Home

Service Manual Marine

Contents

1. 4 LEVER MAY LOCATED ANYWHERE BL hiorgossar _4u9s_ 1017179 2 xwe7seri ie 42707AD amp e703BA 1860 e7o 10171294 x 24518 ea MG SI41SC MOVEMENT WITHIN THE S0 CTOTALD PGi MA1OSBE 2 PISTON SEE CHART E EI oe ee HEU ROTATION AXIAL MITIUN WASHER 1017522 sess ae araea s s s pewerserues ien toma 2450 cass 10171290 x exce sees 48 REQUIRED FOR CONTROL ic ARE NOT POLARITY SENSITIVE memes ana ect ntes es cheer are oes ce SE 222 GASKET B1334C PORT COVER ASSY 1017336 NEUTRAL SPRING A2705AH 2 BALL 19906 M T PARTS TR UNITS WITHOUT NEUTRAL SOLENOID AND SOLENOID A CARRIER Tien SOLENOID A2711R 2 BALL M1990L 2 25 0 lbf ft HYDRAULIC LOCK XDPTIDNAL CONDITION with OR WITHOUT d e WIRING DIAGRAM OPTIONAL wo x 125 6 TH BLA HYORAULIC LOCK ee ON T SPRING ASSY gt gt 7b MANUAL OVERRIDE 361 NISY 95 SEE CHART 2 PORT CATSDEENDID POSITION 7 m VALVE BODY ASS Y 1017444 ELECTRIC 247 a N PISTON B1399H 2 BODY 1017443 PORT SOLENO
2. 11 Preventative Maintenance 1 1 13 Er 13 Ordering Parts and Obtaining Services 14 Source of Service 15 ne 16 Description and Specifications 17 topo M tt ce X 17 Power Ratings 18 Constr ction MI 19 Lubrication d 20 H te 26 Optional Hr m 28 Torque Values for Fasteners nnana 31 Clutch Plate Wear 22 2 34 EN e 35 35 Hydraulic System with Manual Control Valve 36 Hydraulic System with Electric Control Valve 44 Trolling Valve Optional eere 54 Power Take off 57 Trailing Pump OpLIOnal 58 la Ma fce 59 Preventative Maintenance 63 Marine Tran
3. Description Screw hex head cap Washer flat Gasket filter head mounting Spring compression filter differential pres sure bypass Plug assembly includes O ring Filter head O ring filter body to filter head Element group consists of items 57 through 62 Spring compression Washer sealing 49 50 51 52 53 54 55 56 57 58 59 60 61 62 230 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Optional Heat Exchangers 71 mcn E mn FE 6 72 E D Ww amp OPTIONAL DITC PLA lt CUSTOMER SUPPLIED Gasket adapter plate mounting Screw socket head cap Plate adapter Closure oil ports 2 Screw socket head cap Plug O ring water drain Gasket adapter plate mounting Housing heat exchanger Plate adapter Screw hex head cap Closure water ports Exchanger heat exchanger element Gasket heat exchanger housing Gasket heat exchanger element 1 1 1 1 1 14 2 1 1 1 Marine Transmission Service Manual 1020304 Illustrations 231 Illustrations Twin Disc Incorporated Transmission Rear View
4. ees 2 ssi o we seospe 10180856 41152 1018688 xwezserMe pu 2415 350 10171298 1017554 10 7 x 21 65 4 524518 eeh we se esc 4222 OPTIONAL e ET C MATING WIRING HARNESS 1017502 1018085 41256 1018688 2 xme759FM24 7072 27072 703 1725 lt 250 10171294 1017554 10 7 x 20 60 4 4 45 5 0 1 SERIES SPECIFY LENGTH 1018085 41255 1018688 759 7072 427072 703 1725 lt 250 10171294 1017554 1038 x 20 c 4 B245iB MG S20 1HP HOSS 1266 arias Raar 2 RU ER 4 _ 1018085M 41304 1017179 xwe7s9rMe 4 vnc 707 270 860 270 10171294 1017554 10 7 20 6 4 24518 6 51415 1018085Nn 41305 ELE sss heztsm uer a E dois 1018688 xwe7s9rMe4 vpc xae7o7ap ae7o7ap 270 2000 lt 290 10171298 1017554 10 8 7 x 20 6 4 824518 geo e seses
5. 2 2 14 oft 1 gt 4518 lt 1 3 basme 6 OPTIONAL eu 2 2 MATING WIRING HARNESS 1017403 1 1 Meoesr 2 3 X A2703 P000 250 10171298 xcer er Baarn 9 hainean 2 EP Qe 10180842 40761 1017583 1017569 1017613 1018688 no e 75 2 vnc xae7o7z 27072 ae703T 2000 290 10171298 x 0 824518 0 2 2 560 573 Sa 1018084k 40762 10171334 1017134 1337 1017179 xme759FM24 4270740 1565 lt 230 gt 10171294 10 7 x 20 64 24518 1052 2 2 CONNECTOR SHROUD 1001825 106064 40763 10171330 1017134 B1337F_ 1017179 75 1 voc 8707 0 1585 lt 230 1017129A watoaeewe7 x 20 6 B24513 2 2 2 1018084 40764 1017383 1018688 xM2759FMe4 vnc 27028 270480 ast CLIP CONNECTOR 1017 TET E Lco mea UL A ci Rc cc E AE Ep AL Mead d CONTRE ong QE
6. mock exexe DETIREQI DESCRIPTION 512 fieteszass pem ME BEARING DRIVER FOR CUP Jm ser 1 w 1 MG 930l re WE MG 5301 T 18050 771 rev marc sv TWIN DISC ING RACINE STAMP 19330 MG 540 X 9882 A SPRING A2708AM STAMP T 19330 DET X 9882 A 20 27 THRU MG 540 SPRING A2708 AM 0 58 C SINK 82 PLCS 20 27 THRU 1156 2 58 BC SINK 82 3 PLCS e71 871 1 2 CLEAN UP CLEAN UP RING PLATE 1 4 80 THD X 8 DEEP 02 PLCS 4 6 stk FLAT 502 ____ 1 4 20 THD 1 C 3 3 Ms SUPPORT BARS 93 4 X 20 1 PLCS SOLID END PLATE 975 X 5 SYMBOL CHARACTERISTIC SYMBOL MODIFIER 1 1 5 RING PLATE 75 5 PLATE 97 5 X 5 7 MO 0 b W SCHEEL Scole HALF PARALLELISM CONDITION NAME SPRING DE COMPRESSER e elisa d UPDATED PRINT TOOL ADD 3 amp 4 CORNERS SYMBOL NAME 20 SE SP B DRAWING RTR FOR SHEET OF 1 0 FOUR JENSI CIRCULAR RUNOUT t ier PAGE DENA DATUM FEATURE AUTOCAD FILE 1 19550 A 5 375 X WAS 525 9882 A2708AM SPRING NEL 2 POSTION DESCRIPTION DATE TWIN DISC INC RACINE WIS 19550 i M pel SECTION CAD
7. 225 Clutch Group Assemblies 1017020 1017020 1017607 226 Clutch Group Assemblies 1017020B 1017607B 228 ella fM 230 Optional Heat Exchanges 231 Transmission Rear 232 Transmission Section View 234 Torsional Input Coupling 236 Mechanical Control Valve 1 eene 238 Electric Coniral EUM EI 239 Trolling Valve optional 241 Engineering Drawings 243 List of Engineering Drawings 243 1017020 sheet 1 of 6 Marine transmission 245 1017020 sheet 2 of 6 Marine transmission 246 1017020 sheet of 6 Marine transmission 247 1017020 sheet 4 of 6 Marine transmission 248 1017020 sheet 5 of 6 Marine transmission 249 1017020 sheet 6 of 6 Marine transmission 250 1017020A Marine transmission eese 251 1017020B sheet 1 of 6 Marine transmission 252 1017
8. 232 Marine Transmission Service Manual 1020304 PpOLOZOL Jenuey uoissiusueJ SUNEN Description Item Description Caps crew hex head manifold Anode heat exchanger Pin dowel manifold amp bearing carrier Heat exchanger raw water Plug O ring M16x1 5 speed ports Closure water ports Plug pipe temperature sensor Gasket heat exchanger housing Control valve assembly Gasket stiffener plate Adapter plate gaskets and screws Plate instruction lube electric control valve models only Plate instruction identific ation Plate stiffener Screw drive instruction plate O ring Breather Plug O ring raw w ater drain 5 link Ey ebolt lifting Chain Housing raw water heat exchanger Clip Caps crew hex head heat exchanger Gauge oil level Gasket anode Tag oil gauge Caps crew hex head anode Tube assembly oil level gauge Washer sealing pe1e10djo2u OSIA UIML suoneusnyl Twin Disc Incorporated Illustrations Transmission Section View HACO 85 A 9 DO G Sy 5 Gy 8 5 ey Ne 9 iw lt XS RS NS AS AS SS AS EE 1
9. 20017 118688 2759 24 0 AE7U7AD 70 2000 2900 10171298 x seem g Sera pe Race gene ELECTRIC 10180840 4084 1017133 1017134 B1337F 1018688 NO 759 4 vnc xae7o7z 427072 a2703T 1725 250 10171298 1 8 7 6 B2451B 3 1052 2 052 2 52025 fioieoeae 40935 117383 017179 3 werssree nzvoapufesis postes x even 124513 _ 6557 5 SCREW MA1052P 4 eeu 10180843 40954 1018584 1018594 231174 1019688 759 4 7072 427072 7 725 eso 10171298 x 24518 5 __ Bae TORQUE TD 542 N m vic ener tona 8 L Moeaa NOTE 400 Taf aot e e ors aee SECURE LEVER IN THE DEPRESSED TOP VIEW seer rane pw 2 vod eao ook Ru ELECTRIC CONTROL MODE POSITION 1017153 1017134 1 7 1018688 2 7 voc e7072 70st mise peuseever 1c en em secnm 2 a
10. RS RS RS RS RS RS RS RS RS ttt tette bos 556 95 MA1040A DRAIN PLUG LOCATION M33 X 2 THREAD PER MARINE TRANSMISSION INSTALLATION AND ASSEMBLY DRAWING MG 9301DC HYDRAULIC DIAGRAM GRAPHICAL SYMBOLS OIL PUMP ME STRAINER MATERIAL NDTICE THIS PRINT T IER AAS IENSIONS ARE mm ko NOT TD BE U DETRIMENTAL THE INTERESTS DF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE 15 NOT_INTENDED NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT IFIRST USE assy 1017020 MG 5301DC B UNLESS DTHERVISE SPECIFIED DIMI MACHINED DIMENSIDNS x 0 75 SURFACE TREATMENT NAME OPTIONAL AUXILIARY LUBE SYSTEM USER TO SUPPLY COMPONENTS AND TO INSTALL LUBE HOSES TO MEET REQUIREMENTS OF 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 gt REMOVE MA1038A M10 X 1 PLUG FROM MANIFOLD PER MARINE TRANSMISSION INSTALLATION DRAWING AND INSTALL LUBE LINE DIRECT LUBE FLOW INTO TRANSMISSION HYDRAULIC CIRCUIT CHECK VALVE STRAINER 15 8 MIN 10 HOSE 25 MICRON FULL FLOW FILTER ELECTRIC MOTOR DRIVE PUMP 23 41 L min 19 0 DIA MIN 1 0 HOSE THIRD ANGLE PROJECTION INCORPORATE RACINE
11. s N NP His 2 X 3 16 TUBE ALL LOCATIONS CH2 REF TU O77 3 16 D amp T 1 2 NC yz 3 16 PLCS 1 SE R4 69 00 01 R4 41C 00 015 TL T 19987 WT 180 LB CAPACITY 800 LBS LETELLIER e 201 WEST 155TH STREET 1 16 SOUTH HOLLAND ILLINOIS 060 mE HORIZONTAL XX TOL 040 _ GEAR LIFTER XXX TOL 010 peas JK DET NUMBER pare JK 4770 0 53 C SINK FOR 1 2 FLT HD SCREW e naa p GEAR LIFTING FIXTURE FIXTURE 5301 19987 2 uescuezua TOP HYD HOSE LOCATION LN PARTIAL VEIW p KA SPACER SHAFT 15 REQ D MS HDN 45 49 Rod LA lt 2 ZZ P LE 22 f OUTPUT SHAFT 1017000 HU mue EARN POWER TEAM DOUBLE ACTING RAM 100 TONS 6 625 STROKE MODEL RD 1006 13 782 LONG SSS See GEAR SHAFT PULLER NOTE REF THIS DRWG FROM 20023 MG 5301 wc 6650 amp 13 amp 14 77 8 FIRST USED UN 62516 bme xm 1 20023 3 g Wie Jalal ei s
12. db SCREW MA996L 4 2 SPACER 1020043 SH RING MI904L 4 6 a ne aa VA SHIM 1017041 SHIM 1017042 5 REQ D SHIM 1017043 SEE NOTE 4 IN S570AJ L 2 SEE 1017020 1017607 SHEETS 1 6 FOR ALL OTHER INFORMATION CONSULT SALES DEPT APPLICATION ENGINEERS ENGINEERS FOR NEW BILL OF MATERIAL FOR MARINE TRANSMISSION NAMEPLATE 4 5 A KIT BOM K1315 DOES NOT INCLUDE SECONDARY SHAFT ASSEMBLY e BOM K1318 INCLUDES SECONDARY SHAFT ASSEMBLY 1017020A IS THE STANDARD POWER RATING UNIT REFER TO S856 1017607 IS A HIGH POWER RATING UNIT REFER 58564 MERIT 755 a dene INCORPORATED 1 1 4 Es 19176074 TO oR ens MG 53010 DC epee a SCREW 996 24 WASHER 1039 242 7 a 7 PART RENS FUR M INPUT OPTIONS A SEE SHEET 5 AS q SAE 00 S Ss 2 HOUSING ASS Y 1016524 N HOUSING 1016523 N TUBE 1017031 NI 4 BEARING 1017081 2 CONE ASS Y 585 CUP MASSOAT 5 m 7 ZA lt AES 7 2222271 7772772 7 PLUG 1945 SEAL MA297 SHAFT ASS Y 1016988 SHAFT 1016987 BALL 1034 SEE NOTE 6 RING
13. 1017020 sheet 1 of 6 Marine transmission 1017020 sheet 2 of 6 Marine transmission 1017020 sheet 3 of 6 Marine transmission 1017020 sheet 4 of 6 Marine transmission 1017020 sheet 5 of 6 Marine transmission 1017020 sheet 6 of 6 Marine transmission 1017020 Marine transmission 10170208 sheet 1 of 6 Marine transmission 10170208 sheet 2 of 6 Marine transmission 10170208 sheet 3 of 6 Marine transmission 10170208 sheet 4 of 6 Marine transmission 10170208 sheet 5 of 6 Couplings and hub 10170208 sheet 6 of 6 Marine transmission 7119 Hydraulic diagram 7108 Valve assembly control Marine Transmission Service Manual 1020304 243 Engineering Drawings 244 D D DO D O 1018084 1018085 1017554 1017555 1016473 Twin Disc Incorporated Valve assembly control without trolling valve Valve assembly control with trolling valve Valve assembly trolling Valve assembly trolling Pump assembly trailing Marine Transmission Service Manual 1020304 ASSEMBLY INSTRUCTIONS COVER ASS Y 1017025 ASSEMBLE AND TEST PER 55704 SCREW MA996F 24 COVER 1017024 NOTES 1 THRU 8 ARE IN S570AJ 24 ADAPTER 1966 SCREW 9600 3 WASHER 9 24 GASKET 1017028 WASHER M2081D 3 THESE STANDARDS APPLY Fa 4 FASTENER TORQUE REQUIREMENTS E Y NUT MA1054A 3 SCREEN MA993 SPRING
14. 7 SCREW 1042 FLUSH WITH SURFACE HYDRAULIC DIAGRAM A7119W SHEET 1 OF 2 SCREW M2000L SEE CHART FOR 1018883 TROLLING VALVE IS REQUIRED PROVIDE CLEARANCE METRIC FROM THE HYDRAULIC PTO THIRD ANGLE PROJECTION ATMOSPHERIC PRESSURE A NOT SERVICEABLE SEPARATELY mE e ATMOSPHERIC PRESSURE INTERMEDIATE PRESSURE THESE PARTS ARE TO BE PACKAGED CLUTCH PRESSURE SEPARATELY AND SHIPPED WITH UNIT T 4 18 01 NOTICE THIS PRINT CONTAINS MATERIAL xd MENS Ae 3 e3 98 s 8 2 06 1 BE USED iN ANY MANNERS 100 5 RACINE WI 53403 USA 20462 ium cD Perm A LI amem ai dis 1018085 B LEVER 2103 bam STR TH D 0 RING 1506149 MAIN PRESSURE DIL INLET WHEN NDT INTERNALLY mE THREAD SIZE AT PDRT 1 4 18 NP T F WHEN 05 REDUCER BUSHING IS SPECIFIED THIS NOTICE IS NOT INTENDED TO NULLIFY LIMIT RIGHTS BOTTOM VIEW 30015 4 12 00 U 49 6 20 01 GRANTED TD THE US GOVERNMENT Se Rev zone zone no UR OTHERS BY CONTRACT SURFACE TREATMENT NAME RM BJE SERIES VALVE ASS Y CONTROL WITH TROLLING VALVE UT DAS SHEET 1 oF 1 A CONNECTOR SHROUD 1001426 CLIP CONNECTOR 1017322 FEMA VALVE 1017170 TORQUE
15. FRONT amp REAR BEARING PINION SHOWN DISENGAGED 1724 kPa i 7108 MARINE TRANSMISSION CONTROL VALVE E Y HEAT EXCHANGER RELIEF VALVI 690 kPa Sx 3 EaD 555 Wie FILTER 4 1 BY PASS 138 kPa oll FILTER 52 REMOVE 1 10 1 PLUG AND INSTALL OPTIONAL N tak TEMPERATURE INDICATING 5s DIL PUMP SWITCH HERE E Y STRAINER N SUMP pe1e10d402u 3510 UIML Operation 38 Twin Disc Incorporated Manual Control Valve Neutral Refer to Figures 8 and 9 Oil enters the control valve body through passage A and fills chamber B The oil causes the pressure regulating piston to partially compress the piston outer and inner springs against the pressure rate control piston This pressurizes the oil in chamber B This pressure varies with engine speed The movement of the pressure regulation piston against the springs exposes port C in the valve body Port C directs overage oil to the lubrication oil circuit Passage D which is the engaging outlet to the primary clutch and Passage E which is the engaging outlet to the secondary clutch are interconnected by slot F in the control valve stem when in the ne
16. PORT CONFORMS ISO 6149 PORT CONFORMS TO ISO 6149 16 1 5 THREAD METRIC PORT CONFORMS TO 50 6149 PRIMARY CLUTCH SHAFT CENTER OF GRAVITY FOR CLOSE COUPLED TRANSMISSION 55 1 OPTIONAL DITCH PLATE FOR CUSTOMER SUPPLIED HEAT EXCHANGER RH ENGINE ROTATION DRIVING THRU SECONDARY CLUTCH THRU IOLES EQUALLY SPACED 1016523 THREAD METRIC METRIC PORT CONFORMS ui Q CE ad D oz ____ i LI ALL POINTS AVAILABLE FOR TESTING ARE CODED ho Ba m ae 1017020 E p P EE OR OTHERS BY CONTRACT MARINE TRANSMISSION ser 4 oF 6 rev AL A SHAFT ASS Y 1016988 SHAFT ASS Y 1016988 7 SES SHAFT ASS Y 1016988 77 B SHAFT 1016987 BALL 1 4 NS B SHART 1016987 7 BALL 10348 2 RASS d RING B1048AM RING B1048AM SN INNER GROOVE FOR lt p RING B1048AM ENS _ BS SY pet 55 X SEE NOTE 6 ASSEMBLE RING INTO SAE No 460 ASSEMBLE RING INTO S COUPLINGS RING B1048AM LL ESSA OUTER GROOVE FOR ESSAYS ESS HY COUPLING C WITH TORSIONAL STOP 23 2 COUPLING A HOUSE OTRA COUPLING D emnes SAE 00 SHAFT ASS Y 1016988 WITHOUT TORSIONAL STOP SHAFT 11016087 HOUSING 1017013 Hoare 1017018 SA 0 0 1017769 3 HOUSING SEE SHEE
17. IN SAS De Fe m 777 ME ere HOLES EQUALLY SPACED EYEBOLT FOR LIFTING MARINE TRANSMISSION E EACH SIDE ON BOTH MARINE TRANSMISSION ONLY 1 ENGAGES SECONDARY SHAFT CLUTCH LEVER MAY BE LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTAL ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL 6 4 9 THRU ENGAGES PRIMARY SHAFT CLUTCH 8 X 1 25 6 THREAD 36 1 2 HOLES MANUAL FOR REMOTE CONTROL OVERRIDE RACKET POSITION 24 ELECTRIC CONTROL a POSTION 4717 23 4 5 pm o y ELECTRIC CONTROL MODE SWITCH CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE CENTER OF GRAVITY FOR CLOSE COUPLED TRANSMISSION STOCK BORE SIZE CUSTOMER TO FINISH BORE USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS ISO 898 1 AND TORQUE 5574 OR SERVICE MANUAL VALUES 200 06 0 03 9 374 00 M24 3 0 THREAD 40 0 DEEP 20 HOLES 10 EACH SIDE USE ALL 20 HOLES FOR MOUNTING UNIT USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO S574 OR SERVICE MANUAL VALUES om C TRANSMISSION FLYWHEEL No A 10 065 E F G H J K L NOTICE THIS PRINT CONTAINS 460 711
18. x 3725 LG sm soc wm cap screw s 9 16 x 250 460 COLLAR HDN 45 49 Rc 1804 x 325 THK RUD 4 REQ D STAMP T 20023 3 DET 4 He Ss ee PLATE HON 45 49 4140 45 49 Rc so RID 45 49 RO 100 DIA x 3600 LG 4140 HDN 45 49 RO 14 45 49 RO 104 DIA x 3600 LG 2 DIM 3581 FOR MG 5301 EE 1 17 e L L 1 DUTPUT GEAR SHAFT PULLER Seer 2 O DIM 37 02 FOR MG 6650 SC NOTE GROUND SURFACES MUST PARALLEL NOTE UNLESS OTHERWISE SPECIFIED 960 WAS 100 DIA 7 31 96 5301 amp MG 6650 8 OF 3 WITHIN 0005 OF EACH OTHER BREAK ALL SHARP CORNERS 7 5 MG 5301 66 T 2000353 AUTOCAD FILE T20023 3A SS gt RSIS 100 TONS 6 625 STROKE WH MODEL RD 1006 13 782 LONG PUWER TEAM DOUBLE ACTING RETRACTED LENGTH OF PRESS RAM DRILL 5 16 3125 DIA 1 25 DP 3 8 16 x 100 DP REQ D 180 USE FOR LIFTING 2 44 MID STROKE NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE ALL GRD DIA S amp SURFACES MUST SQUARE amp CONCENTRIC TO WITHIN 005 OF EACH OTHER 06 TYP SEE SHI 3 LATEST REVISION
19. HYDRAULIC LOCK ONLY NOTE LEVER MAY BE LOCATED ANYWHERE BLU 2 ON ITS SHAFT THAT PERMITS FREE LUG MA1038E MOVEMENT WITHIN THE 50 TOTAL PISTONS SEE CHART ROTATION amp 11 4mm AXIAL MOTION WASHER 1017522 SOLENOID ASS Y SEE CHART TORQUE 33 9 N SPRING 270 2 2 S amp GASKET B1334C G OE COVER ASSY 1017336 NEUTRAL WITH OR WITHOUT HYDRAULIC LOCK CARRIER 1017335 SOLENDID SPRING ASSY SEE CHART BALL M1990Y PISTON B1399H REQUIRED FOR CONTROL VALVE BODY ASSY 41017445 BODY 1017 BALL 11 BALL M1990Y 6 PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND HYDRAULIC LOCK lt OPTIONAL CONDITION WIRING DIAGRAM OPTIONAL MATING WIRING HARNESS 1017501 CONNECTOR SERIES SPECIFY LENGTH PORT SOLENOID PORT SOLENDID D BALL 19906 2 BALL M1990L 2 BALL MI990M VALVE GASKET 10171368 SCREEN 221336 M8 X 125 6 TH D 1 1001426 2 HOLES S vy MANUAL DVERRIDE 361 2 POSITION S WHITE WIRE WITH PIN 2 2 ELECTRIC 847 PORT RN Ww 12 CONNECT
20. WK Lee Curt SSS 9 N MSS p We T S les AN i f SABE S e ASQ 1 UP TROLLING VALVE TIONAL MANUAL DE i 52 d E SECONDARY SHA SHOWN DISENGAGED PORT ON LOSED WITHIN ESE IS REQ D FO EYD PED ONLY TH I ge TONAL REAR P CLUTCH CLUTCH HYDRAULIC P CONTRO VAL VE Xe A7119Y FOR H DI TAG RAM OF CONTRO SEE CHART YDRAULIC VALVES CS CO 4 STRAI NER 3510 UIML 4 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 Actuatin
21. By JPL Scate FULL Hei em e ___ amp DET 8 ADDED ES FLANGE FIXTURE 21 97 J DET 5 REV D PL FOR SHEET 3 DF 3 SHT 3 ADDED amp MG 5301 CAD FILE nance _ nescmenow av TR DISC Wc meme vis 21433 FLAME 1 74 DRILL 7 8 875 DIA THRU 1 8 15 REQ D DRILL 29 32 906 DIA THRU 5 REQ D FOR CLEARANCE THREADED ROD 1 REQ D DRILL ROD OR THREADED STOCK FLAME HDN AS SHOWN FLAME SQUARE 7 8 8 THREAD DRILL 1 1 8 1 125 DIA THRU 5 REQ D FOR ROD CLEARANCE DRILL 2 00 DIA 8 REG D EASIER LIFTING 12 x 175 THREAD 3 ROD 5 REG D MAT FIRM X FLAME AS SHOWN NOTE GROUND SURFACES MUST BE PARALLEL 1018363 WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BEARING ASS Y BREAK ALL SHARP CORNERS M2950 4 ______ BEARING ASS Y E 12 x 30 s Ro 1 8 THREAD x 58515 s FLANGE NUT 776 6 THREAD s s Fre f 10 8256 1 s soo 125 LII D 111 puare 70 x75 THK 1 WELDMENT ASS Y 1 REQ D e Date 10 22 98 1018372 SHAFT WELD NORMALIZE amp HARDEN E BEARING DRIVER r CAD FILE 21506 Ss a me 1721506 KNURL
22. DRILL 7 2010 DIA x 1 00 DP DRILL THRU amp C BORE FOR TAP 1 4 80 UNC x 88 DP 162 REQ D DRILL 49 64 7656 DIA x 175 DEEP i NUR EMS LOCATED AS SHOWN FOR TAP 7 8 9 UNC x 1 47 DEEP DET 12 GRD 8 2 000 DIA 8 REQ D FOR RODS 5 amp amp 4 906 DIA DRILL 27 64 4219 DIA 2 138 1 1 2313 UNC x 125 DEEP i TYPICAL KEY SLOT 8 REQ D RADIAL LOCATION 180 USED FOR LIFTING 12 SPLIT CENTERED 1 38 TYPO STAMP 20023 3 DET 1 DRILL 27 64 4019 DIA THRU TAP 1 2 13 UNC 1 REQ D DRILL THRU amp C BORE FOR 3 4 SOC HD CAP SCREW 4 REG D TO MOUNT TOP PLATE TO RAM 1 COLLAR 45 REQ D STAMP 20023 3 4140 45 49 Rc DET 8 TOP PLATE D REQ D MS 45 49 Rod STAMP 20023 3 BOTH DET S 3 amp 4 U CUT TYP BOTH DETS 3 amp 4 ROD 42 REQ D MAT 4140 45 49 STAMP 20023 3 DET 3 7 8 9 UNC TYP BOTH RODS DIM 35 81 FOR 5301 NOTE BOTH ENDS AS SHOWN 29 00 FOR 5301 DRILL THRU LA BORE AS SHOWN 37 02 FOR MG 6650 SC 960 DI S SPACER 8 REG D BY 30 21 FOR MG 6650 SC MAT 4140 52 59 o 2 e 4 4140 ROD 45 49 100 x 37 25 LG 4 a140 op 45 49 Ro 100
23. Marine Transmission Service Manual 1020304 234 Twin Disc Incorporated Qty Description Item Gear output Bearing tapered roller output shaft front Shaft output Shield oil distribution Housing front Shaft assembly primary Seal input oil Plug seal protector Housing assembly Screw hex head cap SAE 0 front housing Screw hex head cap SAE 00 front housing Washer flat Screw hex head cap top cover Cover assembyy top Gasket top cover Baffle assembly Nut caged Screw hex head cap baffle Washer sealing O ring breather cap Screen oil filler Plate cover location Screw hex head cap PTO valve cover Marine Transmission Service Manual 1020304 Illustrations Qty Description Gasket PTO valve cover Gasket bearing carrier Carrier bearing Gasket manifold Gear transfer primary shaft RH helix Plug O ring M18x1 5 pressure test ports Manifold O ring primary shaft end cover Cover primary shaft end Screw hex head cap primary shaft end cover Fitting grease Plug O ring flange removal oil injection port Flange output Screw hex head cap output flange Washer retaining output flange Seal output oil Carrier output oil seal Screw hex head cap output seal carrier O ring output oil seal carrier Shim bearing 0 005 0 007 0 020 Bearing tapered roller output shaft rear Plug O ring M33x2 oil drain 235
24. N S N N NA N N 2 N 25 SM oN N NON KN N WN LA N 24 L INS NN N lt FS Y 00 6 2 lt N u Se 0 5 Qs L1 KY DN 5 7 one gt 4o EIL ZS E Ya vo Yn 2 oe lt Ll n s 20 1 no 23 Figure 3 Vulkan VL3411S Series Torsional Coupling SAE 00 Marine Transmission Service Manual 1020304 Description and Specifications Twin Disc Incorporated JUPLINGS 906 ONLY DYNAMIC ORQUE ORSIONAL kN m STIFFNESS kN m rad HOUSING 1017013 11 SAE 0 22 60 200 320 470 COUPLING 1019717 SCREW 996 20 SAE 0 HSG SHAFT ASS Y 10169884 D SHAFT 10169874 __ BALL MAl034B RING B1048AM N 46 4 St RVICE RE RENCE ROLLER 1116 10 5 55 12525528282 2555 5 SCREW MA996F 23 SAE 800 HSG pd COUPLING 1019718 27277 a IDUSING 1017014 SAE 00 enero DYNAMTC COUPLING WR SAE J620 COUPLING cqueLin DYNAMIC kg me FLYWHEEI NUMINAL TORQUE
25. RU MECHANICAL DIA 7108 4mm lt v we Figure 148 Mechanical Control Valve Installation Specifications 196 Marine Transmission Service Manual 1020304 PpOLOZOL uoissiusueJ SUNEN 261 5 214129 3 WIRING DIAGRAM CONNECTOR CONNECTOR 7 SECONDARY CLUTCH SOLENOID oP SECONDARY CLUTCH 7 PRIMARY CLUTCH SOLENO n PRIMARY CLUTCH SOLENOID NEUTRAL SOLENOID OPTIONAL Te MATING WIRING HARNESS 1017404 OPTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH NOTE LEVER MAY BE LOCATED ANYWHER ON ITS SHAFT THAT PERMITS FRI MOVEMENT WITHIN THE 50 lt TOTALD ROTATION amp 11 4mm AXIAL MOTION MANUAL OVERRIDE NEUTRAL STARI REQUIRED FUR CONTR SWITCH CLOSED ONLY WHEN ENGAGES MANUAL OVERRIDE IS IN USE amp SECONDARY 64 9 THRU TRANSMISSION IS IN NEUTRAL SHAFT CLUTCH ENGAGES PRIMARY SHAFT CLUTCH ANUAL VERRIDE 361 M8 X 25 6 IRE AD POSITION e HOLE FOR REMOTE CONTR ELECTRIC BRACKET CONTROL POSITION Zoe 1 E e ELECTRIC
26. SCREW MA1062M 2 ELEMENT GROUP XM2934 SCREW MA1062P 2 POPPET 204367 BODY B3133 BOLT 204365 ELEMENT M2725 SPRING 204369 VALVE ASS Y 24 VDC 1018084P WASHER A2888AY 40 064 WASHER MA1039B 4 OO 494949 2525290 SCREW MAS96A 4 OOD 5500 5 5 5 O 9 5 52 Q2 LLY 5 TAG MA656C XS 5 a S M2051FL GAUGE B1703D 2221 GAUGE B3631AH PLUG MA1038C 2 83 205 F 10350 2 CLOSURE M2067 2 SCREW 996 14 EXCHANGER 1017121 HOUSING 1017125 PLATE 1017127 GASKET 1017126 GASKET 1019905 GASKET 1017124 PLUG MA1038A Vane AN pf N SCREW MA1062D 12 OPTIONAL FRESH WATER HEAT EXCHANGER PLATE 1017127 CLOSURE M2067T 2 GASKET 1019905 SCREW MA1062D 12 te a RS PE wed 1017020 5340 s 1017607 J 9 THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO S574 OR SERVICE MANUAL VALUES FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 No 530 9 Be FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 No 460 K e THRU 16 0 SAE 400 6222727222225 lt lt gt AAS N DAY
27. 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 1020304 111 Cleaning and Inspection Twin Disc Incorporated Valve Seats Inspect valve seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the valve is seating properly after reworking the valve seat Bearings Inspect bearings for roughness of rotation Replace the bearing if the rotation is rough Inspect bearings for corrosion and for indication of wear of balls or rollers Inspect for scored scratched cracked pitted or chipped races If you find one of these defects replace the bearing Inspect bearing bores and shafts for grooved burred or galled conditions that would indicate the bearing has been turning in its housing or on its shaft If you cannot repair the damage with a crocus cloth replace the part Bushings and Sleeves Inspect bushings for size and out of roundness Inspect for scores burrs sharp edges and evidence of overheating Remove scores with a crocus cloth If the bushing is out of round deeply scored or excessively worn replace it Thrust Washers and Spacers Inspect thrust washers for distortion scores burrs and wear Rework or replace any defective thrust washers or spacers 112 Marine Transmission Serv
28. alternating each spring s orientation Figure 89 Correct Spring Stacking left and Installation right 5 Install the pinion rear tapered roller bearing cone onto the shaft 136 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 6 Install the external retaining ring over the bearing Use T 18050 704 to compress the springs and expose the retaining ring groove Figure 90 External Retaining Ring Installed 7 Beginning with a friction plate alternately install 10 friction plates and 9 steel plates into clutch housing transfer gear against clutch apply piston Marine Transmission Service Manual 1020304 137 Assembly Twin Disc Incorporated 8 Install clutch backplate and internal retaining ring Figure 91 Installing Clutch Backplate Note Some models use a clutch backplate without external splines and a spiral internal retaining ring Refer to unit BOM for parts usage 9 Align plates in clutch pack and install pinion on clutch shaft so that external teeth on clutch hub mesh with internal teeth of steel plates in clutch pack Assure that clutch hub is in mesh with all clutch plates 138 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 10 Install external retaining ring to retain pinion on shaft i Figure 92 Installing External Retaining Ring Onto Clutch Shaft Marine Transmission Service Manual 1020304 139 Assembly Twin Disc
29. particularly if the unit is being disassembled because of an internal failure De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher screw locations Marine Transmission Service Manual 1020304 109 Cleaning and Inspection Twin Disc Incorporated 110 Cleaning Bearings Do not remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease 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 old gasket material or silicone Clean surfaces with solvent to remove oil and grease residue Test clean surfaces by applying few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface ina film If the water pu
30. 1020304 Twin Disc Incorporated Operation Main pressure oil flows from the spools above to the clutch passages of the transmission below via connecting slots in the manual override stem These connecting slots are aligned with passages in the valve body when the valve is in the electric mode Figure 18 Flow Path in Override Spool Main pressure from the energized solenoid operated pilot valve also acts ona pin on the return spring side of the opposite spool to ensure the opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Marine Transmission Service Manual 1020304 49 Operation Twin Disc Incorporated Hydraulic Lock Feature some models Some control valve models have a hydraulic lock feature and are identifiable by a third solenoid operated pilot valve This feature keeps the engaged clutch pressurized as long as the engine remains running should electrical power fail or malfunction occur while the clutch is engaged The hydraulic lock is accomplished by allowing pressurized oil from the pressurized clutch passage to flow inside the spool Oil pressure inside the spool forces the dowel pin against the O ring plug Neutral solenoid Figure 19 Hydraulic Lock Units The resulting reaction is a force on the spool that overcomes the spool s return spring force Should the solenoid become de energized while the spool has its clutch pressurized oil pressure w
