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Service Manual Marine

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11. E Es RIFICE 1021751 27 2 0 RING PORT SEE CHART 2 5 STAMP VALVE ASSEMBLY 119 4 FE NOTE D GASKET 1020531
12. 11 _ WAVE SPRING mm DOUBLE i P GASKET L APPLY LIQUID SEALANT n 1 ei i dL PUMP if Em i l um COVER HeH STI eb 720 ma D SPRING JUMPER TUBER PUMP SUCTION ADAPTER PLATE 738166 Figure 182 Pump Component Identification and Location 1 Place MA1015 sealant on the sealing surface of the pump suction adapter plate 2 Install the pump suction adapter plate 1 if removed Torque the screws to 46 Nem 34 Ibeft
13. gt SOLENOID B ON OY RED LED am 25 q WIRING SCHEMATIC Am EUTSCH CONNECT 9 3 ae 0704 2 012 GREEN Rf wt a E IEUTSCH TERMINAL lt 2 TEMPERATURE SENS pe Dg UM i AR 0460 905 16141 EUTSCH WEDGE LOCK 1 mn E AR WEP Y zu gt x 4 a we Cc Iu iy eee aan 9 2 a Sea SOL A 2 S ON P i GREEN LED ES 2 UU 51222 x p C ue 2 ETRI PACK CONNECT 2 a a _ E Or i NE eee BLACK Jad 5 NORMALLY CLOSED amp uz LENDID RE NIN GND oa 4 4 TT
14. TWIN il PAR ER J1128 TYPE USE 1020282 5 ENAB C NE CLUS M PINK E pres S ER CONN DLL ENABLE RED Als V TROLL E SP HM OY OLL VIN 0460 202 16141 RANGE 05 V y ae O REE LL SEE 5 2 amp 4 D OLL I IN x LAS S 2 gt GND E VI 2 Sieh GND i S E P IN M GREE 20 _ GINE SPEED GREE r EN c uj 2 GINE SPEED 5 e E 27 5V PROP SPEED Cc oO oO ee SPEED IN O T m 2 e vtm OP SPEED GND Z a PENIS OL A TA K SENS EIS SE SDH zt d Y DL B E RED l gt E 1 162 201 16141 sas gt 2 ROWN OUTPUT q gt gt E R lt w em GND
15. DITCH HYD SOLENOID VALVE SPRINGS CLUTCH SHIMS MOUNTING SCREWS DATE VALVE BOM DITCH TRANSMISSION ORIFICE x FIRS LATE PISTON JRAULIC VOLTAGE CONSISTS OF kPa PSD p d AND WIRING DIAGRAM 2 273 4 557 PLATE Nol GASKET GASKE Lack QT Y No bu DUTER INNER NOM PLATE No PART a TO SS gary USE APPR CONNECTOR 2 2 NEUTRAL START 146 00 101808 0750 1017133 1017134 B1337F 1018688 YE 3 XM2759FM 24 VDC 70 A270 27031 25 250 1017129 MA1038E M 7 X 2 0 6H B2451B MA1052A 2 MALOS2A 2 5202 37128 Fyi SWITCH CLOSED ONLY WHEN Raa TL LL 2 Br 3 17 98 POR An S NOID MANUAL OVERRIDE IS IN USE amp Tfi nett a 134 70 E 0180844 0751 7383 L 9 2 2759 24 VDC A2707BD 42704 0 2415 lt 3502 1017129 1038 lt 27 X 20 ay 2451 MG 6619RV
16. BACKING PLATE WAVE SPRINGS BRONZE THRUST WASHER 18 GROOVES SE TAINING RING T i 1 0mm ORIFICE PLUG CLUTCH PORT T ON WITH DUMP q EN oi LUBE PORT 2 L5 7 Mth Sen E SEALING RING ILU PINION GEAR THRUST ASSEMBLY STEEL PLATES 12 FRICTION PLATES 11 549607 Figure 64 Primary Clutch Shaft Component Identification and Location 1 Position the shaft with the clutch sealing rings up 2 Remove bearing from shaft if it did not remain in the housing 3 Remove seal rings from shaft 4 Hemove round retaining ring 4 from the shaft 5 Remove the bronze thrust washer 5 Note The rear bronze thrust washer is equipped with 18 radial grooves both sides around the thrust washer for lubrication purposes 106 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly TE AR184 Figure
17. PHAR n 21 7 Lee 3 CLUTCH PORT BEARING CARRIER Sce N PUMP DRIVE A cime 2 COUPLING LUBE PASSAGE PINION GEAR SEALING RING ASSEMBLY THRUST RACE RICTION PLATES 11 STEEL PLATES 12 549607 Figure 72 Secondary Clutch Shaft Component Identification and Location 2 Remove the rear tapered roller bearing from the bearing carrier if it did not remain in the housing The bearing is a slip fit on the bearing carrier Hemove the bearing carrier 2 from the end of the shaft Use the pinion to pull the bearing carrier bronze thrust washer and bearing carrier simultaneously Tag the bronze thrust washer for identification purposes A CAUTION Use caution to prevent damage to bronze thrust washer when remov ing bearing carrier from the shaft assembly Note The rear bronze thrust washer is equipped with 18 radial grooves both sides around the thrust washer for lubrication purposes Marine Transmission Service Manual
18. BEARING CARRIER RICTION PLATES 11 549607 Figure 127 Secondary Clutch Shaft Component Identification and Location Marine Transmission Service Manual 1021629 153 Assembly Twin Disc Incorporated 1 Inspect the clutch piston dump valve 5 for proper operation Be sure the dump valve ball is free to move The clutch piston dump valve is not serviced separately 1023 1020 BE Figure 128 Clutch Piston with Dump Balls 5 2 Install the pump drive coupling 6 into the rear end of the shaft if removed Place the coupling in the end of the shaft and press the retaining pin through the components When the
19. DRILL 27 64 4219 prm Bes DIA THRU DIA TAP Wee CREE aN 4 00 E le lt lt ASS 4505 G 3 00 1 50 DIA 4 Uh 172 13 STUD o MG 659 DJ JACK TH Hol 50 7 1 WELDMENT ADJ JACK BASE D
