSION FRONT amp REAR BEARING PINION LUBE RELIEF VALVE amp CLUTCH LUBE 100 PSI SHOWN DISENGAGED 5 PORTION ENCLOSED WITHIN THESE LINES IS REQ D FOR OPTIONAL HYD P T O ONLY FILTER BY PASS 20 PSI 5
69. ND OF PRIMARY SHAFT FW D SHAFT BY SLIDING DRIVING RING ONTO DOWEL PINS AND PUSHING CAREFULLY FORWARD INTO SHAFT BORE AND AGAINST PRIMARY SHAFT FWD SHAFT FASTEN USING 2 11806 SCREWS PROVIDED AND TORQUE PER S574 OR TO SERVICE MANUAL VALUES 11 SLIDE ASSEMBLY STILL AIR PRESSURIZED CAREFULLY FORWARD OVER DRIVING RING SO THAT RING ENGAGES THE TEETH OF THE CLUTCH PLATES ASS Y MAY NEED TO BE ROTATED SLIGHTLY IN EITHER DIRECTION TO ENGAGE THE PLATE TEETH IF DOES NOT LINE UP WITH DOWEL PINS ENGINE MUST HAND TURNED UNTIL P T O DOES LINE UP DO NOT RELEASE AIR PRESSURE TO CLUTCH PACK SECURE P T O 4 MA996 S CAP SCREWS OR THE 4 PM 14369 Y STUDS AND 4 PM 1599J NUTS PROVIDED AND TORQUE PER 5574 OR TO SERVICE MANUAL VALUES 12 AIR PRESSURE MAY NOW BE RELEASED DISCONNECT AIR LINE AND FITTINGS FROM CLUTCH HOUSING PX 1 1611 13 ASSEMBLE BODY ASS Y PX 11610 ON CLUTCH HOUSING SECURE WITH 5 PM 3254B CAPSCREWS amp TORQUE PER 5 574 OR TO SERVICE MANUAL VALUES 14 ASSEMBLE CLUTCH ENGAGING PRESSURE FITTINGS FROM THE BODY VALVE PX 11610 TO THE CONTROL VALVE AND HEAT EXCHANGER HORSEPOWER RATING 162HP AT 1800 oro ened MAX P T O WORKING TORQUE 641Nm 473 LB FT PRESSURE OPERATING SPEED 2500 R P M zi RECOMMENDED MAX ENGINE SPEED WHEN ENGAGING CLUTCH 5x MATCH POINT SPEED P T O SHAFT ROTATION SAME AS ENGINE ROTATION
70. NEUTRAL A RED SOLENOID CUSTOMER SUPPLIED BLUE MP SOLENOID A ON BLACK 200 mA MAXIMUM e e RED LED em O BLACK SOLENOID B SWITCH Ld YELLOW CUSTOMER SUPPLIED us SEE MODULE POWER CIRCUIT CONNECTION CHART O TRANSMISSION MANUAL OVERRIDE SWITCHES SOLENOID RETURN Figure 179 Profile Module Wiring Diagram Final Checks Be sure the transmission is filled with oil before starting See Description and specifications and Preventative Maintenance for proper oil and filling procedure Marine Transmission Service Manual 1021569 Twin Disc Incorporated Special Tools Special Tools List of Special Tools The following pages include the special tool drawings that are specific to this model The special tool drawings included are listed below and continued on the following page 118502 Release Spring Compressor TD 300492 Seal Installation Input TD 300493 Seal Installation Output TD 300494 1 Gear Installation Tool Output Shaft TD 300494 2 Gear Installation Tool Output Shaft TD 300495 Rear Inner Bearing Race Installation Primary and Secondary Shafts TD 300496 Output Shaft Inner Bearing Race Installation TD 300497 Outer Bearing Race Installation MA590BF TD 300498 Outer Bearing Race Installation MA590CS Marine Transmission Service Manual 1021569 209 Special Tools Twin Disc
71. P T O CAN BE USED WITH R H OR L H ROTATION ENGINES P T O ACCEPTS 5 J744 SIZE C PUMP HORSEPOWER RATING 162HP AT 1800 R P M MAX P T O WORKING TORQUE 641Nm 473 LB FT MAX P T O OPERATING SPEED 2500 R P M RECOMMENDED MAX ENGINE SPEED WHEN ENGAGING CLUTCH 5x MATCH POINT SPEED P T O SHAFT ROTATION SAME AS ENGINE ROTATION P T O CAN BE USED WITH R H ROTATION ENGINES ONLY BACKDRIVING OF P T O 15 NOT PERMITTED _ MAX EXTERNAL THRUST LOAD ON P T O SHAFT IN EITHER DIRECTION 5xSIDE LOAD CAPACITY WITH NO SIDE LOAD ON P T O SHAFT J744 SIZE C PUMP MOUNT FOUR 4 M12x1 75 THREADED STUDS WITH NUTS EQUALLY SPACED ON 161 92 6 375 DIA MAX P T O SIDE LOAD BASIC H C 2 THE FOLLOWING GENERAL FORMULA a SHOULD BE USED FOR DETERMINING THE ACTUAL APPLIED LOAD 1 xHP xF y x in 560 67xHP_ xF in N NxD 115704 28 aN te acTUAL PEED RE Doo N OR LBS N SHAFT SPEED RPM CAE Dx PITCH DIA mm OR In OF SHEAVE ETC F LOAD FACTOR 1 0 FOR CHAIN OR GEAR DRIVE 1 5 FOR TIMING BELTS 2 5 FOR ALL V BELTS 3 5 FOR FLAT BELTS FOR RECIPROCATING COMPRESSORS 0 8 01 6 AND OTHER SEVERE SHOCK DRIVES 25 4 2 00 4 00 MULTIPLY ABOVE FA RS 1 00 3 00 METRIC O e THIRD ANGLE ARST USE xxx 0 13 5 5 ASSEMBLY PX 11380 ALL ANGULAR TOLERANCES 1
72. Pressure LJ Engaging Pressure Figure 6 Mechanical Control Valve Primary Cutaway View PRIMARY CONTROL VALVE BODY TO PRIMARY CLUTCH TO SUMP TO SECONDARY CLUTCH CONTROL VALVE STEM L ATMOSPHERIC PRESSURE encacinc pressure Figure 7 Mechanical Control Valve Primary Sectional View 44 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Manual Control Valve Secondary When a shift to the secondary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 8 and 9 The pressurized oil in chamber B is directed through ports G and K to passages E and J Passage E is aligned with a passage directing main pressure to the secondary clutch Pressurized oil from port G travels through passage J and seats the ball against its seat thus preventing oil from exiting chamber L to sump Oil also travels from chamber A through an orifice into chamber L This orifice meters the oil for a steady smooth pressure rise from the neutral regulated pressure in chamber L As chamber L fills with oil the pressure rate control piston moves against the springs until the piston is stopped by a shoulder in the valve body This causes the pressure in chamber B to rise to clutch engaging pressure When in primary passage D remains at atmospheric pressure because slot F remains open to sump When a shift is made fro
73. RE PORT Mi2x1 5 THD CONFORMS ISD 6149 RING A2916JT 2 M6X1 0 X 16 4 PLACES TYP IPD nf HuH 2222 e QPLUG SEE CHART Me7xe 0 D RING PORT DIL INLET GASKET 1020531 OQO VALVE ASS Y 1021873 VALVE 1020670A ORIFICE 1021751 SEE NOTE 0 VALVE BODY 1020518 D PRESSURE REGULATOR INITIAL ADJUSTMENT PROCEDURE 1 WITH NO OIL FLOW TO VALVE TURN ADJUSTMENT STEM OF THE 1020670A VALVE COUNTER CLOCKWISE UNTIL REACHING POSITIVE STOP 2 WITH A MINIMUM OF 1 gpm ALLOW OIL TO FLUSH Q PRESSURE RGEULATOR 3 AFTER FLUSHING TURN ADJUSTMENT STEM OF THE 1020670A VALVE CLOCKWISE UNTIL REACHING REQURIED PRESSURE SPCIFIED IN MARINE TRANSMISSION PRODUCTION TEST SPECIFICATION 4 LOCK ADJUSTMENT STEM IN PLACE USING JAM NUT AND CAP REFER TO MARINE TRANSMISSION ASSEMBLY DRAWING OR BILL OF MATERIAL FOR VALVE MOUNTING GASKET AND SCREWS VALVE 1020152 TORQUE TO 33 VALVE VALVE ASSEMBLY ASSEMBLY VALVE SENSOR QPLUG PLUG SEE NOTE VAL VE PSD PART NOD IDENTIFIER F 10207298 42426 5 1 1 NONE wAioset NONE 1018528 250 o d Lwewesc seez c ioeo None 20515 marose none 19528 esm 10207290 22126 n 1oero00a None 0 8 None 1020520 350 e A 5 SCREW MA961X lt 6 OU PLUG M1038B MAIN PRESSURE PORT Mi2x1 5 THD CONFORMS
74. RESSURE REGULATOR ADJUSTMENT 1 REMOVE 10027144 CAP AND LOOSEN 1002145 NUT 2 CLOCKWISE ROTATION OF 1020939 A PISTON INCREASES TO ISO amp 149 PRESSURE COUNTER CLOCKWISE DECREASES PRESSURE E REFER TO MARINE TRANSMISSION ASSEMBLY DRAWING OR 4 FILTER P10784 BILL OF MATERIAL FOR VALVE MOUNTING AND SCREWS 2 F APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS GASKET 1071663 AROUND CORE PLUG JUST BEFORE FINAL ASSEMBLY REFER TO S774 FOR FURTHER INFORMATION PORT A COVER 1021662 G MODIFICATION KIT TO UPGRADE EXISTING 1020729 1020696 SERIES VALVE ASSEMBLIES 1021658 SERIES VALVE ASSEMBLY 7 0522 SCREW MA960M 4 PM B d P E i Li a e C ap Suet QU NU LE e b ke 3 VALVE 1020947 BODY 1021659 SEE CHART STAMP VALVE ASSEMBLY IDENTIFIER HERE A B VALVE VALVE PRESSURE s COSE MODIFICATION ASSEMBLY ASSEMBLY BOM PUIG PROPORTIONAL PARTNO IDENTIHER ips SPRINGS va vE SENSOR PLUG PLUG SCHOL VALVE SEE s 102016584 A 4310 1030008 0515 MAIONRE NONE 1020820 10216588 AM XL 0 65 MY2IQODA NONE 20515 MATOGSE NONE 1018528 K1418 1021558 43112 240526 Susa 10210004 M20519 MATOGBE NONE 1020520 K1420 10215580 42195 Un Sp 2913404 1021000 1016122 NONE NONE 1020520 K1417 1021658E F 43196 VAR 10210004 1016122A NONE NONE 1018528 K1418 10216458F F A3197 uas awe 102100
75. S USE S A E API SERVICE CLASS CD ENGINE OIL CERTIFIED BY VENDOR TO PASS TO 2 OIL TEST ALSO APPROVED ARE S A E API SERVICE CLASS CC ENGINE OIL MIL L 2104B AND TRANSMISSION FLUID TYPE C 3 VISCOSITY BASE SELECTION ON SUMP OIL TEMP CONDITIONS TABULATED BELOW START UP STEADY OPERATION VISCOSITY 32 F MIN 150 150 F 0 C MIN 65 85 S A E NO 30 32 F MIN 175 210 F 0 C MIN 80 99 S A E NO 40 STEADY OPERATION BELOW 150 F 65 C OR ABOVE 210 F 99 C IS NOT RECOMMENDED TWIN DISG INCORPORATED RACINE WI 65403 U S A B2411D B2411D 26 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Oil Pressures The following tables give oil pressures at different soeeds and ranges Check your unit s identification plate for the Minimum Oil Pressure When Cruising Use this value to determine which table applies to your unit See MG 5145A rear view for location of oil pressure checkpoints Table 3 1725 kPa 250 psi Transmission Oil Pressure Specifications Control Valve 1725 kPa 250 psi Springs Input Shift Main Pressure at Valve Primary Secondary Position Inlet Clutch Min Clutch Min swa o 0 0 seme Note It is required that primary and secondary clutches must be within 21 kPa 3 psi of each other Table 4 Limits for Marine Transmission Equipped with Hydraulic Clutched PTO Limit
76. Shaft Note The MG 5145A transmission requires the use of a SKF THAP 300 Oil Injection Kit See Special Tools or similar device to separate the output gear from the output shaft 1 Place the main housing in the face down position to separate the output gear from the output shaft Be sure the main housing is securely supported Be sure the output seal carrier is installed on the main housing to hold parts being separated with oil pressure The parts may separate with extreme force Marine Transmission Service Manual 1021569 101 Disassembly Twin Disc Incorporated 2 Install the oil injector into the output shaft Note that these are special 1 4 19BSP threads Note Take precaution measures to prevent damage to the main housing when separating the output gear from the shaft Aluminum bar stock also aids in removal of the gear from the housing MG 043 DCP 1035 Figure 50 Output Shaft Injection Location Inject oil with a viscosity of 900 mm S 900cSt at room temperature into the output shaft until the output gear lifts from the output shaft taper Note The bearing outer race and roller usually comes out of the housing when the output gear comes off the taper 4 Lift the unit and remove the SKF fitting Output Shaft Seal Carrier 1 Position the main housing with input end down to remove the output shaft seal carrier and speed pickup bracket Be sure the main housing is securely Supported 2 Remove the eig
77. TO SUMP TO SECONDARY CLUTCH 2 CONTROL VALVE STEM C atmospHeric pressure pressure Figure 9 Mechanical Control Valve Secondary Sectional View 46 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation GP Control Valve with Electronic Interface The General Purpose GP control valve is a hydraulic valve assembly for use with Twin Disc Marine Transmissions that may include an integral electronic interface control module The valve assembly contains current controlled proportional cartridges i i T ur Figure 10 GP Valve Assembly mounted on Marine Transmission Marine Transmission Service Manual 1021569 47 Operation 48 Twin Disc Incorporated GP Control Valve Hydraulic Portion The hydraulic portion of the GP Control Valve is made up of two blocks a lower main regulator valve body and an upper valve body The upper valve body contains two electrically actuated proportional valves and a manual direction control cartridge valve The lower valve body contains the hydraulic pressure regulating valve and a temperature sensor if the application requires it There are two versions of the lower valve assembly The hydraulic pressure regulating valve in earlier versions Assembly 1020729 consists of two cartridge assemblies a pilot relief cartridge assembly and a main spool cartridge assembly The hydraulic pressure regulating valve in later versions Assembly 1021658
78. TRANSMISSION IS LUBRICATED AND MAINTAINED AS SPECIFIED IN THE SERVICE MANUAL AVAILABLE ON REQUEST REFER TO MARINE TRANSMISSION LUBRICANT PLATE SHIPPED WITH UNIT TWIN DISC INCORPORATED RACINE WI 53403 B2387J Figure 1 Example of MG 5145A Nameplate 18 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Power Ratings Changing The MG 5145A transmission can be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation ditrection when viewing rear of engine Always reference the Bill of Materials BOM or Specification number when ordering service parts Rotation When shipped form the factory each unit is designated for use with a particular engine rotation Within their rated capacities these units may be operated continuously in either forward or reverse Theunit can be adapted to either left or right hand engine rotation To adapt to opposite engine rotation remove the heat exchanger hose from the rear end of the pump Remove the pump turn it 180 and reinstall it Remove the plug from the rear of the pump and install where the heat exchanger hose was Install the heat exchanger hose where the plug was When changing from RH rotation to LH rotation install an engine rotation plate Arrow to indicate the new direction of rotation Direction of D
79. Transmission Service Manual 1021569 23 Description and Specifications Twin Disc Incorporated Table 1 Heat Exchanger Requirements HEAT EXCHANGER H E REQUIREMENTS PERMISSIBLE OIL TEMPERATURE INTO HEAT EXCHANGER RATIO OIL VISCOSITY ALL RATIOS SAE 30 85 C 185 F C 150 F ALL RATIOS SAE 40 99 C 210 F 175 MIN HEAT TRANSFER CAPACITY KW BTU MIN PER ENGINE RTD H P APPLY APPROPRIATE SERVICE FACTOR CONTINUOUS DUTY P C amp INT DUTY FOR FRESH AND RAW WATER 026 1 484 022 1 272 APPROX OIL FLOW 2 3 L MIN 61 GPM PER 100 ENGINE HR P M 1965 285 PSI MAX ALLOWABLE OIL PRESSURE DROP ACROSS H E WITH 207 KPa 66mm 2 300 SUS OIL AT RATED ENGINE R P M 30 PSI WATER FLOW TO USE 1 5 TO 3 0 TIMES OIL L MIN GPM H E WATER PRESSURE RATING MIN 1 5 X H E INLET WATER KPa PSI o o o lt Z DATA H E PURCHASER MUST ALSO TELL VENDOR STATE IF RAW OPEN CHANNEL amp SEA OR FRESH CLOSED ENGINE JACKET AND OR KEEL COOLER WATER WILL COOL H E STATE MAX WATER TEMP INTO H E TYPICAL RAW WATER 29 C 32 C 85 F 90 F KEEL COOLER WATER 46 60 C 115 F 140 ENGINE JACKET WATER 74 85 C 165 185 STATE MIN ALSO MAX L MIN GPM OF WATER FLOW TO H E H E INSTALLATION amp SERVICE REQUIREMENTS OIL LINES TRANSMISSION TO H E AND RETURN 1 MAX VELOCITY IN FITTINGS PIPE HOSE AND TUBES 7 6m sec 25FT SEC 2 BURST PRESSURE MIN 10 x PE