31. 186 1 Ring internal retaining 202 1 Ring internal retaining 187 1 Ring internal retaining 203 1 Coupling assembly SAE 0 188 1 Hub coupling 204 1 Ring internal retaining 189 16 Screw hex head cap coupling hub 205 1 Ring internal retaining 190 1 Coupling assembly SAE 0 w out torsional stop 206 1 Coupling assembly SAE 00 consists of items 191 through 193 207 1 Element to service item 203 or 206 191 1 Ring drive 208 1 Hub input 192 1 Element coupling 209 3 Screw hex head cap input hub 193 1 Ring spacer 210 1 Washer retainer input hub 211 1 Ring internal retaining payesodioou OSIA UIML suoneusnyl Illustrations Twin Disc Incorporated Mechanical Control Valve Item Qty Description Item Qty Description 151 1 Lever 164 AR Shims pressure adjustment 152 1 Detent 165 1 Piston rate of rise 153 1 Spring compression detent 166 1 Spring set pressure regulating 154 1 Plug O ring 167 1 Piston pressure regulating 155 1 Bushing reducer 168 1 Stem selector 156 1 Plug pipe 169 1 Bearing ball 157 1 Body valve 170 1 O ring cover 158 1 Spring compression check ball 171 1 Gasket cover 159 1 Ball steel 172 1 Cover 160 1 Plate orifice 173 4 Screw hex head cap cover 161 5 Screw hex head cap orifice plate cover 174 1 Stop collar 162 1 Cover orifice plate 175 1 Pin roll 163 2 Gasket orifice plate cover 176 1 Screw socket
32. 2 GEAR 1 101 017767 2 OF 6 AND PART NUMBERS RING A2916DA 3 35 RATIO 46T INSTALLATION X DRAWING SHIM 1017038 INSTALLATION SHIM 1017039 AS REQ D SEE NOTE 4 DRAWING SHIM 1017040 GEAR 1017115 BEARING M2950 COUPLING INPUTS 4 42 0 13 j ASS Y 5850 GEAR 1017116 CUP 59 4 06 1 RATIO 134T NS SEAR 1017766 B3504AQ CUSTOMER NOTES 35 1 RATIO 1541 PLUG MA1040A GEAR RATIOS OIL CAPACITY 5151 391 ASS Y 1017020 ONLY HEAT EXCHANGER 5 THIS UNIT CAN BE USED WITH A LEFT HAND ENGINE x 925 COMPANION FLANGE ASSEMBLY 1017084 42 DIAGRAM MANUAL TROLIN VALE 1017020 IS THE STANDARD POWER RATING UNIT REFER TO S856 35 Quran PTO 10178200 2 1017607 IS A HIGH POWER RATING UNIT REFER TO 5856 101711 3 6 39 1 RATIO 115T ASS Y 1017020 ONLY e SEAR 1017008 96 1 RATIO 143T ASSN 1017020 ONLY GEAR 101 7642 5 96 1 RATIO 1437 ASS Y 1017607 ONLY CEMR 1017114 212 27 7 7 FLEXIBLE COUPLING INPUTS SEE SHEET 5 5 MERRIE ADAPTER KT INTEGRAL HEAT EXCHANGER FESS WATERS OIL TT COOLER TD INN REMOTE HEAT EXCHANGER DITCH PLATE FOR CUSTOMER SUPPLIED OIL COOLER SEE SHEET 2 TRALING PUMP 1016473 ae a es CERNI PRINT CONTIN ELECTRIC VALVE WITH MECHANICAL BACKUP 12 VDC 10
33. 34 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation Operation General The control valve obtains primary neutral and secondary positions When these positions are selected the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate control piston within the control valve assembly provides a rapid smooth oil pressure increase in the hydraulic system during clutch engagement Marine Transmission Service Manual 1020304 35 Operation Twin Disc Incorporated Hydraulic System with Manual Control Valve 36 The oil pump draws oil through the strainer from the oil sump and discharges it through the oil filter Filtered oil enters the control valve through the inlet port The incoming oil forces the pressure regulator piston against the springs to open the path to the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the heat exchanger to the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings There is a lubrication oil pressure relief valve to limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication sy
34. 360 IN WHICH THE LEVER MAY BE CLAMPED PROVIDED CLEARANCE EXISTS FOR FULL 90 OF TRAVEL NNN aa i 2 Y 72 7 CS VALVE BODY 1017529 VA LLL 6 4 9 THRU ONE HOLE 2 INSTALL USING MA908 LOCTITE 242 CRUISE MODE AT DETENT MIN TROLLING PRESSURE SECTION A A MAX TROLLING _ CAPSCREW M2000H 70 75 NUT 2027 TROLLING RANGE LEVER B2103 TROLLING PRESSURE 11 NO TROLLING SETSCREW M2041AB ADJUST SETSCREW SO THAT THE TORQUE REQUIRED ON STEM TO OVERCOME DETENT 15 1 1 1 7 10 15 Ibf in SPRING 10504 BALL M1990U O RING A2916DD RING 29168 SHIM 2057 5 REQ DO PIN PM 3036 M INSERT SPRING A2701BN OVER ROLLPIN PM 3036 M UNTIL FIRST SPRING COIL REMAINS LOCATED AGAINST STEM FACE pi M p A ANS 4 277 in A T 67 1 S SPRING A2701BM SPRING A2701BN SECTION B B BOM NO 40588 M8 X 1 25 TH D 19 1 DEEP GASKET 1017553 2 HOLES METRIC PLATE 9 GREASE APPLICATION PROCEEDURE E THIRD ANGLE BEFORE INSTALLING VALVE STEM INTO BODY GASKET 1017130 PLATE IS NOT INCLUDED IN ASSEMBLY T ALG CONSISENG TO SIMILAR TD USE EXISTING PLATE FROM CONTROL VALVE THE VALVE STEM FROM THE RING GROOVE 8671 TO NECKED DO
35. B1783M 14 lt gt e 22227222222 PLATE 1017026 PLATE 206063 18 o PART NUMBERS FOR GEAR 1016994 6 9 9 INPUT OPTIONS SEE SHEET 5 Ac 1 1 1017031 SCREW 996 4 2060676 20 S m SPRING A2706AC RING 2078 2 GASKET 1017035 a HOUSING MA929 BACKPLATE 1017034 GASKET 1017029 BALL MA1034C BEARING M1989 2 CONE ASS Y MA585AA SCREW MA960E 2 GASKET 1017030 CUP 590 CARRIER 1017016 WASHER MA1039A 2 AZIXDA NEY A GEAR 1016993 6 9 9 RING A29038H 2 PLUG MA1038D 4 TUBE 1017095 MANIFOLD 1017012 WO GASKET 1017589 SUM 5752 Has REQ D SEE NOTE 4 q SS 3 1 LL SU il P2 IZ SHIM 1017043 KS PUMP 1017584 D RoI BEARING 1017081 2 ASS Y MASBSHN SP pM E N XX eem s gt AS NN gt ANN NSS SEE NOTE 6 9 drin m RING M26935 2 22 222 BEARING 628 2 22 lt lt Ce SN ASS Y MASBSDL 2 22 1017046 2 SSM un X ULL RS EAR Po N E aS RING A2915CG 2 was A 2 X Ds RSS V 2 m RING A2916KD 2 N AN RING M1904L 4 lt SNS PLATE 101558 S
36. CAPACITY USTEMER GAL MARINE ANSMISSIUN LUBR RICA ION MIN HIL PRESSURE WHEN CRUISING PSS V SE ICE RS UR DAILY CHECK DIL LEVEL WITH ENGINE RUNNING AND WHERE A GREASE FITTING IS PROVIDED SEALS WITH WATER PUMP GREASE TO PREVENT BILGE WATER HOURS OR 6 MONTHS WHICHEVER COMES FIRST RAIN CLEAN OIL REMOVE AND REPLACE FILTER ELEMENT WHERE APPLICABLE S VOID UN ESS TRANSMISSION IS LUBRICATED AND MAINTAINED AS NE UN REQUEST REFER ARINE TRANSMISSION CL UF MATERIAL NO MUST ui HEN ORDERING PARTS i 2 x ALN MADE IN USA RA USA 4 Figure 1 Nameplate for MG 5301DC Marine Transmission Marine Transmission Service Manual 1020304 17 Description and Specifications Twin Disc Incorporated Power Ratings The MG 5301DC transmissions can be operated through either the primary shaft or secondary shaft at its full rated horsepower when driven by a standard right hand rotation engine counterclockwise flywheel rotation when viewing rear of engine This series of marine transmissions cannot be driven by a left hand rotation engine Contact an authorized Twin Disc distributor for more information Transmission clutches are hydraulically applied using main oil pressure All bearings clutches and gears are lubricated and cooled with low pressure oil Always reference the Bill of Materials BOM or Specification number when ordering service parts 18 Marine Transmission Se
37. CONTROL CLOSED WHEN MANUA STEM IS LOCKED IN L1 3510 UIML Installation 198 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 stem Selecting neutral must place the selector valve in the neutral detent position Improper installation of power engaging devices could cause failure of the selector valve stop permitting improper positioning of the selector valve and resulting in control malfunction Electrical Controls All electrical wires and connectors must be adequately supported to prevent rubbing chafing or distress from relative movement All electrical connections must be tight and free from any corrosion Final Checks Be s
38. EYE BOLT AS SHOWN DRILL 1 28 5002 DIA THRU 552 REQ D AS DIMENSIONED V UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF EACH OTHER ICE PLATE Cl dS ES REWORK JERGENS 18506 OR EQUIV 2 1 PUR JERGENS SHD ER EYE BOLT 3 4 10 unc MS amp HDN2 CARB amp HIND Tm T 18050 714 SHAFT PICK UP FIXTURE 01 SHEET 1 OF 1 MG 53 BREAK ALL SHARP CORNERS TOLERANCE UNLESS OTHERWISE SPECIFIED SORS m Tm CAD FILE 050 714 CHANGE DESCRIPTION DATE TWIN DISC INC RACINE WIS 1 4 UN ANGULAR DIMENSION NOTE SPHT WELD amp LOCATE SHD ER EYE BOLT DRILL 27 64 4219 DIA THRU 1 2 1 UNC WELD ROD DRILL 172 5002 DIA THRU PLATE AS SHOWN 02 REQ D AS SHOWN STAMP EDGE ONLY OR BOTTOM STAMP TOOL NUMBER T 18050 715 SHAFT NUMBER 1016987 MODEL NUMBER MG 5301 UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS CLUTCH WPICK UP PEATE Cl REG GROUND SURFACES MUST BEPARALLEL MS CCARB amp WITHIN 005 OF EACH OTHER ee JERGENS 18504 OR EQUIV 1 DR extension 50 DIA x 425 LG 1 1 1 ms PIck uP PLATE 362 DIA x 88 DESCRIPTIUN STUCK SIZE 1016987 CLUTCH SHAFT mas es UD 35 MOD 25 DETI NAME 1 CLUTCH PICK UP FIXTURE STAMP TOOL NOs
39. Lt LUBE RELIEF AVE 690 kPa ROSS 22222222224 7 KN BBQ QQ QQ AAL AES 2 RR LLL LLL LL AN G SECONDARY SHAFT FRDNT amp REAR BEARING PINIDN SHOWN DISENGAGED SQ FILTER BY PASS 138 kPa TEMPERATURE INDICATING SWITCH HERE AHR 995922 PLUG FROM MANIFOLD AND INSTALL OPTIONAL LI T 2 23 29090 1 25 99 1 22 29644 7 5 23 28123 10 22 97 A e6 279617 85 97 me CUSTOMER TO INSTALL PRESSURE GAUGE LINE HERE PRESSURE GAUGE TO BE MOUNTED N PILOT HOUSE SEE MARINE TRANSMISSION NSTALLATION DRAWING PRIMARY CLUTCH SPRING RELEASED EI _CLUTCHES _ TUBE GEAR LUBE CLUTCH PRIMARY amp SECONDARY SHAFT LUBE FRONT SHAFT REAR PINION BEARING BEARING FRONT PINION LAL SECONDARY CLUTCH CUSTOMER INSTALL G PRESSURE GAUGE AND LINE HERE XA7108 MARINE TRANSMISSION CONTROL VALVE SHOWN IN NEUTRAL Tid kPa XA7108 MARINE TRANSMISSION CONTROL VALVE FILTER BY PASS FILTER BY PASS pm SS lt CHANGE OVER DUPLEX FILTER REMDVE 1038 10 1 PLUG FROM MANIFOLD AND INSTALL OPTIONAL TEMPERATURE INDICATING SWITCH HERE
40. M2693S 22 RING B1048BH 2 BEARING 217 22 SAE 0 SHIELD 1017032 SHAFT 1017000 BEARING M2909 ASS Y 585 2 CUP MAS90CD e GEAR 1017113 391 RATIO 1157 24 10170208 ONLY GEAR 1017008 5 961 RATIO 1 10170208 GEAR 1017642 96 1 RATID 143T ASS Y 10176078 ONLY GEAR 1017114 4 961 RATIO 139T GEAR 1017115 4 421 RATIO 137T GEAR 1017116 4061 RATIO 134T GEAR 1017766 CUSTOMER NOTES 3 351 RATIO 154T DIL CAPACITY 5151 Ye COVER ASS Y 1017025 COVER 1017024 ADAPTER 1966 GASKET 1017028 lt lt lt 5 SIS BAFFLE ASS Y 1019068 BAFFLE 1019067 NUT 1054 3 Je C ER LLLLLLL WSN 77 LENG ANT sl stall QNS pa b gt THIS UNIT CAN BE USED WITH A LEFT HAND ENGINE DP TIONAL EQUIPMENT FLANGE ASSEMBLY 1017084 CDMPANIUN FLANGE F R SHAFT BRAKES 1019642 LIVE PTO CAUXILIARY PUMP DRIVE HYDRAULIC 1017820C 10170208 IS THE STANDARD POWER RATING UNIT REFER S856 2112 7 7 AY AY A A A SCREW MA960D 3 WASHER M2081D 3 SEE NOTE 9 RING A2916W SCREEN MA993 PLATE 1017026 SCREW MA996F 4 GASKET 1017035 GASKET 1017089 CARRIER 1017016 GASKET 1017030 GEAR 1016993 6 PLUG 10380 4 MANIFOLD 10170124 SPRING A2704CN 322 RETAINER 1019951 22 PLATE 206063C 182 PLATE 2060676 20 RING M207
41. Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 7 Use tool T 18050 704 to compress the belleville springs and remove the external retaining ring Figure 39 Close up of External Retaining Ring 8 Remove tapered roller bearing cone from shaft bearing supports rear of pinion This bearing is a slip fit and should remove easily 9 Remove belleville clutch release springs and spring retainer 10 Remove the clutch piston by applying air to the hydraulic pressure port between the seal ring grooves to force the piston from the bore Use caution to avoid damaging the piston 11 Remove clutch piston outer multi piece seal ring from groove in piston 12 Remove clutch piston inner seal ring from groove in shaft 13 Removethe orifice plug from the front end of the secondary shaft some models 14 Proceed to page 93 Marine Transmission Service Manual 1020304 87 Disassembly Twin Disc Incorporated 88 Assemblies 1017020B and 1017607B Note The following procedures apply to assemblies 1017020B and 1017607B which use coil spring clutch release springs If the transmission has belleville spring clutch release springs refer back to page 84 1 Remove two piston rings from rear end of shaft 2 If rear bearing must be removed remove bearing retaining ring from rear end of shaft Remove the bearing as follows Note Do not remove rear bearing unless bearing must be replaced B
42. Passage Oil Pressure Chamber C Pressure Overflow Port D Engaging Passage E Oil Engaging Passage Oil Interconnection Slot Oll Directional Port Connection Port J Oil Pressure Passage Directional Port L Oil Pressure Chamber A HIGH PRESSURE REGULATOR PISTON RATE OF RISE PISTON CONTROL VALVE LEVER PISTON SPRINGS CONTROL VALVE STEM CONTROL VALVE BODY ATMOSPHERIC PRESSURE 0 ENGAGING PRESSURE Figure 12 Control Valve Secondary Sectional View SECONDARY CONTROL VALVE BODY TO PRIMARY CLUTCH TO SECONDARY CLUTCH CONTROL VALVE STEM g ATMOSPHERIC PRESSURE o ENGAGING PRESSURE Figure 13 Control Valve Secondary Cutaway View Marine Transmission Service Manual 1020304 43 Operation Twin Disc Incorporated Hydraulic System with Electric Control Valve 44 The oil pump draws oil through the strainer from the oil sump and discharges it through the oil filter Filtered oil enters the control valve through the inlet port The incoming oil forces the pressure regulator piston against the springs to open the path to the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the heat exchanger to the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings There is a lubrication oil pressure relief valve to
43. THIS DIA THIS WIDTH 0 08 X 45 BOTH ENDS AND STAMP TOOL ND 721506 DET 6 PART MG 5301 SHAFT SECTIOUN 611 14140 SPACER RING Rc32 36 TUBING 7 25 OD X 2 25 DESCRIPTION STOCK SIZE STAMP TOOL ND 10 07 99 GDL FPN ______ 5 FULL PART ND BREAK ALL SHARP CORNERS TOLERANCE UNLESS OTHERWISE SPECIFIED 001 ON THREE PLACE DECIMAL DIMENSION 010 FOR SHEET 2 OF 2 DN FRACTIONAL AND TWO PLACE 5301 21506 DECIMAL DIMENSION 1 4 ANGULAR DIMENSION 1 21506 60 THRU TOP SIDE ONLY 2 00 THREAD LENGTH IN ZZZ 2277 2222224 ANNA 571555555 ULLA 1 2 13 UNC SECTION A A 9 69 48 502 mn AUTOCAD FILE T 506000 DWG KNURL HANDLE 913 mm 2 NOTE HOLD DRILLED C BORED AND OR TAPPED HOLES 005 NOTE LIFTING CAPACITY 325 POUNDS L3 1 fixem 4 Ls xim 5 jeesxzsvuixus 1 ve mewe Ls smxes es 5 Jeexesx oom ma x esm 1 oom ma Scole 1 1 mps P amp S SHAFT LIFTING DEVICE DO IN BDAT CLUTCH REPAIR rem bist ane meme 11 206000 Twin Disc Incorporated Illustrations Illustrations List of Illustrations The following pages include illustrations that are specific to this model The illustrations included are
44. TO 33 9 WHITE WIRE BLACK WIRE lt gt SECTION GASKET 1017334 VALVE COVER ASSY 1017185 COVER 1017184 PLATE x BALL 1034 BOM NO 40537 GASKET 1017130 Mp FREIE THIRD ANGLE PLATE IS NOT INCLUDED IN PROJECTION ASSEMBLY USE PLATE FROM CONTROL VALVE PX 8671 Z NOT SERVICEABLE SEPARATELY Ae NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED DATE oe JH D 1 29503 RACINE VI 53403 USA assy 1015207 52020 PER ANSI Y14 5M 1982 2 ERES EAE 4 T 29350 6 24 99 novice 15 NOT INTENDED e 1 4 ez 28585 3 95 gR LIT RIGHTS pe VALVE ASS Y TROLLING cu wr awe zone pare OTHERS BY CONTRACT 1 2 2 INSTALLATION NOTE 0 6 0 9N 5 5 8 3 Ib AT THE 46 0 1 81 LOCATION OF THE 6 4 1 4 DIA HOLE IS REQUIRED CAPSCREW MA1042B 2 TO OVERCOME DETENT REMOTE CONTROL ACTUATOR MUST PROVIDE 65 0 mm 2 56 TOTAL LINEAR TRAVEL AT THE 6 4 1 4 DIA HOLE LOCATION STEM 1017901 SEAL 5591 ADAPTER 1017530 F d 22 SETSCREW MA1037D SCREW IN UNTIL POINT BOTTOMS THEN LOOSEN E 1 2 TURN BALL STOP IN NO TROLL POSITION PISTON P 10491 THE 90 LEVER ROTATION REQUIRED FOR CONTROL MAY FALL ANYWHERE WITHIN THE
45. The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and oil pump in the hydraulic circuit The strainer can be replaced if necessary Filter Assembly A canister style filter is located between the oil pump outlet and the selector valve in the hydraulic circuit The replacement element is Twin Disc part number M2725 This should be replaced at 1000 hour or six month intervals whichever comes first Gears All gears are helical carburized hardened and ground for smooth quiet operation All gears are in constant mesh The primary and secondary transfer gears and the output gear are mounted on keyless tapers 20 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Description and Specifications Flexible Torsional Input Coupling The purpose of the torsional coupling is to transmit power from the engine to the marine transmission through a rubber or silicone element that will Dampen torsional vibrations Change the natural frequencies of a system to move critical frequencies out of the operating speed range Accommodate a certain amount of misalignment Absorb shock and reduce noise Minimize gear rattle Several couplings are available from Twin Disc and are selected based on the customer supplied engine information Final coupling selection must be confirmed by the packager based on the torque rpm ratings and the result
46. and capscrews torquing them to 112 Nm 83 ft lb The torque specification for the M22x1 5 screws that attach the coupling element to the coupling hub is 820 N m 605 ft lb with lubricated threads Marine Transmission Service Manual 1020304 161 Assembly Twin Disc Incorporated Assembly and Installation of Control Valve Assembly of Mechanical Control Valve 1 Install the O ring and ball bearing into the valve cover Figure 113 Installing O ring left and Ball Bearing right 2 Apply assembly grease or oil to the shaft of the valve stem and install the stem into the valve cover 3 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 Figure 114 Installing Stop Collar onto Stem 162 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 4 Place the cover gasket over the stem assembly against the cover Install the assembly into the valve body and torque the attaching screws to 20 Nm 15 ft lb Figure 115 Installing Stem Assembly into Valve Body 5 Install the detent plunger spring and O ring plug Torque the plug to 16 N m 12 ft lb Figure 116 Installing Detent left and O ring Plug right Marine Transmission Service Manual 1020304 163 Assembly Twin Disc Incorporated 6 Install the valve lever alig
47. bearing cup with an electric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced 8 Remove input oil seal Remove input oil seal protector plug only if replacement is necessary 9 Press the rear tapered roller bearing cone off of the output shaft Marine Transmission Service Manual 1020304 83 Disassembly Twin Disc Incorporated Disassembly of Primary and Secondary Clutch Shafts Assemblies 1017020 1017020A 1017607 and 1017607A Note The following procedures apply to assemblies 1017020 1017020A 1017607 and 1017607A which use belleville clutch release springs If the transmission has coil spring clutch release springs proceed directly to page 88 1 Remove two piston rings from rear end of shaft 2 If rear bearing must be removed remove bearing retaining ring from rear end of shaft Remove the bearing as follows Note Do not remove rear bearing unless bearing must be replaced Bearing is an interference fit with shaft and will be destroyed during removal a Remove the external retaining ring from the shaft b With ahammer and chisel cut cage off bearing to remove bearing cage and rollers C Use a split type bearing puller cheese cutter to grip flange at small end of tapered inner race d With a hydraulic jack pull on bearing inner race while pushing on rear end of shaft to remove bearing inner race from shaft 3 Set shaft upright with input end u
48. each of the two bores of the valve body Figure 123 Dowel Return Spring Spool and Plug 3 Install one spool into each of the two bores of the valve body 4 On units equipped with the hydraulic lock feature install one spring followed by one pin small diameter into each of the spools 5 Install the two O ring plugs into the valve body and tighten to 85 Nm 63 lb ft 6 Apply lubricant such as Dow Corning 200 30 000cSt fluid to the O rings of the solenoids and plug plug used on units without hydraulic lock Install solenoids and plug if equipped into the valve body and torque them to 34 Nm 25 Ib ft 7 Insert the wires pins into the Weatherpak connector according to the location markings made at disassembly Close the end of the Weatherpak connector to lock the wires in position 8 Install the Weatherpak connector onto its retaining clip on the top of the valve body Marine Transmission Service Manual 1020304 167 Assembly Twin Disc Incorporated Assembly of Electrical Control Valve lower body half 1 2 Install the steel shuttle ball into its bore in the valve body Install the O ring onto the shuttle ball seat Apply lubricant such as Dow Corning 200 30 000cSt fluid to the O ring and install the seat into the valve body Be sure to align the roll pin holes in the seat with the holes in the valve body One of the valve s 8 1 25 cover screws threaded into the seat can be use
49. excess oil behind the rate of rise piston through the ball and spring regulator T Ball and Spring Regulator Figure 15 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation Control Valve Assembly in Primary or Secondary Pressurized oil is directed to one of the transmission s clutches to engage it The pressurized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the passage to the opposite clutch The pressurized oil also forces the ball of the ball and spring regulator against its seat on the orifice plate stopping the flow of oil from the rate of rise chamber to sump Since oil continues to flow into the rate of rise chamber through the orifice the oil pressure in the rate of rise chamber increases This increased oil pressure forces the rate of rise piston to stroke over to its stop in the valve body compressing the pressure regulating springs even further yet Figure 16 Rate of Rise Piston in Neutral left and Rate of Rise Piston with Clutch Engaged right The travel rate of the rate of rise piston and resulting pressure rate of rise is controlled by the orifice size regulator spring stiffness and the final main pressure after completion of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the rate of rise piston is against the stop pressure regulating sprin
50. for primary shaft is exactly the same as for the secondary shaft 132 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 4 Install clutch shaft assemblies into transmission housing Use caution to prevent damaging the shafts gears and bearings Use tool T 18050 715 for lifting the primary and secondary shafts Figure 86 Installing Clutch Shaft Assembly 5 Install bearing carrier gasket over dowels onto rear face of housing 6 Install two alignment studs into face of transmission housing Install bearing carrier over studs and onto dowels in housing face Use a soft hammer near the dowels to seat carrier against gasket and over dowels Be sure bearing carrier is fully seated 7 Install cups for rear tapered roller bearings on primary and secondary shafts into bores in bearing carrier Tap cups down gently with soft hammer or brass drift to seat against bearing cones on shafts 8 Install manifold gasket over alignment studs and against bearing carrier 9 Install the bearing spacers over the bearing cups 10 Rotate the shafts at lease three revolutions to seat the bearing rollers while pressing down on both bearing spacers Marine Transmission Service Manual 1020304 133 Assembly 134 Twin Disc Incorporated Push tapered roller bearing cups with bearing spacers firmly against roller bearing cones on rear of primary and secondary shafts Use a depth micrometer to measure from top of ma
51. head cap lever 238 Marine Transmission Service Manual 1020304 Illustrations Twin Disc Incorporated Notes 240 Marine Transmission Service Manual 1020304 REMARKS SOCKET HEAD DOG POINT HEAD OME MODELS UTER INNER e 5 N SOME MODELS HEX TROLLING VALVE GROUP SF S N PLATE ORIFICE SEAL VALVE BODY SCREW NUT PIN LEVER BALL O RING O RING WASHER SPRING SPRING SETSCREW BS lt LONS AN 27222 Y E 22 7 2 QE SECTION SECTION Illustrations Twin Disc Incorporated Notes 242 Marine Transmission Service Manual 1020304 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
52. intended to be given by Twin Disc Incorporated The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering The exclusive rem Incorporated be either the repair or replacement of any T win Disc Incorporated part or Disc Incorporated to be defective and the labor to rm that work and to remove and reinstall or equivalent credit In this context labor is defined asthe flat rate labor hours established Twin Disc Incor i Incorporated be liable for economic loss incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part
53. limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation The pressure in the rate of rise chamber is controlled by a ball that is spring loaded against the orifice plate The passage behind the ball and spring is connected to the sump atmosphere in Neutral and to main pressure when either clutch is engaged A shuttle ball connected to both clutch pressure ports permits pressurizing this passage with oil from the engaged clutch without allowing oil to flow to the disengaged clutch Figure 14 Location of Shuttle Ball The electric control valve can be used in a manual override mode in the event of an electrical power failure When the control valve is energized or shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively increases the clutch engaging pressure causing the clutches to engage at a cont
54. listed below Note Any part numbers listed in the following illustrations are for reference only Please refer to your bill of material for part numbers specific to your model Clutch Group Assemblies 1017020 1017020A 1017607 1017607A Clutch Group Assemblies 1017020B 1017607 Oil Filter Optional Heat Exchangers Transmission Rear View Transmission Section View Torsional Input Coupling Mechanical Control Valve Electric Control Valve D D D D D D B Trolling Valve optional equipment Marine Transmission Service Manual 1020304 225 Illustrations Twin Disc Incorporated Clutch Group Assemblies 1017020 1017020A 1017607 1017607A x NES EMI A gt X CUN lt lt lt 12 S x gt on St P Ne 226 Marine Transmission Service Manual 1020304 pOLOZOL Jenuey uoissiusueJ SUNEN ON 10 11 13 15 16 17 18 19 20 21 22 23 Qty gt PD Description Bearing tapered roller primary amp secondary shaft front bearing Bearing needle roller Shaft ass
55. output shaft Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces The following discussion contains frequent reference to the transmissions parts and components Refer to Engineering Drawings Marine Transmission Service Manual 1020304 115 Assembly Twin Disc Incorporated Prior to Assembly Use the following reference The input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing the output side of the transmission from the rear Identify and place the following bearing components in an oven at 120 C 250 F for 30 minutes output shaft rear tapered roller bearing cone and the rear bearing cones for both clutch shafts Submerge all new friction clutch plates in transmission oil for a minimum of one hour prior to installation Identify and place the following bearing components in a deep freeze 51 C 60 F for at least two hours prior to assembly front output bearing cup all pinion bearing cups and both pinion inner needle roller bearings 116 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Preliminary Assembly 1 Lay the transmission on blocking with the rear side up 2 Install the seal protector into input shaft front bearing area using a soft hammer Figure 69 Seal Protector Installation 3 Install the chilled cups for the primar