20. LING N E lt AGNI CRE W Wis eo eo FORM 13904 Op ba DIA 6 50 THRU 12 REQ D Eu 0 9 118 0 50 10 b ud M C 03 a 295 J DRILL 10 25mm 4035 DIA x 3 25 DEEP 12M x 1 5 x 2 959 DP 1 4 BPI SLIDE EDUC MAT Miss CIO Nel f Lg FEMALE EL
21. dem Variable exit orifice closed Flow control piston Figure 21 Trolling Valve in Non trolling Position Marine Transmission Service Manual 1021629 53 Operation Twin Disc Incorporated Rotation of the trolling valve lever into the trolling mode opens the variable orifice allowing some of the oil in the trolling valve to flow to sump This reduction in oil pressure within the trolling valve allows the piston assembly to move towards the lever end of the valve reducing the amount of compression in the spring behind it Since the spring is no longer fully compressed the flow control piston moves in its bore and restricts the flow of main pressure oil to the engaged clutch This causes the clutch apply pressure to be reduced allowing the clutch plates in the transmission to slip The amount of pressure reduction and resulting clutch slip is ultimately controlled by the trolling valve lever position Trolling mode Bh RB Variable exit orifice opened Flow control piston Figure 22 Trolling Valve in Trolling Position 54 Marine Transmission Service Manual 1021629 Twin Disc Incorporated
22. 1 1 5 d m Fo TT ES MEN EZ ILLAS 1 ee ee 27 eer uu Dr a a 1 i L Lo Lak 4 C I wed Rb Bear do e 1 r 1 4 1 1 1 1 4 41 usd 1 P Bd T E 1 1 _ SEE am 1 1 1 E a eH PET 1 tpr 1 1 FU pds A 197wW PTs T _ r mo ie ad DIAGRAM HYDRAULIC a SUT TROL WAL 1 i I MN i 1 QUO L 10404040404 amp 1 Li rh 1 I 1 k n r1 OUTER DIA 85 SPRINGS gt 42 15 8 8 2 BOLTS HEXAGON ii a hile elk HHH rere HO ae SECTION FOR HEAT EXCHANGER WAVE SPRING La 42 N mrtJlS3 DOUBLE 42 H R A pen w 4 NimtJ IS BOLTS HEXAGON HEAD ee NOTICE THES PRINT CONTAINS PROPRIETARY HOT TO BE USED ANY THIN DISC RACINE WI 53403 USA 15 NOT INTENDED THIS NOTICE T RI
23. 262 T 21482 2 Input Seal Drive and Protection Sleeve 263 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Table of Contents Engineering Drawings 265 List of Engineering Drawings eus 265 168753G Valve Assembly Trolling 267 349460 Hydraulic Schematic Transmission 268 738165A Marine transmission General View 269 738166 Marine transmission Sectional View 270 350178 Output Shaft Assembly o uses dedi vedo eine 271 549402 Pump Assembly trailing 272 A7119W Hydraulic Diagram Electric Valve 273 549607A Marine Transmission Sectional View 274 738166 Marine Transmission Sectional View 275 737431B Marine Transmission General View 276 738165A Marine Transmission General View 277 1018084 Valve Assembly Control without trolling valve 278 737639 Live Pump Mount Power Take off 279 736957E Clutchable Pump Mount Power Take off 280 1020583 Control E Troll Wiring Diagram
24. LA Y L PII B al 2 C 5 C2 ab D PD 2 ON T SUMP Z CO Cc gt C UID se pe Rp p m O CJ 4 Vo 2 PII PM PO PO PO gt VMI MIMO I 119 4 j 1 Wr vom N Es MEINER EX PROPORTIONAL VALVE Elea cede rus D stots 80 Minos dee MANIF EE n 4 1020729D 4212 1021000 TUSSE E ZOE Sou z i 2 1020729 42516 10205 NON 051 1038E 19455 11018528 250 A A 1020729F 42974 B 1021000 NUN 0515 11185 ITS IES Ke OU LUBE 1021000 lt N 4 CSHOWN g
25. Dp x of AN T n IAS e Lih ae r zn tatapta t A a EN EN rx Tan QUEE m M 2 IB QUO MTSE OC JILA BAD ZINN EET PAID x M a np ae x i x u Er Tode __ p x i WF OEE E 40 Ue em 9 Van us f Mm FT DM salile aaa 2 DG uan ean LI tct one M Iou N D asu DU pet Tenet E Ut r 7 ut Gr 7 o 7 I JEI CNET m ERE LI E xn repe 2 een T TR ET RET Wi TiMAC O Sztn Np Leno MN CODLINS WATER 9 LET AND OUTLET FLANSE star m een IA ayes a DETAI GF SELECTOR VALVE Aoi SETA 0 VIEW 83 ill aft OC VDO WAN E cet i DO A j ug r m LL 1 inet mo L DM etc won 2 ME TH L d40 77 r7 IRIS DETAIL OF CLOGGING INDICATOR ILL rth M I Sb n aV 1 1 TE UAL Gh RO mt NT 1 THIR ANGLE ARGJCET 0H SIPILAR TO aor a PRIMED T Ibas EOSIN LLP NITE ORLO 7H DETALL GF OUTPUT FL Bounce tes CDL LCOOCL
26. plat FEE SECTIGN FOR ATTACHING Ol LEVEL GAUGE METRIC T c p 2 Hl 1 TO VIEW THIRD ANGLE PROJECT 1DH FH e TWIN DISS h Gg E FO F amp F CE OO RALLWE Sa 381E85tmg SHEET TOF Rey ___ ez ub Wl a Vr 7I SOSii Lh DYETAITT wi 3 SED LNSv MARAL ERR CE 1 2 T Zi 2 SEd RS i ET 1 PAAR i Ll cece ge 1 144 DETAIL OF SELECTOR VALVE x BD Tai W Lee A CLS HH at FORT 2035 m Pda wae ETAL BGLEND I mei EL I NAME die SLE ANG 2 T EE LOGS CIR LET ING PARIME OAR Gl CJ LE TA RAAF MT EM ANSA a y el eee ee ee ee MUTE e EEL 3E a oc Ier IEE Ch Fecal ETAT M MARINES 1 UA tg HEAT FEAT CANTED THE U 3 GF OTHERS BY CONTRAST 1 a er i1 1 1 _ P Ie i bens 7 wv me mm u ILI BL SAAU SCENES