80. Y A el A ts EN N _ N EN PLUG SEE CHART OPTIONAL INLET PORT d M27x2 0 THD CONFORMS ELMO TO ISO 4149 COVER 1021661 i SPOOL 1021660 mu SCREW MAS amp DA 4 02 XN m 4 P ut B WASHER A2782AV CAP 1002144 PRIN SEF NOTE D SEE CHART NUT 1002145 RING A291 6LV PISTON 10209394 Li D PORT HERD PORT MC Coca BOTTOM VIEW me APE oz BC 2 175 1 7 28 04 _ sun Bs ud 8 28 04 _ m O RING A2916JT 12 zl _ PLATE 1018175 SCREW MA 10GB A PROPORTIONAL CONTROL VALVE OPERATION 1 WARNING DO NOT CONNECT VALVE COIL DIRECTLY TO BATTERY POWER SUPPLY VOLTAGE 2 OPFRATION TO PERFORMED WITH GNI Y TWIN DISC CONTROL SYSTEMS OR MODULES PROPORTIONAL VALVE B MANUAL DIRECTIONAL CONTROL VALVE OPERATION SEE CHART 2 1 WITH MANUAL DIRECTIONAL CONTROL VALVE IN ui SEE NOTE A CENTERED POSITION PUSH TO ENGAGE PORT A uu 2 WITH MANUAL DIRECTIONAL CONTROL VALVE IN b dd CENTERED POSITION PULL TO ENGAGE PORT B UN NN 22 C MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH PLUG 2 CLUTCH PRESSURE PORT KA 2x1 5 THD CONFORMS 1 SWITCH IS NORMALLY CLOSED WHEN MANUAL DIRECTIONAL CONTROL VALVE IS IN THE CENTERED POSITION AND OPEN WHEN LEVER 5 ACTUATED FROM CENTERED POSITION 2 CURRENT 20 AMPS 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE DRAWING D P
81. abrasives and reclean them if necessary Clean all oil passages by working 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 stone or file in the vicinity of all pusher screw locations Marine Transmission Service Manual 1021569 135 Cleaning and Inspection Twin Disc Incorporated 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 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
82. ads and the boat s age The following steps may be taken to secure proper marine transmission alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure Install the mounting brackets on the side mounting pads of the marine gear Install the driving ring on the engine flywheel Bolt an indicator to the engine block and set the indicator stem on the engine flywheel housing Marine Transmission Service Manual 1021569 193 Installation 194 Twin Disc Incorporated INDICATOR INDICATOR STEM MARINE GEAR i SUPPORT BRACKET Figure 171 Marine Gear Alignment Set the indicator gauge at zero 0 Lift the marine gear with a hoist or other Suitable means and place the unit in position against the engine flywheel housing Secure the flange of the marine gear main housing to the engine flywheel housing Use a feeler gauge between each mounting bracket and engine bed rail Add shims between the brackets and bed rails to equal the feeler gauge readings Carefully release the lifting force on the marine gear while observing the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading moves from zero lift the marine gear and insert additional shims Continue this procedure until the marine gear
83. ameter 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 Note The following power flow illustrations are shown merely as examples of power flow and may not pertain specifically to your unit Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed amp Driving Gear if Primary Shaft _ secondary Shatt Driven Gear Output Gear Figure 20 Example of Power Flow in Neutral Marine Transmission Service Manual 1021569 61 Operation Twin Disc Incorporated Primary When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping
84. amp plate will retain the output flange when it separates from the output shaft Always use the retainer bolts or a safety strap to hold parts being separated with oil pressure The parts may separate with extreme force 92 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 2 Install the oil injector into the output flange Note that these are special 1 4 19BSP threads DCP_1011 Figure 36 Clamp Plate and Output Flange Injection Location 3 Inject oil with a viscosity of 900 mm S 900cSt at room temperature into the hub until it lifts the output flange from the output shaft taper 4 Remove the three output flange capscrews Remove the clamp plate 5 Remove the output flange from the output shaft 6 Leave the output seal carrier installed to the main housing The carrier must be in place to safely remove the output gear from the output shaft DCP_1012 MG_040 Figure 37 Clamp Plate and Output Flange Removal Marine Transmission Service Manual 1021569 93 Disassembly Twin Disc Incorporated Manifold 1 Remove the screws still retaining the manifold 2 The manifold is equipped with two pusher screw locations to assist in the removal of the manifold Thread two 12 mm fully threaded capscrews lubricated into the pusher screw locations to push the manifold away from the bearing carrier A IMPORTANT Always lubricate the pusher screw threads before use Always tighten the pushe
85. and the gear bore with an appropriate solvent Dry the shaft and clear all oil passages in the shaft with compressed air CAUTION If the gear or shaft is damaged and cannot be repaired wihtout material removal replace the part CAUTION The tapered surface of the shaft and matching tapered gear bore must be completely free of grease oil dirt and solvent residue Failure to properly clean mating parts could prevent proper advance of the gear on the shaft and adversely affect torque carrying capacity of the assembled joint 2 Place Special Tool T 300494 on a press Place the main housing on the tool The housing can be blocked in place in the absense of the special tool _306 Figure 119 Main Housing Placed on spacers or Special Tool T 300494 152 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 3 Place the output gear into the main housing and position it on the mounting hub of the tool or an appropriate spacer ring 4 Use a hoist to carefully place the output shaft into the bore of the gear and into the tool 5 Measure from the end of the output shaft to the face of the output gear Measure three locations around the shaft The three readings should be identical Record this distance as Dimension A reference drawing Dimension A 6 Press the output shaft into the output gear up to the shoulder of the shaft A static press force of 543 to 760 KN 62 to 85 tonf will be r
86. and the second one pilots in the pinion bore DCP_1045 Figure 56 Front Two Thrust Races and Needle Bearing Removal 5 Slide the pinion assembly from the shaft DCP_1046 Figure 57 Pinion Assembly Removal Marine Transmission Service Manual 1021569 107 Disassembly Twin Disc Incorporated 6 Remove the rear two thrust races and needle bearing Note Record location of the rear two thrust races and needle bearing for proper assembly The first race removed pilots in the bore of the pinion and the second pilots on the shaft This thrust race also has a counterbore to fit over the snap ring DCP 1048 MVC 763F Figure 58 Rear Two Thrust Races and Needle Bearing Removal 7 Remove the internal snap ring and back plate from the clutch housing MG 051 Figure 59 Internal Snap Ring and Back Plate Removal 108 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 8 Remove the 10 steel plates and 11 friction plates from the clutch housing MG_052 Figure 60 Steel Plate and Friction Plate Removal 9 Position the primary shaft and clutch housing under a hydraulic press a Place Special Tool T 1802 on the spring retainer b Compress the release spring enough to expose the snap ring Remove the snap ring Figure 61 Compressing Release Spring and Snap Ring Removal Marine Transmission Service Manual 1021569 109 Disassembly Twin Disc Incorporated d Careful
87. anifold to ensure correct installation Do not remove the pump pipe plug Do not disassemble pumps They are not serviceable 2 Hemove the five capscrews securing the hydraulic pump to manifold assembly and remove the pump and gasket 90 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Remove Internal Parts Note Position the main housing with input end down Be sure the main housing is securely supported Suction Strainer 1 Remove the M12 1 5 screw with washer directly below the suction strainer plug Remove the clamp plate 2 Thread a M8 1 5 screw into the suction strainer plug and pull a Remove the plug and suction strainer DCP1007 DCP1008 Figure 33 Suction Strainer Removal Oil Level Gauge Remove the oil level tube from the main housing DCP1009 Figure 34 Oil Level Gauge Tube Removal Marine Transmission Service Manual 1021569 91 Disassembly Twin Disc Incorporated Hydraulic Oil Filter 1 If equipped remove the filter element from the manifold 2 Hemowve filter bypass valve cover a MG_107_1 1010 Figure 35 Filter Element and Filter Bypass Valve Cover Removal Output Flange Note The MG 5145A transmissions require the use of a SKF THAP 300 Oil Injection Kit See Special Tools or similar device to remove the output flange 1 Loosen the three output flange capscrews securing the clamp plate approximately five turns The capscrews and cl
88. ansmission Equipped with 2415 kPa 350 psi Proportional Valves Cooling Range Min Act Max Min Act Min Act Min Act Max kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa psi psi psi psi psi psi psi psi psi psi Primar ee Y 250 1725 1931 1696 280 246 280 0 Boma 1586 1827 1558 Y 230 265 226 Secondary 1586 1827 0 230 265 0 Neutral 1586 1827 0 230 265 0 0 Cooling temperature range Delvac 1110 Oil at 29 35 85 95 F or Mobilkote 501 at 32 38 90 100 F Required Primary lube pressure secondary lube pressure within 21 kPa 3 psi ALL SHIFTS MUST BE DONE AT OR BELOW 1800 RPM 0 0 1725 1931 0 250 280 28 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Optional Equipment The following optional equipment is available for the MG 5145A marine transmission except where noted through the nearest authorized Twin Disc distributor Power Take off A live power take off pump mount Is available in sizes SAE J 744 No 127 4 and SAE J 744 No 32 4 SAE C 4 bolt A clutchable pump mount power take off is available in sizes SAE J 744 No 127 4 and SAE J744 No 32 4 A clutchable shaft drive power take off is available PTO adapter from SAE J 744 size 127 4 to 101 4 SAE to SAE Mounting Brackets Steel fabricated mounting brackets for rigid mounti
89. ast relative out of true parallel measurement Figure 174 Checking Output Flange Face Runout Marine Transmission Service Manual 1021569 197 Installation Twin Disc Incorporated Figure 175 Checking Output Flange Pilot Eccentricity some boats are not structurally rigid and some carry their load in such a way that they will hog or go out of normal shape with every loading and unloading Where this condition exists it important to apply common sense alignment techniques to minimize the potential damage to any of the components During the process of securing final alignment it may be necessary to shift the engine many times When the final alignment is accomplished mark and drill the holes for the lag studs or locating dowel pins Then with final alignment secured make up the necessary poured steel or hardwood shims and fasten the engine and transmission in place Then recheck the alignment and if satisfactory bolt the coupling together 198 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation There are many types of flexible couplings in the market today that solve a variety of problems Couplings 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 coup
90. c Incorporated Troubleshooting Table 19 Troubleshooting Chart GP Manual Control Valve continued 7 Harsh engagement Faulty Proportional Valve Replace Proportional Valve 8 Low lube pressure 9 Oil spilling out of breather 10 Low Clutch Apply Pressure Faulty Temperature Sensor if equipped Profile Generator defective or out of adjustment Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Low Main Pressure Defecive Proportional Valve Low voltage to Profile Generator Marine Transmission Service Manual 1021569 Replace Temperature Sensor Replace Profile Generator Adjust if proper equipment is available Replace pump Remove clean inspect and install the suction screen Inspect and correct cause of suction leaks Hemove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil See Paragraph 1 Replace Proportional Valve Verify that green voltage supply light and red clutch energized lights are bright 79 Troubleshooting Twin Disc Incorporated NOTES 80 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Disassembly The following procedure is for complete disassembly of the unit Prior to this
91. capscrew the retaining plate and the proportional valve cartridges from the top valve body Aslight rotating motion while pulling will help to with the removal of the valves Proportional Valve Figure 93 Remove Proportional Valve Cartridges Marine Transmission Service Manual 1021569 127 Disassembly Twin Disc Incorporated 6 Valve Assembly 1020729 Remove the main pressure regulator pilot relief valve and main valve from the main regulator valve body Regulator Valve Body 3 8 npt plug or Temp Sensor o ring Main Regulator Spool Pilot Relief Valve Figure 94 Remove Main Pressure Regulator Valve Components 128 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Valve Assembly 1021658 Remove the main pressure regulator from the main regulator valve body a Remove the regulator adjusting screw cap and loosen the jam nut Turn the adjusting screw counter clockwise to reduce the spring load on the valve Evenly loosen the four M 8 x 25 capscrews and remove the cover assembly and gasket followed by the spring s and spool Remove the four M 8 x 20 capscrews and remove the cover and gasket Remove the orifice and screen assembly for cleaning Remove the ball check assembly only if necessary Removal will require destruction and replacement of the assembly Temperature Sensor Filter Check Valve 4 Figure 95 Remove Main Press