56. regulator springs and rate of rise piston Engine idle speed too low Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Regulating valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Remove and clean oil strainer Disassemble the valve and clean the piston Remove the collector and inspect piston rings Replace damaged or worn oil pump assembly pump is not serviceable Adjust linkage so that control valve stem is indexed properly by detent Remove orifice plate cover Clean parts Shim as required Raise engine speed Remove and clean strainer Check oil le vel and correct Correct cause of air leak Disassemble and repair as required Remove disassemble clean and repair the regulating valve Replace oil pump Replace heat exchanger Marine Transmission Service Manual 1020304 Twin Disc Incorporated Troubleshooting Table 14 Troubleshooting Chart continued symptom High main oil pressure High temperature Excessive Noise Regulating valve stuck Improperly shimmed Lube relief valve malfunction Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure or damaged input coupling Excess
57. replaced Marine Transmission Service Manual 1020304 89 Disassembly Twin Disc Incorporated 5 Remove internal retaining ring at front of clutch housing and remove clutch backing plate Figure 41 Clutch Backing Plate and Retaining Ring Removed Note Some models use a Spiral internal retaining ring at the clutch backplate and a clutch piston without external splines 6 Remove clutch plates 9 steel 10 friction maintaining the respective order for inspection purposes 7 Remove tapered roller bearing cone from shaft Bearing supports rear of pinion This bearing is a slip fit and should remove easily 90 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 8 Remove clutch apply piston a Place clutch in a press input side up Use special tool T 19330 to compress clutch release springs and expose round retaining ring Figure 42 Removing Spring Retainer Retaining Ring b Remove retaining ring Slowly release pressure on press and remove shaft from press Remove special tool T 19330 and spring retainer Remove clutch release springs form pockets in face of piston Marine Transmission Service Manual 1020304 91 Disassembly Twin Disc Incorporated 92 Remove the clutch piston by applying air to the hydraulic pressure port between the seal ring grooves to force the piston from the bore Use caution to avoid damaging the piston J E
58. section 1 Remove the Weatherpak connector from the valve body by sliding it in the direction of the opening in the shroud 2 Mark the wires with the location letters that are on the Weatherpak connector Open the end of the Weatherpak connector to allow removal of the pins and wires 3 Remove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool Tool is Packard Electric P N 12014012 Figure 60 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them 5 Remove the third Neutral solenoid units with hydraulic lock or plug units without hydraulic lock 102 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 6 Remove the filter screen from the valve body Figure 61 Removing Filter Screen 7 Remove the two socket head O ring plugs from the bores in the end of the valve body 8 Remove the two spools from the valve body 9 Remove one dowel pin and spring from each of the spools hydraulic lock units only 10 Remove the spool return spring and dowel pin from the bottom of each of the spool bores in the valve body Marine Transmission Service Manual 1020304 103 Disassembly Twin Disc Incorporated 1017555 Trolling Valve Optional Equipment 1 Remove the trolling valve attaching screws Figure 62 Removing Trolling Valve Attaching Screws Steel ball is under pressur
59. sht 8 1 5 7 1 ms WASHER cams 488 56 THICK reali pur 44 6 s o Es us NUT WELDMENT 4 5 stk soc screw x 175 80 MM LG NUT WITH HANDLES see a 1 PULLER RP SEC 1016529 HSG THREAD SIZE 2 4 172 UNC GRADE 8 1017009 FLANGE 194 GRADE 2H HEAVY HEX FULL p ee ee ee D ES DET REPACES DET 1 amp 2 LIUTPUT FLANGE FIXTURE CHANGE DET 5 REWORKED 2 21 97 JPL FOR SHEET 1 F 3 SHT 3 ADDED MG 5301 DESCRIPTION TWIN DISC INC RACINE WIS 1433 CAD FILE 2 495 1740 4 1016523 HSG 1017000 SHAFT DUTPUT 1017009 FLANGE 0 926 2 1 498 6 63 2 010 DIA 2 503 DIA 2 508 DIA 5 PULLER BASE 1 FILE MAT 21433 1 M S HDN 45 49 2 00 4 1 2 UNC 2A THREADS TO BE GROUND AFTER HEAT TREAT 1 250 HEX FLATS CENTERED BELL CENTER BOTH ENDS PULLER ROD 1D REGO SAE 4340 H AIRCRAFT QUILITY HEAT TREATMENT HARDEN amp TEMPER TU 44 48 CHECK HARDNESS UN 2 000 DIA UNLY DO NOT TOUCH THREADS INSPECTION CHECK ALL SURFACES WITH MAGNIFLO EQUIPMENT DRILL 5 16 3125 gt DIA x Leo DEEP 3
60. the momentary misalignment In some cases the proper alignment of these couplings requires an accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Marine Transmission Service Manual 1020304 189 Installation Twin Disc Incorporated Torsional Input Couplings Installation For Models Provided by Twin Disc CAUTION Be sure the internal retaining ring is properly installed inside the torsional input coupling hub See Engineering Drawings section of this manual for correct ring location Assembly Instructions for CENTAFLEX R on Flange Mounted Gears Information Taken Directly from CENTA Drawing 26 60062 91 3 1 Bolt flywheel flange onto flywheel and tighten bolts as follows Y a B Figure 144 Assemble Flywheel Flange to Flywheel 190 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation Table 16 Centa Torque Chart a Torque Bacall lbs ns 98 Tightening torque is for slightly oiled bolts tolerance is 5 Securing of the bolts by adhesives e g Loctite is possible Assembling of output hub This procedure is for gears with splined shaft where the output hub of the coupling is axially free Marine Transmission Service Manual 1020304 191 Installation Twin Disc Incorporated 2 Place rubber rollers in the deepest section of the cam in the output hub Normally they
61. 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 1017170 valve contains no user serviceable parts and is available only as an assembly Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation Power Take off Optional There is a separate manual part number 1020075 which describes the operation installation troubleshooting and service of the optional Power Take off PTO for this marine transmission Live Power Take off The live PTO drives accessories using engine horsepower Since the live PTO connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven when the engine is running Hydraulic Clutche
62. with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment Only a Twin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subseq
63. 0 679 45 647 639 571 5 12 OF 2 E 5 E 15 7 17 0 AL TO THE IN OF TWIN DISC INCORPORATED m mo omo ses Jone L Qmm 17 0 TO OR ners MG 5301DC CAOR OTHERS CONTRACT Rap MARINE TRANSMISSION bas ser 3 or 6 rev WATER IN TO HEAT EXCHANGER WATER OUT FROM HEAT EXCHANGER M42x2 0 THREAD METRIC M42x2 0 THREAD METRIC Go PORT CONFORMS TO ISO 6149 PORT CONFORMS TO ISO 6149 PRIMARY CLUTCH ACTUATING PRESSURE CONNECT OL PRESSURE GAGE EYEBOLT M18x1 5 THREAD 281 50 METRIC PORT CONFORMS M27 x 2 0 THREAD TO ISO 6149 x METRIC PORT CONFORMS TO ISO 6149 MOUNT GAGE IN PILOT HOUSE 282 50 LUBE PSI 6 M18x1 5 THREAD METRIC PORT CONFORMS 150 6149 LUBE PSI IT OPTIONAL AUXILIARY 18 1 5 THREAD 5 LUBE SUPPLY INLET METRIC PORT CONFORMS x SEE HYDRAULIC SPEED PICK UP PORT 1506149 M16x1 5 THREAD e OPTIONAL AUXILIARY METRIC PORT CONFORMS LUBE SUPPLY INLET TO 150 6149 SEE HYDRAULIC SECONDARY CLUTCH ACTUATING PRESSURE 18 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 MAIN PRESSURE PICKUP PORTS 1 4 18 DRYSEAL THREAD TEMPERATURE PICK UP PORT 1 4 18 DRYSEAL OIL IN FROM HEAT EXCHANGER OIL OUT TO HEAT EXCHANGER 33 2 0 THREADS METRIC M33x2 0 THREAD METRIC SPEED PICK UP PORT
64. 020B sheet 2 of 6 Marine transmission 253 1017020B sheet 3 of 6 Marine transmission 254 1017020B sheet 4 of 6 Marine transmission 255 1017020B sheet 5 of 6 Couplings and hub 256 1017020B sheet 6 of 6 Marine transmission 257 Hydraulic diagram 258 XA7108 Valve assembly control sss 259 1018084 Valve assembly control without trolling valve 260 1018085 Valve assembly control with trolling valve 261 1017554 Valve assembly trolling 262 1017555 Valve assembly trolling 263 1016473 Pump assembly trailing 264 10 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc MG 5301DC 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 ma
65. 0304 147 Assembly Twin Disc Incorporated E Install external retaining ring to retain pinion on shaft Figure 102 Installing External Retaining Ring Onto Clutch Shaft 6 Assemble primary shaft Repeat previous procedure steps as assembly procedure for primary shaft is exactly the same as for the secondary shaft 148 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Installation of Clutch Shafts Bearing Carrier and Manifold 1 Install clutch shaft assemblies into transmission housing Use caution to prevent damaging the shafts gears and bearings Use tool T 18050 715 for lifting the primary and secondary shafts Figure 103 Installing Clutch Shaft Assembly 2 Install bearing carrier gasket over dowels onto rear face of housing 3 Assemble lube relief valve spring and lube relief valve steel ball into lube relief valve housing Attach assembled lube relief valve to inner face of bearing carrier with the screws and washers Torque the screws to 33 Nm 24 ft lb Figure 104 Lubrication Oil Pressure Relief Valve Installed Marine Transmission Service Manual 1020304 149 Assembly 150 Twin Disc Incorporated Install two alignment studs into face of transmission housing Install bearing carrier over studs and onto dowels in housing face Use a soft hammer near the dowels to seat carrier against gasket and over dowels Install lube tube through keyed hole in bearing car
66. 1017607A 1017120B 1017607 0 013 mm 0005 in 0 063 mm 0025 in Transmission Output Shaft Bearing Endplay Assembly No Minimum Maximum 0 05 mm 002 in 0 15 mm 006 in Table 5 Front housing and Output Flange Rounout Limits Feature Maximum allowable total indicator Dmm SAE 0 and SAE 00 front 0 and SAE 00 front housing face face 0 41 016 000 41 mm 016 in SAE 0 and SAE 00 front housing pilot diameter 0 30 mm 012 in Output flange face near O D 0 10 mm 004 in Output flange pilot diameter 0 10 mm 004 in This note applies to a continous 270 arc if the balance ofthe pilot is negative in readings otherwise it means all 360 30 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Description and Specifications Torque Values for Fasteners Note All threads and bearing face to be lubricated with light oil film prior to assembly Table 6 U S Standard Fine and Coarse Thread Capscrews Bolts and Nuts Thread SAE Grade 5 SAE Grade 8 Diameter Ib ft Nm Ib ft Nm 1 4 6 8 8 11 10 12 14 16 5 16 13 17 18 23 20 24 27 32 3 8 25 29 34 39 35 41 48 55 7 16 37 43 51 58 55 65 75 88 1 2 60 70 81 95 83 97 113 131 9 16 82 98 111 132 120 140 163 190 5 8 120 140 163 190 165 195 224 264 3 4 205 245 278 332 295 345 400 467 7 8 330 390 448 528 470 550 638 745 1 495 585 671 793 715 835 970 1132 11 8 615 735 834 997 1015 118
67. 154 Installation of Output Flange erre 156 Installation of Top Cover Assembly Heat Exchanger and Oil CLHDIDA 159 Installation of Input Oil Seal and Front Housing 160 Assembly and Installation of Control Valve 162 Installation of Electric Control Valve 176 8 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Table of Contents Mrana 177 Prior to InstallalloHl 177 Alignment also reference SAE J 1033 and 617 178 182 Special Tools 199 LIGt Of Special 199 Recommended Pump Set and Fluids 201 T 18050 704 Clutch piston hold down retainer sheet 2 of 2 203 T 18050 705 Bearing driver for pinion needle roller bearings 204 T 18050 706 Input seal driver and protection sleeve 205 T 18050 708 Bearing cup 206 T 18050 711 Bearing cone driver primary and secondary SHAS DT 207 T 18050 712 Seal protector plug driver 208 T 1
68. 18050 715 PART ND BREAK ALL suas TOLERANCE UNLESS OTHERVISE SPECIFIED 71 FU MG 5301 SHEET 1 OF 1 001 DN THREE PLACE DECIMAL DIMENSION Po 1016987 SH AFT 010 ON FRACTIONAL AND TWO PLACE NES yt CAD FILE T 18050 715 dwg DESCRIPTION pate mise we Rame wis 1 18050 15 1 4 UN ANGULAR DIMENSION MARK 18050 723 FOR PART 38 DIA gt REQ D 628 BEARING CONE 1916987 UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS 1016987 SHAFT 2 GROUND SURFACES MUST 1017010 SHAFT PARALLEL WITHIN 0005 OF EACH OTHER WELDMENT 1 REQ D 1016993 GEAR SEE DEES us LL CARB amp HDN caps 4 75 THK 9294 GEAR amp an BODY 475 rem 1016987 BEARING GENE DRIVER Lucem 11 8 oss 0 6980 loro 1016394 UDE TV BSc ING RACINE 18030 7 3 62 50 6 HOLES THRU EQUALLY SPACED LOCATION NOT CRITICAL 1 50 31 4 DRILL 5 16 THRU 3 8 16 X 100 THD HOLES FOR LIFTING 42 191 212 INDUCTION OR FLAME RADIUS MAS90CD BEARING s 1 pur teco 54973 TAPER INDEX BUSHING 1 bur i e THREADED INSER s 1 1 x 16 3 4
69. 18084Y BALANCING REQUIRED FOR SURVEY AL fat fone EM a e 30151 6 2 00 71 29712 1 4 99 1 5 NOT TO BE USED MANNER 10 7 pan N PX gt ISS TED SOCIETY APPLICATIONS SEE SAD szs 4 10 00 DA e OIL TEMPERATURE INDICATING SWITCH pest ron INSTALLATION LOCATION SEE HYDRAULIC DIAGRAM AND 3 PARTS DRAWINGS ERE 29995 CUM a 71017 7020 30354 9 27 04 1 29974 3 16 00 1 2129417 6 24 99 12 5 28703 8 4 98 panel 1017607 S NOT SERVIGEARLE SEPERATELY L5 aa 50304 8 3 0 Tez aa 129876 3 s oo 1 u 9175 18 98 5 ee 28670 7 22 s8 d MG 5010 1017607 REMOVE BEFORE OPERATING 2 PLACES CLOSURES MARINE ES SCREW MA960D WASHER M2081D ANODE 1017049 FILL ENTIRE TAPPED HOLE WITH SILICON SEALANT EXCHANGER 1017051 ALON PROPER OURE TME CLOSURE M2067J 2 PLATE B2415 GASKET 1017050 A SCREW 996 12 6 BREATHER pissy HOUSING 1017037 Ln AD 7 25 i De VL S LINK A2007 SPRING A2706Z EYEBOLT MA1047A 2 4 CHAIN M1072 7777 PLUG 55 XM2080B PLUG MA1038A CLIP 176 77 FILTER HEAD 9892 og 0 OS E H GASKET B1974 RING A2916EH oO gt 29 X PLATE 1017583 GASKET 1017613 GASKET 1017569
70. 4 81 Disassembly Twin Disc Incorporated 3 Install eyebolts into the end of the output shaft and into the main housing mounting pads 4 Thread a heavy strap through the eyebolts in the output shaft and the strap to the eyebolts in the main housing The strap will restrain the output shaft during disassembly Figure 36 Heavy Strap Restraining Output Shaft Always use retainer bolts or a safety strap to hold parts being separated with oil pressure Oil pressure applied between the two parts for disassembly can reach 300Mpa 43500psi The use of proper safety equipment is mandatory when working with high pressure hydraulic tools The parts may separate with extreme force 5 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature dismounting fluid into the output shaft until the shaft and gear separate Note Use caution to prevent damaging the taper of the output gear or shaft as the torque capacity can be reduced 6 Remove the output shaft output gear and front output bearing cone Use special tool T 19987 2 to remove gear from housing 82 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 7 Tapered roller bearing cups for front bearings on primary pinion secondary pinion and output shaft are an interference fit in their respective bearing bores Remove these bearing cups only if replacement is required To remove these bearing cups weld a light bead around the 1 0 of the
71. 5 1377 1606 11 4 850 1000 1163 1355 1375 1625 1865 2203 Table 7 Metric Coarse Thread Capscrews Bolts and Nuts Thread Property Class 8 8 Property Class 10 9 Property Class 12 9 Sue won nm wh m m 16 18 21 25 23 26 31 35 25 29 34 40 32 36 43 49 44 51 60 68 51 59 70 80 714 820 1235 1421 1674 1926 1475 1697 Marine Transmission Service Manual 1020304 31 Description and Specifications Twin Disc Incorporated Table 8 Tapered Pipe Plugs with thread lubricant NPTF Size in Nm or 5 lb ft or 5 Nm 5 If ft or 5 1 16 27 7 5 5 5 1 8 27 14 10 5 9 6 5 1 4 18 34 25 22 16 3 8 18 37 27 23 17 1 2 14 68 50 41 30 3 4 14 73 54 46 34 1 11 1 2 108 80 68 50 1 1 4 11 1 2 115 85 75 55 1 1 2 11 1 2 115 85 75 55 32 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Description and Specifications Table 9 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal Thread Diameter Nm lb ft Thread Nm lb ft 0r 5 07 5 Diameter 5 0 5 Marine Transmission Service Manual 1020304 33 Description and Specifications Twin Disc Incorporated Clutch Plate Wear Limits Clutch steel plates Maximum cone 0 20 mm 0 008 inch Clutch friction plates Maximum cone 0 25 mm 0 010 inch Minimum thickness 3 48 mm 0 137 inch
72. 8 16 x 1 00 DEEP REQ D DRILL 31 64 64844 DIA THRU 23 32 7187 DIA x 94 DP 552 REQ D FOR 175 BOLTS DRILL 5 16 63125 DIA x 125 DEEP 1 PUSHER PLATE lt 1 378 16 100 DEEP 2 REQ D MS 45 49 sear AUS o i hasson Porce RO 25 16 EM ns DETIREQ DESCRIPTIDN STOCK SIZE NOTE NOTE 5 UNLESS OTHERWISE SPECIFIED ALL GRD DIA S amp SURFACES MUST BREAK ALL SHARP CORNERS SQUARE amp CONCENTRIC TO WITHIN B DET 8 ADDED 005 EACH OTHER CS E 2 21 97 JPL FUR MG 5301 SHEET 2 OF 3 DESCRIPTION TWIN DISC INC RACINE VIS 21433 RETRACTED LENGTH OF PRESS RAM x 45 DRILL 5 16 3125 DIA x 125 DP 3 8 16 x 100 DP REQ D 180 USE FOR LIFTING 2 44 MID STROKE LL eZ __ UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS NOTE REWORK DET 5 ALL GRD DIA S amp SURFACES MUST SQUARE amp CONCENTRIC TO WITHIN DIMS SHOWN 005 OF EACH OTHER m ince I 45 49 Rof 1 MS PUSHER PLATE 57 REWORKED TO THIS DRWG 5 i ms Puer sase Ba ET see 3 1 saon PULLER ROD 1016523 DETRE JESCRIPTION 1 STOCK SIZE 1017009 FLANGE Date 2 21 97
73. 8050 713 Output seal 209 T 18050 714 Shaft lifting fixture output shaft 210 T 18050 715 Shaft lifting fixture primary and secondary shafts 211 T 18050 723 Bearing cone and transfer gear driver primary and secondary 212 T 18050 771 Front output bearing cup driver 213 T 19330 Spring retainer compressor coil spring units 214 T 19987 2 Output gear lifting fixture 215 T 20023 3 Output gear installing fixture sheet 1 of 3 216 T 20023 3 Output gear installing fixture sheet 2 of 3 217 T 20023 3 Output gear installing fixture sheet 3 of 3 218 T 21433 Output flange installing fixture sheet 1 of 3 219 T 21433 Output flange installing fixture sheet 2 of 3 220 T 21433 Output flange installing fixture sheet 3 of 3 221 T 21506 Output shaft bearing driver sheet 1 of 2 222 T 21506 Output shaft bearing driver sheet 2 of 2 223 T 506000 Lifting Bracket for Clutch Removal in Boat 224 Marine Transmission Service Manual 1020304 9 Table of Contents Twin Disc Incorporated ILU Ling 225 List mee
74. 8CE 2 BACKPLATE 1020371 2 BEARING 1019971 22 CONE ASS Y MAS85JH CUP MAS90B RING M2693T 2 TUBE 1017095 SHIM 1017041 SHIM 1017042 AS REQ D SEE NOTE 4 SHIM 1017043 SPACER 1017046 22 RING 2915 2 ASSEMBLE TAPERED EDGE SIDE AWAY FROM BEARING RING A2916KD RING M1904L 4 E 2 222 zz lt lt lt PLATE 1015518 SCREW MA996D 42 SS SS lt a 22222 BEARING 628 2 gt ASS Y MAS8SDL CUP MAS90CM RING M1904FS 22 PISTON 1019950 2 RING M2059L FITTING 1275 PLUG 1016191 FLANGE 1017009 N EK 47 7 NOTE 3 adi SEAL 1017085 2 CARRIER 1017019 SCREW 996 102 RING A2916DA SHIM 1017038 SHIM 1017039 AS REQ D SEE NOTE 4 SHIM 1017040 BEARING M2950 CONE ASS Y MAS8SDC CUP MAS90CE PLUG 1040 SS AR r 7 7 ERN A SHAFT ASS Y 1019954 SHAFT 1019953 BALL MA1034B LOCKNUT MA1048A 14 SCREW 996 52 WASHER 15046 E 2772777 WE NS SS LN ASS Y 10170208 ONLY PINION ASS Y 1017006 22 1017005 ASS Y 10170208 ONLY PINION ASS Y 1017644 2 1017643 1017007 5 961 RATIO 24T ASS Y 1017607B ONLY PINION ASS Y 1017110 2 R 1017106 4 961 RATIO 28T PINION ASS Y 1017111 22 17107 1700 4 421 PINION ASS Y 1017112 GEAR 1017108 HUB 1017007 4 061 33T
75. 955 97050201 enuen uoissiusueJ SUNEN COUPLING COUPLING COUPLING WITHOUT TORSIONAL STOP WITH TORSIONAL STOP sbe int ou HUB F SAE 0 00 SAE f 74 ONSISTS DF 5 24 WM pata X n gt NS n aN SERVICE REFERENCE 2 19 693 lt ASSEMBLE RING INTO eo OUTER GROOVE 0 N 592 2 7722272 2 ta COUPLING WITH TORSIONAL STOP COUPLING SAE 0 SAE 00 ae 4012 15 jeuoisioL 1 UIML PpOLOZOL Jenuey uoissiusueJ SUNEN LEZ Qty Description Item Qty Description 178 1 Coupling assembly SAE 0 w torsional stop 194 1 Coupling assembly SAE 00 w torsional stop consists of items 179 through 183 consists of items 195 through 199 179 1 Ring spacer 195 1 Ring drive 180 1 Plate inner fail safe 196 1 Plate outer fail safe 181 1 Plate outer fail safe 197 1 Element coupling 182 1 Element coupling 198 1 Plate inner fail safe 183 1 Ring drive 199 1 Ring spacer 184 16 Screw hex head cap coupling hub 200 16 Screw hex head cap coupling hub 185 1 Hub coupling 201 1 Hub coupling
76. BOTH MARNE TRANSMIS GN MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE 8 TRANSMISSION IS IN NEUTRAL 64 THRU FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 No 530 ENGAGES SECONDARY SHAFT CLUTCH E ENGAGES PRIMARY SHAFT CLUTCH M8 X 1 25 6 THREAD 361 e HDLES MANUAL _ FOR REMOTE CONTROL OVERRIDE BRACKET POSITION 5 ELECTRIC CONTROL POSITION AAS 238 7 IN f CREF CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE SAS UD ines NN CENTER OF l GRAVITY FOR CLOSE COUPLED ONONO TRANSMISSION STOCK BORE SIZE CUSTOMER TO FINISH BORE FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 460 oe THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISD 898 1 AND TORQUE TO S574 OR SERVICE MANUAL VALUES 200 06 0 03 374 00 4 x 3 0 THREAD 40 0 DEEP 20 HOLES 10 EACH SIDE USE ALL 20 HOLES FOR MOUNTING UNIT USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 574 OR SERVICE MANUAL VALUES METRIC O Xm C TRANSMISSIDN FLYWHEEL 0 065 ET REE NUR a TWIN 9 pe pma eme press es an man pr s 10170208 MARINE TRANSMISSION
77. CREW MA996D 4 QAR SS Sg SS Sf p WE LY RING B1048BH 2 2 CUP 590 SCREW MA996G 4 BEARING MA217K 2 RING M1904FS 2 amp a Wess PISTON 1017027 2 RING M2059L 2 SHAFT ASS Y 1017581 SHAFT 1017580 FITTING M1275 BALL MA1034B H PLATE 2127548 PLUG M2051FQ SEE NOTE 8 Y RING A2916HP COVER B2502B PLUG 1016191 i CE 22 FLANGE 1017009 SCREW MA996T 2 j GEAR 45 m HUB 1017007 6 93 1 RATIO 18T 4 222558 L 1017020 ONLY OPTIONAL SHAFT ARRANGEMENT PINION ASS Y 1017006 2 GEAR 1017005 10170 ASS Y 1017020 ONLY PINION ASS Y 1017644 2 7 SHIELD 1017032 1 GEAR 101 643 S i 5 96 1 RATIO 24T ASS Y 1017607 ONLY SHAFT 1017000 42 MS PINION ASS 100710 2 p 1017007 ASS Y 1017581 SU Wy e 4 96 1 RATIO 28T E e SUR BEARING M2909 NY 2 Wye PION ASS TOTTI T 2 PLUG MOSQ SEE NOTE 8 CONE ASS Y 585 2 fm 1017007 ADAPTER N FLANGE ASSY 1017084 CUP 590 4 42 1 31 SCREW MATION 2 FLANGE SCREW MAYOAGA 14 SEAL 1017085 2 PINION ASSY 1017112 2 AUB 7007 o SHI CROSS SECTION CARRIER 1017019 SCREW 996 5 4 06 1 RATIO 33T WASHER B1504GF PINION ASSY 1017768 2 SHEET CROSS SECTION SCREW MA996F 10 9
78. D METRIC METRIC PORT CONFORMS 97 PROJECTION TWIN 208 NOTICE THIS PRINT CONTAINS Sond ene ANY pan raw i9 501 004 RACIE VI uma IDTE N pu PDINTS AVAILABLE F R TESTING ARE men Disc INCOR PORATED RE E ares 10176078 CANIS De MARINE TRANSMISSION ac seer 4 or 6 D 1016523 OR OTHERS BY CONTRACT WITHOUT TORSIONAL STOP HOUSING 1017013 SAE 0 SEE SHEET 3 FOR DIMENSIONS COUPLING 1017123 ELEMENT 1015472 PLATE 1003847 RING 1004361 SCREW MA996F 20 SAE 0 HSG SCREW 1055 16 HUB 1017023 SHAFT ASS Y 1016988A SHAFT 10169874 BALL MA1034B RING ASSEMBLE RING INTO INNER GROOVE FOR RING B1048AM 460 COUPLINGS B1048AM HUB 1017023 SCREW 1055 16 COUPLING 1017865 ELEMENT 1015472 PLATE 1003847 PLATE 1004244 PLATE 1004362 RING 1004359 COUPLINGS D amp ONLY DYNAMIC TORSIONAL STIFFNESS kN m rad COUPLING C TORQUE WITH TORSIONAL STOP kN m UPLING COUPLING D HDUSING 1017014 SAE 00 gt SHAFT ASS Y 1016988 SHAFT 10169874 BALL 1034 HOUSING 1017013 SAE 0 SAE 0 HUB 1017769 HOUSING FOR USE WITH CENTA LINK DRIVELINE COMPONENTS SEE SHEET 3 FOR DIMENSIONS SEE SHEET 3 FOR DIMENSIONS COUPLING 1015475 ELEMENT 1015472 PLATE 1004244 P
79. G PUMP 1016473 ELECTRIC VALVE WITH MECHANICAL BACKUP 12 VDC 1018084Y OIL TEMPERATURE INDICATING SWITCH B3424 FOR INSTALLATION LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 3 X NOT SERVICEABLE SEPERATELY REMOVE BEFORE OPERATING 2 PLACES CLOSURES CONSULT SALES DEPT APPLICATION ENGINEERS FOR LIMITING CONDITIONS LL Ee fe ess 10170208 s s pe MG 530 UU 10176078B MARINE ac ser 1 o 6 BALANCING REQUIRED FOR SURVEY SOCIETY APPLICATIONS SEE PARTS DRAWINGS _ ________ TAIN DISE 8 2 01 Fe meas masc a VI 53 FS eso eia A Hm PUES GE CONTRACT GRANTED THE US OR OTHERS BY SPRING A2706Z 277222272 PLUG ASS Y 2080 H GY le PLUG M2080B ZA ECTS T 8 RING 2916 o Ze ize GASKET B1974 CN RING A2916EH FILTER HEAD 9892 oO gt 29 7 5 oS Q2 WASHER 1039 4 0 0 2505060 SCREW 996 42 QOS 040 Q2 5 ELEMENT GROUP 2934 POPPET 204367 BODY B3133 BOLT 204365 ELEMENT M2725 SPRING 204369 WASHER 2888 5 57 5 5 gt xX Q2 SOOO 555505060 5 52 7 90905 CLOSURE M2067J SCREW 996 142 HOUSING 1017125 PLATE 1017127 GASKET 1019905 PLUG 1038 SCREW MA1062D 12 gt FILL ENTIRE TAPPED HOLE W
80. Gear Ourput Gear Figure 24 MG5301DC Power Flow in Neutral 60 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation Primary When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel plates are spline connected through the clutch hub assembly to the pinion Because the primary input pinion is in mesh with the output gear the output gear and shaft will rotate in anti engine direction The secondary input pinion will be backdriven engine direction when the unit is in the primary position Primary Clutch Engaged Figure 25 MG5301DC Power Flow with Primary Clutch Engaged Marine Transmission Service Manual 1020304 61 Operation Twin Disc Incorporated Secondary In secondary the same parts are turning that were turning in neutral When the secondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates together The secondary input pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pini
81. HIPPING FILTER REPLACEMENT ELEMENT FILTER PRODUCTS CORPORATION 30 25 PARKER 4925023 CROSS 119023 DA 3 4 NPT QUICK DISCONNECT um INSTALL PLUGS FOR SHPPING OIL IN 3 4 14 N P T THREAD FEMALE PIPE SWIVEL PUMP FLOW RATE IS 11 0 l min AT 102 C 100 MESH INLET STRAINER REMOVABLE SCREEN M E T R I C AN THIRD LARGE PLUG REMOVE THIS ENDCAP SMALL PIPE PLUG EXTRACT SCREEN FOR CLEANING REMOVE TO CLEAN D AC SIE zoel pete DIVERS BY CONTRACT pas seer tot rev 2 1020304 10 01 Disc 2 POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
82. IC NOMINAL TORQUE TORSIONAL STIFFNESS 2800 12 50 PER CHART 2500 12 50 PER CHART SAE J620 COUPLING FLYWHEEL SIZE COUPLING coupLinc NOT SERVICEABLE SEPARATELY 60161 60164 SEE SHEET 1 FOR MAXIMUM TRANSMISSION r p m THE OF INNER PARTS INCLUDES HUB AND 1 4 SHAFT Ce FOR OTHER TRANSMISSION MASS ELASTIC DATA REFER TO B3504AQ FOR OTHER TRANSMISSION INSTALLATION DIMENSIONS REFER 1017020B 1017607B SHEETS 3 amp 4 ND REF X Cla STIFFNESS A 249 B 2400 vems eso 20 DYNAMIC TORSIONAL STIFFNESS DYNAMIC TORSIONAL STIFFNESS TOLERANCE 720 WR WITH TORSIONAL STOP 510 025 050 075 100 PARTS INNER PARTS 26 0 kNm rod 310 kNm rod 40 0 kNm rod 590 kNm rad 100 0 kNm rad 108 078 kg n 830 x 106 tb in racb C874 x 106 of 354 x 106 tbf 522 x 106 lbf 1 885 x 106 in rad 3690 16 lt 2660 tb in 26 0 kNn rod 310 kNm rod 40 0 kNm rod 590 kNm rod 100 0 kNn rod 2 56 kg m 1 04 kg m 6274 105 bf 354 x 106 tbf in rad 522 x 106 tof in rad gt 885 x 106 8750 2 3545 lb 5 310 kNm rod 40 0 KNm rad 59 0 kNm rad 100 0 kNm rad 482 112 kg m 885 x 108 bf in rad 16470 l