27. 16 Source of Service 346 215 1 17 I UU TT 18 Description and Specifications 19 MTA 19 Ral aaa 20 Construction 21 Lubrication 2 0 0 2 1 11 1 121 22 24 Optional Equipment 26 Torque Values for Fasteners 1 1 28 Clutch Plate Wear Bm 32 33 Gener LENT 33 Hydraulic System with Electric Control Valve 34 General Overview of GP Valve with Electronic Interface 4 4 GP Control Valve Hydraulic Portion 2er ni x HR EHE KE EX KEKEHE MNxR VENE MAKE KENN UA EE 45 GP Control Valve Electronic Control Interface Profile or E Troll Module 47 Hydraulic System with GP Control Valve 49 Trolling Valve Optional eese ss 53 Power Take off 55 Trailing Pump Optional eere 56 OI TET ETT 57 Preventative Ma
28. 281 1020585 Control Profile Module Wiring Diagram 282 1020729 GP Valve ASSembDIV Fax id d a 283 Marine Transmission Service Manual 1021629 11 Table of Contents Twin Disc Incorporated 12 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Introduction Introduction General Information This publication provides service information for the Twin Disc MG 6449RV marine transmission Specific engineering details and performance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wisconsin USA Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and application of the material in this manual will result in consistent performance from the unit and help reduce downtime Safety and General Precautions General All personnel servicing this equipment should employ safe operating practices Twin Disc Inc will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unacceptable maintenance working practices Marine Transmission Service Manual 1021629 13 Introduction Twin Disc Incorporated Important Safety Notice Proper installation maintenance and operation procedures must be followed due to the possib
29. x oed Sf an EHA ETA b orm sil pressure piston at tre end of the euipulk 1 UA E D ond posh in the gear to the desigred pos tion ai 0 im WR ERE 17 f Check the outl me wesentricity should moat exceed U pr maximam total iadicater reading Check the Sete deviation should met exces 01 lim b AAS BF xr BIT BEFORE ASSCMB_ING amp H 3Z 1 LAF TER ASSEMBLING meee MOGBb4494 RY EE HAY co mg 1 6 VL TESUSANDTHS INDICATOR MEME INSTALATION GEAR Ify asiy ors E A Xv AB AZ 54 ee Ss CT oO usn ANGLE in PAWIS 111 EAKALHI PUSH GEAR UNTIL KEEPING SAME En LEVEL WITH SHAFT REV SIDNS Hitachi Mico Transmission Co LEA 2 PARIS MC HoA ML HL MARKE d4 53114 F PLR TROCHOID 52905 8 GASKET TORGU 3O0M m 3 NI 13805050 Suea SOCKET HEAD LUhresbsnd 1130 1 1 ___ __ 13 HOUNT AS 200 DENN 4 O L i 4 TORQUE JON m m cee ee ce Theeebond 1130 u Ps 15 4 59795 PTEMNNGE __________ 22 M NO85310035 SOREN MEX HEAD jE gt P 3 possuud a cash ag JOPI2 A VALVE NONREWURN _ __ Sait finda K TALUS HEAD 1 ___ i 12 H3701826 5 BASEE T COPP
30. 148271009096 QR A RaCIME B3405 USA Y x ALL TOLERAMRCES 31 GEQHETHIC TOLER ARC iMG PER ANGI 114 54 1882 ATI F EE Meo Je HEL 171 A O a a E iii SECTION FOR HEAT EXCHANGER nas r 223 r _ A CSO BLS Urn 225 Wes S058 Be 2 07175 Hoes CFE Faz Em i 1 aM adk a kl L 22 Bo B 35A SCOT nean epi uis 8n Ta Warm nyo ne yn FO ACH TE SENAY HEAT 2 a E MN E SECTION FOR REVERSE SHAFT n 7 L D regen fll a MEET E AFLP Soe SEAT SAR MET atkins FEEL YASEPDLG AND 1 m k p Tak Ve AMD 15 TO USED MANMER TO THE INTERESTS HF THIN DISE INCORPORATED RACINE 53403 15 THIS NOTICE 15 MOT INTEMDED TA HLLLIFT_ DE LIMIT RIGHTS SRANTED TO THE 1 5 GOVEANMENT CR THEIS CONTRACT H ASET PEL HG 64 49 00 8 F dg M e 1255 2E Pi eo d Gye Don AAT OA V AAT carpe qoae f EC ES FES amp 5 EMS
31. AAR263 DCP 5707 Figure 171 Secondary Clutch Shaft Bearing Cone 3 and Lowering Secondary Clutch Shaft into Transmission Housing 5 Install the sealing rings on the secondary 6 shaft Apply a light coat of grease to all of the sealing rings Install the O ring located in the transmission housing behind the manifold DCP 5708 Figure 172 Clutch Shaft Sealing Ring Installation 186 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Install Manifold 1 Place a thin film of MA1015 sealant on the sealing surface 8 of both the manifold and housing 2 Place MA1015 sealant around the dowel pin holes 9 in the main transmission housing 265 AAR265 Figure 173 Seal Manifold Surface 8 and Dowel Pin 9 Locations 3 Install the O ring 1 located in the transmission housing behind the manifold 4 Install the manifold 2 onto the main transmission housing DCP 5743 DCP 5744 Figure 174 Install O rings 1 in Transmission Counter Bores Marine Transmission Service Manual 1021629 187 Assembly Twin Disc Incorporated 9 Install the manifold to housing screws with washers loosely 4 of M10 1 5x 90mm 5 of M10 1 5 x 65mm and 11 of M10 1 5 x 45mm Loosen the dowel pin nuts on the manifold Drive the dowel pins 3 into the housing to locate the manifold properly on the transmission housing Tighten the manifold screws to 46 Nem 34 lb ft 6 Install the primary sh