92. d Clutch Piston Installation 142 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 3 Position the primary clutch shaft under a hydraulic press a Slide the release spring over the shaft b Place the spring retainer on the release spring Use Special Tool T 18502 to compress the release spring far enough to expose the snap ring groove in the shaft d Install the snap ring MG 054 MG 053 Figure 105 Release Spring Spring Retainer and Snap Ring Installation 4 Install the clutch plates as follows Install a sintered faced clutch plate and alternate with steel and sintered plates until the ten steel and eleven sintered plates are installed finishing with a sintered plate MG 052 DCP 2001 Figure 106 Clutch Plates Installation 5 Install the clutch back plate 5 Press the back plate firmly into the clutch housing to ensure the splines of the clutch are aligned Marine Transmission Service Manual 1021569 143 Assembly Twin Disc Incorporated 6 Place the internal snap 6 ring next to the clutch back plate AAR6557 069 AAR6557 1012 Figure 107 Clutch Back Plate 5 and Internal Snap Ring 6 7 Install the front thrust bearing onto the input shaft in this order thrust race pilots on shaft with recessed bore over the snap ring needle bearing and thrust race pilots in bore of pinion DCP 1048 Figure 108 Installing Front Thrust Needle Bearing and Thrust Races
93. d Components 168 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Heat Exchanger 1 Install the support bracket to the main housing 2 Place the heat exchanger in its support bracket 3 Connect the oil out hose to the fitting on the main housing 4 Connect the oil in hose to the fitting on the oil pump housing Speed Sensors 1 Apply MA908 Locktite 242 to the threads of the output sensor 2 2 Assemble the output speed sensor until it contacts tip of a gear tooth 3 Back out the output sensor two full turns 4 Secure the output sensor in place with two jam nuts 5 Apply MA908 Locktite 242 to the threads of the input sensor 1 6 Assemble the input speed sensor until it contacts tip of a gear tooth 7 Back out the input sensor full turn 8 Secure the input sensor in place with two jam nuts DCP_1000 Figure 139 Input Speed Sensor 1 and Output Speed Sensor 2 Installation Marine Transmission Service Manual 1021569 169 Assembly Twin Disc Incorporated Mechanical Control Valve Assembly PX 9975 1 Install the thrust race thrust bearing and second thrust race onto the stem MG 235 Figure 140 Installing Thrust Bearing and Races 2 Install a new oil seal and O ring into the valve cover 3 Apply grease or oil to the shaft of the valve stem oil seal and O ring Install the stem into the valve cover 170 Marine Transmission Service Manual 1021569 Twin
94. e 123 Output Speed Sensor Pickup Bracket Installation 156 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Output Flange 1 Lift the output shaft and the main housing Place a spacer thick enough under the front end of the output shaft to allow clearance between the special tools The clearace should allow the press load to act only on the output shaft and output flange 2 Install the output flange a Place the output flange on the output shaft Be sure that the flange face is parallel with the ram face Use a level on the flange face while blocking the housing to insure proper alignment b Press the output flange onto the shaft A static force of 595 to 743 KN 66 9 to 83 5 tonf is required The actual advance of the output flange should be between 6 0 to 7 62 mm 0 236 to 0 300 In C secure the clamp plate to the output flange Torque the M16 2x50 mm screws to 192 Nem 141 Ib ft d Hemove the main housing from the press and special tool oo Level Flange MG_308 Figure 124 Output Flange Installation Marine Transmission Service Manual 1021569 157 Assembly Twin Disc Incorporated Install Internal Parts Output Gear Pan Note Place the main housing in the upright position Be sure the main housing is securely supported 1 Place new seal washers on the three M18 output gear pan capscrews 1 The bottom capscrew is shorter 2 Torque the capscrews to 23 Nem 18 Ibeft
95. e Electronic Interface is not being replaced it can be set aside without disconnecting the remaining wires from the installation Solenoid B on Red LED Powerok gt Green LED Solenoid Red LED Figure 88 Electronic Profile Module typical 2 Remove the six M10 1 50 x 70 capscrews that retain the top valve body assembly to the transmission and remove the top valve body assembly with gasket if not previously removed 124 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Proportional Valves Manual Override Valve amp CC _ Ic Top Valve Body E cA Y 3 53 d a Figure 89 Top Hydraulic Valve Body Assembly 3 Remove the four capscrews that retain the main regulator valve assembly to the transmission housing or ditch plate and remove the valve assembly and gasket Temperature Sensor CR Regulator Spool Figure 91 Main Regulator Hydraulic Valve Assembly 1021658 Marine Transmission Service Manual 1021569 125 Disassembly Twin Disc Incorporated 4 Remove the manual direction control valve with switch or the plug assembly from the top valve body Override Valve with Neutral Switch Locking Pin Plug if applicable Figure 92 Manual Direction Control Valve or Plug 126 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 5 Remove the M6 1 00 x 16 Allen head
96. e following steps Cracks the surface of the rubber May be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate or deterioration of the rubber to metal bond See above Marine Transmission Service Manual 1021569 Twin Disc Incorporated Preventative Maintenance Deterioration of the rubber element as evidenced by sponginess or by black carbon like dust on rubber surface may be caused by contaminants or excessive heat either external or internal to the coupling Cracked bent or otherwise damaged flex plate or coupling plate Bolt holes in flex plate or coupling plate elongated or deformed This could be caused by improperly assembled parts loose parts vibration or improperly torqued parts Bolts nuts bent worn or stripped threads Inspect the hub looking for the following E E Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found Heat Exchanger Check Inspect heat exchanger oil lines for leaky connections kinks cracks or other damage Replace damaged lines Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be ch
97. e the main housing and remove the primary clutch shaft front bearing carrier Tag the components with identifying information 2 Reach inside the main housing and remove the secondary clutch shaft front bearing carrier Tag the components with identifying information DCP 1028 Figure 46 Front Bearing Carriers Removal Input Housing Note Place the main housing in the upright position to remove the following parts Be sure the main housing is securely supported ls Hemove the twelve M12 1 5 x 35 mm capscrews securing the input housing 2 Remove the input housing from the main housing DCP 1030 Figure 47 Input Housing Cover Removal Marine Transmission Service Manual 1021569 99 Disassembly Twin Disc Incorporated Front Output Cover 1 Thread a M10 1 5 eyebolt into the front output cover 2 Use a lever and a block of wood to pry on the screw to overcome the friction of the front cover O ring e Remove the front cover Discard the O ring DCP 1032 MVC 054F Figure 48 Front Output Cover Removal 100 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Remove Output Gear and Shaft Output Gear Pan 1 Remove the three capscrews with sealing washers securing the output gear pan to the main housing The bottom capscrew is shorter 2 Remove the output gear pan through the top opening Figure 49 Output Oil Pan Removal Separate Output Gear form Output
98. e with Electronic Interface 1020729 Disconnect the wiring and remove the electronic module and six capscrews that secure the GP valve top plate to the lower plate Remove the gasket and four capscrews that retain the assembly to the housing and remove the GP valve lower half MG 202 Figure 30 GP Control Valve with Electronic Interface 4 Removal 88 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Top Cover and PTO Cover 1 Remove the twelve M12 x 30 screws with washers retaining the top cover Gently tap the top cover to break the gasket loose from the main housing Remove the top cover 1 and gasket from the transmission housing Remove the PTO cover 2 a Remove the four M12 1 5 x 30 mm PTO cover screws b Gently tap the PTO cover if necessary to break the cover loose from the main housing C Remove the PTO cover and O ring DCP 1001 12 25 Figure 31 Top Cover 1 and PTO Cover 2 Removal Marine Transmission Service Manual 1021569 89 Disassembly Twin Disc Incorporated Input Coupling 1 Remove shipping wire if equipped retaining the input coupling to the input housing 2 Remove input coupling from input shaft Hydraulic Pump Remove the hydraulic pump from the main housing TEN Figure 32 Hydraulic Pump Removal The hydraulic pump can be installed two ways therefore before removing the pump place indexing marks on the pump and the m
99. ecked every 90 days If over 50 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist it is evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush Marine Transmission Service Manual 1021569 69 Preventative Maintenance Twin Disc Incorporated NOTES 70 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting of Mechanical and Electric Control Valves General Note Some of the troubleshooting procedures vary depending on the type of control valve that is installed on the transmission A thorough understanding of the valve operation is important to properly troubleshooting the problem that is occurring The following charts are 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
100. eedle bearing Note Record location of the front two thrust races and needle bearing for proper assembly The first race to be removed pilots on the shaft and the second one pilots in the pinion bore DCP_1045 Figure 65 Front Two Thrust Races and Needle Bearing Removal 9 Slide the pinion assembly from the shaft DCP_1046 Figure 66 Pinion Assembly Removal 6 Remove the rear two thrust races and needle bearing Note Record location of the rear two thrust races and needle bearing for proper assembly The first race removed pilots in the bore of the pinion and the second pilots on the shaft This thrust race also has a counterbore to fit over the snap ring 112 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly DCP 1048 MVC 063 Figure 67 Rear Two Thrust Races and Needle Bearing Removal 7 Remove the internal snap ring and clutch back plate from the clutch housing Figure 68 Internal Snap Ring and Clutch Back Plate Removal Marine Transmission Service Manual 1021569 113 Disassembly Twin Disc Incorporated 8 Remove the 10 steel plates and 11 clutch friction plates from the clutch housing MG_052 Figure 69 Steel Plate and Clutch Friction Plate Removal Position the secondary shaft and clutch housing under a hydraulic press a Place Special Tool T 18502 on the spring retainer b Compress the release spring enough to expose the snap ring Remove the sna
101. eel 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 20 Table 20 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations and Bore Eccentricity mm in 0 48 0 019 0 41 0 016 0 30 0 012 0 28 0 011 0 2 0 36 0 014 2 190 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation 3 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 Housing Figure 168 Checking Flywheel Housing Bore Eccentricity 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the previous Table for allowable tolerances D 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 Figure 169 Checking the Flywheel Face Runout Marine Transmission Service Manual 1021569 191 Installation 192 Twin Disc Incorporated 6 With the indicator mounted as in the paragraph above adjust the indica
102. equired to press the shaft in place 7 Again measure from the end of the output shaft to the face of the output gear Measure three locations around the shaft The three readings should be identical Record this distance as Dimension B reference drawing Dimension B 8 Determine the actual gear advance Subtract Dimension A from Dimension B The actual gear advance should be between 3 81 to 5 33 mm 0 15 to 0 21 in A CAUTION If the calculated advance falls outside the range given in the table check to ensure all measurements calculations are correct If no errors are found it will be necessary to change parts Contact the Product Service Department of Twin Disc Incorporated Marine Transmission Service Manual 1021569 153 Assembly Twin Disc Incorporated 9 Place the output gear pan in position around the output gear DCP_1034 Figure 120 Position Output Gear Pan 10 Install the output bearing cones onto the output shaft a Heat both output shaft rear bearing cones to 120 C 250 F for 30 minutes Handle the bearing cones with care The bearing cones are HOT b Lubricate the output shaft C Place the cones onto the output shaft back to back Install the larger diameter cone onto the shaft d Use Special Tool TD 300496 to install the smaller diameter cup against the first one with the cage facing the rear of the housing DCP 1040 Figure 121 Output Bearing Cones Installation for example o
103. f any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old resulting from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty 14 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Introduction Source of Service Information For the latest service information on Twin Disc products contact any Twin Disc distributor or service dealer This can be done on the Twin Disc corporate web site found at http www twindisc com Provide your model number serial number and bill of material number to obtain information on your unit If necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com Warranty Equipment for which this manual was written has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual For details of the warranty contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Inc Racine Wisconsin U S A Marine Transmission Service Manual 1021569 15 Introduction Twin Disc Incorporated NOTES 16 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Descript