83. ID PORT sA CONTROL NN S S 26 BALL MA1034A 11 POSITION POSITION RN PLATE SEE e 40 M vf BALL 1990 6 THESE SOLENOID CONNECTIONS SEAL MA778 Y SHIM SEE CHART ALI j PN ARES NOT EOCARITY SENSITIVE 3 ERIS IY COVER 1017128 hte 204 VALVE GASKET 1017136B 366 2 SN N Teal a EL A SNAP H H d 182 xe ecc dA n DURANA 777 WN NA Ni CONNECTOR SHROUD 1001434 OOP N SEE CHART w 1018163B NG 55 D RING MA379CP B lj GASKET 1017334 WG a 2 77 pi DANKE eS U RING A2916FT SNAP RING 429155 GASKET 1017130 2 LA 2 PLUG 1017389 PORT BY BALL MI990H D D PEST TION uA SCREW 1042 42 SPRING A2702T SHIM 1020005 AS SPRING 1801 BALL 1990 SETSCREW A2870K sor VALVE BODY ASSY 1018095 1 RING A2916AT OTTER PLATES SEE CHART CO MESE E BODY 1018094 SPRING A2705AK WASHER A2782AS SCREW SEE CHART EAM BAL 55 2 BALL M1990H SECTION A A BALL 1990 52 a PICKUP PORT SPOOL 1017433 2 CDRYSEAL TH D NOTE INSTALL USING 908 LOCTITE 242 TOP DF SCREW MUST SWITCH MA866A 2 APPLY MA895 THREAD SEALANT WITH TEFLON 95 TO THREADS TORQUE TO 30 0 lbf ft NUT M2027C
84. IN 15 X ER kPotpsi DATA CHASER MUST ALSU VENDUR STATE IF RAW OPEN JACKET AND UR KEE CHANNEL amp SEA OR FRESH WATER SED ENGINE STATE MAX WATER INTO TYPICAL RAW F 90 FO KEEL ENGINE JACKET WATER xX STATE MIN ALSU MAX WATER 46 C 60 C 4 85 65 F 185 F gt FA L min WATER eoe HE INSTA UN amp SERVICE OIL LINES TRANSMISSION H E AND RETURN 1 VELOCITY IN BURST PRESSURE 3 HOSE SAE 517 INGS PIPE HUSE AND TUBES 7 6m s lt 25 1 5 REQUIREMENTS 10 x PEAK OIL PR 100R1 MEETING USCG 46CFR C2 5 F TEMP RATING 4 PROTEC NES FROM MECHANICAL DAMAGE ZINC ANUDES PROTEC HE RAW WATER PASSAGES FROM CORROSION CHECK amp REPLACE IEM FREQUENTLY x FUR CLUS NGINE JACKE 83 F MAX MAY BE IMPOSSIBLE OR IMPRAC ER SUITABLE IL TEMPER LUKE CAL TO HAVE AINING 85 Figure 5 Heat Exchanger Specification Information Marine Transmission Service Manual 1020304 25 Description and Specifications Specifications 26 Maximum operating speed 2400 rom Maximum oil sump temperature Oil capacity 51 5 liters 13 6 gal Twin Disc Incorporated 85 C 185 when using SAE 40 oil 93 C 200 F wh
85. ITH SILICON SEALANT ALLOW PROPER CURE TIME GASKET 1017050 SCREW 996 122 HOUSING 1017037 MA1047A 22 PLUG MA1038A RING A2916W 2 PLATE 1019906 PLATE 1017583 GASKET 1017613 GASKET 1017569 SCREW MA1062M 2 SCREW 1062 2 VALVE ASS Y 24 VDC 1018084P PLUG M2051FL GAUGE B1703D PLUG MA1038C 2 PIN MA1035D 2 SCREW MA996U 18 EXCHANGER 1017121 GASKET 1017126 GASKET 1017124 OPTIONAL FRESH WATER HEAT EXCHANGER PLATE 1017127 GASKET 1019905 SCREW 10622 122 CLOSURE M2067T 2 SCREW MA960D WASHER M2081D ANODE 1017049 EXCHANGER 1017051 CLOSURE M2067 2 PLATE 2415 PLATE 204098C BREATHER SCREW M422B 8 S LINK A2007 CHAIN M1072 RON bg lt CLIP 1763 TAG MA6S6C GAUGE B3631AH TUBE ASS Y 23010 gm px 1 1 o TJIN DISC ES Ee 1017020 10170208 5 ev ac 1017607B ine PADE seer 2 J 9 THRU NOTE HOLES EQUALLY SPACED LEVER MAY BE LOCATED ANYWHERE USE 8 8 PROPERTY CLASS QUALITY ITS SHAFT THAT PERMITS FREE CAPSCREWS PER 150 898 1 AND EYEBOLT FOR LIFTING MOVEMENT WITHIN THE 50 TOTAL TORQUE TO 574 OR SERVICE MARINE_ TRANSMISSION ROTATION amp 114mm AXIAL MOTION MANUAL VALUES lt 2 BOLTS ONE EACH SIDE gt REQUIRED FOR CONTROL EQUALIZE LOAD ON
86. Incorporated Installation of Clutch Shafts Bearing Carrier and Manifold 1 Install the clutch shaft assemblies into the transmission 2 Install bearing carrier gasket over dowels onto rear face of housing 3 Assemble lube relief valve spring and lube relief valve steel ball into lube relief valve housing Attach assembled lube relief valve to inner face of bearing carrier with the screws and washers Torque the screws to 33 Nm 24 ft lb Figure 93 Lubrication Oil Pressure Relief Valve Installed 4 Install two alignment studs into face of transmission housing Install bearing carrier over studs and onto dowels in housing face Use a soft hammer near the dowels to seat carrier against gasket and over dowels Be sure bearing carrier is fully seated 5 Install cups for rear tapered roller bearings on primary and secondary shafts into the same bores in bearing carrier as previously installed Tap cups down gently with soft hammer or brass drift to seat against bearing cones on shafts 140 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Install lube tube through keyed hole in bearing carrier and into machined pocket in front inner face of housing Rotate tube so elongated key of tube fits into corresponding key in bearing carrier Properly installed lube tube will be flush with rear face of bearing carrier Figure 94 Key Orientation of Installed Lube Tube 14 Instal
87. L INLET ALTERNATE DIL INLET PUD UIl BALL 1990 SPRING A2703P 2 SPRING 2700 THIRD ANGLE e e PROJECTION SIMILAR TO XA6573AA UNLESS OTHERWISE SPECIFED DATE 2 15 75 1157 MACHINED DIMENSIONS INCORPOR RACINE WI 53403 USA XA7108 SERIES A ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING PER ANSI 14 5 1982 WIRIN AGRAM DITCH SOLENOID VALVE SPRINGS CLUTCH sums MOUNTING SCREWS VALVE BUM DITCH IANSHISSION ORIFICE FIRST ASSY No Sen emm GASKET LE nm Ree eg PLATE rere 757 ary CONNECTOR MANUAL DVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN e 1018688 ves 759 4 vod penses 2 PORT A SOLENOID ZEE d orf eros re crm menm pousser ea PORT BY SOLENOID MAX 15 NEUTRAL 1017133 1017134 7 1017179 2 75 24 voc ae707aD 1585 eso 10171298 535 5 5 2 Memes 2 oo siav D PLUG M2051K 2 x s 1 3 ire eee en 12 vpc a2707ap 585 10171294 EST pager
88. LATE 1004464 RING 1004359 RING 1004511 23 0 mm THRU 8 HOLES EQUALLY SPACED USE 10 9 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO so 7 4 Z ww SEE NOTE 6 COUPLING 1019717 7 133 55 SCREW 996 20 SCREW MA996F 23 GAE 0 HSG SAE 00 HSG SCREW 1055 16 CT 553 1017023 SHAFT ASS Y 1016988 V Y SHAFT 10169874 IN BALL MA1034B SHAFT ASS Y 10169884 DSHAFT 1016987 BALL MA1034B N 2 SCREW MA996D 3 RING 1048 RING 1048 ASSEMBLE RING INTO DUTER GROOVE FOR SAE No 530 COUPLING SEE NOTE 64 n 9 WASHER 1504 280 00 REF 174 988 01 AA gt SERVICE REFERENCE SEE NOTE 6 ROLLER 1116 lt 10 RING B1048L pop 22 SG 26262626 556 55550 e 2 Y 22 1 55 THRU 8 HOLES EQUALLY SPACED USE 10 9 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 574 OR SERVICE MANUAL VALUES HUB x 525 0505 5 SCREW 996 23 SAE 00 gt E COUPLING 1019718 N F H HOUSING HUB HOUSING HOUSING 1017014 SAE 00 COUPLING WITH B TORSIONAL STOP COUPLING COUPLING WR kg me INNER PARTS 0 589 0 589 DYNAM
89. LL SHARP CORNERS was 550 ______ 5 30 57 HHe24346 BRG rrr CAD FILE T 18050 708 dwg MUN 1 4 UN ANGULAR DIMENSIDN 0 13 DRILL 3 8 3752 DIA THRU 4 HOLE USE FOR PICKING BRG DRIVER UP KNURL FULL LENGTH SHAFT 748 SF DIA DRILL 5 16 3125 DIA x 1 00 DP 3 8 16 UNC x 88 DP D REQ D CAD FILE 050 711 1 50 DIA 6 x 45 06 x 30 DRILL 5 16 3125 DIA THRU 3 8 16 UNC 02 REG D STAMP T 18050 711 BEARING DRIVER FOR INSTALLING CUP 1017081 0 750 DIA BEARING DRIVER 15 REQ D MAT CARB amp HDN NOTE GROUND SURFACES MUST BE PARALLEL WITHIN 0005 OF EACH OTHER NOTE UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS el cR a imu umcms sre 50 cae screw a roo CANCELLED 1 1 MS BEARING DRIVER 875 DIA x 138 THK IDETIREG DESCRIPTION STOCK SIZE ME BEARING DRIVER FOR CUP L MG 5301 _ __ 2 1017081 T 18050 TOOL NUMBER 18050 712 PART NUMBER M 1945 BY MODEL NUMBER 5301 1 06 x 45 KNURL HANDLE 10 0 TOTAL 1 00 DIA DRILL ROD OR EGIV 20 00 EEN SEES WERE M 1945 BY WITH PLUG DRIVER POUSE X GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF EACH OTHER UNLESS OTHER
90. MAIN ERE SSUR E PORT PORT 40 7 Nem SCREW 1042 4 FLUSH WITH SURFACE HYDRAULIC DIAGRAM A7119W SHEET 1 OF 2 SCREW M2000L ATMOSPHERIC PRESSURE C OBSOLETE FOR PRODUCTION crus ND SERVICE CLUTCH 550 PROJECTION aD A NOT SERVICEABLE SEPARATELY x eR AB Bi THESE PARTS ARE BE PACKAGED LEVER 210 SEPARATELY AND SHIPPED WITH UNIT e9876 33 06 2 NOTICE THIS PRINT CONTAINS is c E all xX STR RING 1506149 Es 1829757 uc Y ICA A IN ANY MANNER KE MAIN PRESSURE DIL INLET lt WHEN LR 3 29694 11 22 99 x NOT INTERNALLY SUPPLIED THREAD SIZE PORT 1 4 18 N P T F WHEN M20S2AA REDUCER BUSHING IS SPECIFIED TREAT M RACINE WI 3403 USA TWIN DISC INCORPORATED ejen EE e 79 1018084 9 13 4 4 12 00 THIS NOTICE IS NOT_INTENDED TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT p SERIES LN 29232 4 15 99 u 29954 3 22 00 GRANTED THE Us GOVERNMENT uem VALVE ASS Y CONTROL ZONE pare REv zuwe pate UR OTHERS BY CONTRACT WITHOUT TROLLING VALVE 1 pr i rev AD BOTTOM VIEW PLUG M2051K 2 MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN SOLENOID VALVE SPRINGS CLUTCH T
91. Manual 1020304 Twin Disc Incorporated Assembly Installation of Top Cover Assembly Heat Exchanger and Oil Gauge 1 Turn transmission over and block securely in upright position 2 Attach oil baffle to top cover if removed Install the sealing washers onto the screws apply MA908 threadlocker to the screw threads and torque them to 18 Nm 13 ft lb Install top cover assembly with its gasket Install attaching screws and torque to 112 Nm 83 ft lb Install the two lifting eyebolts 3 Install breather filler cap 4 Install oil gauge tube assembly and oil level gauge 5 Install PTO valve cover plate onto top of the transmission housing and torque the screws to 112 Nm 83 ft lb 6 Install the heat exchanger The use of M12x1 75 guide studs will ease the installation of the heat exchanger Units with Remote Heat Exchanger Install the adapter plate and gasket Torque the attaching sockethead capscrews to 130 Nm 96 ft lb Install protective plugs to prevent the entrance of contaminants into the transmission s lubrication oil circuit Units with Integral Fresh Water Heat Exchanger Install the adapter plate and gasket Torque the attaching sockethead capscrews to 130 Nm 96 ft lb Install heat exchanger element and gasket over adapter plate Install heat exchanger cover and gasket and torque the attaching screws to 112 Nm 83 ft Ib Install protective plugs into cover to prevent the entrance of contaminants into the t
92. Nm rad 40 0 kNm rad 59 0 kNm rad 100 0 kNm rad 4 82 kgm 1 12 kg m TARD ANGLE 2400 70 85102 in 230 x 108 274 106 veiy 554 x 10 522 108 885 108 16470 Ib in2 3820 S ae 9 42 12 96 TRON DISC RACE W 55405 USA tea __ 53010 1017607 lt o ON ow 9 on 167 e 3 O Er 2947 2 ESL gt WAS EX8487 58 ass NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS DIMENSIONS ARE 9 24 96 TUN 1 NOT TO BE USED IN ANY MANNER X SCALE INCORPORATED DETRIMENTAL TO THE INTERESTS OF 20 1 00 RACINE 53403 USA TWIN DISC INCORPORATED c JORN RACINE 53403 USA 5 MEYERS 1017020 THIS NOTICE IS NOT INTENDED TOTES 45 1017607 GRANTED THE U S GOVERNMENT ve Se S A 7 OR OTHERS BY CONTRACT THESE STANDARDS APPLY ASTENER TORQUE REQUIREMENTS S622 BEARING SHIMMING S765 TAPERED JOINT ASSEMBLY o NNNNN GASKET 1017613 1017569 1017030 MANIFOLD 1017012A GASKET 1017589A GASKET 1017589 PILOT 1020047 ADAPTER 1020046 PUMP 1017584 de I 2 SA SCREW MA1062B 2 1 N SS m y ES SEE NOTE 8 IN 5570
93. OR LEVER NS 77 OY d FEMA VALVE ECT POSITION NS THESE SOLENOID CONNECTIONS SEAL MA778 RAY LPA jn Z j Z ARE NDT PDLARITY SENSITIVE SON L 1 1 Wy 7 5 BLACK WIRE WITH SOCKET 4042227 42 42 NN E NN CY SB a ELIZIA og ZEE TROLLING VALVE NS SSN Cia ASSEMBLY SEE CHART ae NN ASSEMBLY 1017554 SHOWND SUNS STEM 1018163B 05 E SO 4 m D RING 79 SNAP RING is LL H LANG PORT n P section 1 U D D LEVER o SCREW 1042 49 B SEE CHART TRANSMISSION GASKET A lt C PLATE SEE CHART SPRING 1801 SEE CHART D BALL 1990 SETSCREW A2870K U RING 2916 0 RING 29160 DITCH PLATE GASKET SPRING A2702T PIN 1927 SEE CHAR SPRING 2705 WASHER 4278245 Shin 1020005 RED SEAT o MESA scum A A DITCH PLATE SEE CHART VALVE BODY ASSY 1018095 SCREW SEE CHART BALL MA1034A BALL 10340 2 MAIN PRESSURE PICKUP PORT ALL M1990H z SWITCH MABGGA 2 PORT BY 174 18 NP T F CDRYSEAL TH D NOTE BALL Mi990Y 5 SPOOL 1017433 2 APPLY 895 CTHREAD SEALANT INSTALL USING MA908 LOCTITE WITH TEFLON gt THREADS PORT 242 TOP OF SCREW MUST BE TORQUE TO 300 NUT
94. OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS P GROUND SURFACES MUST BE PARALLEL Li r ws sewuws peiver se 275 A BEARING DRIVER CAGED ROLLER TOLERANCE UNLESS DTHERWISE SPECIFIED 06 217 BRG 718050705 001 ON THREE PLACE DECIMAL DIMENSION Troe va ENO CAD FILE T 18050 705 dwg GRIND 62 FLATS UP TO WIDE TO INSTALL DIA THRU SEAL EASIER WITH OIL CDREQ D DRILL 5716 3125 DIA THRU D REQ D TAP 8 16 UNC USE FOR PULLING KNURL SEAL MA 297 DIA 1016987 SHAFT 25577 3 004 DIA 3 002 E p Exi 3 064 DIA 3 062 NYL Date 11 18 96 JPL FPN Scoate FULL sue mo T 18050 706 _ scu 0 SEAL DRIVER amp SLEEVE ie OC o T T aeae C 001 DN THREE PLACE DECIMAL DIMENSION 010 ON FRACTIONAL AND TWO PLACE 297 SEAL A BIER DATE Twin BC ence wi 1119090 706 T 18050 708BRG DRIVER STAMP T FOR 1017005 PINION BEARING CUP 590 CUST 47679 4e X 15 456 DIA e BEARING DRIVER 1 PEO D MAT x HD x NOTE GROUND SURFACES MUST BE PARALLEL E seems eem S25 DET REG MAT DESCRIPTION STOCK SIZE pM STAMP TOOL NO 18050 708 NOTE UNLESS OTHERWISE SPECIFIED 1017005 SHEET 1 OF 1 PART NO MG 406 4 gt BREAK A
95. OVIDE 41 41 LINEAR TRAVEL SHOWN FROM NEUTRAL AT THE 25 DIA HOLE LOCATION WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT SPRING AND PIN MAY BE OMITTED THEN THE FORCE WILL BECOME 3 7 LBS THE DETENT FEATURE IS PROVIDED IN THE FULL FORWARD FULL REVERSE AND NEUTRAL LEVER POSITIONS SHIM IF NECESSARY ACHIEVE THE PRESSURES OUTLINED IN TEST SPECIFICATIONS 5570 SERIES AS APPLICABLE PLUG M2051L PLUG 2052 ORIFICE VALVE ORIFICE AE Posto XA7108 B3418A B3419 81999 2001 7108 B3418B B3419A B1999A M2001R XA7108B B3418A B3419 B1999 2001 4 4 18 1 4 18 NP T F CDRYSEAL TH D PORT 1 D RING 2916 PLUG 2782 156 gg DIA THRU ONE HOLE CTX 7 7 L 7 _ WAL 22 MRSS b gt XR DETENT 81139 CAPSCREW 2001 42 STOP 81867 B POSITION STOP 2097 2 POSITION CAPSCREW 17 1 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE 53403 USA WEIGHT HEAT TREAT FIRST USE assy 7084 _ 530 THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED 0 5 GOVERNMENT OTHERS BY CONTRACT B DIL PRESSURE CHECK 3 4 14 NP T F CDRYSEAL TH D DI
96. Output gear installing fixture sheet 2 of 3 T 20023 3 Output gear installing fixture sheet 3 of 3 T 21433 Output flange installing fixture sheet 1 of 3 T 21433 Output flange installing fixture sheet 2 of 3 T 21433 Output flange installing fixture sheet 3 of 3 T 21506 Output shaft bearing driver sheet 1 of 2 T 21506 Output shaft bearing driver sheet 2 of 2 T 506000 Lifting Bracket for Clutch Removal in Boat SPX Power Team RD1006 100ton x 6 375 inch stroke double acting ram no drawing SPX Power Team PE554T electric over hydraulic pump no drawing Two SPX 9764 hoses drawing Two SPX 9795 couplers no drawing 200 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Special Tools Recommended Pump Set and Fluids Twin Disc recommends the following products for use in the assembly and removal of tapered shafts using the oil injection method THAP 300 Air Driven Pump Set This set consists of the air driven pump with accessories such as an adapter block pressure gauge high pressure pipe or pressure hose with quick connection couplings and connection nipples The set includes one of each air driven pump THAP 300 adapter block 226402 pressure gauge 1077589 and high pressure pipe 2m 6 5 ft 227957 Figure 150 THAP 300 Air driven Pump Set Marine Transmission Service Manual 1020304 201 Special Tools Twin Disc Incorporated Mounting F
97. PINION ASS Y 1017768 22 GEAR 1017767 HUB 1017007 3 35 RATIO 46T 6 391 5 961 4 961 4 421 4 061 3 351 m NEP an ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER SS70AJ NOTES 1 THRU 9 ARE IN 55704 THESE STANDARDS APPLY 8574 FASTENER TORQUE REQUIREMENTS 692 BEARING SHIMMING 8765 TAPERED JDINT ASSEMBLY GEAR 1016994 SPRING A2706AC HDUSING MA929 BALL MA1034C SCREW MA960E 2 WASHER 1039 22 GASKET 1017589 GASKET 1017589 PILOT 1020047 ADAPTER 1020046 PUMP 1017584 Sie NA SCREW 1062 2 SEE NOTE 8 SCREW MA996L 4 SPACER 1020043 RING A2916HP COVER 2502 PLATE 212754 z NCLIZAL SCREW 996 2 STRAINER B1479 SHEET CROSS SECTION 1 OF 6 AND PART NUMBERS SHEET CROSS SECTION 2 OF 6 AND PART NUMBERS SHEET INSTALLATION 3 OF 6 DRAWING SHEET INSTALLATION 4 OF 6 DRAWING SHEET FLEXIBLE 5 OF 6 COUPLING INPUTS SHEET PE MASS ELASTIC 3350440 S HEAT EXCHANGER 536499 REQUIREMENTS HYDRAULIC 67191 DIAGRAM THIRD ANGLE GEAR RATIOS ASS Y 1017020B ONLY EUR Sa Sin 1017607B IS A HIGH POWER RATING UNIT REFER TO 856 BOM 195 METRIC NPTF ADAPTER KIT INTEGRAL HEAT EXCHANGER KIT BOM 254 METRIC KIT REMOTE HEAT EXCHANGER FRESH MAS DIL COOLER SEE DIT ATE CUSTDMER SUPPLIED COOLER SEE SHEET 2 TRAILIN
98. RDLLING sums MOUNTING SCREWS VALVE BON DITCH TRANSMISSION ORIFICE OF HIRST ETE OF kPa PSD VALVE Noj Gasket i PLATE MAIOA2A forr forr 57 TRANSMISSION IS IN NEUTRAL CONNECTOR PORT SULENDID A is 1018085 ere mee eM EE i mee T Ei mesa 40760 merzsss 07179 CES 7554 x eres pews 6 a 1 NEUTRAL SOLENOID E th 1018085 41079 1017383 1017179 xwe7s9rMa 2655 385 1017129 1017554 0 7 x 20 69 4 BeasiB 6449 F d A ees ess 6 CONNECTOR m 1018085 7 1017383 1017179 0 75 24 vnc 1 2450 355 1017129 1017554 1038 x 20 69 4 2451 Rep 649 sax FEMA VALVE pre f no 2 puezsores vocxaeroran 2707 2000 eoo 1171294
99. RES d HOUSING SAE 00 HOUSING HOUSING 1017014 COUPLING B 3 3 3 WITH TORSIONAL STOP COUPLING E SAE J620 DYNAMIC COUPLING WR2 COUPLING FLYWHEEL NOMINAL TORQUE TORSIONAL 2 SIZE kN m STIFFNESS OUTER PARTS INNER PARTS D NOT SERVICEABLE SEPARATELY L D 460 2800 12758 389 SEE SHEET 1 FOR MAXIMUM TRANSMISSION it NO 530 8510 02 2500 12 50 PER CHART 0 589 THE WR OF INNER PARTS INCLUDES HUB AND 1 4 SHAFT C FOR OTHER TRANSMISSION MASS ELASTIC DATA REFER TO B3504AQ FOR OTHER TRANSMISSION INSTALLATION DIMENSIONS REFER TO 1017020 1017607 SHEETS 3 amp 4 MAX 2 2 NOMINAL TORQUE DYNAMIC TORSIONAL STIFFNESS DYNAMIC TORSIONAL STIFFNESS TOLERANCE 729 NO REF STIFFNESS 0 10 0 25 0 50 0 75 OUTER PARTS INNER PARTS OUTER PARTS INNER PARTS 8 00 26 0 kNm rad 31 0 kNm rad 40 0 kNm rad 59 0 kNm rad 100 0 kNm rad 1 08 kg m 0 78 kg m 34115 2400 70 85 105 in 230 M 274 x 108 VIC 354 x 10 ACER 522 x 10 AER 885 x 10 3690 Ib in 2660 Ib in 8 00 kN 26 0 kNm rad 31 0 kNm rad 40 0 kNm rad 59 0 kNm rad 100 0 kNm rad 2 56 kg m 1 04 kg m B 5415 2400 70 85 105 in 230 x 108 274 106 354 108 DOR 522 x 106 885 x 10 o 8750 Ib in2 3545 Ib in METRIC 8 00 kN 26 0 kNm rad 31 0 k
100. T 3 AA 4 74 108 1017 FOR DIMENSIONS 1 SEE SHEET 3 eM FOR DIMENSIONS FOR DIMENSIONS DRIVELINE COMPONENTS COUPLING 1017123 COUPLING 1015475 ELEMENT 1015472 ELEMENT 101547 COUPLING 1019717 PLATE 1003847 PLATE 1004244 133 55 RING 1004361 PLATE 1004464 RING 1004359 RING 1004511 555555 SCREW MA996F 20 SAE 0 SCREW MA996F SAE 00 HSG SCREW MA1055C 16 HUB 1017023 im 1017023 SCREW 996 20 SAE 0 HSG 22 77 SCREW 1055 16 GA LZ on WU as 5 ZZ p RR SSS PRIMARY SHAFT CNN E 7 SEE NOTE 6 SERVICE REFERENCE HUB 1017023 ROLLER 11160 10 RING B1048L N A e 2 ZZ gt SCREW MA996D 3 2 WASHER B1504BE 280 00 REF 174 988 012 9 IY SAE No 530 COUPLING DRBCRAA SAT 55054 lt SCREW MA1055C 16 55 exo 50 24 5 ro 50 22 1 5 THRU 8 HOLES EQUALLY SPACED B SAN USE 10 9 PROPERTY CLASS QUALITY CAPSCREWS SCREW MA996F 23 ISO 898 1 AND TORQUE COUPLING 1017865 SAE 00 Pg 5574 OR SERVICE MANUAL VALUES ELEMENT 1015472 PLATE 1003847 E PLATE 1004244 N COUPLING 1019718 H U B F PLATE 1004362 RING 1004359 52 24 52 S
101. TORSIONA SIZE P kN m STIFFNESS GUTER PARTS INNER PARTS D NO 460 2800 12 50 0 94 0 589 530 2500 PER CHART 106 0 589 Figure 4 Centa Style Torsional Coupling SAE 0 and 00 24 Mari ne Transmission Service Manual 1020304 Twin Disc Incorporated Heat Exchanger Description and Specifications The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh water through the heat exchanger HEAT EXCHANGER PERMISSIB EMPERATURE INTO CHE gt REQUIREMENTS EXCHANGER RATIO VISCOSITY RATIOS SAE 40 SI CUBI F 65 RATIOS SAE 50 93 CC200 F D 80 CU 5 F gt MIN HEAT SANS APPLY APPROPRIATI ER CAPACI SERVICE FACTUR CUNT amp M WCIBtu min PER ENGINE RTD INT LIGHT amp DUTY IR FRESH AND WATER 035 1 4840 030 41878 APPROX OIL FLOW 2 91 PER 100 ENGINE rpm EAK DIL PRESSURE PROOF TEST 15 X kPa psi 690 kPo X100 psi MAX ALLOWAB IIL PRESSURE DROP ACROSS 207 kPa 66mm 2 5 3002 SUS AT RATED ENGINE rom 30 psp TRAS 5 10 3 ALLOWABLE WATER PRESSURE DROP ACROSS sei WATER FLOW O USE 15 30 TIMES min opm H WATER PRESSUR ING M
102. TWIN DISC INCORPORATED __ Service WELL ual Marine Transmission Components MG5301DC Document Number 1020304 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 1020304 October 2001 Marine Transmission Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE TRANSMISSION Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of shipment by Twin Disc Incorporated to original customer but not to exceed twelve 12 months of service whichever occurs first This is the or
103. 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 1020304 177 Installation Twin Disc Incorporated Alignment also reference SAE J 1033 and J 617 1 Bolt a thousandths increment dial indicator or gauge to the engine flywheel so that the indicator is perpendicular to the face of the engine flywheel housing and the indicator stem is riding on the face of the flange Thousandths Indicator Engine woe Flywheel Engine J Engine Flywheel Housing Figure 135 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keeping a thrust in the same direction and note the face deviation of the engine flywheel housing flange The face deviation must not exceed the figures given in Table 15 178 Ma
104. WATER IN TO HEAT EXCHANGER WATER FROM HEAT EXCHANGER N42x2 0 THREAD METRIC M42x2 0 THREAD METRIC PORT CONFORMS TO ISO 6149 PORT CONFORMS TO ISD 6149 PRIMARY CLUTCH ACTUATING PRESSURE CONNECT DIL PRESSURE GAGE EYEBOLT 18 15 THREAD LINE HERE 281 50 METRIC PORT CONFORMS M27 x 20 THREAD TO 150 6149 METRIC PORT CONFORMS TO 150 6149 MOUNT GAGE IN PILDT HDUSE LUBE PSI 6 18 1 5 THREAD METRIC PORT CONFORMS TO 150 6149 PTIONAL AUXILIAR LUBE SUPPLY INLET SEE_HYDRAULIC PEED PICK UP PORT LUBE PSI MIGxLS THREAD DIAGRAM M16x1 5 THREAD METRIC PORT CONFORMS i 150 6149 METRIC PORT CONFORMS TO 150 6149 IPTIDNAL AUXILIAR LUBE SUPPLY INLET SEE HYDRAULIC DIAGRAM SECONDARY CLUTCH ACTUATING PRESSURE 18 1 5 THREAD METRIC PORT CONFORMS TO 150 6149 MAIN PRESSURE PICKUP PORTS 1 4 18 CDRYSEAL THREAD TEMPERATURE PICK UP 1 4 18NPTF DRYSEAL DIL IN FROM HEAT EXCHANGER DIL DUT TD HEAT EXCHANGER M33x2 0 THREADS METRIC M33x2 0 THREAD METRIC PORT CONFORMS TO ISD 6149 PORT CONFORMS TO ISD 6149 SPEED PICK UP PORT 16 1 5 THREAD METRIC PORT CONFORMS TO 150 6149 GREASE FITTING PRIMARY CLUTCH SHAFT SECONDARY CLUTCH SHAFT CENTER OF GRAVITY FOR CLUSE COUPLED 1 OPTIONAL DITCH PLATE FOR TRANSMISSION CUSTOMER SUPPLIED HEAT EXCHANGER RH ENGINE ROTATION DRIVING THRU 325 0 9 REF HC SECONDARY CLUTCH 5 THRU 14 HOLES EQUALLY SPACED THREA
105. WI 53403 USA Ta THIN DISC i ALL ANGULAR TOLERANCES 1 GEDMETRIC TOLERANCING PER ANSI Y14 5M 1982 31 64 17 32 THRU 4 HOLES HOLES SHOWN FOR MOUNTING PORT 2 25 R ies RE st 23 ON QJ e 00 38 Eo A a UNO Dg 0 GASKET B1334A PIN M1927B 2 77 m 194 pec Zr GASKET B2251 2 GASKET B3404 WE SECTION PISTON B2235 STEM A4347H BEARING Me167 O RING 916 COVER B1368B LEVER 204087 SEE NOTE 1 SPRING ASS Y XA2707BU SPRING A2707BU SPRING 427034J NOT SERVICEABLE V l 48m 5 ON IRTI UA N dup e COVER SEE CHART CAPSCREW SEE CHART 5 25 DIA THRU ONE HOLE SEE NOTE 1 3 POSITION amp 2 POSITION VIEW 3 POSITION 3 POSITION amp 2 POSITION DRIFICE PLATE SEE CHART SHIM B2234 CAS REQ D G SEE NOTE 2 PISTON SEE CHART BODY ASS Y XA7089 BODY 7089 BALL 1990 BALL 1990 SEPARATELY 2 SECTION C C _ _ E 27659 44971 rev no owe mv zone ASSEMBLE AND TEST OPER 12 10 20 LBS AT THE 220 R LOCATION OF THE 25 DIA HOLE IS REQUIRED TO OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PR
106. WISE SPECIFIED BREAK ALL SHARP CORNERS 2 1 RoD HANDLE 100 DIA x 2025 LG a 1 MS PLATE CARB amp HDN 625 DIA x 75 THK DESCRIPTION STOCK SIZE ee Eee ma E DRIVER TOLERANCE UNLESS OTHERWISE SPECIFIED 5301 JM DM FRACTION AND VO PLACE I CORE PLUG M 1945BY ME CAD FILE T 18050 712 dwg ae 06 45 2 0 31 1 05 REF 10 U CUT DIA 9 990 12 x 15 d SEAL DRIVER D DUTY DRIVER MAT MS CARB amp PRESS SEAL INTO CARRIER WITH SEAL DRIVER FLANGE DOWN INSERT THIS SEAL FIRST AS SHOWN 1017019 CARRIER 1 7 DITE TOOL NUMBER 1518050713 CARRIER NUMBER 107019 SEAL NUMBER 1017085 MODEL NUMBER MG 5301 ge N a 1 FLANGE UP PRESS 1017085 SEAL 111 i FLANGE DOWN PRESS IN FIRST SEAL IN SECOND SEAL UNLESS OTHERWISE SPECIFIED BREAK ALL SHARP CORNERS GROUND SURFACES MUST BE PARALLEL WITHIN 005 OF EACH OTHER ibt ans i m 188 VAL ETE BSCHPTUN e 1017019 CARRIER sca DRIVER ee ee DISC INC RACINE VIS T 18050 713 CAD FILE 050 713 DRILL 21 32 66563 DIA THRU TOOL NUMBER T 1805 714 SHAFT NUMBER 1017000 TAP 374 10 UNC 0 REQ D MODEL NUMBER MG 5301 REWORK NOTE SPOT WELD amp LOCATE SHLD ER
107. WN DIAMETER AT LEVER END bo dE 29117 2 4 99 NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT wee UNLESS OTHERWISE SPECIFIED TV b DISE __ _____ PEF 29015 12 17 98 USED IN ANY MANNER went MACHINED DIMENSIONS ae te ara edi L LL 2 28585 6 3 98 TO Y RENT TREAT FIRST USE 35 RACINE VI 53403 USA 2455255 cipes VIN DISC 4 menn P 29863 1 31 o0 B a 4 28315 1 21 98 THIS NOTICE 15 NOT INTENDED VARIOUS PER ANS 1982 1 1 7 5 E E e7 293s0 s 2 se A ALL 28208 11 26 97 LIMIT pe VALVE ASS Y TROLLING ess cw no ame ame cs wo pore OR OTHERS CONTRACT CENTER LABEL 1018729 HERE CAUTION MAX TEMP 100 C REDUCE SHAFT SPEED IF EXCEEDED 100 C SINGLE PHASE CAPACITOR TYPE C THERMALLY PROTECTED DUAL VOLTAGE DUAL ROTATION 8 LEAD S dene DR REDUCE PROPELLER SHAFT RPM 222222222222222222222222222222222222224222222222222222222222222222222222222224 2 HEAT EXCH FAN MAXIMUM TEMP SSSSSSSSSSSSSSSSSSSSS RED PILOT LIGHT LIT WHEN MOTOR 15 OPERATING REMOVE PLUG TO INSTALL CUSTOMER SUPPLIED IESSURE ALARM 13 8 41 4 kPa SETTING SEE TOP VIEW FOR LOCATION FLTER WITH 172 kPa BYPASS OL AIR HEAT EXCHANGER 25 MICRON OIL OUT 1 2 14 THREAD INSTALL PLUGS FOR S
108. art numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number on the unit s nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc warranty Marine Transmission Service Manual 1020304 Twin Disc Incorporated Introduction Source of Service Information For the latest service information on Twin Disc products contact any Twin Disc distributor or service dealer This can be done on the Twin Disc corporate web site found at http www twindisc com Provide your model number serial number and bill of material number to obtain information on your unit If necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com Marine Transmission Service Manual 1020304 15 Introduction Twin Disc Incorporated Warranty Equipment for which this manual was written has a limited warranty For details o
109. b in X3820 lb in 5 6230 x 106 lbf in raod 274 x 106 in rad 354 106 lbf in rad gt 522 x 10 lbf in rad METRIC d THIRD ANGLE WY PROJECTION 26 0 kNm rad 230 x 105 thf in rad NOTICE THIS PRINT CONTAINS ae ae nae DETRIMENTAL TO THE INTERESTS OF INCORPORATED TWIN DISC INCORPORATED r RACINE WI 53403 USA uM z Mie 10170208 MARINE TRANSMISSION 5 OF 6 rev D LLL NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED_IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE 15 NOT_INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT THIRD ANGLE e PROJECTION SIMILAR TO ae THIN DING MAHINED SAE og 1 RACINE WI 53403 USA ALL ANGULAR TOLERANCES DRN GEOMETRIC TOLERANCING ID MEYERS 1 0 1 7 0 e 0 R ANSI 14 5 1982 CHK 10176078 A FJ gt LUBE TUBE 6 4 I I lt f KAK ZZ Lr L Ze M Ke SONS SSS SNS gt b zz PRIMARY SHAFT FRONT amp REAR BEARING PINION SHOWN ENGAGED RY 4 AN ou LUBE A NI HEAT EXCHANGER