32. DCP 0956 136 Figure 58 Removing Output Gear From Transmission 16 Place the transmission in the upright position Be sure transmission is supported securely 17 Remove the coil springs 6 from behind the output shaft spherical roller bearing cup in the transmission housing 5 if they have not already been removed Tag and number the coil spring to identify during assembly process O60BE AR141 Figure 59 Output Shaft Spherical Bearing Coil Spring 6 Removal 18 Remove the trailing pump drive gear from the output gear only if parts replacement is required 102 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Remove Trailing Pump and Shaft Remove Pump Cover and Shaft 1 Place the transmission in the upright position sure transmission is supported securely 2 Remove the trailing pump cover 7 from the rear of the transmission d v i i t i DCP 0164 AR49 Figure 60 Trailing Pump Cover 7 Removal 3 Remove the external snap ring 8 from the trailing pump driven shaft 4 Use special tool T 21482 17 to drive the shaft out of the bearings and into the housing Marine Transmission Service Manual 1021629 103 Disassembly Twin Disc Incorporated Use extreme caution when removing the trailing pump drive shaft to prevent damage to the drive slot in the end of the shaft The trailing pump drive shaft and gear are not serviced sep
33. IDENTIFIER HER N H VALVE BODY 1020518 PROPORTIONAL CONTR VALVE PERATION J PRESSURE REGULATOR INITIAL ADJUSTMENT PROCEDURE F APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS AROUND 1 WARNING D NOT C NECT VALVE CUI 1 WITH N F W VALVE URN ADJUSTMENT CORE PLUG JUST BEFDRE FINAL ASSEMBLY REFER 774 FUR TO BATTTERY POWER SUPPLY VDLATAGE STEM OF THE 1020670A VALVE COUNTER CLOCKWISE FURTHER INFORMATION 2 OPERATION TO BE PERFORMED WITH ONLY TWIN DISC UNTIL REACHING POSITIVE STOP D ES REPLACED CONTR SYSTEMS OR ULE 2 WITH A MINIMU F 1 gpm A W DIL TO FLUSH FOR PRE DUI N AND EF RVICE Q PRESSURE RGEULATOR B MANUA IRECTIUNAL C RUL VALVE 9 3 AFTER FLUSHING TURN ADJUSTMENT STEM OF THE 1 WIT ANUA NAL CONTR VALVE IN 10206 0 VALVE CLOCKWISE UNTIL REACHING REQURIED CENTERED POSITION PUS ENGAGE PORT A PRESSURE SPCIFIED IN MARINE TRANSMISSION PRODUCTION a E 2 WIT ANUA CUNTR VALVE IN EST SPECIFICATION CENTERED POSITION PUI E NGAI PORT 4 CK ADJUSTMENT STEM IN PLACE USING JAM NUT AND THIRD ANGLE C MANUAL DIRECTIONAL CONTROL VALVE E SWITCH 55 1 SWITCHES ARE RMALLY CLOSED WHEN MANUAL E REFER 1 MARINE TRANSMISSION ASSEMBLY DRAWING 8 SIMILAR C ROL VALVE IS I CENTERED BIL F MATERIAL FUR VALVE UNTING GASKET AND SCREWS REVISED AND REDRAWN SUPERSEDES 1020
34. Marine Transmission Components MG 6449RV Document Number 1021629 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 1021629 April 2005 Marine Transmission Service Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY MARINE PLEASURE CRAFT Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of thirty six 36 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twenty four 24 months of service whichever occurs first Thisisthe only warranty made by Twin Disc Incorporated and i
35. oo MN SS FEE VALVE SEE CHART Tj O TORQUE TO 36 N m I PS 44 5 U 9 N P H D 14 AN i 2 un OOO VALVE ASS 1021873 VALVE 1020670A Q PLUG SEE mes
36. Ql1018084W 40958 1017133 1017134 B1337F 1018688 2 XM2759FM 24 VDC 270 A270 A2703T 1725 250 1017129 MA1038E e7 x 2 0 6H B2451B 1 1052 2 MALOSeA 2 5202 118798 BY NG PLA RAP THRU Hai ee 018084x 40964 10171334 1017134 B1337F 1018688 xXM2759FM 24 VDC XA270 A270 703 1725 250 10171294 MAi1038E e7 x 2 0 6H B2451B 5 IMeogoar 2 Me089AR MG 5141 11724 98 E BEHIND PULL TIGHT TRIM X89 1018084 41028 018688 2 XM2759FL 12 VDC XA2707AD 2707 2703 2000 2902 1017129 MA1038E Me7 x 2 0 6H B2451B dea MG 6650SC TOME DRS END SHORT 10180847 045 017134 018688 2 XM2759F M24 VDC XA2707AD 707 2 70 2000 2902 1017129B 10 8 7 x 2 0 6H B2451B MG Se05DC 2589 STRAP M2942B 2 101808444 1017583 1017569 1017613 1018688 2 XMe759FL 12 VDC XA270 A270 2703 2000 2909 1017129B 10 8 7 x 20 64 2451 0 1062 8 2 MA1068J 2 6 018084 41093 1017133 1017134 B1337F 1018688 2 75 19 VDC 70 A270 A27037 1785 250 1017129B MALO38E Me7 X 2 0 6H 2451 den MA10524 2 MA10524 2 MG 5808DC 5528599 nos 018084 40967 0173863 ri 017179 YES 3 xMe759rMe4 VDC ases 078D xu 2655 385 1017129 Maio38E ez x 2 0 6 24518 5 MG 6449 RV 757048