104. flushing of oil through the valve assembly followed by adjustment of the main pressure 1 Install a main pressure gauge into the port on top of the top valve body 2 Remove protective cover cap located at the end of the cartridge This will expose a 1 4 hex head adjustment stem Loosen the jam nut on the stem Adjusting screw Figure 159 Pilot Relief Valve Assembly 3 Turn this adjustment stem counterclockwise until it reaches a positive stop This allows the engine transmission to be started and flush any debris past the relief valve Note This must be done with the transmission in Neutral 4 Start engine with controls in Neutral Main pressure should be approximately 100 psi or less Allow the fluid to flush the valve for approximately 1 minute 5 Turn the 1 4 hex head adjustment stem clockwise to achieve the main pressure setting Ahelpful practice is to turn the adjustment stem slightly beyond the desired setting approximately 5 psi and then adjust for the target pressure This aids in reducing variance in pressure setting due to torsional wind up of the spring Note If main pressure is to be set with cold oil adjust the main pressure approximately 5 to 10 psi higher than the desired value with hot oil 6 Tighten the jam nut to a torque of 20 Nem 15 Ib ft install the protective cap and torque it to 14 Nem 10 Ib ft Marine Transmission Service Manual 1021569 183 Assembly Twin Disc Incorporated Valve
105. gine idle speed too low Oil pump strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Regulating valve stuck open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Regulating valve stuck Improperly shimmed Lube relief valve malfunction Marine Transmission Service Manual 1021569 strainer Disassemble the valve and clean the piston Remove the collector and inspect piston rings Replace damaged or worn oil pump assembly Adjust linkage so that 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 level 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 Remove and clean regulating valve Shim as required Inspect repair or replace parts as necessary 73 Troubleshooting 74 Table 17 Troubleshooting Chart Twin Disc Incorporated Mechanical and Electric Control Valves continued 4 High temperature 5 Excessive noise 6 Noneutral Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Wor
106. he oil causes the pressure regulating piston to partially compress the piston outer and inner springs against the pressure rate control piston This pressurizes the oil in chamber B and the rate of rise chamber This pressure is controlled by the neutral regulator spring and shims The movement of the pressure regulation piston against the springs exposes port C in the valve body Port C directs overage oil to the lubrication oil circuit Passage D which is the engaging outlet to the primary clutch and Passage E which is the engaging outlet to the secondary clutch are interconnected by Slot F in the control valve stem when in the neutral position The slot is aligned with a drilled hole and cored cavity in the face of the valve body The drilled hole and cored cavity are aligned and drilled holes that pass through the main housing to sump Therefore passages D and E are at atmospheric pressure at this time Also passage J is at atmospheric pressure because port H interconnects with slot F This area between pistons and around springs is vented to the sump of the transmission This area is at atmospheric pressure at all times permitting the return to sump of any leakage oil past the pistons Marine Transmission Service Manual 1021569 41 Operation Twin Disc Incorporated High Pressure Regulator Piston Orifice Rate of 0 08 Engaging Passage Riise Piston E Oil Engaging Passage interconnection Sipt G Oil Directional Port
107. her Regulating piston or rate of rise piston stuck Orifice plate ball in control valve not seating properly Blown gasket on either side of orifice plate Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Marine Transmission Service Manual 1021569 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 75 Troubleshooting Twin Disc Incorporated Troubleshooting of GP Control Valve with Electronic Interface General The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Electronic Interface LED Indicators The electronic interface control modules have one green and two red led indicator lights The green power light is illuminated ony when the transmission is in gear The fol
108. ht screws retaining the output seal carrier and speed pickup bracket 102 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 3 Lift the seal carrier and shims from the output shaft DCP 1038 DCP_1039 Figure 51 Output Shaft Seal Carrier Removal 4 Remove the seal from the seal carrier 5 If the rear bearing cup needs to be replaced remove the cup from the seal carrier Note Only remove the cup from the seal carrier if it needs to be replaced If removed a new bearing must be installed during assembly Marine Transmission Service Manual 1021569 103 Disassembly Twin Disc Incorporated Output Shaft 1 Use a hoist and lift the output shaft from the main housing DCP 1040 Figure 52 Output Shaft Removal 2 Hemove the output gear through the top cover opening of the main housing Set the output gear aside DCP 1041 Figure 53 Output Gear Removal 104 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Main Housing 1 Remove the input shaft seal from the main housing 2 If replacement is necessary remove the bearing cups for the primary and secondary clutch shafts and the output shaft If removed a new bearing must be installed during assembly Note Bearing cups are an interference fit in the main housing Place a bead of weld all around the bearing face This will cause the bearing cup to shrink so it can be removed using an in
109. i 53403 USA DATE E TWIN DISC INCORPORATED RACINE WI 53403 USA a LL 81 1195 9 XX 7 Ce ie A THIRD ANGLE O 20 40 60 PROJECTION cel SIMILAR TO 0 1 0 2 0 3 0 pNOTICE THIS PRINT CONTAINS MATERIAL TJIN 5086 2 7 O USED IN ANY MANNER 1 RACINE WI 53403 USA MODEL 108 50 THIS NOTICE IS INTENDED NAME STD LE MG5145 A MARINE TRANSMISSION OR OTHERS BY CONTRACT REF 10850 gt wc B A HEAT EXCHANGER H E REQUIREMENTS WHEN MOUNTING ENGINE TRANSMISSION IN BOAT ALL THE 112 0 4 41 MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE REFER TO B3649 FOR HEAT EXCHANGER REQUIREMENTS TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW 4 x 34 0 2 THE 10830 CONFIGURATION IS NOT SUITABLE FOR REMOTE S 054 MOUNTING z RECOMMENDED Never tee 917 0 DRILL THRU ON PADS 4PLACES 8 3 o X 5 4 1349 4 PM 2145 1 11261 WATER IN 4 629 0 24 76 G 171 2 1 PM 4360 Z 4 PM 12357 B PROF UTILE 20 0 79 1 M 2031 D 9 154 0 6 06 4 PM 2057 AJ 1 PM 3533 AU WATER OUT G 1172 PROF UTILE 20 0 79 8 S 1 10864 T 12 5570 S 9 2 g 5 wa 1 11789
110. iner Contamination on Pilot Relief Valve seat Contamination in Main valve Cartridge Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Engine idle speed too low Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Pilot Relief Valve or Main Regulating Valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Pilot Relief Valve is out of adjustment Main Regulating Valve orifice missing Marine Transmission Service Manual 1021569 Remove and clean oil strainer Disassemble the Pilot Relief Valve and clean Service the transmission oil filter Clean or replace Main Valve cartridge and service the transmission oil filter Remove the collector and inspect the piston rings Replace damaged or worn oil pump assembly pump is not serviceable Raise engine speed Hemove and clean strainer Check oil level and correct Correct cause of air leak Disassemble and repair as required Hemove disassemble clean and repair the Pilot Relief Valve Remove clean or replace the Main Regulating Valve This valve cannot be disassembled Replace oil pump Replace heat exchanger Adjust Pilot Relief Valve Replace if necessary Replace Main Regulating Valve cartridge 77 Troubleshooting Twin Disc Incorp
111. ion and Specifications Description and Specifications General The MG 5145A is a reverse and reduction Marine Transmission This transmission has a 10 down angle for near level engine installation offer conical gearing for quieter operation and are available in the following ratios 1 26 1 1 48 1 1 75 1 1 96 1 and 2 50 1 The MG 5145A transmission is controlled by hydraulics Both the primary and secondary clutches are operated by main pressure oil supply The bearings clutches and gears are lubricated and cooled with low pressure oil Drawing PX 10830 identifies the installation information for the MG 5145A marine transmission Marine Transmission Service Manual 1021569 17 Description and Specifications Twin Disc Incorporated 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 NO MARINE TRANSMISSION BILL OF MATERIAL NO MUST BE GIVEN WHEN ORDERING PARTS OIL CAPACITY GALS MIN OIL PRESSURE AT RATED RPM P S I LUBRICATION EVERY 10 SERVICE HOURS OR DAILY CHECK OIL LEVEL WITH ENGINE RUNNING AND MARINE TRANSMISSION IN NEUTRAL EVERY 1000 SERVICE HOURS OR 6 MONTHS WHICHEVER COMES FIRST DRAIN AND REFILL HOUSING WITH CLEAN OIL REMOVE AND REPLACE FILTER ELEMENT WHERE APPLICABLE REMOVE CLEAN AND REPLACE SUCTION SCREEN IN REAR COVER IMPORTANT WARRANTY IS VOID UNLESS
112. ire or harness passes through a sheet metal hole Check wire or harness for cracks effects of vibration abrasion brittleness or abuse Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation Wiring Connections General The vessel wiring for the Profile or E Troll Module must be of sufficient size to prevent excessive voltage drop no greater than 0 5 Vdc between the battery connections positive voltage and ground and the Profile or E Troll Module The modules operate from nominal 12 VDC or 24 VDC batteries The battery power connection must be protected by an electrical over current protection component fuse or circuit breaker as required by the vessel s approval agency The minimum current capacity should be 5 amps DO NOT connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System The customer supplied selector switches for each of the transmission clutches and for troll if equipped must be connected directly to the wires of the Profile or E Troll Module and connected to the power source as shown in the table that follows No other electrical loads should be connected to this circuit Make the following Connections The following power connection chart lists the possible configurations for connecting Electronic Profile or E Troll Module to the power source for the three possible wiring options LJ Option 1 connections are used when the Profile or E T
113. iven whenever the engine is running Hydraulic Clutched Power Take off PX 11615 Series The PX 11615 model has a keyed PTO output shaft The PX 11615A model has internal splines and accepts an SAE J744 size C pump 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 is directed to the PTO control valve with the overage oil flowing to the transmission s control valve Marine Transmission Service Manual 1021569 59 Operation Twin Disc Incorporated Power Flow 60 Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is splined to the forward end of the primary forward clutch shaft causing the primary shaft to rotate in engine direction during engine operation Power is transmitted to the secondary shaft by means of the transfer gear teeth on the outer di
114. ize Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels Inspect dowel 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 1021569 137 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Bearings Inspect bearings for roughness of rotation Replace the bearing if the rotation is rough Inspect bearings for corrosion and for indication of wear of balls or rollers Inspect for scored scratched cracked pitted or chipped races If you find one of these defects replace the bearing Inspect bearing bores and shafts for grooved burred or galled conditions that would indicate the bearing has been turning in its housing or on its shaft If you cannot repair the damage with a crocus cloth replace the part Bushings and Sleeves Inspect bushings for size and out of roundness Inspect for scores burrs sharp edges and evidence of overheating Remove scores with a crocus cloth If the bushing is out of round deep
115. lView Sheer dfEam 225 PX 10830 5145 Marine Transmission GeneralView E 226 PX 10830 5145 Marine Transmission GeneralView Sheel EE 227 10830 MG 5145A Marine Transmission GeneralView Sheel 7 228 A7119M MG 5145A Hydraulic Diagram 229 ee 230 PATIOS 2 c 231 1020 29 nce ee eee ee 232 QUA OG MCER 233 10 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc MG 5145A marine transmission 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
116. lace the rear bearing carrier on the main housing 3 Install the bearing spacers and excess shim pack DCP 1023 1022 DCP 1020 Figure 131 Rear Bearing Carrier and Spacers Installation 3 Install the manifold using a new gasket Torque the M10 1 5x45 mm manifold capscrews to 46 Nem 34 Ibeft 4 Install eyebolts to the end of the primary and secondary clutch shafts 5 Using a dial indicator and two levers lift the shafts Record the endplay measurement for each shaft 162 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 6 Calculate the shim pack thickness The correct shim pack thickness require a preload of 0 0 to 0 07 mm 0 0 to 0 003 in i e a normal preload of 0 035 mm 0 0014 in Example Endplay measurement 1 27 mm 0 05 in Required shim pack thickness 1 27 mm 0 035 mm 1 305 mm 0 05 in 0 0014 in 0 0514 in 7 Remove the manifold Be sure to reuse the same gaskets on assembly that were used to determine the required shim pack 8 Install required shims aligning hole with roll pin in spacer Oil Lubrication Tube 1 Install the tube into the rear bearing carrier 2 Be sure the tube is aligned with slot Piston Rings Install the piston rings in the grooves at the end of the primary and secondary clutch shafts DCP_1019 Figure 132 Piston Ring Installation Marine Transmission Service Manual 1021569 163 Assembly Twin Disc Incorporated