110. ble Manifold and Bearing Carrier 1 Remove the primary shaft end cover plate and O ring 2 Remove manifold attaching screws Install two of the removed screws into the threaded pusher screw holes of the manifold near the dowel pins Tighten the screws alternately and evenly to push the manifold off of the bearing carrier and dowel pins Remove the manifold and gasket Figure 29 Pusher Screws Installed in Manifold 3 Remove the shims and bearing spacers from the bearing bores of the bearing carrier Mark the shims and spacers for location identification 4 Remove the lubrication tube from the bearing carrier Figure 30 Lube Tube in Bearing Carrier 78 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 5 Install two of the removed screws into the threaded pusher screw holes of the bearing carrier near the dowel pins Tighten the screws alternately and evenly to push the bearing carrier off of the housing and dowel pins Remove the bearing carrier and prevent the bearing cups from falling out of the bores Figure 31 Pusher Screw Installed in Bearing Carrier 6 Remove the bearing cups from the bearing carrier Mark the bearing cups for location identification 7 Remove the lubrication oil pressure relief valve from the bearing carrier Figure 32 Lubrication Oil Pressure Relief Valve Marine Transmission Service Manual 1020304 79 Disassembly Twin Disc Incorporated Remove Pri
111. bove check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance Marine Transmission Service Manual 1020304 119 Assembly Twin Disc Incorporated 4 Connect the oil injector to the output shaft 5 Use portable press 1340 150 ton capacity and fixture T 20023 3 to seat hub using 1340 300 Ibf load Figure 73 Output Gear Advancing Tools Installed 6 Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating surfaces 7 Advance gear to shaft shoulder stop with the portable press 8 Release injection oil pressure between the mating surfaces and wait five minutes before lowering the press force and removing the assembly tool 9 Remove the assembly tools from the output shaft and gear 10 Confirm that the output gear has been advanced completely such that there is no gap between the shaft shoulder and the gear hub 11 Install the pinion front bearing cones for primary and secondary shafts onto bearing cups previously installed in transmission housing 120 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Installation of Output Shaft Rear Bearing 1 Install heated rear output shaft tapered roller bear
112. brication Conditions where backdriving may occur Vessel is being towed more engines multiple transmission vessel are shut down while under way Sailboat under sail with auxiliary engine shut down Vessel tied up or docked in a heavy current The following solutions are applicable for all MG 5301 transmissions if any of the above conditions are present Lock the propeller shaft to prevent rotation Add electric driven auxiliary oil pump into the lubrication circuit Refer to the hydraulic system prints for more details on auxiliary pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Marine Transmission Service Manual 1020304 13 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services 14 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 from the p
113. c 41310 EE 2 rere ELECTRIC CONTROL MODE SWITCH SCREW MA1052P 4 1017134 1018688 759 24 7 A2707AD 270 2000 lt 290 gt 10171298 1017554 10 8 7 4 824513 lt CLOSED WHEN MANUAL VALVE se Nom 10180857 erint EO 4 ren STEM IS LOCKED IN ELECTRIC 400 Ibf Pt 0180850 ea pels I 20 VIEW f ECURE LEVER IN THE DEPRESSED CLIP CONNECTOR 1017322 2 ELECTRIC CONTROL MODE POSITION i _____ 5 PUN Pi ASTIC Se THRU ASSEMBLY SEE Ci fior8085x 1 4 HOLE IN LEVER amp M8 THREADED CONNECTOR SHROUD 1001825 ASSEMBLY SEE CHART 1018085X HOLE BEHIND PULL TIGHT TRIM KASSEMBLY 1018883 SHOWN SS o o END SHORT 0 ________ STRAP M2942B NOTE INSTALL USING MA908 LOCTITE 1018085 1 1 242 THREAD DOG POINT INTO nee DETENT GROOVE UNTIL SNUG BACK OFF 1 2 TURN 101808540 ___ 018085 THESE SOLENOID CONNECTIONS eee ARE NOT POLARITY SENSITIVE SETSCREW 2038 018085 1 1101808 5 SPRING 270280 2 HYDRAULIC LOCK 29 PIN A2711AC 2 SPOOL 1017432 2 4 HYDRAULIC LOCK ONLY
114. coil spring clutch release springs If the transmission has belleville clutch release springs refer back to page 130 1 Installation of clutch return springs A Install 16 clutch return spring into pockets in face of clutch apply piston Install spring retainer over springs with groove toward springs Working through holes in retainer use a small punch or probe to assure that all springs are in pockets in face of piston and that springs are aligned correctly stand straight up Tw Figure 96 Return Springs and Spring Retainer Ready for Installation Marine Transmission Service Manual 1020304 143 Assembly Twin Disc Incorporated C Install external retaining ring over shaft to rest against spring retainer Move shaft assembly to press and install tool T 19330 Press down tool T 19330 to compress springs and expose retaining ring groove of shaft Keep force on springs and install retaining ring into exposed groove of shaft Figure 97 Installing Spring Retainer Retaining Ring D Slowly release force on springs assuring that spring retainer counterbore covers retaining ring and prevents retaining ring from coming out of the groove Remove tool T 19330 2 Install the pinion rear tapered roller bearing cone onto the shaft Note This bearing is a slip fit and will not require special tools for installation 3 Beginning with a friction plate alternately install 10 friction plates and 9 steel plates into clutch
115. d Power Take off The hydraulic clutched PTO also allows accessories to be driven using engine horsepower Since the PTO is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The PTO is engaged by the PTO control valve which is very similar to the valve used to control the transmission clutches The hydraulic clutched PTO operates with an engaged clutch pressure greater than that of the transmission s primary and secondary clutches For this reason the PTO control valve pressure increasing valve is in the transmission s hydraulic circuit before the control valve s inlet and pressure regulator Pressurized oil from the filter is directed to the PTO control valve with the overage oil flowing to the transmission s control valve Marine Transmission Service Manual 1020304 57 Operation Twin Disc Incorporated Trailing Pump Optional The trailing pump is used to supply oil flow to the transmission lubrication circuit when the transmission is in a backdriving condition Backdriving sometimes referred to windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller The trailing pump is driven by an electric motor and oil flow from the trailing pump flows through a check valve into the transmission s lubrication circuit via one of the pressure test ports 58 Marine Transmission Service Manua
116. d be against the bearing cup Repeat this process for the other shaft Install the shaft seal rings into the grooves of the clutch shafts Apply a coat of assembly grease or oil to the seal rings of both clutch shafts Center the seal rings in the shaft grooves to prevent seal ring damage during manifold installation Install the manifold over the bearing carrier and gasket Use a soft hammer near the dowels to seat manifold against gasket and over dowels Install the manifold attaching screws and torque to 112 Nm 83 ft lb Marine Transmission Service Manual 1020304 151 Assembly Twin Disc Incorporated 16 Confirm shaft endplay Note Some early production manifolds will not allow the secondary shaft endplay to be confirmed as the opening at the oil pump blocks the threaded hole s in the shaft end Such transmissions require a modified manifold enlarged opening to be used as a tool to confirm correct secondary shaft endplay A With a felt tip pen make a mark across the rear end of the secondary shaft Install a dial indicator on a machined surface on the manifold with the probe resting on the mark made on the secondary shaft Figure 107 Confirming Secondary Shaft Bearing Adjustment B Install an eyebolt into the end of the shaft and exert 890 N 200 lbs downward force while rotating the shaft several revolutions in each direction Stop so that the dial indicator probe is resting on the mark C Zero the dial in
117. d to adjust the seat location in the valve body Install the roll pin to retain the shuttle ball seat Drive the roll pin in until it is flush with the gasket surface of the valve body Figure 124 Installing Shuttle Ball Seat Roll Pin 168 Install the stem into the valve body aligning the slot in the stem with the threaded hole in the valve body for the dog point setscrew Be sure the slot in the stem is aligned with the setscrew hole in the valve body to prevent damage to the stem and valve body Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 6 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn Figure 125 Installing Dogpoint Setscrew 7 Install the steel detent ball into the valve body 8 Install the detent spring over the detent ball 9 Apply MA908 threadlocker to the threads of the hollow setscrew and install into the threaded hole A stepped Allen wrench or one wrapped with tape will ease the installation of the hollow setscrew Tighten the setscrew until itis flush with the gasket surface of the valve body Check the stem rotation and detent action Figure 126 Installing Detent Ball Setscrew Marine Transmission Service Manual 1020304 169 Assembly 170 10 11 12 13 14 Twin Disc Incorporated Install the thrust washer over the end of the stem Press the o
118. ddles or forms beads use fresh solvent and reclean Marine Transmission Service Manual 1020304 Twin Disc Incorporated Inspection Cleaning and Inspection Housings Cast Parts and Machined Surfaces Replace cast parts or housings that cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will cause loss of press of bearings or races Inspect oil passages for obstructions If you find an obstruction remove it with compressed air or work a wire back and forth through the passage and flush it with solvent Inspect machined surfaces for burrs scratches nicks and foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part Inspect ground tapers for burrs or nicks If you cannot remove the defect with a soft stone replace the part Inspect ground tapers for scratches galling or scoring damage If any of these the defects replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels This applies where a matched set of parts is not involved Inspect dowel pin holes for wear due to movement between mating parts
119. dicator D Remove downward pressure and exert 1334 N to 1557 N 300 lbs to 350 Ibs lifting force on the shaft Rotate the shaft several revolutions in each direction stopping with the dial indicator probe resting on the mark 152 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly E Dial indicator reading is secondary shaft endplay Endplay should be between 0 013 mm to 0 063 mm 0 0005 in to 0 0025 in Add or remove shims as necessary to achieve correct endplay Use dial indicator and above procedure to confirm that desired endplay has been attained Confirm endplay for primary shaft by repeating previous steps on primary shaft 17 Install new O rings onto the M18 O ring plugs used for the clutch and lube pressure test ports Lubricate the O ring and threads and install the plugs torquing them to 74 Nm 55 ft lb Marine Transmission Service Manual 1020304 153 Assembly Twin Disc Incorporated Installation of Manifold and Exterior Components 1 Install suction strainer into bore in manifold Figure 108 Installing Suction Strainer 2 Install O ring into groove in suction screen cover Apply assembly grease or oil to the O ring 3 Install suction screen cover and secure with clamp plate and screw Torque attaching screw to 112 Nm 83 ft lb Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 4 Install O ring into groove in face of manifold at primar
120. e ball neutral pressure regulator and rate of rise functions remain exactly the same as when the valve is in the electric mode In the manual override position shifting is controlled by rotating the lever on the manual override stem In the Neutral position both clutches are vented to sump by two pockets in the stem Figure 21 Stem Pocket or Passage Main pressure oil can flow through the hole in the end of the stem to a narrow slot between the two pockets This slot does not connect to any other passages when the stem is in the Neutral position When the lever and stem are rotated to engage either the primary or secondary clutch main pressure oil flows through the slot in the stem to the appropriate clutch pressure port The opposite clutch port passage remains connected to sump by the same pocket in the stem as when the stem was in the Neutral position When the stem is rotated back to the Neutral position the main pressure oil slot in the stem is no longer aligned with either clutch port Both clutches are again vented to sump by the two pockets in the stem 52 Marine Transmission Service Manual 1020304 PpOLOZOL Jenuey uoissiusueJ SUNEN 69 WWELLZV ec 1 t 1 t zt 1 UBE TUBE 1 1 SS ew
121. e from the spring Care must be taken when removing the trolling valve and orifice plate to prevent loss of steel ball 2 Remove the trolling valve from control valve 3 Remove the gaskets orifice plate and steel ball from control valve 4 Remove the screw and nut clamping the lever to the stem Remove the lever from the stem It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 104 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 6 Remove the detent setscrew spring and detent ball Figure 63 Removing Detent Setscrew left and Detent Spring and Ball right 7 Remove the dog point setscrew from the valve body Figure 64 Removing Dog point Setscrew Marine Transmission Service Manual 1020304 105 Disassembly Twin Disc Incorporated 8 Slide the stem and adapter out of the valve body together as one piece Push the stem out of the adapter such that the spring end of the stem exits the adapter first Note that the inner spring will come out with the stem Figure 65 Removing Stem and Adapter from Valve Body left and Removing Stem from Adapter right 9 Remove the O ring from the groove in the end of the stem Figure 66 Removing O ring from Stem 106 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 10 Remove the inne
122. earing is an interference fit with shaft and will be destroyed during removal a Remove the external retaining ring from the shaft b With ahammer and chisel cut cage off bearing to remove bearing cage and rollers C Use a split type bearing puller cheese cutter to grip flange at small end of tapered inner race d With a hydraulic jack pull on bearing inner race while pushing on rear end of shaft to remove bearing inner race from shaft 3 Set shaft upright with input end up Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 4 Remove and disassemble pinion s a Remove round retaining ring from input end of shaft and remove pinion from shaft g x Figure 40 Removing Round Retaining Ring from Input End of Shaft b Remove internal retaining ring from input end of pinion and remove straight roller bearing Note The straight roller bearing in the bore of the input end of the pinion is an interference fit and will likely be destroyed during removal Remove the straight roller bearing with the use of a puller behind the roller ends Remove tapered roller bearing outer race from bore at rear of pinion if bearing requires replacement This bearing race is an interference fit in the pinion bore To remove use an electric welder to weld a light bead around the I D of the bearing race This will shrink the bearing cup to facilitate removal Bearings removed with this method must be
123. ed bore of flange must be completely free of grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance measurement of flange on shaft and adversely effect torque carrying capacity of the assembled joint Both parts must be at the same temperature 2 Seat flange onto the taper of the shaft using only the weight of the flange 3 With a depth micrometer measure distance from inner shoulder of output flange to end of output shaft This is the potential advance and it must be 8 13 mm to 9 91 mm 0 320 in to 0 390 in Figure 110 Measuring Output Flange Advance Distance Note Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be necessary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 4 Connect the oil injector to the output flange 5 Install tool T 21433 onto the output shaft to advance the flange onto the shaft 6 Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating surfaces 7 Advance flange onto shaft with the portable press POWER TEAM Figure 111 Advancing Output Flange Onto Output Sha
124. embly secondary Plug orifice some models Ring external retaining primary amp secondary shaft needle bearing Ring internal retaining pinion needle bearing Pinion assembly primary amp secondary Tube lube Bearing tapered roller primary amp secondary pinion rear bearing Backplate clutch Spring belleville clutch release Retainer spring Gear transfer secondary shaft LH helix Piston clutch Ring piston clutch piston inner Ring assembly piston clutch piston outer Housing lube relief valve Spring compression lube relief valve Ball steel lube relief valve Screw hex head lube relief valve Washer lube relief valve Bearing tapered roller primary amp secondary shaft rear bearing Item 24 25 26 27 31 32 33 36 37 38 39 40 41 43 44 45 46 47 48 Qty Description Spacer bearing Plug pipe temperature sensor port Ring piston primary and secondary shaft Manifold po 1 Pump oil 4 Screw hex head cap oil pump Gasket oil pump gt Screw hex head cap suction strainer cover Plate clamp suction strainer cover O ring suction strainer cover Cover suction strainer Strainer suction Gasket manifold Carrier bearing Gasket bearing carrier R Shim bearing 005 007 020 primary amp secondary shaft bearing adjustment gt up 2 Ring external retaining primary amp secondary shaft rear bearing 20 Pla
125. en using SAE 50 oil Oil type and viscosity See data plate below Approximate Dry weight 1570 kg 3460 Ibs Oil pressure See Tables 4 and 5 Oil temperature to be in normal operating range IL SERVICE CLASS USE SE SERVICE CLASS CD ENGINE OIL CERTIFIED BY VENDUR TO PASS e DM SI ALSO APPROVED IS SAE API SERVIC CLASS CC ENGINE 2104 JISCUSITY BASE SELECTION ON SUMP DIL TEMP CONDITIONS TABULATED BELUW START UP STEADY OPERATION VISCOSITY MIN NO50 10 MIN STEADY OPERA BOVE 2001 4 2415 2 Figure 6 Specification Plate Example Marine Transmission Service Manual 1020304 Twin Disc Incorporated Description and Specifications Table 1 250psi Transmission Oil Pressure Specifications Mechanical Valve 250 psi Springs Main Pressure at Valve Primary Secondary Shift Inlet Clutch Min Clutch Min o Lube Position Tite Seconda zem o o aw rs momo o nae Socana os 45 Table 2 290psi Transmission Pressure Specifications Electric Valve 2000 kPa 290 psi Springs Main Pressure at Valve Primary Secondary Lub Input Shift Inl
126. ermine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist it is evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush In boat Repair Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures are 0 O0 B Note Note Removing and installing the oil pump Changing the filter Removing cleaning and installing the suction strainer Removing and installing the control valve Removing and installing the manifold or top cover bearing carrier and lube tube Removing and installing the primary and secondary shaft assemblies See special tools section for lifting bracket to aid in shaft removal or installation Changing primary and secondary clutch plates Further disassembly reassembly of the primary or secondary shafts will require use of tools and equipment normally not available on board the vessel Marine Transmission Service Manual 1020304 67 Preventative Maintenance Twin Disc Incorporated Overhaul Interval Acomplete overhaul of the unit should be made at the same time that the engine is overhauled Periodic Visual Inspection Check the mountings for tightness damage such as cracks Tighten loose mountings and replace damaged parts Check pressu
127. et Clutch Min Clutch Min Speed Position kPa psi psi_ kPa psi kPa psi o 1860 Primary 1860 2000 270 290 1860 270 1960 2140 285 310 1960 100 380 15 55 1960 2140 285 310 1960 100 380 15 55 Note It is required that lube pressure with primary clutch engaged must equal lube pressure with secondary clutch engaged within 21 kPa 3 psi Marine Transmission Service Manual 1020304 27 Description and Specifications Twin Disc Incorporated Optional Equipment The following optional equipment for use with the model MG 5301DC is available through the nearest authorized Twin Disc distributor Optional Trailing Pump A 115 vac electric powered trailing pump system is available It is identified as part number 1016473 A drawing is included in the Engineering Drawings Power Take off A live power take off pump mountis available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 A hydraulically clutchable PTO is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 Metric to NPTF Adapter Kit Adapter kits are available to convert the oil drain plug opening the pressure test ports and the heat exchanger connections from metric to NPTF threads Kit K1195 is for units with an integral heat exchanger and kit K1254 is for units with a remote heat exchanger Mounting Bracket
128. f the warranty refer to the warranty statement at the front of this manual For details of the warranty contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Inc Racine Wisconsin U S A 16 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Description and Specifications Description and Specifications General The 1017020 series assembly drawing identifies a standard power rating unit The 1017607 series assembly drawing identifies a higher power rating unit Both versions are available as either an engine mounted unit that attaches directly to the engine flywheel housing or as a free standing unit The suffix on the assembly number designates the revision level of the transmission Assemblies 1017020 1017020A 1017607 and 1017607A utilize belleville springs as clutch piston return springs Assemblies 1017020B and 1017607B use coil springs as clutch piston return springs Service information is provided for both variations with this manual and the assembly drawing number is identified on the bill of material BOM 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 b ND RATIO SERIAL NO 7 NO JIL
129. flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE MALE FEMALE STRAIGHT EDGE Figure 141 Checking Parallel Alignment of the Coupling Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation As the engine and marine transmission come into their aligned position it will be possible to mate the output flange and propeller coupling and prepare for bolting together Care should be taken not to burr or mar this connection because the fit is very critical Place a 0 05 mm 0 002 in feeler gauge between the flanges of the coupling Move slide the feeler gauge completely around the coupling Rotate the marine transmission flange coupling in 90 degree increments and move the feeler gauge around the flange in each successive position The feeler gauge will fit snugly with the same tension all around the flange coupling in all four positions if the alignment is correct If the alignment varies during rotation additional alignment is necessary or the marine transmission and shaft couplings should be checked for proper face runout Runout must not exceed 0 10 mm 0 004 in Excessive face runout on the marine transmission output flange can usually be corrected by repositioning the coupling on its spline or taper Excessive shaft coupling runout is usually due to inaccuracy of the taper fit or key to keyway interference The optimum relative mating location will be w
130. ft 8 Release injection oil pressure between the mating surfaces and wait five minutes Slowly remove the retainer washer screws and confirm that the output flange shoulder is within 0 05 mm 0 002 in of the end of the output shaft Marine Transmission Service Manual 1020304 157 Assembly 158 10 11 12 Twin Disc Incorporated Reinstall the retainer washer and torque the screws to 112 Nm 83 ft lb Note It is possible to advance the flange using the retainer washer and its five retaining screws The screws must be tightened evenly in small increments and in an alternating star pattern to advance the flange squarely onto the shaft New screws must be installed if the old screws were over torqued during the advancing process Attach dial indicator to housing with probe resting on face of output flange Locate indicator probe as close to O D of flange as possible Check flange face runout by rotating flange Total indicated runout must not exceed 0 10 mm 0 004 in Attach dial indicator to housing with probe resting on O D of output flange pilot Check pilot runout by rotating output flange Total indicated runout must not exceed 0 10 mm 0 004 in Note Should total dial indicator runout exceed 0 10 mm 0 004 in the flange must be removed and reinstalled on the shaft taper Install the O ring plug into the oil injection port of the output flange and torque to 16 Nm 12 ft lb Marine Transmission Service
131. g the spline on the primary shaft 76 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly Remove Output Flange 1 Loosen the output flange retaining washer capscrews approximately 6 turns each The capscrews and washer will retain the output flange when it separates from the output shaft Always use retainer bolts or a safety strap to hold parts being separated with oil pressure Oil pressure applied between the two parts for disassembly can reach 300Mpa 43500psi The use of proper safety equipment is mandatory when working with high pressure hydraulic tools The parts may separate with extreme force 2 Install the oil injector into the output flange at the O ring plug location Note that the threads are 1 4 19 BSP Figure 28 Output Flange Oil Injection Location 3 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature into the flange hub until the flange separates from the output shaft Remove the oil injection equipment Remove the capscrews and washer and remove the output flange Note Use caution to prevent damaging the taper of the output flange or shaft as the torque capacity can be reduced 4 Remove the output seal carrier 5 Press the oil seals out of the seal carrier and remove the O ring from the seal carrier 6 Remove the output bearing adjustment shims Marine Transmission Service Manual 1020304 77 Disassembly Twin Disc Incorporated Remove and Disassem
132. g the trolling function reduces clutch apply pressure to reduce the propeller speed 54 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation 1017555 Mechanical Trolling Valve This trolling valve is a variable orifice that controls the pressure in the rate of rise chamber The pressure in the rate of rise chamber determines the rate of rise piston position which ultimately controls the main and clutch pressures for the transmission When the trolling valve lever is in the detent non trolling position the orifice in the trolling valve is closed Oil cannot exit from the rate of rise chamber through the trolling valve s orifice and the 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 orifice closed orifice opened Figure 23 Mechanical Trolling Valve Rotating the trolling valve lever into the trolling mode opens the variable orifice allowing some of the oil to escape from the rate of rise chamber to sump This reduces the oil pressure in the rate of rise chamber Since oil is always flowing into the rate of rise chamber through the orifice in the orifice plate the pressure in the rate of rise chamber is controlled by how much oil is al