37. Disassembly Housings Cast Parts and Machined Surfaces Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts DO NOT remove excess material by sanding This will cause loss of press of bearings or races Inspect oil passages 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 you find any of these defects replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels This applies where a matched set of parts is not involved Inspect dowel pin holes for wear due to movement between mating parts If a dowel pin hole is worn re bore and sleeve the hole when possible Otherwise replace the parts This applies where a matched set of parts is n
38. Note It is required that primary and secondary clutches must be within 97 kPa 14 psi of each other Marine Transmission Service Manual 1021629 25 Description and Specifications Twin Disc Incorporated Optional Equipment 26 The following optional equipment for use with the model MG 6449 RV is available through the nearest authorized Twin Disc distributor Optional Trailing Pump A trailing pump kit 5 49402 is available that bolts onto the output end of the marine transmission A drawing is included in the Engineering Drawings Power Take off A live Pump Mount power take off and a hydraulically clutchable power take off are available and mount on the rear of the transmission They rotate at the Same speed and direction as the engine Electric Control Valve Electric control valve are standard with either 12 24 actuating solenoids Coupling Flange A coupling companion flange is available Trolling Valve A mechanical trolling valve is available for mounting on the electric control valve The part number is 1019988 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Description and Specifications Table 2 Bearing End Play Specifications Transmission Primary and Secondary Shaft Tapered Roller Bearing Endplay Assembly No minimum 0 05 mm 0 002 in 0 05 mm 0 002 in Transmission Output Shaft Bearing Endplay Assembly No Minimum Maximum S 0 00 mm
39. O b N GREEN zt L B POWER E 5 BLACK a RMALLY CLOSED alc E ERMINAL 4 BLACK NE IN NEUTRAL RELAY sem Au 22 ED IN NEUTRAL L Dp L RED SOLENOID Sa SE BLUE 4 BLACK 200 mA MAXIMUM 6 85 WHITE 55 27 1 87 BLACK O 30 YELLUW UG RING bias pu SAI 1201 4 0 CIRCUIT po PRAE E N CHART gll i RANSMISSI VERRIDE o eee 55 2 CUN 5 U 3 CUNNE 5 VE PUTS 1 C 125 0 SHOU CONNEC G E l RS ED I IS GREATE VIL TS E ILLU VE N e FL ASHIN N CIRCUI GIZED VALV CIRCUIT ENABLE E E THER URRENT E E TURN 5 BY P S FLASH ENTE EU VULTAGE AND E C R P EN ESEN R IS AP AND Sy CH I B m C E ERNA EITHE ED SIGNALS MISSING IN gt T p S 2 N UT IS U PRO PEED INPUT W CTRI HER WII HRINK C ECU ED FD AND RES SECURE e C PU IS REI RUI S VI UST BE D SECURE 9 PE BE TW ED PAR HE INI 05 V D AT MINIMUM D R 8 100 AND TH l N RCUIT IS INSULATE AND 2 6 0 AR Ld USE N 020583 Mr 20 0 0905834 35 a 10205831 Sey amp 020583C SIMILAR TD M ULE a 020583 STAINLE 06 1 5 2 NTAINS WEIGHT 2 2 JV V 1 J SC 3 EC D ES _ Kg G uc CORPORATE OD D EC 3 RAT FIRST USE 2 RACINE WI 53403 USA EC 3 C ASSY LAR TOLERANCES 1 1020282 2 3 USA MODEL Ti SS D n une SURFA
40. 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 arebuilt transmission check the filter element after eight hours of operation If the filter is clean install a new filter element and then change the oil and filter element after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the 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 oil drain flanges at the bottom of the housing on the driveline side Marine Transmission Service Manual 1021629 61 Preventative Maintenance Twin Disc Incorporated Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary The suction strainer is located at the lower end of the pump See Engineering Drawings for suction strainer location Type Oil Recommended see Description and Specifications Filling 1 Remove the filler breather in the top cover of the transmission 2 Fill the transmission s sump with 18 liters 4 8 U S gal Of the proper weight and type oil See Description and Specifications for oil recommendations 3 Start the engine and let
41. 032 8 377 MG WATER b ET AMD FLANGE Bete 412 E ee a 7 2r 3Q7i7 ZR j FATER aL L DETRIMENTAL TO THE NTERESTS OF INC ORPCRATED 594403 15 THIS mu ICE MOT INTERCED MALTIY OF LAIT RIGHTS EU VEPRSPENT AIT FAG cit viarum T Oi GREASE 1 uer FILS c IPANGE AC Sein SM ILEMEMCO 2 f3aT 24 AMD 8 841 5604 EA THANG INTERNA c7 ERA r ar LFS 11143 F 4 WETTING Dn TTi e Lv 5 AR Day THE NEWT otal mes Stet pen ONE Selec SISTES ETI foal Be vabe he CECCO Leis ei CHE DATED EYERI d asat Fema pasos Sate HAIL ED BO UT un TEMPESATURE SE CEO NG wale ce RPT CNA AC EETA FI wince Din Lou Sale FEPER LENG ID 556 _ TH 2L MIT CLONES urb QUEE giL DRESULSE 2 m EO eT SGNTIF 624 Pl 21 8 TE 4 eo Duet 2 5 SRE pzzu D2 HER 2 3 ESS natn m wee jz T EG t X XX 13 via j AMOUR TOLERANCES 5 DEC LI TOOL Mi 64ag OQ Rv O REA MDE YU OA EE DEM vy GENERAL y Lr PEST GF TN