117. le 16 Banjo Fittings amp Sealing Plugs with Copper Washers Torque Values for Banjo Fittings amp Sealing Plugs with Copper Washers Thread Size Recommended Torque N m Lb ft M14 x 1 5 64 47 M16 x 1 5 83 61 M24 x 1 5 186 137 Marine Transmission Service Manual 1021569 35 Description and Specifications Twin Disc Incorporated Clutch Plate Wear Limits Clutch steel plates Minimum thickness 2 3 mm 0 091 in Clutch friction plates Minimum thickness 3 1 mm 0 122 in 36 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Operation General The control valve obtains primary neutral and secondary positions When these positions are selected the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate control piston within the control valve assembly provides a rapid smooth oil pressure increase in the hydraulic system during clutch engagement There are several control valves available for the MG 5145A These will be discussed individually Marine Transmission Service Manual 1021569 37 Operation Twin Disc Incorporated Hydraulic System with PX 9975 Series Manual Control Valve 38 The oil pump draws oil through the strainer from the oil sump and discharges it through the oil filter if equipped Filtered oil enters the control valve through the inlet port The incoming oil forces the pressure regulator piston against the
118. le the bearing cup with care The bearing cup is extremely COLD b Lubricate the bearing bore in the main housing e Install the bearing cup into the main housing Be sure the bearing cup is bottomed in the bore as the bearing cup warms to the ambient temperature 2 If removed install a new output shaft bearing cup in the main housing a Deep freeze the bearing cup to 51 C 60 F for at least two hours before installing it Handle the bearing cup with care The bearing cup is extremely COLD b Lubricate the bearing bore in the main housing C Install the bearing cup into the main housing Be sure the bearing cup is bottomed in the bore as the bearing cup warms to the ambient temperature 9 Install new input shaft seal a Apply MA1015 sealer to the outside diameter of a new input shaft seal b Press the seal into the housing using Special TD 300492 Lip of seal should face away from the main housing when installed and rear of seal should be flush with the rear of the front housing bore Marine Transmission Service Manual 1021569 151 Assembly Twin Disc Incorporated Output Gear and Output Shaft Assembly Note Position the main housing with the input end down Be sure the main housing is securely supported 1 Clean and inspect the output gear tapered bore a Prepare the gear tapered bore surface for assembly by using a Scotchbrite pad to remove any burrs b Clean the shaft tapered sruface
119. lings Always use the alignment procedures recommended by the coupling manufacturer Controls Installation Transmission Controls A 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 1021569 199 Installation Twin Disc Incorporated 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 ste
120. ll Module and sealed This can be field adjusted if necessary by authorized personnel with the proper instrumentation There are two types of control modules for the MG 5145A marine transmission with and without the trolling E Troll feature All electrical wiring for the marine transmission system controls are routed through this interface module The vessel battery power 12 VDC or 24 VDC is supplied to the electronic interface only and never directly to the hydraulic proportional valves Two red LED lights are used to identify the proportional cartridge valve that is energized and a green LED is used to identify when power is provided to energize one of the clutches Signals are provided to power a customer supplied relay to allow engine starting only when in Neutral Atransmission oil temperature sensor is required for the MG 5145A marine transmission Engine speed and propeller speed sensors are required for transmissions with E Troll The following figures show the various versions of Electronic Profile or E Troll Module Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Solenoid B on Red LED Power ok Green LED Solenoid on Red LED Figure 14 Electronic Profile Non Troll Module Solenoid Bon Red LED Power ok Green LED Solenoid Aon Red LED Figure 1
121. llOD cn 199 Wiring ConBebcllofiS uus 205 Pinal 208 Special Tools 209 LISTE OF 0015 209 Recommended Pump Set and Fluids 210 T 18502 Release Spring Compressor 212 TD 300492 Seal Installation Input 213 TD 300493 Seal Installation Output 214 TD300494 Gear Installation Tool Output Shaft 215 TD 300495 Rear Inner Bearing Race Installation Primary and Secondary adane 216 TD 300496 Output Shaft Inner Bearing Race Installation 217 TD 300497 Outer Bearing Race Installation MA590BF 218 TD 300498 Outer Bearing Race Installation MA590CS 219 Marine Transmission Service Manual 1021569 9 Table of Contents Twin Disc Incorporated List of Engineering Drawings 221 List of Engineering Drawings 1 1 221 PX 10830 MG 5145A Marine Transmission Section View Chl 222 10830 MG 5145A Marine Transmission General View E a 223 10830 MG 5145A Marine Transmission GeneralView Sheer S OTT 224 PX 10830 MG 5145A Marine Transmission Genera
122. lowing table lists the reasons for the various conditions where lights are illuminated This should guide in troubleshooting problems See the wiring schematics in the Installation Section Troubleshooting Tables begin on the next page Table 18 LED Light Status Light Status Profile Generator E troll Module Non trolling Green light on Supply voltage gt 9 0 volts Supply voltage gt 9 0 volts Red light on Valve coil command on Valve coil command on One red light flashing Open circuit in an energized Open circuit in an energized valve coil circuit valve coil circuit or valve coil leads shorted togethe MG 5145A only Valve coil or low coil current leads shorted together or low coil current Both red lights flashing MG 5145A only Power is After entering troll from simultaneously applied tosolenoid A and B neutral with both voltage and switch inputs at the same time current troll speed signals present or power is applied MGX 5145A only Not applicable to solenoid A and B switch inputs at the same time Both red lights flashing Not applicable Either or both speed signals alternately missing 76 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Table 19 Troubleshooting Chart Troubleshooting GP Manual Control Valve with Electronic Interface 1 Low main oil pressure 2 Nooil pressure or erratic low pressure at control valve tap 3 High main oil pressure Partially clogged oil stra
123. ly remove tension on the release spring Remove the spring retainer and release spring MG_054 Figure 62 Spring Retainer and Release Spring Removal 10 Remove the clutch piston from the clutch housing a Thread two 8 1 25 mm rods into the piston 180 apart Lift clutch piston out of the clutch housing Compressed air can be used to aid in the removal of the piston b Remove the O ring from the inside diameter of the piston Note DO NOT disassemble the clutch shaft from the clutch housing These parts are not serviced separately MG 302 Figure 63 Piston and O ring Removal Twin Disc Incorporated Disassembly Secondary Clutch Shaft Disassembly 1 Remove the rear bearing cone Note Only remove the cone from the secondary clutch shaft if it needs to be replaced If removed a new bearing must be installed during assembly a Cut off the bearing cage and remove the rollers b Use a cheese cutter type puller to pull on the rear shoulder of the inner bearing race C Heat the inner race to assist in its removal CAUTION overheat the inner race as it could result in annealing the clutch shaft Handle the inner race and shaft with care The inner race and shaft are HOT 2 Position the secondary clutch shaft with the input end facing up 3 Remove the snap ring DCP1043 Figure 64 Snap Ring Removal Disassembly Twin Disc Incorporated 4 Remove the front two thrust races and n
124. ly 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 138 Marine Transmission Service Manual 1021569 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 If you cannot remove these defects with a soft stone replace the gear splined Parts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found Springs Inspect springs for broken or distorted coils Replace the spring if either of these defects is found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses Clutch Plates Inspect clutch plates for signs of overheating pitting or excessive wear of the friction and splined surfaces Replace the clutch plates if one of these defects is found Refer to wear limits in Description and Specifications Marine Transmission Service Manual 1021569 139 Cleaning and Inspection Twin Disc Incorporated NOTES 140 Marine Tra
125. m Selecting neutral must place the selector valve in the neutral detent position Improper installation of power engaging devices could cause failure of the selector valve stop permitting improper positioning of the selector valve and resulting in control malfunction Electrical Controls All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connections must be tight and free from any corrosion It is strongly recommended that the control harnesses and wiring guidelines be followed to ensure proper installation of all wiring Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation Figure 176 Mechanical Control Valve Installation Specifications Marine Transmission Service Manual 1021569 201 Installation Twin Disc Incorporated Figure 177 Electric Control Valve Installation Specifications 202 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation Control Harnesses and Wiring guidelines Install all control wires and harnesses as follows 1 The connector end of the control wire or harness must be secured to its own support six inches back from each connector The wire or harness must be secured at 18 inch intervals to its own frame supports between the wire or harness ends 2 Keep wire or harness away from hot surfaces moving parts and locations 3 Attach wire or harness to machine
126. m secondary to neutral the valve stem is rotated to the position illustrated by Figures 4 and 5 Under these conditions passage E is connected to the sump by slot F Passage J is also connected to sump by port the valve stem Because passage E is connected to slot F oil drains rapidly from the secondary clutch to sump Because passage J is now at atmospheric pressure the oil pressure in chamber L unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back until the cavity is once again at the neutral regulated pressure The secondary clutch is now disengaged and main system pressure reduced to neutral pressure Marine Transmission Service Manual 1021569 45 Operation Twin Disc Incorporated Entry Passage Chamber High Pressure C Od Pressure Overflow Regulator Piston Orifice 0 09 Engaging Passage E Oil Engaging Passage hate of F O8 interconnection Slot Risa Piston G Oil Directional Port H O Connaction Pari d Oll Pressure Passage Directional Port Control Valve Lever w LL ay ILL Piston Springs Control DI Le Control Valve Body Atmospheric Pressure ES Engaging Pressure Figure 8 Mechanical Control Valve Secondary Cutaway View Secondary CONTROL or VALVE BODY TO PRIMARY CLUTCH
127. main housing in the upright position to remove the following parts Be sure the main housing is securely supported Input and Output Speed Sensors If Equipped Ts Disconnect the input speed sensor 1 and output sensor 2 connector 2 Loosen the jam nut securing each sensor 3 Remove the input speed sensor and the output speed sensor from the main housing DCP 1000 12 Figure 28 Input 1 and Output 2 Speed Sensor Removal 86 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Heat Exchanger If Equipped 1 Remove the oil in hose connector from the fitting on the oil pump housing 2 Remove the oil out hose from the fitting on the main housing 3 Hemove the heat exchanger from its support 4 Remove the support from the main housing Control Valve Note Io aid in assembly be sure to mark all wire connectors prior to removing the control valve Mechanical Control Valve PX 9775 Remove the four capscrews that secure the selector valve assembly 2 to the housing and remove the selector valve assembly Electric Control Valve PX 10225 Remove the two solenoid coils Remove the four capscrews that secure the selector valve assembly 3 to the housing and remove the selector valve assembly MG 2002 MG 201 3 Figure 29 Mechanical 2 and Electric 3 Control Valve Removal Marine Transmission Service Manual 1021569 87 Disassembly Twin Disc Incorporated GP Control Valv
128. n or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Clutch plates warped Control valve incorrectly indexed Solenoid malfunction units equipped with electric selector valve Hydraulic lock piston stuck units equipped withelectric selector valve Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch Overhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve Overhaul marine transmission Remove marine transmission Replace a worn or damaged coupling Select proper torsional coupling Overhaul marine transmission Check alignment of engine transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine Remove clutch plates Overhaul unit Check and adjust control linkage Replace defective solenoid Inspect repair or replace hydraulic lock spool Marine Transmission Service Manual 1021569 Twin Disc Incorporated Table 17 Troubleshooting Chart Troubleshooting Mechanical and Electric Control Valves continued Cause Remedy 7 Harsh engagement 8 Oil spilling out of breather 9 Oil spilling out of breat