133. gs are compressed the most the main oil pressure reaches approximately 290 psi When the control valve is shifted to Neutral the clutch that was engaged is vented to sump within the valve As a result the passage behind the ball and spring regulator is vented to sump and induces a high differential pressure between the rate of rise chamber and the passage behind the ball and spring Since the pressure in the rate of rise chamber is much greater than the pressure itis to be regulated at the ball unseats from the orifice plate allowing main oil pressure to return to the neutral pressure level rapidly and again be regulated by the ball and spring regulator The ball returns to the pressure regulating position once the spring force is equal to force induced by the pressure at the rate of rise piston Marine Transmission Service Manual 1020304 47 Operation Twin Disc Incorporated Electric Operation The transmission normally operates with the control valve in the electric mode Two spools each controlled by a solenoid operated pilot valve control clutch engagement When a solenoid is energized it opens the pilot valve and allows main pressure oil to flow to the end of the spool The pressure acting on the end of the spool overcomes the return spring at the opposite end causing the spool to stroke over and connect the clutch passage with main pressure passage Figure 17 Pilot Spool Passages 48 Marine Transmission Service Manual
134. gt Figure 43 Removing Clutch Piston Note Remove piston ring from ring groove in shaft seals of clutch piston and multi piece piston ring from ring groove in O D of clutch piston Do not separate clutch housing transfer gear from the secondary shaft unless the shaft or the clutch housing must be replaced and the mating part remains serviceable Use the following procedure to separate the housing transfer gear from the primary or secondary shaft To remove clutch housing place shaft and clutch housing on a press front end of shaft down Place a sleeve over input front end of shaft with an 1 0 only slightly larger than the O D of the shaft taper large end 101 6mm 4 00 in Rest one end of sleeve on a heavy wood block while the other end supports the inner face of the clutch housing Apply press force to rear end of shaft to separate shaft from clutch housing The shaft must be protected and restrained to prevent damage as the tapered joint separates Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly Selector Valve Disassembly Mechanical Valve 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 orifice plate and check ball Figure 44 Removing Orifice Plate and Check Ball 2 Remove the check ball spring from the valve body Fi
135. gure 45 Removing Check Ball Spring Marine Transmission Service Manual 1020304 93 Disassembly Twin Disc Incorporated 3 Remove the rate of rise piston and remove the pressure regulator adjustment shims from the rate of rise piston Figure 46 Removing Shims from Rate of Rise Piston 4 Remove the pressure regulating springs and pressure regulator piston Figure 47 Removing Pressure Regulator Piston 94 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 5 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 splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem lever or bearing might get damaged 6 Remove the O ring plug detent spring and detent Figure 48 Removing O ring Plug Detent and Spring 7 Remove the cover and stem together as a unit Figure 49 Removing Stem and Cover Together Marine Transmission Service Manual 1020304 95 Disassembly Twin Disc Incorporated 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 Figure 50 Removing Stop Collar 9 Slide the stem out of the cover 10 Remove the bearing and O ring from the cover F
136. here the measured runout dimensions of the transmission flange and the shaft coupling flange compliment each other to result in the least relative out of true parallel measurement Figure 142 Checking Output Flange Face Runout Marine Transmission Service Manual 1020304 187 Installation Twin Disc Incorporated Figure 143 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 188 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation There are many types of flexible couplings in the market today that solve a variety of problems Couplings to reduce noise and vibration Couplings to allow a permanent angular misalignment Couplings that allow engines to be flexibly mounted and take out
137. housing transfer gear against clutch apply piston 144 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 4 Install clutch backplate and internal retaining ring Figure 98 Installing Clutch Backplate Note Some models use a clutch backplate without external splines and a spiral internal retaining ring Refer to unit BOM for parts usage Marine Transmission Service Manual 1020304 145 Assembly Twin Disc Incorporated 5 Assembly of pinion A Use special tool T 18050 708 to install chilled tapered roller bearing cup into rear of pinion for secondary shaft Bearing cup is installed with small 1 0 of taper toward the front and seated against shoulder of bore in clutch hub of pinion Figure 99 Installing Tapered Roller Bearing Cup Into Pinion B Install chilled needle roller bearing into bore at front of pinion with the radiused edge of the outer race entering the pinion first Figure 100 Needle Roller Bearing Installed 146 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly C Install internal retaining ring into groove in pinion bore Figure 101 Installing Internal Retaining Ring Into Pinion Align plates in clutch pack and install pinion on secondary shaft so that external teeth on clutch hub mesh with internal teeth of steel plates in clutch pack Assure that clutch hub is in mesh with all clutch plates Marine Transmission Service Manual 102
138. ice Manual 1020304 Twin Disc Incorporated Cleaning and Inspection Gears Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the defect with a soft stone replace the gear Inspect gear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear Inspect thrust faces of gears for scores scratches and burrs you cannot remove these defects with a soft stone replace the gear Splined Parts Inspect splined parts for stripped twisted 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 1020304 113 Cleaning and Inspection Twin Disc Incorporated 114 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Assembly The MG 5301 DC transmission requires the use of a SKF THAP 300 Injection Kit See Special Tools or similar device to install the output gear onto the
139. igure 51 Removing Bearing and O ring from Cover 96 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly Selector Valve Assembly Electric Valve 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 Loosen and remove four of M8 x 25 socket head capscrews and remove orifice plate cover and gasket Figure 52 Removing Orifice Plate Cover Gasket 2 Remove orifice plate Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket Marine Transmission Service Manual 1020304 97 Disassembly Twin Disc Incorporated 5 Remove rate of rise piston Note that shims are located between the piston and springs Figure 53 Rate of Rise Piston left and Regulator Springs right 6 Remove pressure regulating springs 7 Remove pressure regulating piston with an external retaining ring pliers Figure 54 Removing Regulating Piston with Pliers 8 Remove external retaining ring from the lever end of the stem 9 Loosen the clamping nut and remove the control lever from the stem may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 10 Remove the washer and spring from the stem 98 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disas
140. il gauge Allow the oil temperature to cool to normal cold oil conditions perhaps overnight Check the oil level while cold at low idle engine speed while in neutral Make note of the oil level in the cold conditions for future reference as it corresponds to the correct oil level at operating temperature Marine Transmission Service Manual 1020304 Twin Disc Incorporated Preventative Maintenance Torsional Coupling Do not obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling The ambient temperature of the air around the coupling should be between 6 C 22 F and 80 C 176 F Assure baffles are installed properly so hot air is ported out of the housing Visually inspect the element after the first 100 hours of operation and every 2000 hours thereafter or every six months whichever comes first Torsional vibration misalignment degradation by contaminants oil heat ultraviolet radiation and excessive system torque can cause cracks or other signs of distress to appear on the surface of the rubber The above described items affect the life of the coupling element Marine Transmission Service Manual 1020304 65 Preventative Maintenance Twin Disc Incorporated When inspecting the flexible coupling look for evidence or conditions identified in the following steps Cracks in the surface of the rubber be caused by torsional vibrations excessive misalignment or exposure t
141. il seal into the cover assembly until flush with the adjacent cover surface Install the O ring into the counterbore in the cover assembly Apply grease to the stem O ring and oil seal lip Install cover assembly and gasket onto valve body Be sure to align the oil drain hole in the gasket with the hole in the valve body Figure 127 Holes in Gasket and Cover Must be Aligned 15 16 17 18 19 20 21 Install cover capscrews and torque to 23 Nm 17 lb ft Install washer over stem and against oil seal Install spring over stem against washer Install lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew may be damaged Torque the lever s attaching screw to 9 5 Nm 7 Ib ft Install external retaining ring onto stem Install the steel balls and electrical switches into the bores in the sides of the valve if equipped Note that the small diameter ball is inboard of the large diameter ball at each switch location Install the pressure regulating piston into valve body with spring pocket out Marine Transmission Service Manual 1020304 Twin Disc Incorporated 22 2 24 Assembly Install pressure regulating springs into valve body and into piston spring pocket Install the shims that were removed into the bore of the rate of rise piston Install the rate of rise piston
142. ill keep the spool in that position This keeps the transmission in gear as long as the engine is running 50 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation The hydraulic lock is disabled when either the engine is stopped or the neutral solenoid is energized When the neutral solenoid is energized it sends pressurized oil to the dowel pins at the return spring end of each spool Since the dowel pin used at the return spring side of the spool is larger in diameter than the dowel pin inside the spool the hydraulic force acting on the larger pin forces the spool to connect the clutch passage to sump with assistance from the return spring H 1 4 a Dowel pin Return spring 4 po t B Figure 20 Neutral Solenoid Engaged Marine Transmission Service Manual 1020304 51 Operation Twin Disc Incorporated Manual Override Operation The control valve has a manual override feature which is a lever operated selector When the manual override lever is rotated counterclockwise and pulled outwards the upper portion of the valve is disabled because the connecting slots in the manual override stem are no longer aligned with the oil passages in the valve body Oil pressure from the solenoid operated pilot valve controlled spools cannot reach the clutch pressure passages in the transmission The main oil pressure regulator shuttl
143. ing cone Install with small O D of bearing to the rear Press drive bearing to shaft shoulder using special tool T 21506 to hold bearing in place while temperatures equalize Figure 74 Output Bearing Tool T 21506 2 Install output bearing cup into housing bore until it contacts bearing cone Marine Transmission Service Manual 1020304 121 Assembly Twin Disc Incorporated Output Shaft Tapered Roller Bearing Adjustment 1 To determine the estimated shim thickness required proceed as follows A With a depth micrometer measure the distance from the housing face where the seal carrier contacts down to the tapered roller bearing cup Record this measurement as dimension A With a depth micrometer measure the pilot length of the output seal carrier Record this measurement as dimension B Subtract dimension from dimension and record this as dimension Build a trial shim pack having a thickness 0 05 to 0 15 mm 0 002 to 0 006 in less than dimension Install the trial shim pack over the bearing cup Figure 75 Output Bearing Shims Location 2 Install the output seal carrier without output seals or O ring and torque the screws to 112 Nm 83 ft lb 122 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 3 Install dial indicator onto the housing with finger resting on rear of output shaft or on lifting fixtures Zero the dial i
144. inst the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The primary clutch is now disengaged and main system pressure reduced to neutral pressure Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation Entry Passage B Oil Pressure Chamber C Pressure Overflow Port D Oil Engaging Passage E Oil Engaging Passage Oll interconnection Slot G Oil Directional Port H Oil Connection Port J Oil Pressure Passage Directional Port L Oil Pressure Chamber 4 N Qu FS VALVE STEM HIGH PRESSURE REGULATOR PISTON QN RATE OF RISE PISTON SO SPRINGS CONTROL Q VALVE BODY LJ ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 10 Control Valve Primary Sectional View PRIMARY TO PRIMARY CLUTCH TO SUMP TO SECONDARY CLUTCH CONTROL VALVE STEM B ATMOSPHERIC PRESSURE LJ ENGAGING PRESSURE Figure 11 Control Valve Primary Cutaway View Marine Transmission Service Manual 1020304 41 Operation Twin Disc Incorporated 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 12 and 13 The pressurized oil in chamber B is directed through po
145. ive torsional vibration Worn or damaged gears Im proper alignment Damaged propeller Misfiring engine Marine Transmission Service Manual 1020304 Remove and clean regulating valve Shim as required Inspect repair or replace parts as necessary Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch O verhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve O verhaul marine transmission Remove marine transmission Replace a worn or damaged coupling Select proper torsional coupling O verhaul marine transmission Check alignment of engine and transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine 71 Troubleshooting 6 7 8 9 72 Twin Disc Incorporated Table 14 Troubleshooting Chart continued Symptom No neutral Harsh engagement Low lube oil pressure spilling out of breather Clutch plates warped Control valve incorrectly indexed Solenoid malfunction units equipped with electric selector valve Hydraulic lock piston stuck units equipped with electric selector valve and hydraulic lock Regulating piston or rate of rise piston stuck Orifice p
146. l 1020304 Twin Disc Incorporated Operation Power Flow Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is splined to the forward end of the primary forward clutch shaft causing the primary shaft to rotate in engine direction during engine operation Power is transmitted to the secondary shaft by means of the transfer gear teeth on the outer diameter of the primary clutch housing These teeth are in constant mesh with gear teeth on the of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in anti engine direction Application of the secondary clutch locks the secondary pinion to the secondary shaft causing the pinion to turn in the shaft direction and causing the output shaft to rotate in engine direction Marine Transmission Service Manual 1020304 59 Operation Twin Disc Incorporated Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Driving Gear Primary Shaft _ secondary Shaft
147. l manifold gasket over alignment studs and against bearing carrier Install the previously established shim packs into the respective bearing bores over the bearing cups Install the bearing spacers into the same bores as previously installed and over the shim packs Install the shaft seal rings into the grooves of the clutch shafts Apply a coat of assembly grease or oil to the seal rings of both clutch shafts Center the seal rings in the shaft grooves to prevent seal ring damage during manifold installation Install manifold over alignment studs and dowels Use a soft hammer near the dowels to seat manifold against gasket and over dowels Install manifold attaching screws and torque to 112 Nm 83 ft lb Install new O rings onto the M18 O ring plugs used for the clutch and lube pressure test ports Lubricate the O ring and threads and install the plugs torquing them to 74 Nm 55 ft Ib Proceed to page 154 Marine Transmission Service Manual 1020304 141 Assembly 142 Twin Disc Incorporated Alternate In boat Procedure for 1017120 1017020A 1017607 and 1017607A Assemblies It is possible to assemble the transmission and then establish the primary and secondary shaft bearing clearance This procedure requires the use of a fixture that will apply 3115 700 Ib force to the clutch shaft to compress the belleville springs Once the belleville springs are compressed the shaft endplay can be measured by releasing the pre
148. late 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 Cil level too high W rong type of oil Remove clutch plates O verhaul unit Check and adjust control linkage Replace defective solenoid Inspect repair or replace hydraulic lock spool Disassemble control valve Clean parts Replace parts if necessary Remove orifice plate cover Clean parts Replace parts if necessary Replace gasket Replace pump Remove clean inspect and install the suction screen Inspect and correct cause of suction leaks Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly Disassembly The following procedure is for complete disassembly of the unit Prior to this procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility The physical size and weight of many of the parts for this transmission assembly are such that adequate lifting devices and procedures are necessary for safety considerations This requires that the transmission assembly be adequately supported and properly po
149. lling a new marine gear to an engine already mounted in the bed rails the flywheel housing should be checked for deflection using the following procedure Install the mounting brackets on the side mounting pads of the marine gear Install the driving ring on the engine flywheel Bolt an indicator to the engine block and set the indicator stem on the engine flywheel housing INDICATOR INDICATOR STEM MARINE GEAR SUPPORT BRACKET ENGINE SHIM HERE Figure 139 Marine Gear Alignment 182 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation Set the indicator gauge at zero 0 Lift the marine gear with a hoist or other suitable means and place the unit in position against the engine flywheel housing Secure the flange of the marine gear main housing to the engine flywheel housing Use a feeler gauge between each mounting bracket and engine bed rail Add shims between the brackets and bed rails to equal the feeler gauge readings Carefully release the lifting force on the marine gear while observing the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading moves from zero lift the marine gear and insert additional shims Continue this procedure until the marine gear is completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of the engi
150. lowed 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 1020304 55 Operation 56 Twin Disc Incorporated 1017554 Electric Trolling Valve This trolling valve is a variable orifice that controls the pressure in the rate of rise chamber The pressure in the rate of rise chamber determines the rate of rise piston position which ultimately controls the main and clutch pressures for the 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 controlled amount of current through the valve s coil As
151. luid LHMF 300 and Dismounting Fluid LHDF 900 SKF LHMF 300 and LHDF 900 are recommended when using SKF hydraulic equipment like hydraulic pumps HMV nuts oil injection equipment etc The fluids contain anticorrosives and are non aggressive to seal material like nitrile rubber Buna N Perbunan chrome leather PTFE etc SKF LHMF 300 and LHDF 900 are available in 5 liter 5 3 qt cans Designation LHMF 300 5 and LHDF 900 6 Figure 151 SKF LHMF 300 and LHDF 900 Note Order Through Your Local Authorized SKF Distributor 202 Marine Transmission Service Manual 1020304 1 00 DIA 32 RODS EQUALLY SPACED ON 5 75 DIA 7 00 DIA BOTH ENDS 5 250 DIA PRESS INTO DET 1 amp SPOT WELD IN PLACE T 18050 704 NOTE UNLESS OTHERWISE SPECIFIED DOE BREAK ALL SHARP CORNERS CAD FILE T 18050 704 dwg nu 10 1 5 BEARING cue USE BRG CUP 590 1 1 __ 7 25 DIA x 62 100 DIA x 20 50 7 25 DIA 62 THK DET REG MAT DESCRIPTIDN ST CK SIZE SPRING HOLD DOWN RETAINER NAME MG 5301 sens TWIN DISC INC RACINE VIS SHEET 2 OF 2 T 18050 704 2 940 3 720 DIA DIA MARK T 18050 705 BRG DRIVER 217 CAGED ROLLER FOR MA 217 BEARING CAGED ROLLER 1017005 GEAR 1 BEARING DRIVER D MS CARB UNLESS
152. ly Twin Disc Incorporated 11 Install the detent ball and spring into the remaining hole in the valve body Apply MA908 threadlocker to the threads of the detent setscrew and install until flush with the valve body Figure 132 Installing Detent Ball Spring and Setscrew 11 12 13 14 Check the torque required to overcome the detent The torque should be 1 1 1 7 Nm 10 15 in Ib Adjust the detent setscrew if necessary to achieve the proper torque to rotate the lever out of the detent position Install the lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged Rotate the lever if necessary on the stem to the position shown on the valve installation drawing see Engineering Drawing Section of this manual Install the screw and nut to clamp the lever to the stem Tighten the screw and nut to 9 5 Nm 7 ft lb Install the neutral pressure regulating spring into the bore of the control valve if removed Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 15 Install the steel ball onto the neutral pressure regulating spring Figure 133 Installing Neutral Pressure Regulating Spring and Ball 16 Install the orifice plate gasket orifice plate trolling valve gasket and trolling valve onto the control valve Install the attaching screws and torque them t
153. mary and Secondary Clutch Shaft Assemblies 1 Lift out primary and secondary shafts Disassembly of the primary and secondary shafts are covered later in this section Use caution with the front pinion bearing cones They are loose on the pinion diameter and should remain in the housing On some ratios the diameter of the output gear will allow the bearing to come out with the shaft and it could easily fall off causing damage Set the shafts aside for further disassembly Figure 33 Lifting Out Primary or Secondary Clutch Shaft Assembly 2 Remove front pinion tapered roller bearing cones that were pulled off by output gear as primary and secondary shafts were removed Note Tapered roller bearing cups of front bearings on the primary and secondary shafts are an interference fit in the housing Removal of these bearing cups should not be attempted unless replacement of the bearing is necessary 80 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly Remove Output Gear and Shaft 1 Use a hoist to lift output shaft and gear assembly until gear contacts housing Place blocks under gear to support the gear and shaft assembly in position Figure 34 Supported Gear and Shaft Assembly 2 Connect oil injection equipment to the 1 4 19 BSP threaded port on the rear end of the output shaft Figure 35 Oil Injection Equipment Connected to Output Shaft Marine Transmission Service Manual 102030
154. meter end Install the stem into the adapter with the reduced diameter end entering the adapter first Adjust the position of the stem if necessary to bring the helical slot into alignment with the dog point setscrew hole 6 Install the large diameter washer used on some models inside the bore of the adapter and over the inner spring until it lays flat on the end of the stem 7 Install the small washer used on some models inside the piston The washer must lie flat at the bottom of the bore in the piston 172 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 8 Apply assembly grease to the adapter where it contacts the trolling valve body and install the adapter into the valve body Be sure to align the setscrew holes in the adapter with those in the valve body Figure 130 Installing Trolling Valve Parts Into Trolling Valve Body 9 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn The end of the setscrew should protrude approximately 3mm from the valve body when the dog point of the setscrew is fully engaged in the helical slot Figure 131 Installing Dog point Setscrew 10 Check the action of the stem in the trolling valve If the stem does not rotate 90 smoothly loosen the dog point setscrew 1 8 turn and recheck the action of the stem Marine Transmission Service Manual 1020304 173 Assemb
155. ndicator and mark the spot where the reading was taken Figure 76 Measuring Output Shaft Endplay 4 Using hoist and tool T 18050 714 exert 2225 N to 4000 500 Ibs to 900 Ibs of lifting force onto the shaft Minimum of 2224 N 500 Ibs lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 N 300 Ibs lifting force on bearing Rotate shaft several revolutions with lifting force applied Stop rotation with dial indicator finger on mark previously made continuing to hold lifting force Read shaft endplay on dial indicator 5 Add remove shims as necessary to bring output shaft endplay within the 0 05 to 0 15 mm 0 002 to 0 006 inch specification Arrange the shims such that the thinnest shims are in the center of the shim pack 6 Remove lifting fixture Remove output seal carrier Marine Transmission Service Manual 1020304 123 Assembly Twin Disc Incorporated 7 Install O ring in groove O D of output seal carrier Figure 77 O ring Installed onto Output Seal Carrier 8 Install oil seals into output seal carrier using driver T 18050 713 per the following description A Install forward seal with spring loaded lip toward the inside of the transmission Start inner seal with flanged side of driver T 18050 713 facing down and complete its installation with tool inverted as shown below in Figure 78 B Install rear seal with spring loaded lip of seal toward rear of
156. ne Indicator Crankshaft C Figure 137 Checking Flywheel Face Runout Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation With the indicator mounted as in the paragraph above adjust the indicator tip so that it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot bore eccentricity of the engine flywheel should not exceed 0 13 mm 0 005 in maximum total indicator reading Thrust on the flywheel should be in one direction at all times to obtain a correct reading Engine Flywheel Engine Housirig 4 E lU m A S FEED i Thousandths A Indicator Engine vl Crankshaft Engine r v Flywheel Figure 138 Checking Flywheel Pilot Ring Bore Eccentricity Marine Transmission Service Manual 1020304 181 Installation Twin Disc Incorporated Installation Alignment Proper alignment of an engine and marine unit is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boat to change its form with various loads and with age Engine and shaft alignment can also change on a boat due to varying loads and the 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 insta