42. 1021629 Twin Disc Incorporated 10 11 12 13 14 Assembly Install the thrust washer over the end of the stem Press the oil seal into the cover assembly until flush with the adjacent cover surface Install the O ring into the counterbore in the cover assembly Apply grease to the stem O ring and oil seal lip Install cover assembly and gasket onto valve body Be sure to align the oil drain hole in the gasket with the hole in the valve body Figure 199 Holes in Gasket and Cover Must be Aligned 15 16 17 18 19 20 21 Install cover capscrews and torque to 23 Nem 17 Ib ft Install washer over stem and against oil seal Install soring 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 Nem 7 Ibeft Install external retaining ring onto stem Install the steel balls and electrical switches into the bores in the sides of the valve body 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 1021629 205 Assembly 22 23 24 Twin Disc Incorporated Install pressure regulating springs into val
43. 549402 Pump Assembly trailing A7119W Hydraulic Diagram Electric Valve 549607 Marine Transmission Sectional View 738166 Marine Transmission Sectional View Ll 737431 Marine Transmission General View Ll 38165A Marine Transmission General View 1018084 Valve Assembly Control without trolling valve 737639 Live Pump Mount Power Take off 36957E Clutchable Pump Mount Power Take off Marine Transmission Operator s Manual 1021629 265 Engineering Drawings 266 0D D D 1020583 1020585 1020729 1021658 Twin Disc Incorporated Control E Troll Wiring Diagram Control Profile Module Wiring Diagram GP Valve Assembly GP Valve Assembly Marine Transmission Operator s Manual 1021629 AGH EE oe 1 52545 BUSH _ 5 1 52540 PISTON rsh 1 8241 WASHER al 7 i 53508 E PISTON A5 1 s i nioen au tt 7 af J22 1 54 LOWER 1 81158 0 BASKET NORE OG025 SCREW HEX HEAD HODEL MGESS84SC HARE BOLLING BRAWIHG LUBE FWARD VALVE REVERSE VAL VE ELECTRIC MCHE SMC IG VALVE L ORWARD 30 VALVE REVERSE SL REEN FILTER TDI NICO SEAR PUMP HANGE s SLUTC4 REL ALE METRIC 2 L MES CRESS E arem ANGLE 2ROJECT ON HATETIAL Wr IHF UNLESS OTHERWISE SPECIFIES IHS
44. ADJ JAI br PUMP Cm ACK BASE Cy IN PLACE WHEN PR NG Ms d le GARE se EM B L BEARING MAIN H 1 1B We RE e eT se 00 lx VPE LTS JACK BUTTON MACHINERY FACTORY 1B 1 PUR Lest STUD PT 10706 1 2 13 x 4 00 LG mu 1A 1 TS JACK BASE 3 00 DIA x 50 THK NOTE UNLE HER WI WELDMENT JACK BASE BREAK HARP CUR DET REQ DESCRIPTION STOCK SIZE Date 2 23 98 By JPL FPN Scale FULL SS NOTE ALL GROUND C DIA S amp SURFACE mm ADJUSTABLE JACK 21 SPECIFIED KE Q m AR 5 m N R EE Sio IN T DENIS eet ESIN i 1 ar H N S F H FOR M G 5 5 B SH 1 F 1 T UM chance DESCRIPTION bate mv TVIN DISC me vis 21482 44 POU IS qr esos Yo UMP REDD No06206H00 BALL BEARING 2 REQ SPACER Q REQ xX 019865 SPMAFT XD JE s 7 00 03 Ae De oR C AI e 902 R 2 400 tes 125 DIA DIA ERI FOR MG
45. b Drive the inner seal single lip seal until it is flush with the inside surface of the oil seal carrier Install seal with the spring loaded lip toward the inside of the seal carrier Drive the outer seal double lip seal until it is flush with the outside surface of the oil seal carrier Install seal with the spring loaded lip toward the inside of the seal carrier d Apply grease to the oil seal lips and to the oil seal sleeve surface on the output shaft 168 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Output Shaft Seal Carrier Apply MA1015 or Equivalent Double Lip Single Lip EE UOI ed Seal Seal m Carrier 5g5 IO Inside of Seal Carrier MG 6557 17 Figure 151 Output Shaft Seal Carrier Assembly 4 Install oil seal carrier 3 onto the output shaft 5 Install the correct previously selected shim pack 4 onto the output shaft AAR239 AAR238 Figure 152 Oil Seal Carrier 3 and Shim Pack 4 Installation 6 Install the output shaft tapered roller bearing cup 5 Marine Transmission Service Manual 1021629 Assembly 170 Twin Disc Incorporated The following steps of this procedure require components to be heated prior to installation Use caution when handling the heated components 7 Install the output shaft tapered roller bearing cone 6 a Heat the output shaft tapered roller bearing cone to 120 C 250 F