129. nance 65 In boat Maintenance and Repair 65 General Maintenance uoces ninixu mici tq ERE REED OC EINE E UE 66 Periodic Visual Inspection ss 68 Troubleshooting 71 Troubleshooting of Mechanical and Electric Control Valves 71 Pressure Test 4 4 nnmnnn 72 Troubleshooting of GP Control Valve with Electronic Interface 76 Disassembly 81 Prepare Transmission for Disassembly 81 ROMOV acs E 85 Remove External Parts 2 86 Remove Internal Parts 91 Remove Output Gear and Shaft 101 Main TOUS UG e 105 Output Shaft Disassembly 105 Primary Clutch Shaft Disassembly 106 Secondary Clutch Shaft Disassembly 111 Mechanical Control Valve Disassembly PX 9975 116 Electric Control Valve Disassembly PX 10225 121 Disassembly of GP Control Valve with Electronic Interface 123 US ASSO IMO EE ETE 124 T
130. ne to 120 C 60 F for 30 minutes before installing it A CAUTION Hand the bearing cone with care The bearing cone is HOT b Deep freeze the sleeve or bushing to 51 C 60 F for at least two hours Handle the sleeve with care The sleeve is extremely COLD C Lubricate the sleeve d Press the sleeve into the cup and cone 2 Lubricate and install the primary clutch shaft front bearing and carrier assembly Lubricate and install the secondary clutch shaft front bearing and carrier assembly DCP_1028 Figure 128 Primary and Secondary Front Bearing Carriers Installation 160 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Install Secondary Clutch Shaft 1 Install a lifter eye into the end of the secondary clutch shaft 2 Lubricate the input end of the shaft 3 Use a hoist to install the secondary clutch shaft in the main housing DCP_1027 Figure 129 Secondary Clutch Shaft Installation Install Primary Clutch Shaft 1 Install an eyebolt into the output end of the primary clutch shaft 2 Lubricate the input end of the shaft 3 Use a hoist to install the primary clutch shaft in the main housing DCP 1026 Figure 130 Primary Clutch Shaft Installation Marine Transmission Service Manual 1021569 161 Assembly Twin Disc Incorporated Primary and Secondary Rear Bearing Adjustment 1 Install new bearing cups into the bearing carrier 2 Using anew gasket p
131. ng are available Torsional Input Coupling several models of torsional input couplings are available including Silicon Vulkan VKE and Centa CF R Oil Filter A spin on oil filter is available for MG 5145A models that are not equipped with a standard oil filter It is located between the heat exchanger outlet and control valve in the hydraulic circuit Heat Exchanger A heat exchanger is available shipped loose or mounted Marine Transmission Service Manual 1021569 29 30 Description and Specifications Twin Disc Incorporated Companion Flange Assembly The companion flange assembly consists of the companion flange and mounting hardware Mechanical Control Valve A mechanical control valve is available Electric Control Valve An electric control valve is available for either 12 VDC or 24 VDC actuating solenoids GP Control Valve with Electronic Interface There is also a GP valve assembly available for models with optional input and output speed pickups mounted on the transmission Trolling Valve Mechanical and electrical trolling valves are available Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Table 7 Bearing End Play Specifications Transmission Primary and Secondary Shaft Tapered Roller Bearing Endplay 0 00 mm 0 000 in 0 07 mm 40 003 Transmission Output Shaft Bearing Endplay 0 00 mm 0 000 in 0 05 mm
132. ng range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval Maximum Note A suction screen is located in the suction line to the pump and the oil filter if equipped is located in the pump outlet line Both should be checked and cleaned at the stated intervals With a new transmission change the oil and filter element if equipped and clean the suction strainer screen within the first 50 hours of operation Change oil and filter element and clean the screen after each 1000 hours thereafter or more often if conditions warrant For a rebuilt transmission check the filter element and or screen after eight hours of operation If the filter and or screen is clean install a new filter element if equipped and then change the oil and filter element after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the filter is clean and then change the oil and filter after 1000 hours of service or more often if conditions warrant Marine Transmission Service Manual 1021569 Twin Disc Incorporated Preventative Maintenance Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Use a 38 mm wrench to loosen the drain plug Oil Suction Strainer Hemove and clean the pump suction strainer at every oil change or sooner if necessary The
133. ngaged at a time and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs overcome any centrifugal head that may exist behind the piston and move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Nt 5 5 Hiii eT Hi ieri m urba PALOS Urna Ba le UE DE m E TRUCO FELADTM CHAT TET ihi ERE gin 1 28 inr i i ete i Gm BTE B HE TEER x Per AE LAGER CO Siem Eae Cms 1 1 STH dk sad RN cr EC LE PLUIE LES min Ta rer T p Figure 2 A7119V Hydraulic Schematic 1 Marine Transmission Service Manual 1021569 39 Operation 40 PoE Wa d Be VE Roe PRIMARY gm r BE p ee stain L Twin Disc Incorporated p REVERSE PRIMARY Ee SE CONDART CLUTCH CLUTCH PELE B z CLUTCHES i Bf 4 a 3 4 1 EJ I
134. nly 154 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Output Shaft Seal Carrier 1 If removed install a new bearing cup in the seal carrier a Deep freeze the bearing cup to 51 C 60 F for at least two hours before installing it Handle the bearing cup with care The bearing cup is extremely COLD b Lubricate the bore of the seal carrier Install the bearing cup using Special Tool TD 300496 2 Install new output shaft seal in the seal carrier a Apply MA1015 sealer to the outside diameter of a new output shaft seal b Install the seal into the carrier using Special Tool TD 300494 Lip of seal should face away from the seal carrier when installed Install the seal until it bottoms in the bore i Install a new O ring in the pilot diameter groove a Coat the O ring with grease b Install the O ring in the groove 9 Install the output shaft seal carrier to the main housing a Place the shims and seal carrier on the main housing b oecure the seal carrier Torque the M12 1 25 capscrews to 80 Nem 59 Ibeft Marine Transmission Service Manual 1021569 155 Assembly Twin Disc Incorporated Verify the bearing endplay remains within its tolerance Adjust bearing end play to proper setting of 0 to 0 05 mm 0 to 0 002 In DCP 1039 DCP 1038 Figure 122 Output Shaft Seal Carrier Installation 6 Install the output speed sensor pickup bracket DCP 1037 Figur
135. nsmission Service Manual 1021569 Twin Disc Incorporated Assembly General Assembly During service of this unit all O rings gaskets and seals must be replaced Refer to cleaning and inspection information in this manual prior to assembly It is good practice to compare the new parts with those being replaced during the assembly process to make sure you dont mistake the quantity or size Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces Pipe threads called out as PT British Standard Pipe Tapered on drawings and in this text are different from NPT threads PT threads and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Where grease Is specified use a lithium based grease NLGI 2 Submerge all new clutch friction plates in clean transmission oil for a minimum of one hour prior to installation This transmission uses liquid sealer in many locations The approved sealant is Loctite 518 MA1015 applied per S774 a thin layer of sealant is all that is required with Locktite Primer N MA1012 Avoid getting sealant into the O ring counter bores This transmission uses thread lockers MA908 and MA1007 at specified capscrew locations Note In the discussion that
136. oats are built with flexibility and may change shape as the loading varies Marine Transmission Service Manual 1021569 195 Installation Twin Disc Incorporated When a heavy boat is dry docked it naturally undergoes some bending Therefore it is always good practice to unbolt the marine transmission coupling to prevent bending of the shaft With the engine and transmission in position on the engine bed arrangements must be made to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine can be raised by screwing down or lowered by backing off on the jacking screws to obtain the desired adjustment 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 At the same time a straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE FEMALE STRAIGHT E
137. old gasket material or Loctite Clean surfaces with solvent to remove oil and grease residue Test for clean surfaces by applying a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface in a film If the water puddles or forms beads use fresh solvent and reclean 136 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Cleaning and Inspection Inspection Housings Cast Parts and Machined Surfaces E Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding or grinding This will cause loss of fit of bearings or races Inspect oil passages for obstructions If you find an obstruction remove it with compressed air or work a wire back and forth through the passage and flush it with solvent Inspect machined surfaces for burrs scratches nicks and foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part E Inspect ground tapers for scratches galling or scoring damage If any of these are present replace the part Inspect ground tapers for burrs or nicks If you cannot remove the defect with a soft stone replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct s
138. on Locking Pin ore niin ME 1 Gan Switch a de 57 Figure 18 Manual Direction Control Valve Marine Transmission Service Manual 1021569 55 Operation Twin Disc Incorporated Trolling Valve Optional The trolling valve is used to reduce and control propeller soeed below that normally attained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure to reduce the propeller speed A CAUTION Install the pilot house instruction plate B2464 in an area near the trolling valve control head in the pilot house where it may be easily read Failure to obey this operating limit can result in major damage to marine transmission components which can cause an unsafe operation condition to occur Unsafe operating conditions could result in loss of vessel maneuvering control vessel damage and or loss of property and or life Note Be sure to observe and record marine transmission sump oil temperature If temperature drops below 135 F during mode operation it is recommended that a thermostatic by pass valve be installed in the transmission s hydraulic circuit Consult Twin Disc for appropriate recommendation The operator must select the trolling mode with the control valve lever in neutral and set the engine speed at or below the recommended maximum trolling rom See Description and Specifications A CAUTION Do not operate marine transmissi
139. on in the trolling mode at engine speeds above the maximum trolling rpm The maximum engine speed in trolling is 1100 rpm or 40 of match point engine speed whichever is smallest 56 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Operation Mechanical Trolling Valve PX 8871 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 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 Detent position Trolling mode orice A orifice A MG 211 Figure 19 Mechanical Trolling Valve PX 8871 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
140. orated Table 19 Troubleshooting Chart GP Manual Control Valve continued 4 High temperature 5 Excessive noise 6 Noneutral 78 4 1 Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Worn or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Clutch plates warped Disengaged clutch has apply pressure Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure Is normal remove disassemble and repair slipping clutch If pressure is low replace Proportional Valve and service the transmission oil filter Overhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve Overhaul marine transmission Remove marine transmission Replace a worn or damaged coupling Select proper torsional coupling Overhaul marine transmission Check alignment of engine transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine Remove clutch plates Overhaul unit Replace Proportional Valve Service Transmission oil filter Marine Transmission Service Manual 1021569 Twin Dis
141. ould be an indication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage caused by engine to Twin Disc component interference regardless of the cause of interference This engine crankshaft endplay check is considered mandatory The transmission housing flange and pilot the engine flywheel and the flywheel housing must be checked for trueness Clean the engine flywheel and flywheel housing mounting surfaces thoroughly before any measurements are made Note To isolate engine vibration and prevent transferring it to the hull through the propeller shaft the distance from the marine gear output flange to a fixed stuffing box or the first fixed bearing must be a minimum of 20 times the shaft diameter If the distance is less than this a flexible coupling may be necessary to isolate the engine vibration Marine Transmission Service Manual 1021569 189 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 na f l Cuna N Engine Housing Figure 167 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywh
142. ove the rate of rise piston and remove adjustment shims MG 226 Figure 75 Removing Shims from Rate of Rise Piston 4 Remove the pressure regulating springs and pressure regulator piston z MG 227 228 Figure 76 Removing Regulator Springs and Regulator Piston 5 Remove the O ring plug detent spring and detent ball MG_229 Figure 77 Removing O ring Plug Detent Spring and Ball Marine Transmission Service Manual 1021569 117 Disassembly Twin Disc Incorporated 6 Mark the lever and the stem to indicate the position the lever was installed on the stem Loosen the screw clamping the lever to the stem and remove the lever It may be necessary to spray the lever with penetrating lubricant to be able to remove it DO NOT apply any impact force to the lever as the stem lever or bearing might get damaged MG_229 Figure 78 Removing Lever 7 Remove the cover stem together as a unit MG_231 Figure 79 Removing Stem and Cover Together 8 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 8 Mark the stop collar and the stem to indicate the position the collar was installed on the stem While supporting the collar drive the roll pin out of the collar with a drift punch and remove the collar MG 232 MG 233 Figure 80 Removing Roll Pin and Stop Collar 9 Slide the stem out of the cover 10 Remove the oil seal from the cover 11
143. p ring Figure 70 Compressing Release Spring and Snap Ring Removal d Carefully remove tension on the release spring Twin Disc Incorporated Disassembly Remove the spring retainer and release spring MG_054 Figure 71 Spring Retainer and Release Spring Removal 10 Remove the clutch piston from the clutch housing a Thread two M8 1 25 mm rods into the piston 180 apart Lift the clutch piston out of the clutch housing Compressed air can be used to aid in the removal of the piston b Remove the O ring from the inside diameter of the piston Remove the piston ring from the outside diameter of the piston Note DO NOT disassemble the clutch shaft from the clutch housing These parts are not serviced separately MG_306 Figure 72 Piston and O ring and Piston Ring Removal Marine Transmission Service Manual 1021569 115 Disassembly Twin Disc Incorporated Mechanic Control Valve Disassembly PX 9975 116 A CAUTION Steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Remove the orifice plate cover the orifice plate and check ball MG_224 Figure 73 Removing Orifice Plate and Check Ball 2 Remove the check ball spring and shim s from the valve body MG 225 Figure 74 Removing Check Ball Spring Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 3 Rem
144. power tools or unacceptable maintenance working practices Marine Transmission Service Manual 1021569 11 Introduction Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure safe operations under prevailing conditions Proper guards and other safety devices that may be specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Inc WARNING Selecting NEUTRAL disengages transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a shaft brake or other shaft locking device must be used WARNING To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove ignition key from the switch WARNING Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these points could cause
145. pplicable if any of the above conditions are present Lockthe propeller shaft to prevent rotation Add an optional trailing oil pump into the lubrication circuit Refer to the hydraulic system schematics for more details on the optional trailing pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Marine Transmission Service Manual 1021569 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services WARNING All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you Note Do not order parts using the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number on the units nameplate absolves itself o
146. r B to rise to clutch engaging pressure When in primary passage E remains at atmospheric pressure because slot F remains open to sump When a shift is made from primary to neutral the valve stem is rotated to the position illustrated by Figures 4 and 5 Under these conditions passage D is connected to sump by slot F Passage J also is connected to sump by port H in the valve stem Because passage D is connected to slot F oil drains rapidly from the primary clutch to sump Because passage J is now at atmospheric pressure the oil pressure in chamber L unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back until the cavity is once again at the neutral regulated pressure The primary clutch is now disengaged and main system pressure reduced to neutral pressure Marine Transmission Service Manual 1021569 43 Operation Twin Disc Incorporated Eniry Passage High Pressure B Oil Pressure Chamber Regulator Piston C Oil Pressure Overflow Port D Oill Engaging Passage E Oil Engaging Passage F Oil interconnection eot amp G Oil Directional Port NA Vee J Oil Pressure Passage a EM LL a Ps n lt lt Orifice Rate of Rise Piston H Oil Connection Directional Port L Oil Pressure Chamber PF VW 27 Valve Stam XJ 1 Control Valve Body LJ Atmospheric
147. r screws evenly DCP_1015 _1016 Figure38 Manifold Removal 3 Lift the manifold and gasket taking care not to damage the piston rings on the end of the clutch shafts Discard the gasket DCP 1017 DCP 1018 Figure 39 Manifold Removal 94 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 4 Remove the primary clutch shaft and secondary clutch shaft piston ring bushings and O rings from the manifold Note Only remove bushings if replacement is necessary If removed install new bushings during assembly Piston Rings 1 Remove the two piston rings from the end of the primary clutch shaft 2 Remove the two piston rings from the end of the secondary clutch shaft DCP 1019 Figure 40 Piston Rings Removal Bearing Shims and Spacer 1 Remove the primary clutch shaft shims and spacer Tag the components with identifying information DCP 1021 Figure 41 Primary Clutch Shaft Bearing Shims and Spacer Removal Marine Transmission Service Manual 1021569 95 Disassembly Twin Disc Incorporated 2 Remove the secondary clutch shaft shims and spacer Tag the components with identifying information DCP 1020 Figure 42 Secondary Clutch Shaft Bearing Shims and Spacer Removal 96 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Rear Bearing Carrier and Oil Lubrication Tube The rear bearing carrier is equipped with two pusher sc
148. rew locations to assist in the removal of the bearing carrier Thread two M12 mm fully threaded capscrews lubricated into the pusher screw locations to push the bearing carrier away from the main housing Remove the lubrication tube 1 with the bearing carrier CAUTION Bearing cups are loose in bore and may drop if not handled with care A IMPORTANT Always lubricate the pusher screw threads before use Always tighten the pusher screws evenly DCP 1022 DCP 1028 Figure 43 Rear Bearing Carrier and Oil Lubrication Tube Removal 2 Discard the bearing carrier gasket Marine Transmission Service Manual 1021569 97 Disassembly Twin Disc Incorporated Primary and Secondary Clutch Shaft 1 Install a M10 1 5 lifting eye into the hole of the primary clutch 2 Hemove the socket capscrew that retains the pump drive Install eyebolt to the output end of the secondary clutch shaft DCP 1025 Figure 44 Install Lifting Eye and Eyebolt 3 Lift the primary clutch shaft from the main housing 4 The front bearing carrier will slide off the shaft and remain in the housing Lift the secondary clutch shaft from the main housing 6 The front bearing carrier will slide off the shaft and remain in the housing DCP 1026 DCP 1027 Figure 45 Primary Clutch Shaft and Secondary Clutch Shaft Removal 98 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Front Bearing Carriers 1 Reach insid
149. ring clearance adjusted by use of shims at the front bearing retainer Oil Pump Drive The oil pump is tang connected and driven by the secondary clutch shaft 20 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Lubrication Features The MG 5145A transmission bearings and clutches on the primary and secondary shafts are lubricated through oil passages drilled in the shafts The output shaft bearing transfer gears primary and secondary pinions and their bearings are gravity and splash lubricated Suction Strainer The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and the oil pump in the hydraulic circuit The strainer can be replaced if necessary Oil Filter Assembly A spin on oil filter is a standard feature on some MG 5145A transmissions The filter is located between the heat exchanger outlet and the selector valve in the hydraulic circuit The replacement element should be replaced at 1000 hours or six month intervals whichever comes first The replacement filter part number is PM11652 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 Marine Transmission Service Manual 1021569 21 Description and Specifications Twin Disc Incorporated
150. ring on the outside diameter of the clutch piston b Lubricate and install a new O ring in the inside diameter of the clutch piston Thread the two M8 1 25 mm rods into the clutch piston d Lubricate the clutch piston bore with a thin film of grease Install the clutch piston into the clutch housing Note Ifthe clutch piston is difficult to install by hand remove the clutch piston and inspect the piston rings MG 306 DCP 2000 Figure 112 Piston Ring O ring and Clutch Piston Installation Marine Transmission Service Manual 1021569 147 Assembly Twin Disc Incorporated 3 Position the secondary clutch shaft under a hydraulic press a Slide the release spring over the shaft b Place the spring retainer on the release spring Use Special Tool T 18502 to compress the release spring far enough to expose the snap ring groove in the shaft d Install the snap ring MG 054 MG 053 Figure 113 Release Spring Spring Retainer and Snap Ring Installation 4 Install the clutch plates as follows Install a sintered faced clutch plate and alternate with steel and sintered plates until the ten steel and eleven sintered plates are installed finishing with a sintered plate MG 052 DCP 2001 Figure 114 Clutch Plates Installation 148 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 5 Install the clutch back plate 5 Press the back plate firmly into the clutch housing to ens
151. rive The primary input clutch shaft and driving transfer gear always rotates in engine direction The secondary clutch shaft and driven transfer gear always rotate in anti engine direction because the driven transfer gear is meshed with the driving transfer gear on the primary clutch shaft When the primary clutch is engaged the primary input pinion rotates in engine direction The output gear which is secured to the output shaft is meshed with the primary input pinion and so the output gear and shaft are driven in anti engine direction When the secondary clutch is engaged the secondary input pinion rotates in anti engine direction The output gear is meshed with the secondary input pinion and therefore the output gear and shaft are driven in engine direction Marine Transmission Service Manual 1021569 19 Description and Specifications Twin Disc Incorporated Construction Features Housings The MG 5145A housing consists of a front SAE 0 or SAE 1 housing and a rear half housing They are sealed together with a gasket Taper Roller Bearings The primary and secondary clutch shafts are supported and located by tapered roller bearings The pinions are supported on bushings and the end movement limited by thrust washers Bearing clearances for each clutch shaft are set by use of a single shim pack at the rear tapered roller bearing on each shaft Tapered roller bearings and a spherical roller bearing support the output shaft and have bea
152. roll Module is connected to non electronic lever heads Q Option 2 connections are used when the Profile or E Troll Module is connected to electronic gear controllers Option 3 connections are used when the Profile E Troll Module is connected to electronic control solenoid driver outputs The electronic control s Solenoid A and B returns or negative signals should be connected together and connected to the E Troll module return if equipped Electronic control solenoid drivers must have their solenoid return internally connected directly to ground If not the Profile or E Troll Module must be interfaced to the electronic control with relays Marine Transmission Service Manual 1021569 205 Installation Twin Disc Incorporated Table 21 Module Power Connection Chart Wiring Option Wiring Option 2 Wiring Option 3 Connect to the Negative terminal of the engine battery Troll Enable Switch Return if equipped Connect to the positive terminal of the engine battery through the switch contacts used to energize Solenoid B Solenoid B Switch Connect to the negative terminal of the engine battery Solenoid Return Connect to the positive terminal of the engine battery through the switch contacts Solenoid A Connect to the same ground point used by the gear controller or the engine control Connect to the output in the gear controller that is used to energize Solenoid B Connect to the same
153. rolled 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 slip Main oil pressure is always the same as the oil pressure in the engaged clutch with this type of trolling valve The 1020230 valve contains no user serviceable parts and is available only as an assembly Marine Transmission Service Manual 1021569 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 Takeoffs PTO for this marine transmission Live Power Take off PX 9768 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 dr
154. rolling Valve Disassembly Optional Equipment 130 Cleaning and Inspection 135 Clean ERE 135 lokler reii e Me 137 8 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Table of Contents 1 141 a6 Her dla 141 Primary Shaft Assembly 142 Secondary Shaft 147 Main Housing Assembly 11 151 Output Gear and Output Shaft Assembly 152 instan 158 Install External Parts 166 Mechanical Control Valve Assembly PX 9975 170 Electric Control Valve Assembly PX 10225 175 Assembly of GP Control Valve with Electronic Interface 178 Adjustment of Main Pressure 183 Trolling Valve Assembly Optional Equipment 185 Installation eese 188 TO MSTA d OM SUI CARE d DD RN DNUS 188 Alignment also reference SAE J 1033 and J 617 190 PLLC ue i UE TET EE 193 Iristalld