157. ne 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 1020304 183 Installation Twin Disc Incorporated Torsional Input Coupling Alignment Free Standing Units Alignment of freestanding transmissions must begin by aligning the transmission output flange to the propeller shaft The engine must then be moved to properly align the engine flywheel to the transmission input hub 184 Marine Transmission Service Manual 1020304 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 Recommended Figure 140 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
158. nifold gasket down to shim retainers Measured distance is shaft endplay Use necessary shims to develop a shim pack for each shaft to reduce shaft endplay to 0 13 mm to 0 18 mm 0 005 in to 0 007 in Figure 87 Measuring to Determine Shim Pack Thickness 12 Remove one shim retainer and install the shim pack for that shaft directly over the bearing cup The thinnest of the shims should be in the center of the pack and the thickest shim should be against the bearing cup Repeat this process for the other shaft Install the manifold without shaft seal rings over the bearing carrier and gasket Use a soft hammer near the dowels to seat manifold against gasket and over dowels Install the manifold attaching screws and torque to 112 Nm 83 ft lb Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 15 Confirm shaft endplay A With a felt tip pen make a mark across the rear end of the secondary shaft Install a dial indicator on a machined surface on the manifold with the probe resting on the mark made on the secondary shaft Figure 88 Confirming Secondary Shaft Bearing Adjustment B Install an eyebolt into the end of the shaft and exert 890 N 200 lbs downward force while rotating the shaft several revolutions in each direction Stop so that the dial indicator probe is resting on the mark Zero the dial indicator Remove downward pressure and exert 1334 N to 1557 N 300 lbs t
159. ning the marks made at disassembly Torque the screw to 15 Nm 11 ft lb 7 Install the pressure regulator piston and springs into the valve body Figure 117 Installing Regulator Piston left and Springs right 8 Install the pressure regulator adjustment shims into the rate of rise piston Figure 118 Pressure Regulator Adjustment Shims 164 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 9 Install the rate of rise piston with shims into the valve body Figure 119 Installing Rate of Rise Piston into Valve Body 10 Install the check ball spring and check ball into the valve body Figure 120 Installing Check Ball Spring Marine Transmission Service Manual 1020304 165 Assembly Twin Disc Incorporated 11 Place one orifice plate gasket and the orifice plate onto the valve body Figure 121 Installing Orifice Plate 12 Install the remaining gasket and orifice plate cover onto the valve body Install the attaching screws and tighten them alternating and evenly to 20 Nm 15 ft lb Figure 122 Installing Orifice Plate Cover 13 Install valve onto the transmission and torque the attaching screws to 68 Nm 50 ft Ib 166 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Assembly of Electrical Control Valve upperbody half 1 Install one dowel pin large diameter into each of the two bores of the valve body 2 Install one spring into
160. nout The face runout must not exceed 0 41 mm 0 016 in for both SAE 0 and 00 housings Figure 112 Measure Front Housing Face Runout B Move the dial indicator s probe so it measures the O D of the front housing pilot diameter Rotate the input shaft and note the total indicator runout The pilot runout must not exceed 0 30 mm 0 012 in for both SAE 0 and 00 housings Should total indicator runout exceed the allowable limits contact the Product Service Department of Twin Disc Inc for information and recommendations 160 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly On close coupled units mounted to the engine flywheel housing the input shaft splines are a slip fit If the transmission is to be shipped with the input coupling installed it must be attached to prevent it from sliding off and causing damage Be sure the internal retaining ring is installed into the correct groove of the input hub on units using a Vulkan input coupling refer to transmission assembly drawing The torque specification for the M20 screws that attach the coupling element to the coupling hub is 530 N m 391 ft lb with lubricated threads On free standing units install the input hub The spline fit with this hub is a tight fit therefore it is recommended to heat the coupling to 66 C 150 F to ease installation The use of silicone spray lubricant on the shaft is also recommended Install the retainer washer
161. o 23 Nm 17ft Ib Figure 134 Installing Orifice Plate left and Trolling Valve Onto Valve Body right Marine Transmission Service Manual 1020304 175 Assembly Twin Disc Incorporated Installation of Electric Control Valve 1 Install control valve ditch plate and gasket Torque the ditch plate attaching capscrews to 112 Nm 83 ft lb 2 Install control valve and gasket Torque the valve attaching capscrews to 54 Nm 40 ft lb 176 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation Installation Prior to Installation A CAUTION Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be made before the driven component is installed After installation of the driven component the crankshaft endplay should be measured again The endplay at the second measurement should be the same as the first A difference in these two endplay measurements could be an indication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage caused by engine to Twin Disc component interference regardless of the cause of interference
162. o 350 Ibs lifting force on the shaft Rotate the shaft several revolutions in each direction stopping with the dial indicator probe resting on the mark Dial indicator reading is secondary shaft endplay Endplay should be between 0 13 mm to 0 18 mm 0 005 in to 0 007 in Add or remove shims as necessary to achieve correct endplay Use dial indicator and above procedure to confirm that desired endplay has been attained Confirm endplay for primary shaft by repeating previous steps on primary shaft 16 Remove the indicator and manifold Remove the shims and bearing spacers keeping track of which shaft they correspond to Remove the bearing carrier bearing cups marking them for location identification and clutch shafts Marine Transmission Service Manual 1020304 135 Assembly Twin Disc Incorporated Assemble Primary and Secondary Clutch Shafts Note Assembly procedure is exactly the same for each clutch shaft therefore only one shaft is described 1 Remove external retaining ring and pinion from clutch shaft 2 Remove the pinion rear bearing from inside clutch housing 3 Install spring retainer onto clutch piston 4 Install the belleville clutch release springs over the spring retainer in an alternating fashion The first belleville spring must contact the spring retainer at the outside diameter The second belleville spring must contact the first belleville spring at the inside diameter Install the remaining springs
163. o contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate deterioration of the rubber to metal bond See above Deterioration of the rubber element as evidenced by sponginess or by black carbon like dust on rubber surface May be caused by contaminants or excessive heat either external or internal to the coupling Cracked bent or otherwise damaged flex plate or coupling plate Bolt holes in flex plate or coupling plate elongated oval shaped not round This could be caused by improperly assembled parts loose parts vibration or improperly torqued parts Bolts nuts bent worn or stripped threads Inspect the hub looking for the following Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found 66 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Preventative Maintenance Heat Exchanger Check Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days If over 50 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to det
164. o remove All other MG 5301DC Models Note The following steps of disassembly can be accomplished with transmission standing upright 1 Remove the torsional coupling and hub from the primary shaft spline if not previously removed The coupling hub is a slip fit on the spline Note the position of the internal retaining ring inside the hub it must be reinstalled in that position at reassembly 2 Remove the front housing from the main housing 3 Remove the top cover and gasket 4 Remove the oil pump and gasket Remove the pump spacer plate and pump drive adapter some models Remove heat exchanger housing heat exchanger element and stiffener plate Check the condition of the anode inside the heat exchanger housing units with integral raw water heat exchanger only 6 Remove the oil filter canister housing element and filter head Remove the filter bypass valve parts from the filter head 7 Remove the control valve and set it aside for later disassembly Marine Transmission Service Manual 1020304 75 Disassembly Twin Disc Incorporated 8 Remove capscrew securing clamp plate for suction strainer cover Remove clamp plate suction strainer cover with O ring and suction strainer Figure 27 Removing Suction Strainer 9 Remove the oil level gauge and tube assembly from the housing Note It is necessary to block and support the transmission with the output side facing up Use caution to avoid damagin
165. o the piston seal ring groove Install the first seal ring section into the groove over the expander ring Install the second seal ring section into the groove over the expander ring with the ends rotated 180 from the ends of the first seal ring Install the third seal ring section into the groove over the expander ring with the ends rotated 90 from the ends of the first seal ring Install the fourth seal ring section into the groove over the expander ring with the ends rotated 270 from the ends of the first seal ring Apply a coat of assembly grease or oil to the seal ring Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 7 Install clutch apply piston into piston bore in transfer gear E gt u TN Figure 81 Installing Clutch Piston Note Some models use a clutch piston without external splines Refer to unit BOM for parts usage 8 Install the orifice plug into the front end of the secondary shaft some models Use MA908 Loctite 242 on the threads and torque the plug to 68 Nm 50 ft lb Marine Transmission Service Manual 1020304 129 Assembly Twin Disc Incorporated Assembly of Clutch Assemblies 1017020 1017020A 1017607 amp 1017607A Note The following procedures apply to assemblies 1017020 1017020A 1017607 and 1017607A which use belleville clutch release springs The shaft endplay is established before the belleville springs and clutch plates a
166. ommended Determine if secondary shaft and transfer gear can be advanced properly a Hold secondary shaft in a vertical position standing on its front end b Use adepth micrometer and measure distance from the rear end of the shaft to the shaft shoulder at small end of taper Record this distance as dimension A Install secondary transfer gear secondary shaft taper small diameter of tapered bore up Seat gear on shaft taper with 445 N to 890 100 165 to 200 Ibs of force d Use depth micrometer and measure distance from rear end of shaft to machined face of transfer gear at small diameter of tapered bore Record this distance as dimension e Calculate expected advance Expected advance Calculated advance must be 2 67 mm to 3 71 mm 0 105 in to 0 146 in If calculated advance is not within the range recheck all measurements and calculations for errors If no errors are found contact the Product Service Department at Twin Disc Incorporated for information Set secondary transfer gear on fixture T 18050 723 with large diameter of tapered bore up Move fixture and transfer gear to a press with at least 667 KN 75 tons capacity Install secondary shaft front end up into tapered bore of transfer gear Seat shaft in tapered bore of gear by applying 445 N to 890 100 165 to 200 165 downward force on shaft Marine Transmission Service Manual 1020304 Twin Disc Incorporated A
167. on will be backdriven anti engine direction when the unit is in the secondary position Secondary Clutch Engaged Figure 26 MG5301DC Power Flow with Secondary Clutch Engaged 62 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Preventative Maintenance Preventative Maintenance Lubrication Grease the oil seals on the output end of the output shaft through the grease fitting with water pump lithium soap based NLGI No 2 grease Apply grease every 100 hours or when the boat is docked No other lubrication is required beyond the daily oil check Oil System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil in it With the engine running at low idle and the transmission in Neutral check the oil again The oil level should be near the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval With a new transmission change the oil and filter element within the first 50 hours of operation Change oil and filter element after each 1000 hours thereafter or more often if conditions warrant For a rebuilt transmission check the filter element after eight hours of operation If the filter is clean install a new filter element and then change the oil and fil
168. over the springs and into valve body Install neutral pressure regulating spring into the pocket of valve body Figure 128 Neutral Pressure Regulating Spring Location 25 26 27 28 29 Install orifice plate gasket onto valve body Install orifice plate and steel ball against spring onto valve body Install orifice plate cover and gasket onto valve body Install cover capscrews and torque to 23 17 lb ft Install gasket over lower valve body half Set upper valve body half over lower valve body half Insert the valve attaching screws through valve body halves to keep parts in alignment until installation onto the transmission When installing the valve onto the transmission torque the screws to 54 Nm 40 Ib ft Marine Transmission Service Manual 1020304 171 Assembly Twin Disc Incorporated Assembly of Trolling Valve optional equipment 1 Press a new oil seal into the counterbore in the end of the adapter Install a new O ring into the groove of the adapter Figure 129 Installing O ring onto Adapter 2 Install a new O ring into the groove of the stem 3 Install the roll pin into the end of the stem if removed 4 Install the inner spring onto the roll pin in the stem end with a counter clockwise twisting motion The spring is to be installed onto the roll pin such that the first coil contacts the end of the stem 5 Apply assembly grease to the stem from the O ring to the reduced dia
169. p 84 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 4 Remove and disassemble pinion s a Remove round retaining ring from input end of shaft and remove pinion from shaft g x Figure 37 Removing Round Retaining Ring from Input End of Shaft b Remove internal retaining ring from input end of pinion and remove straight roller bearing Note The straight roller bearing in the bore of the input end of the pinion is an interference fit and will likely be destroyed during removal Remove the straight roller bearing with the use of a puller behind the roller ends Remove tapered roller bearing cup from bore at rear of pinion if bearing requires replacement This bearing cup is an interference fit in the pinion bore To remove use an electric welder to weld a light bead around the of the bearing race This will shrink the bearing cup to facilitate removal Bearings removed with this method must be replaced Marine Transmission Service Manual 1020304 85 Disassembly Twin Disc Incorporated 5 Remove internal retaining ring at front of clutch housing and remove clutch backing plate Figure 38 Clutch Backing Plate and Retaining Ring Removed Note Some models use a Spiral internal retaining ring at the clutch backplate and a clutch piston without external splines 6 Remove clutch plates 9 steel 10 friction maintaining the respective order for inspection purposes 86
170. period it is also advisable to fill the fuel tanks and load the boat in the typical manner that itis to be used Some boats are built with flexibility and may change shape as the loading varies Marine Transmission Service Manual 1020304 185 Installation 186 Twin Disc Incorporated When a heavy boat is dry docked it naturally undergoes some bending Therefore it is always good practice to the marine transmission coupling to prevent bending of the shaft With the engine and transmission in position on the engine bed arrangements must be made to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine can be raised by screwing down or lowered by backing off on the jacking screws to obtain the desired adjustment Steel plates must be inserted under the jacking screws so that the bolts will not damage the engine bed Lifting can also be accomplished by the use of chain hoists or properly placed jacks Adjustable shims also are available and can simplify the alignment process particularly for future realignment It may also be necessary to move the engine and transmission to one side or the other on the engine bed to obtain horizontal alignment This can be done with a jack placed horizontally between the engine and the foundation Atthe same time a straight edge is laid across the edges of the
171. r spring and roll pin from the stem only if replacement of parts is necessary 11 Remove the washer from the bore of the valve body some models Note the washer may have been removed with the stem 12 Remove the outer spring and piston from the bore of the valve body Note that there may be washer s in the bore of the piston some models Figure 67 Removing Spring and Piston from Valve Body Marine Transmission Service Manual 1020304 107 Disassembly Twin Disc Incorporated 13 Remove the O ring from the groove and the oil seal from the end of the adapter Figure 68 Removing O ring from Adapter 108 Marine Transmission Service Manual 1020304 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 by steam cleaning Parts must be dried and oiled immediately to prevent corrosion Examine all parts carefully for grit dirt and abrasives 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
172. ransmission s water circuit Install the M10x1 O ring water drain plug and torque to 25 Nm 18 ft Ib Units with Integral Raw Water Heat Exchanger Install stiffener plate and gasket Install two O rings into counterbores of stiffener plate Install heat exchanger element and cover gasket over adapter plate and O rings Install anode into cover with gasket screw and sealing washer torquing screw to 18 Nm 13 ft lb Fill the remaining threads in the anode below the screw with RTV silicone sealer Be sure sealer has proper curing time before exposing it to water Install heat exchanger cover and torque the attaching screws to 112 Nm 83 ft Ib Install protective plugs into cover to prevent the entrance of contaminants into the transmission s water circuit Install the M10x1 O ring water drain plug and torque to 25 Nm 18 ft lb Marine Transmission Service Manual 1020304 159 Assembly Twin Disc Incorporated Installation of Input Oil Seal and Front Housing 1 Install the input oil seal with the driver of tool T 18050 706 detail 2 Be sure to use the seal sleeve detail 1 to protect the input oil seal from being damaged by the primary shaft splines 2 Install the front housing onto the transmission Torque the attaching screws to 112 Nm 83 ft lb 3 Check front housing runout A Mount a dial indicator on the input shaft with the probe on the front housing machined face Rotate the input shaft and note the total indicator ru
173. re and temperature gauge where applicable Inspect the oil lines and heat exchanger for leaky connections cracks or other damage Replace damaged lines Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required 68 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Troubleshooting Troubleshooting Troubleshooting Chart The following chart is intended as a guide for determining the cause of problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Tables begin on the next page Marine Transmission Service Manual 1020304 69 Troubleshooting Table 14 Troubleshooting Chart Twin Disc Incorporated symptom J Cause Remely 2 70 Low main oil pressure No oil pressure or erratic low pressure at control valve tap Partially clogged oil strainer Stuck pressure regulation piston Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Incorrect linkage adjustment to control valve assembly Clogged or plugged orifice in orifice plate of control valve assembly Shimming required between
174. re installed An alternate procedure is also listed to establish correct bearing settings while the transmission is installed If the transmission has coil spring clutch release springs proceed directly to page 143 Establishment of Correct Bearing Clearance 1 Install the pinion rear tapered roller bearing cone onto the shaft without the belleville springs 2 Assembly of pinion A Use special tool T 18050 708 to install chilled tapered roller bearing cup into rear of pinion for secondary shaft Bearing cup is installed with small 1 0 of taper toward the front and seated against shoulder of bore in clutch hub of pinion Figure 82 Installing Tapered Roller Bearing Cup Into Pinion 130 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly B Install chilled needle roller bearing into bore at front of pinion with the radiused edge of the outer race entering the pinion first Figure 83 Needle Roller Bearing Installed C Install internal retaining ring into groove in pinion bore Figure 84 Installing Internal Retaining Ring Into Pinion Marine Transmission Service Manual 1020304 131 Assembly Twin Disc Incorporated Install pinion on secondary shaft without clutch plates Install external retaining ring to retain pinion on shaft Figure 85 Installing External Retaining Ring Onto Clutch Shaft 3 Assemble primary shaft Repeat previous procedure steps as assembly procedure
175. rier and into machined pocket in front inner face of housing Rotate tube so elongated key of tube fits into corresponding key in bearing carrier Properly installed lube tube will be flush with rear face of bearing carrier wm Figure 105 Key Orientation of Installed Lube Tube Install cups for rear tapered roller bearings on primary and secondary shafts into bores in bearing carrier Tap cups down gently with soft hammer or brass drift to seat against bearing cones on shafts Install manifold gasket over alignment studs and against bearing carrier Install the bearing spacers over the bearing cups Rotate the shafts at lease three revolutions to seat the bearing rollers while pressing down on both bearing spacers Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Push tapered roller bearing cups with bearing spacers firmly against roller bearing cones on rear of primary and secondary shafts Use a depth micrometer to measure from top of manifold gasket down to shim retainers Measured distance is shaft endplay Use necessary shims to develop a shim pack for each shaft to reduce shaft endplay to 0 013 mm to 0 063 mm 0 0005 in to 0 0025 in Figure 106 Measuring to Determine Shim Pack Thickness 11 Remove one shim retainer and install the shim pack for that shaft directly over the bearing cup The thinnest of the shims should be in the center of the pack and the thickest shim shoul
176. rine Transmission Service Manual 1020304 Twin Disc Incorporated Installation Table 15 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face sae ae iad Eccentricity 0 48 0 019 0 41 0 016 0 36 0 014 0 28 0 011 0 25 0 010 0 23 0 009 0 20 0 008 0 18 0 007 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 i NELLE Thousanaths Engine DUE 5 uot Flywheel Crankshaft p TT es AL 2 Flywheel Housing Figure 136 Checking Flywheel Housing Bore Eccentricity Marine Transmission Service Manual 1020304 179 Installation 180 Twin Disc Incorporated Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the previous Table for allowable tolerances Bolt a thousanaths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the surface to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter Engine Engine Flywheel Housing r Engine Flywheel Thousandths Engi
177. rolled rate The control valve allows only one clutch to be engaged at a time and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Marine Transmission Service Manual 1020304 45 Operation 46 Twin Disc Incorporated Control Valve Assembly in Neutral Some of the main pressure oil from the oil inlet chamber flows through a passage to the orifice in the orifice plate The small flow of oil through this orifice fills and begins to pressurize the rate of rise chamber Both clutches are connected to sump when the control valve is in Neutral Since there is no pressure acting on the shuttle ball from either clutch the passage behind the ball and spring regulator is also connected to sump This allows the oil pressure in the rate of rise chamber to be regulated by the ball and spring since the overage oil can flow to sump The oil pressure in the rate of rise chamber acting on the rate of rise piston causes it to stroke over partially which compresses the pressure regulating springs additionally This additional spring compression further resists the movement of the pressure regulating piston resulting in a force balance between the area at the pressure regulator the springs and the area behind the rate of rise piston Neutral main pressure of approximately 40 psi is maintained by relieving
178. rts G and K to passages E and J Passage E is aligned with a passage directing main pressure to the secondary clutch Pressurized oil from port G travels through passage J and enters chamber L through an orifice in the orifice plate The orifice in the plate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against springs until the piston is stopped by a shoulder in the valve body The causes the pressure in chamber B to rise to clutch engaging pressure When in secondary passage D remains at atmospheric pressure because slot F remains open to sump When a shift is made from secondary to neutral the valve stem is rotated to the position illustrated by Figures 8 and 9 Under these conditions passage E is connected to the sump by slot F Passage J is also connected to sump by port H in the valve stem Because passage E is connected to slot F oil drains rapidly from the secondary clutch to sump Because passage J is now at atmospheric pressure the oil pressure in chamber the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The secondary clutch is now disengaged and main system pressure reduced to neutral pressure 42 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Operation A Entry