46. cm J OOO 1018084H 0758 017583 017569 017613 018688 e XM8e759FMe4 VDC 270 e 70 9703 2000 2905 71998 MA1038E Me7 x 2 0 6H B2451B 0 MA10628 2 1062G 2 G 5600 2 EUER AS BJE 5 D pb uh tect ha d T 1018084 40761 1017583 1017569 1017613 1018688 2 2759 1 VDC XA 707Z A2707Z 587031 2000 290 1017129 MA1038E we7 x 20 65 2451 0 MA1062B MA1062G G 5600 Ga 49 E 01808 0768 1017133A 1017134 B1337F 017179 e XM2759FM 24 VDC A2707AD 1585 230 1017129 MA1038E Me7 X 2 0 6H B2451B ya 1052 2 MA1052B 2 G 5114 2 E s E uU M d 5 il x Ra T m 373 AN ae CONNECTOR SHROUD 1001825 0180841 763 1017133A 1017134 B1337F 017179 ZSSF H te AVDG A2707AD 1585 2305 1017129 1038 7 x 2 0 6H B2451B MA1058B 2 MA1058B 2 G 5114 2 353 Z EE i ae mE fy P 9 IDIBUS 0764 017383 018688 2 xXM2759FM 24 VDC A2702BC 7 1270480 2415 350 10171298 1038 lt 27 x 20 6H B2451B 28 TEN A lan MW oN 101808 0775 1017583 1017569 1017613 1018688 2 xMe7S9FM24 VDC xAe707z 427077 A2703T 2000 290 10171298 MA1038E Me7 2 0 6H B2451B 0 MA1062B MA1062 2 560008 808 1 ee ee D 2 OOOO 1018084 40817 018688 e 759 24 VDC XA2707AD A2707
47. x Semm Ss p CTs REK DB KNURL FUI LENGI H 30mm TA 111810 KANE DRILL 13mm 5110 DIM UA THRU RD REAT e Q 2mm x 45 C BUR 923mm CA E DIA x 12mm C472 KID S DB E 12 mm E Ce PU SIAMP NUMBER B Lb b 1 i DIM NUMBE DIM B R MUDEI 01482 06 198mm 20 A MLIDE el 4 9e e 178mm 20 A 108mm 20 UR E NOTE UNLE LAER WISE EE IE EI je e 44mm x 20 6557 BREAK ALL SHARP CURNER 3e 168mm 20 ACRES Ue 23 141m c Ep 6619 TZIAZ 34 188mm c FGP 20 E 3 1 STK SUC HD SCR M16x2 0 x 45mm 1 77 LG NUTE IN 2 1 DR HANDLE 30mmX 8D DIA x 5 25 LG 5 B INE HE 1 1 MESS DRIVER BASE SEE CHART FOR SIZED DE T REG MAT DESCRIPTIUN STOCK SIZE Date 4 2 98 By JPL FPN Scale FULL ES UU DRIVER BEARING E SPECIFIED FOR SHEET F c EM ALL MODE T E TN CAD FILE 21482 26 CHANGE DESCRIPTIUN DATE BY TWIN DISC INC RACINE WIS 2149 SERIES DRAWING RAILING PUMP ASS Y 23 4962726 R MODEL MG 655 C 7S DRILL 2 7 64 44219 DIA IHRU i 1 2 13 41 REG D e SEDE Tus 4 5 e e 12 x 30
48. Ed E my ELI TEE r I M DETAIL eet i 05 23 135 72 1 vt c l at at LE DE Len M ant LEN NE Mo 7 lle Le 4 ee Mae 1 a ac 40 M 1 Pr LI LI Ie toa aa i SECTIEN C 2 THIRD ARGLE PROJECT COM ROTIGE CHIS PRINT SIMIA RATCA IAL In Ir m Wa du ES PRUEAIETAJ INF OWMATIS AMD 75 ne KAI E BE LEED ANT MANNER amp FD RF DETRIMEN aL TO THE IMTERES E DF HE SES THIN 0 56 INSOREPCEATES iS 215 MOTLCE 1 amp HET INTENDED x HILL ET CR LrfUfT RIGHTS TAEA MENT PME OTHERS Br ECHTRATT CULTCKABLE PTO 18 AWG XLPE
49. If the shaft and bearing do not separate remove tool T21482 8 and rotate the transmission so the output flange is up If the shaft does clear the bearing raise the transmission housing off of the output shaft being careful that the output gear bearing or spacer does not slide from the housing NOTE The spherical bearing cup and associated springs may come out of the housing when it is raised If the bearing did not come off of the shaft proceed with the next four steps Support the transmission weight by the eye bolts in the output shaft Raise the unit about two inches above the support table Supply oil from an SKF pump into the port that feeds the bearing removal port Slowly apply high pressure oil to the port in the front of the output shaft Allow the transmission housing and output gear to lower as the high pressure oil expands the bearing 1 inner diameter thus removing it from the shaft Remove the hydraulic fitting and remove the bearing from the housing Raise the shaft from the housing and set aside DCP 5692 DCP 0963 _ Figure 57 Output Shaft Front Bearing Removal Marine Transmission Service Manual 1021629 101 Disassembly Twin Disc Incorporated 15 Slide the output gear 3 out of the transmission housing until two M10 1 5 eyebolts 2 can be installed into the gear to allow it to be lifted with a crane Remove the output gear from the transmission housing Remove the bearing and spacer if not already done
50. Incorporated product only Authorized reasonable travel and living expenses will be considered for payment inall model except MG 340 and MG360 Under no circumstances including a failure of the exclusive rem shall T win Disc Incorporated be liable for economic loss co uential incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair 2 The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated The warranty Is void unless all required replacement parts or products are of Twin Disc origin or equal and