155. rque the retaining nuts to 6 8 Nem 5 Ib ft Solenoid Spool EN Selenoid Cail Jj Clamp 4 Mut ue MG 236 Figure 152 Solenoid Components Marine Transmission Service Manual 1021569 177 Assembly Twin Disc Incorporated Assembly of GP Control Valve with Electronic Interface Prior to assembly all parts must be properly cleaned Carefully inspect all O rings for any damage and replace as necessary Lubricate all O rings and replace both gaskets 1 Valve Assembly 1020729 Assemble the main regulator valve body a Install the Main Pressure pilot relief valve into the valve body and torque to 27 Nm 20 Ibeft b Install the Main Valve into the valve body and torque to 33 Nem 24 Ibeft Install the 3 8 nptf pipe plug or optional temperature sensor into the valve body and torque to 23 Nem 17 Ibeft d Install the M27x2 0 O ring plug into the valve body and torque to 75 Nem 55 Ib ft Regulator Valve Body 3 8 npt plug or Temp Sensor Pilot Relief Valve Regulator Spool Figure 153 Main Pressure Regulator Components Assembly 1020729 178 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly 1 Valve Assembly 1021658 Assemble the main regulator valve body a Install the filter into the threaded hole of the valve body and torque to 7 5 Nem 5 5 Ib ft If removed install a new check valve assembly into the bore
156. s for Marine Transmission Equipped with Hydraulic Clutched PTO PTO Control Valve PTO Control Valve Disengaged Engaged 1724 1862 250 270 Transmission Transmission 1655 1793 240 260 Control Valve 1689 1827 245 265 Disengaged Note Transmission control valve is the right valve and the PTO valve is the left valve w hen view ed the rear of the transmission Note Some early production units operated with lower oil pressures The following table applies to these units only Marine Transmission Service Manual 1021569 27 Description and Specifications Twin Disc Incorporated Table 5 1586 kPa 230 psi Transmission Oil Pressure Specifications Limits for Marine Transmission Equipped with Control amp Trolling Valve with 1586 kPa 230 psi Spring Min Actual Max Min Actual Max Min kPa kPa kPa kPa kPa kPa kPa psi psi psi psi psi psi psi cee et tatal bets 20 70 0 0 8 tat tele 0 0 20 70 8 0 0 0 0 8 Note With trolling at its minimum trolling pressure position primary secondary and cooling pressures must be per chart above at both input and shift specified Readjust with shims to achieve primary and secondary pressures specified Note It is required that primary and secondary clutches must be within 21 kPa 3 psi of each other Table 6 2415 kPa 350 psi Transmission Oil Pressure Specifications Limits for Marine Tr
157. s 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 and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit January 16 2002 TDW P2004 TWIN DISC INCORPORATED 7 Disc FLAT RATE HOUR ALLOWANCE C E MARINE PLEASURE CRAFT Hourly Labor Rates Must Be Acceptable to Twin Disc Incorporated MODEL SERIES R amp R UNIT REBUILD MG340 MG360 0 0 0 0 MG
158. st meet the valve requirements on filtrationand the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1021569 Operation Twin Disc Incorporated Proportional Valves r M12x 1 50 Manual x o ring plug LR Top Valve Body Ee 3 _ x P O Figure 11 Top Hydraulic Valve Body Assembly Temperature Sensor Pilot Relief Valve Regulator Spool Figure 12 Main Regulator Hydraulic Valve Assembly 1020729 Figure 13 Main Regulator Assembly 1021658 49 Marine Transmission Service Manual 1021569 Operation Twin Disc Incorporated GP Control Valve Electronic Control Interface Profile or E Troll Module 50 Note Some installations will consist of the hydraulic portion of this valve and the Electronic Control Interface will be replaced by an appropriate electronic control system The electronic portion of the GP Control Valve fastens to the hydraulic portion of the GP Control Valve and is located on the top surface This module contains electronic circuitry to control the proportional cartridges that are used to engage the clutches based on the commands from the operator Clutch apply pressure rate of rise profile is factory set with the use of internal circuitry The initial fill level is factory set with an adjustment screw that is embedded in the bottom surface of the Profile or E Tro
159. tall until flush with the valve body Rotate the stem to its farthest out position Place the trolling valve lever down with the front face up Place the outer diameter spring and piston over the small spring Marine Transmission Service Manual 1021569 187 Assembly Twin Disc Incorporated 13 Place the manifold with gasket onto the trolling valve and install the three screws and torque them to 30 Nem 22 Ib ft 1391 1370 Figure 165 Installing Trolling Valve to Manifold 14 Install the gasket and manifold with trolling valve onto the control valve Install the attaching screws and torque them to 23 Nem 17 Ib ft 1367 Figure 166 Install the Trolling Valve Assembly to the Control Valve using Four Screws 188 Marine Transmission Service Manual 1021569 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 c
160. ternal puller Output Shaft Disassembly Note Only remove the bearing cones from the output shaft if they need to be replaced If removed new bearings must be installed during assembly Using a press remove the rear bearing cup and cones c m G_ 048 Figure 54 Output Shaft Bearing Cones Removal Marine Transmission Service Manual 1021569 105 Disassembly Twin Disc Incorporated Primary Clutch Shaft Disassembly 1 Remove the rear bearing cone Note Only remove the cone from the primary clutch shaft if it needs to be replaced If removed a new bearing must be installed during assembly a Cut off the bearing cage and remove the rollers b Use a cheese cutter type puller to pull on the rear shoulder of the inner bearing race C Heat the inner race to assist in its removal CAUTION DO NOT overheat the inner race as it could result in annealing the clutch shaft Handle the inner race and shaft with care The inner race and shaft is HOT 2 Position the primary clutch shaft with the input end facing up 3 Hemove the snap ring DCP 1043 Figure 55 Snap Ring Removal 106 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 4 Remove the front two thrust races and needle bearing Note Record location of the front two thrust races and needle bearing for proper assembly The first race to be removed pilots on the shaft
161. tions s Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair 2 The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc 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 person
162. tor 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 i uc v Engine Housing Figure 170 Checking the Flywheel Pilot Ring Bore Eccentricity Marine Transmission Service Manual 1021569 Twin Disc Incorporated Installation Alignment Propeller Shaft Before any attempt to align the engine and gearbox to the propeller shaft proper alignment of the propeller shaft must be determined This includes alignment of the propeller shaft through all struts and intermediate bearings Failure to properly align the propeller shaft may result in premature wear on bearings vibrations or possible damage to other components If the length of the shaft from the last support bearing to the gearbox is excessive or aflexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Engine and Marine Transmission Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boatto change its form with various loads and with age Engine and shaft alignment can also change on a boat due to varying lo
163. tronic Interface and Optional Speed Sensors Marine Transmission Service Manual 1021569 83 Disassembly Twin Disc Incorporated Component Identification Hydraulic Filter LL 3 TE a B Heat LIA Exchanger S e v eo q PORE MG 305 Figure 26 MG 5145A with Hydraulic Filter and Heat Exchanger 84 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly Prior to Removal 1 Remove drain plug 1 and drain oil from transmission Figure 27 Drain Plug 1 2 If equipped disconnect the water supply hoses to the heat exchanger 3 Mark the output flange and companion flange so they will always be assembled identically 4 Disconnect the output and companion flanges Disconnect linkage wiring and plumbing and remove any items that would interfere with the removal of the transmission It may be advisable to remove the input and output speed sensors if equipped to avoid damaging them during transport 6 Support the transmission with a hoist and remove the mounting capscrews 7 Support the rear of the engine with blocks if necessary 8 Remove the 12 capscrews that secure the transmission to the engine Push the tranmission away from the engine Remove the transmission Remove the input coupling from the engine flywheel Marine Transmission Service Manual 1021569 85 Disassembly Twin Disc Incorporated Remove External Parts Note Place the
164. ure Regulator Valve Components Cover with Adjustment Figure 96 Remove Main Pressure Regulator Valve Components Marine Transmission Service Manual 1021569 129 Disassembly Twin Disc Incorporated Trolling Valve Disassembly Optional Equipment 1 Remove the four screws that attach the manifold and trolling valve to the control valve body Figure 97 Removing Manifold Assembly Attaching Screws Note Rotate the trolling valve handle counter clockwise out of the detent position to lessen the spring force on the valve seat before removing screws 2 Remove the trolling valve from the manifold 1370 1377 Figure 98 Remove Trolling valve and gasket 3 Remove the gasket valve plunger and spring from the trolling valve 130 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Disassembly 4 Remove the detent setscrew spring and detent ball 5 Be sure the trolling valve stem is in its furthest out position Support the valve body and the pins through the valve body nd out the other side 1383 1386 Figure 99 Drive the pins through the hole in the valve and body 6 Remove the screw and nut clamping the lever to the stem 7 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 might get damaged 1380 Figure 100 Removing the valve handle Marine Transmission Service Manual 10215
165. ure the splines of the clutch are aligned 6 Place the internal snap 6 ring next to the clutch back plate AAR6557 069 AAR6557 1012 Figure 115 Clutch Back Plate 5 and Internal Snap Ring 6 7 Install the front thrust bearing onto the input shaft in this order thrust race with recessed bore over the snap ring needle bearing and thrust race m Figure 116 Installing Front Thrust Needle Bearing and Thrust Races Marine Transmission Service Manual 1021569 149 Assembly Twin Disc Incorporated 8 Lubricate the area of the clutch shaft that will contact the pinion assembly Install the pinion assembly Gently rotate the pinion as it is lowered into the clutch plates until the splines are fully engaged in all the clutch plates Figure 117 Pinion Assembly Installation 9 Install the larger diameter thrust race into the pinion bore 10 Install the front needle bearing and remaining rear thrust race Note This thrust race pivots on the shaft DCP 1043 Figure 118 Front Thrust Races and Needle Bearing Installation 11 Install the snap ring to retain the front thrust races and needle bearing and pinion 150 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Main Housing Assembly 1 If removed install new clutch shaft input end outer bearing cups in the main housing a Deep freeze the bearing cup to 51 C 60 F for at least two hours before installing it Hand
166. y Ae MG 225 Figure 146 Installing Check Ball Spring Shim s and Spring Marine Transmission Service Manual 1021569 173 Assembly Twin Disc Incorporated 12 Place orifice plate gasket the check ball and the orifice plate onto the valve body MG_224 Figure 147 Installing Gasket Check Ball and Orifice Plate 13 Install the remaining gasket and orifice plate cover onto the valve body Install the attaching screws and tighten them alternating and evenly to 33 Nem 24 Ib ft 14 Install valve onto the transmission and torque the attaching screws to 20 Nem 27 Ib ft MG 200 Figure 148 Installing Selector Valve Assembly 15 Install the remaining O ring plugs Torque the M12 plugs to 16 Nem 12 Ib ft and the M27 O ring plug to 75 Nem 55 Ib ft 174 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Assembly Electric Control Valve Assembly PX 10225 Prior to assembly all parts must be properly cleaned Carefully inspect all O rings for any damage and replace as necessary Lubricate all O rings and replace both gaskets 1 Install the O ring on the end of the shuttle ball seat and lubricate Insert the shuttle ball followed by the seat with O ring Place the spacers against the shuttle ball seat and install the plug with sealing washer Torque the plug to 152 Nem 112 Ibeft Ball Seal Plug a E Washe Shuttle Seat id Ball rm o
167. y nickel anti seize compound to the threads of these stainless steel fasteners before torquing to specification See Standard Sheet S574B for more complete listing of stainless steel fastener torque values Metric Coarse Thread Stainless Steel Capscrews Bolts and Nuts Thread Size Recommended Torque Lb ft 12 8 5 32 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Table 13 Tapered Pipe Plugs with thread lubricant Recommended Torque in N m Lbrft Notes The lubricant is to be John Crane insoluble plastic lead seal No 2 or equivalent or Loctite No 92 or equivalent and plugs are to be capable of removal without damage Overtightening may cause initial leakage plus potential removal damage An option of a maximum of two full turns after finger tightening the plug may be used if required and if removal conditions are met Marine Transmission Service Manual 1021569 33 Description and Specifications Twin Disc Incorporated Table 14 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal Ib ft Ib ft Thread Or 5 Thread OF 4 or 5 Diameter Diameter w _ 34 Marine Transmission Service Manual 1021569 Twin Disc Incorporated Description and Specifications Table 15 Tubing Nuts Torque Values for Tubing Nuts Nominal Tube Size Recommended Torque N m Lb ft Tab

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