179. rvice Manual 1020304 Twin Disc Incorporated Description and Specifications Construction Features Housings The MG 5301DC series transmission has a one piece main housing Front housings in sizes SAE No 0 and SAE No 00 sizes are available A top cover bearing carrier and manifold sealed with gaskets complete the housing enclosure Bearings The primary and secondary clutch shafts and pinions are supported and located by a combination of straight and tapered roller bearings Bearing clearances for each clutch shaft and pinion assembly are set by use of a single shim pack at the rear tapered roller bearing on each shaft Tapered roller bearings support the output shaft and have bearing clearance adjusted by use of shims at the rear bearing carrier Oil Pump and Drive The oil pump is driven by the secondary clutch shaft Marine Transmission Service Manual 1020304 19 Description and Specifications Twin Disc Incorporated Lubrication Features The MG 5301DC series transmission has a lubrication tube located inside the main housing The tube extends from the front to the rear of the inside of the housing The lubrication tube has drilled holes in the tube that spray oil on the transfer gears and the primary and secondary pinions Bearings and clutches on the primary and secondary shafts are lubricated through drilled passages in the shafts Output shaft bearings are gravity and splash lubricated Suction Screen
180. s Steel fabricated mounting brackets for rigid mounting are available Twin Disc part number 1016428AC Torsional Input Coupling Several models of torsional input couplings are available including Vulkan VL3411S and Centa CF R couplings in both SAE 0 and SAE 00 sizes 28 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Description and Specifications Electric Control Valve Electric control valve are available with either 12 vdc or 24 vdc actuating solenoids and are identified as 1018084Y 12 vdc and 1018084P 24 vdc Coupling Flange Two different coupling flanges are available The standard flange assembly is Twin Disc part number 1017084 A coupling flange for disc type propeller shaft brake applications is available part number 1019642 Table 3 Advance Specifications Transmission Primary and Secondary Transfer Gear Advance Minimum Maximum 2 67mm 105 in Transmission Output Gear Advance Minimum Maximum 9 45mm 372 in Transmission Output Flange Advance Maximum 9 91mm 390 in Minimum 8 13mm 320 in Marine Transmission Service Manual 1020304 29 Description and Specifications Twin Disc Incorporated Table 4 Bearing End Play Specifications Transmission Primary and Secondary Shaft Tapered Roller Bearing Endplay Assembly No Minimum Maximum 1017020 1017020A 1017607 0 13 mm 005 in 0 18 mm 007 in
181. s of the system torsional vibration analysis TVA and on engine rotation Care must be taken when servicing that replacement couplings are matched to this criteria Marine Transmission Service Manual 1020304 21 Description and Specifications HOUSING 1017013 CSAE 02 NG 1017123 SCREW 1015472 1003847 RING 1004361 MA996F 202 CSAE 0 HSG gt SCREW 1055 16 Twin Disc Incorporated IUB 1017023 SHAFT ASS Y 1016988 SHAFT 1016987 BALL 1034 COUPLIN RING 1048 WITHOUT URSTIUNAL SIUI ASSEMBLE RING INTO INNER GROOVE FOR SAE No 460 COUPLINGS 1048 RING COUPLING 1017865 1015472 PLATE 1003847 PLATE 1004244 PLATE 1004362 RING 1004359 A SAE 0 HOUSING Figure 2 Vulkan VL3411S Series Torsional Coupling SAE 0 22 Marine Transmission Service Manual 1020304 Description and Specifications Twin Disc Incorporated 7 2 Fi f ANN X X X X X X NN S X NON E N NN 3 2 A AY NN OZ KN UNNN tA AS N gt gt INN re ow SN X NU 2 5 N NV 7 IO NN NS i NI kl 27 lt M f
182. se 2 5 2 ae 1 STRAP M2942B NOTE M INSTALL USING MA908 LOCTITE 9 DETENT GROOVE UNTIL SNUG 40967 1017383 1017179 ves pwe7s9rHe4 vac s UR n ss en pnncmer e BACK UFF 1 2 TURN eee sos meer T e erroe vod THESE SOLENOID CONNECTIONS horsossar 4118 1017133 1017134 B1337F 1018688 xwezseri te voc ARE NOT POLARITY SENSITIVE SETSCREW M2038W sieoseacl anea 1017194 iesse vic 41171 1018688 _ xme759rMe4 voci SPRING A2702BQ 2 hoogsas 4172 75 voc Lock ont Q hosossak 41244 1018584 1018594 31174 1018688 7 1 21250 1018688 voci PIN A2711AC 2 SPOOL 1017432 2 horsossan 41251 1018688 7 xa27072 E 5e0 1HP AUAA NOTE HYDRAULIC LOCK ONLY HYDRAULIC LOCK ONLY jonossa anoe _ 278781 470388 1171098 pitsocoer x
183. sembly 11 Remove four of M8 x 25 socket head capscrews 12 Remove the cover assembly with gasket from the valve body 13 Remove the O ring and oil seal from the cover assembly Figure 55 Removing O ring from Cover 14 Removethe two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body some models 15 Remove the detent setscrew spring and steel ball from the valve body Figure 56 Removing Detent Setscrew and Spring Marine Transmission Service Manual 1020304 99 Disassembly Twin Disc Incorporated 16 Remove the dog point setscrew Note that the setscrew is retained with MA908 threadlocker 4 Me Figure 57 Removing Dogpoint Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 58 Removing Thrustwasher 100 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly 19 Remove the stem from the valve body 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 59 Removing Roll Pin Retaining Shuttle Seat 21 Thread M8x1 25 screw one of the cover screws works well into the seat and remove it from the valve body 22 Remove the shuttle ball from the valve body Marine Transmission Service Manual 1020304 101 Disassembly Twin Disc Incorporated Disassembly of Upper Valve Body Half electric
184. serious damage may occur to the engine 194 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation Propeller Shaft Before any attempt to align the engine and gearbox to the propeller shaft proper alignment of the propeller shaft must be determined This includes alignment of the propeller shaft through all struts and intermediate bearings Failure to properly align the propeller shaft may result in premature wear on bearings vibrations or possible damage to other components If the length of the shaft from the last support bearing to the gearbox is excessive or a flexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Transmission Controls CAUTION Transmission controls must be checked for proper function and alignment after any transmission selector valve is properly indexed in relation to the operator s control lever Failure to do so could cause control system malfunction resulting in personal injury and or damage to equipment and property See specific marine transmission installation drawings for detail and dimensional information needed for the proper installation of control linkages power engaging devices or electrical connections Marine Transmission Service Manual 1020304 195 Installation Twin Disc Incorporated S JE INSTALLATION VALV 3 CONTROL 5 9mm
185. sitioned as identified in the following paragraphs Note The MG 5301DC requires the use of a SKF THAP 300 oil Injection Kit as seen in Special Tools or similar device to service the output flange and output gear Use the following reference The input side of the transmission is the front and the output side is the rear Left and right sides are determined by facing the output side of the transmission from the rear Marine Transmission Service Manual 1020304 73 Disassembly Twin Disc Incorporated Prepare Transmission for Disassembly Note During service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the old O rings gaskets and seals with the appropriate components being disassembled for future reference during the inspection and assembly process to make sure you do not forget the quantity size etc Drain the oil from the transmission sump by removing the hex plug from the bottom of the rear side of the housing Drain the water from the heat exchanger by removing the O ring plug from the bottom of the heat exchanger housing units with integral heat exchanger only 74 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Disassembly Remove Transmission External Components and Sub Assemblies Free Standing MG 5301DC Models Only 1 Remove coupling hub retaining washer and capscrews The hubis a press fit onto the shaft and will require the use of a puller t
186. smission Service Manual 1020304 7 Table of Contents Twin Disc Incorporated TOU SING 69 Troubleshooting Chart 69 70 siipii a 73 Prepare Transmission for Disassembly 74 Remove Transmission External Components and Sub Assem jr P 75 Remove Output Flange 77 Remove and Disassemble Manifold and Bearing Carrier 78 Remove Primary and Secondary Clutch Shaft Assemblies 80 Remove Output Gear and 81 Disassembly of Primary and Secondary Clutch Shafts 84 Disassembly of Upper Valve Body Half electric section 102 1017555 Trolling Valve Optional Equipment 104 Cleaning and Inspection 109 m 109 MeM 111 PSY ete cT 115 PROF 16 ASSemDIy 116 Preliminary Assembly 117 Installation of Output Shaft and Gear 119 Installation of Output Shaft Rear Bearing 121 Output Shaft Tapered Roller Bearing Adjustment 122 Assembly and Installation of Primary and Secondary Shafts 126 Installation of Manifold and Exterior Components
187. ss force from the fixture aa Figure 95 Fixture Used to Establish Secondary Shaft Bearing Clearance To perform this procedure the clutch shafts are completely assembled and then installed into the transmission The bearing carrier is then assembled and installed over its gasket on the transmission The bearing cups are installed and 3115 700 16 of force is applied from the fixture to the bearing cups while rotating the shafts three revolutions to seat the bearing rollers The distance is measured from the manifold surface down to the bearing cup and the manifold gasket thickness added to that measurement A shim pack is used with the bearing spacer so that the overall thickness is 0 013mm 0 005 in thinner than the sum of the previous two measurements The thinnest of the shims should be in the center of the pack and the thickest shim should be against the bearing cup The shim packs are installed against the bearing cups followed by the bearing spacers The manifold gasket and seal rings are installed next and assembly grease is used to hold the seal rings centered within their grooves The manifold is installed and the screws torqued to 112 Nm 83 ft lb At this point proceed to page 154 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Assembly of Clutch Assemblies 1017020B and 1017607B Note The following procedures apply to assemblies 1017020B and 1017607B which use
188. ssembly Center fixture gear and shaft under ram of press and apply approximately 391 kN to 543 kN 44 tons to 61 tons of force on front end of secondary shaft Release pressure and turn fixture shaft and gear 180 Reapply pressure to complete advance 1 Figure 80 Pressing Clutch Shaft Into Transfer Gear Note Using a depth micrometer measure distance from rear end of shaft to face of transfer gear Record as dimension C Transfer gear face should be within 0 05 mm 002 in of the shaft shoulder at the small diameter end of the taper Actual advance must 2 67 mm to 3 71 mm 0 105 in to 0 146 in If transfer gear has not been advanced as specified above contact the Product Service Department at Twin Disc Incorporated for information Marine Transmission Service Manual 1020304 127 Assembly 128 Twin Disc Incorporated Install heated tapered roller bearing cone onto shaft against clutch housing Install bearing with large O D toward transfer gear Use driver T 18050 723 and hydraulic press to ensure bearing is fully seated against transfer gear Install the external retaining ring onto the shaft with the tapered edge side away from the bearing Install clutch piston inner seal ring into groove in secondary shaft Apply a coat of assembly grease or oil to seal ring Install multi piece seal ring in groove in O D of clutch apply piston as follows A B Install the expander int
189. stem The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation When the control valve is shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively increases the clutch engaging pressure causing the clutches to engage at a controlled rate The control valve allows only one clutch to be engaged at a time and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Marine Transmission Service Manual 1020304 PpOLOZOL Jenuey uoissiusueJ SUNEN 26 L6LLZY Be BEARING 2 LUBE PRIMARY SHAF amp REAR BEARING PINION y SHOWN ENGAGED SECONDARY SHAFT
190. stick there by friction View X Figure 145 Insert Rollers and Note Alignment 192 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Installation 3 In case that they should not stick place a tape or a cord with a slipknot around all rollers close to the gear side Let the end of the tape or cord long enough that it is hanging outside the flange Turn the two couplings halves in a position that the arrows of both halves are just opposite See Figure 145 View X tape or cord d plined shaft Figure 146 Coupling into Flywheel Flange Marine Transmission Service Manual 1020304 193 Installation Twin Disc Incorporated 4 Then push the output side of the coupling with the gear into the outer flange If necessary apply some lubricant on the outer flange Suitable lubricants are soap water detergents etc but no oil or grease In case atape or cord had to be used push the coupling only half way together and then take the long end of the tape or cord and pull it away Then grease or oil the gear shaft and plug it into the coupling spline remove tape or cord Figure 147 Final Assembly 5 Bolt the gear flange to the flywheel housing Note When bolting the gear flange to the flywheel housing make sure that no axial thrust is exerted to the coupling by tightening of the bolts Before the engine is started the first time check that the crankshaft has endplay otherwise
191. te clutch friction 18 Plate clutch steel 2 Ring internal retaining clutch backplate Lee payesodioou OSIA UIML suoneusnyl Illustrations Twin Disc Incorporated Clutch Group Assemblies 1017020B 1017607B 20 ama IES TLLA KS ND E 228 Marine Transmission Service Manual 1020304 PpOLOZOL Jenuey uoissiusueJ SUNEN o 10 11 12 13 15 16 17 18 19 20 21 22 23 N gt Description Bearing tapered roller primary amp secondary shaft front bearing Bearing needle roller Shaft assembly secondary Ring external retaining primary amp secondary shaft needle bearing Ring internal retaining pinion needle bearing Pinion assembly primary amp secondary Tube lube Bearing tapered roller primary amp secondary pinion rear bearing Backplate clutch Retainer spring primary amp secondary shaft Ring external retaining primary amp secondary shaft spring retainer Spring compression clutch release Gear transfer secondary shaft LH helix Piston clutch Ring pis
192. ter 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 Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Marine Transmission Service Manual 1020304 63 Preventative Maintenance Twin Disc Incorporated 64 Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located in the manifold below the pump See Engineering Drawings for suction strainer location Type Oil Recommended See Description and Specifications Filling 1 2 Remove the filler breather in the top cover of the transmission Fill the transmission s sump with 51 5 liters 13 6 U S gal of the proper weight and type oil See Description and Specifications for oil recommendations Start the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the oil level to FULL mark on the o
193. terial in this manual will result in consistent performance from the unit and help reduce downtime Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Inc will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unaccepted maintenance working practices Marine Transmission Service Manual 1020304 11 Introduction 12 Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possible danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance 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 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 To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove igni
194. the transmission Install flush with outer face of seal carrier with driver T 18050 713 NOTE START FIRST SEAL INTO CARRIER WITH SEAL DRIVER FLANGE DOWN INSERT THIS SEAL FIRST AS SHOWN SEAL CARRIER j N N OIL SEAL 1 FLANGE DOWN PRESS 2 pe uf FLANGE UP PRESS IN SECOND SEAL Figure 78 Output Seal Driver T 18050 713 124 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly 9 Pack area between the seals with NLGI No 2 grease example Mobilux EP2 Figure 79 Packing Cavity Between Output Seals With Grease 10 Apply acoat of assembly grease or oil to the o ring on the seal carrier 11 Install grease fitting if not previously installed 12 Install shim pack over bearing cup 13 Install assembled output seal carrier onto housing Use caution to avoid damaging the O ring Install attaching screws and torque to 112 Nm 83 ft lb 14 Remove T 18050 714 from output shaft Marine Transmission Service Manual 1020304 125 Assembly Twin Disc Incorporated Assembly and Installation of Primary and Secondary Shafts 126 Installation of Transfer Gear Rear Bearing and Clutch Piston 1 Assembly of transfer gear to secondary shaft A Clean taper on secondary shaft and tapered bore in transfer gear using OSHA approved cleaner Do not touch cleaned surfaces Loctite 7070 cleaner is rec
195. the bearing cup dimension D Dimension must equal dimension A minus dimension minus dimension C within 0 025 mm 0 001 in 118 Marine Transmission Service Manual 1020304 Twin Disc Incorporated Assembly Installation of Output Shaft and Gear 1 Clean tapered surface of output shaft and tapered bore of output gear Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Do not touch cleaned surfaces Loctite amp 7070 cleaner is recommended CAUTION Tapered surface of shaft and matching tapered bore of gear must completely free of grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance measurement of gear on shaft and adversely effect torque carrying capacity of the assembled joint Both parts must be at the same temperature 2 Install front output bearing cone and output gear Use special tool T 19987 2 to position gear into correct location Install the output shaft into the output gear and bearing cone in the transmission housing using T 18050 714 Seat shaft onto the taper of the gear using only the weight of the shaft 3 Use gauge blocks and a feeler gauge to measure between the output gear and shaft shoulder This is the potential advance and it must be 9 45 mm to 11 00 mm 0 372 in to 0 433 in Figure 72 Measuring Output Gear Advance Note Should the calculated advance fall outside the range given a
196. tion key from the switch Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these points could cause failure at the lift point or points and result in damage or personal injury A CAUTION Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Transmission Service Manual 1020304 Twin Disc Incorporated Introduction Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Operators Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment Under the conditions described below the prop shaft must be locked in place to prevent backdriving Failure to do this can damage the marine transmission due to the lack of component lubrication Backdriving 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 lu
197. ton clutch piston inner Ring assembly piston clutch piston outer Housing lube relief valve Spring compression lube relief valve Ball steel lube relief valve Screw hex head lube relief valve Washer lube relief valve Bearing tapered roller primary amp secondary shaft rear bearing Item 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 43 44 45 46 47 48 Qty Description Spacer bearing Plug pipe temperature sensor port Ring piston primary and secondary shaft Manifold Spacer oil pump Pilot spacer Adapter pump drive Pump oil Screw hex head cap oil pump Gasket oil pump Screw socket head cap pump drive adapter Gasket oil pump spacer Screw hex head cap suction strainer cover Plate clamp suction strainer cover O ring suction strainer cover Cover suction strainer Strainer suction Gasket manifold Carrier bearing Gasket bearing carrier R Shim bearing 005 007 020 primary amp secondary shaft bearing adjustment D2 NNDR 2 Ring external retaining primary amp secondary shaft rear bearing 20 Plate clutch friction 18 Plate clutch steel 2 Ring internal retaining clutch backplate 6cc pe1e10dj02u UIML suonesnil Illustrations Twin Disc Incorporated Oil Filter 555 50600006066 gt 5566 lt gt 4 524 5 525 555
198. uent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit September 4 2001 TDW P2003 TWIN DISC INCORPORATED FLAT RATE HOUR ALLOWANCE Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated COMMERCIAL MARINE TRANSMISSIONS ALL RATIOS MODEL SERIES R amp R UNIT REBUILD CLUTCH REPAIR BOTH PACKS MG 502 MG 5010 MG5011 MG5005A MG5015A 10 0 8 0 MG 506 MG5061 MG 5050 MG5055A MG 507 MG 5081 MG5085 MG5090 MG 5091 MG5112 MG5113 MG 509 MG 5111 MG5114 MG5114A MG5114RV MG 514C MG514M MG5141 MG514CHP MG 516 MG 5161 MG 518 1 MG520 1 MG 5202 MG5203 MG5204 MG5205 MG 530 MG530M MG5301 MG 540 MG5600 MG6000 MGN 80 MGN 232 MGN 233 MGN272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN 472 MGN 493 MGN 650 MGN 800 MGN 1000 MGN 1400 MGN 1600 PUMP ALL MODELS VALVE ALL MODELS September 4 2001 TDW P2003A Twin Disc Incorporated Table of Contents Table of Contents EI 11 General m 11 Safety and General Precautions
199. ure 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 1020304 Twin Disc Incorporated List of Special Tools Special Tools Special Tools The following pages include the special tool drawings that are specific to this model The special tool drawings included are listed below and continued on the following page D D D D O Marine Transmission Service Manual 1020304 Recommended Pump Set and Fluids THAP 300SKF Air driven Pump Set T 18050 704 T 18050 705 T 18050 706 T 18050 708 T 18050 711 T 18050 712 T 18050 713 T 18050 714 T 18050 715 T 18050 723 T 18050 77 1 T 19330 19987 2 Clutch piston hold down retainer sheet 2 of 2 Bearing driver for pinion needle roller bearings Input seal driver and protection sleeve Bearing cup driver Bearing cone driver primary and secondary shafts Seal protector plug driver Output seal driver Shaft lifting fixture output shaft Shaft lifting fixture primary and secondary shafts Bearing cone and transfer gear driver primary and secondary shafts Front output bearing cup driver Spring retainer compressor coil spring units Output gear lifting fixture 199 Special Tools Twin Disc Incorporated T 20023 3 Output gear installing fixture sheet 1 of 3 T 20023 3
200. utral 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 1020304 Twin Disc Incorporated Operation A HIGH PRESSURE A Oil Entry Passag y REGULATOR PISTON B Oil Pressure Chamber C Oil Pressure Overflow Port D Oi Engaging Passage E Oil Engaging Passage Oil Interconnection Slot G Oil Directional Port H Oil Connection Port J Oil Pressure Passage Directional Port L Oil Pressure Chamber RATE OF RISE PISTON CONTROL VALVE LEVER SPRINGS CONTROL VALVE STEM CONTROL VALVE BODY ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 8 Manual Control Valve Neutral Sectional View NEUTRAL CONTROL VALVE BODY TO FORWARD CLUTCH p em TO SUMP TO REVERSE CLUTCH CONTROL VALVE STEM ATMOSPHERIC PRESSURE ENGAGING PRESSURE Figure 9 Manual Control Valve Neutral Cutaway Vie
201. w Marine Transmission Service Manual 1020304 39 Operation 40 Twin Disc Incorporated Manual Control Valve Primary When a shift to the primary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 10 and 11 The pressurized oil in chamber B is directed through ports G and K to passages D and J Passage D is aligned with a passage directing main pressure oil to the primary clutch Pressurized oil from port K travels through passage J and enters chamber L through an orifice in the orifice plate The orifice in this plate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against the springs until the piston is stopped by a shoulder in the valve body This causes the pressure in chamber B to rise to clutch engaging pressure When in primary passage E remains at atmospheric pressure because slot F remains open to sump When a shift is made from primary to neutral the valve stem is rotated to the position illustrated by Figures 8 and 9 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 aga
202. y and secondary front tapered roller bearings into their respective bores in the front inner face of the housing Use driver T 18050 711 to press drive cups to the bottom of the bore It is important to maintain downward force as temperatures equalize to ensure that cup is at bottom of bore Figure 70 Front Pinion Bearing Cup Installation Marine Transmission Service Manual 1020304 117 Assembly Twin Disc Incorporated 4 Measure and record the distance from the machined surface of the housing to the bottom of the bearing cup bore where the oil shield contacts dimension A Measure and record the thickness of the oil distribution shield at the outer edge dimension Measure and record the width of the bearing cup dimension Install oil distribution shield into output shaft front bearing bore Be sure shield is properly centered 6 Install chilled front output tapered roller bearing cup into housing bore Use driver T 18050 771 to press drive cup to bottom of its bore Note Care must be taken to ensure that the shield remains centered Tighten puller rod to standard torque limit for thread size of puller rod or 275 Nm 200 ft lb whichever is less Maintain this torque until bearing cup and housing temperatures equalize approx 10 minutes Figure 71 Installing Output Shaft Bearing Cup Remove T 18050 771 Measure and record the distance from the machined surface of the housing to the top of
203. y shaft Install cover onto manifold at primary shaft Install attaching screws and torque to 112 Nm 83 ft lb Figure 109 Primary Shaft Cover O ring Installed left and Primary Shaft Cover Installed right Install oil pump drive adapter if equipped onto the secondary shaft Apply MA908 threadlocker to the cleaned threads of the screws and and torque them to 130 Nm 96 ft lb Install the pump spacer if equipped and its gasket onto the manifold Be sure the pump spacer pilot adapter is present between the spacer and the manifold 6 Install the oil pump gasket and oil pump at mounting location at end of secondary shaft Mesh drive tang on pump shaft with drive slot in secondary shaft or drive adapter Install attaching screws and torque to 112 Nm 83 ft lb 7 Assemble oil filter differential bypass valve parts into oil filter head Install oil filter head onto transmission Install O ring filter element and filter housing onto filter head and torque the bolt to 81 Nm 60 ft lb with its threads and washer oiled Marine Transmission Service Manual 1020304 155 Assembly Twin Disc Incorporated Installation of Output Flange 156 1 Clean tapered surface of output shaft and tapered bore of output flange Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Do not touch cleaned surfaces Loctite amp 7070 cleaner is recommended CAUTION Tapered surface of shaft and matching taper

Download Pdf Manuals

Related Search

Related Contents

Backup_of_MAnual Leroi  File - Dr. Hussein S Abdul  取扱説明書のダウンロード  Product Catalog  ELIGIBLES CD QUERY SYSTEM  Lennox International Inc. WINSLOW PS40 User's Manual  Topcom Speedopulse 1000W User's Manual  ZEISS VICTORY ® - Optics  Bedienungsanleitung deutsch V1.0    

Copyright © All rights reserved. Failed to retrieve file