51. Note Verify that sealing rings are installed on the secondary shaft before installing the pump mount 1 Install the secondary shaft shim pack 7 on top of the rear bearing cup Place the thickest shims on the outside of the shim pack and the thinnest shims in the center of the shim pack 2 Install the secondary shaft O rings into the counter bores 8 in the manifold housing 1 DCP 0136 DCP5753 Figure 180 Secondary Clutch Shaft Bearing Shim 7 and O ring 8 Installation 3 Place MA1015 on the sealing surface of the pump mount secondary shaft rear cover Note Place sealant on the sealing surface of the pump mount and pump suction port 4 Install the pump mounting 9 cover secondary shaft rear cover 4 of M10 1 5 x 115mm 1 of M10 1 5 x 100mm 1 of M10 1 5 x 35mm 1 of M10 1 5 x 60mm and 1 of M10 1 5 x 45mm all with washers Torque the screws to 46 Nem 34 Ib ft 5775 Figure 181 Seal and Install Pump Mount 9 192 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Transmission External Components Pump and Suction Screen Installation
52. REQ D y 10mm 393 UN Sty 1 LN 54mm DIA 40mm 85mm CE LEG 3 346 GOED 522 20MM 42 DMM 7870 5 705 1omn C OU 30mm 1 181 4 WASHER 1 REQ D DMM Coie C O90 100mm x 3 937 6 1 METRIC NUT M16x2 0 5 2 STK Soc HD CAP SCREW 10 15 x 50mm LG 5 LL A M P 12 gt 4 M S WASHER 2 25 DIA x 10mm 03932 THICK MAT 3 M S PROTECTOR SHAFT 2 29 DIA x 10mm 539352 eB STK METRIC THREADED ROD 16 2 0 x 8 50 LG e STK METRIC NUT MI6x2 0 NOTE UNLE FHERVISE SPECIFIED 2 WEL DMEN LI E qu X 1 M S SUPPORT CLAMP 125 162 x 400 LG b AK ALL SH N DET REQ MAT DESCRIPTION STUCK SIZE Date 1 24 98 JPL FPN Scale FULL STAMP TOOL NO T 21482 17 NAME REMOVAL 1 L
53. THRUST RACE ASSEMBLY STEEL PLATES 12 FRICTION PLATES 11 549607 Figure 115 Primary Clutch Shaft Component Identification and Location Marine Transmission Service Manual 1021629 145 Assembly Twin Disc Incorporated 1 Inspect the clutch piston dump valves 1 for proper operation Be sure the dump valve balls are free to move The clutch piston dump valves are not serviced separately 1023 1020BE Figure 116 Clutch Piston with Dump Balls 1 2 Replace the clutch piston seals 2 Lubricate the clutch piston sealing rings before installing the piston into the clutch housing AAR200 AR200B Figure 117 Installing Cutch Piston Seals 2 Lubricate the clutch piston bore with a thin film of grease Install the piston into the clutch housing Gently push the piston by hand until it is fully engaged into the clutch 5 146 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Note If the piston is difficult to install by hand remove the piston assembly and inspect the piston seals 1033BE Figure 118 Clutch Piston Installation 4 Lubricate and insert the steel thrust race 6 thicker onto the shaft Ensure the steel thrust race is seated against the shaft shoulder Lubricate and install the needle thrust bearing followed by the outer steel thrust washer 7 Thinner AAR200 200 Figure 119 Installing Steel Thrust Race 6 and Bronze Thrust Wa
54. When in Neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Driven Gear Secondary Shaft S Output Gear Figure 23 MG 6449RV Power Flow in Neutral 58 Marine Transmission Service Manual 1021629 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 Py iii T XE Primary Clutch Engaged ac Sateen Figure 24 MG 6449RV Power Flow with Primary Clutch Engaged Marine Transmission Service Manual 1021629 59 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 directi
55. and Bronze Thrust Washer 4 Remove steel thrust race 5 from the clutch 10 Remove the clutch piston from the clutch Note If the clutch piston does not have threaded holes compressed air can be used to remove the piston 191 O66BE Figure 78 Steel Thrust Race 5 and Clutch Piston 6 Removal 11 Invertthe shaft placing the rear end of the shaft upward Remove the clutch piston sealing rings 8 from the end of the shaft Twin Disc Incorporated Disassembly 12 Removal of the rear tapered roller bearing 9 requires destruction of the bearing to facilitate removal DO NOT remove the rear bearing unless replacement is required 193 193A Figure 79 Piston Sealing Rings 8 and Clutch Shaft Rear Bearing 9 13 DO NOT remove the drive pin 3 from pump drive coupling 4 unless part replacement is required The pump drive coupling pin is retained by staking in two locations at both ends of the pin 197 170 Figure 80 Piston Sealing Rings 1 Clutch Shaft Rear Bearing 2 and Pump Drive Pin 3 Marine Transmission Service Manual 1021629 115 Disassembly Twin Disc Incorporated Primary and Secondary Clutch Shaft Insert Removal Note Complete the following procedure only if part replacement is required Secondary clutch shaft insert shown The insert removal process is identical for primary clutch shaft insert 1 Remove the screws 5 retaining the shaft rear cover insert 6 2 Weld a washer
56. 1 21482 8 1 21482 17 D D D D T 21482 26 T 21482 44 T 21482 45 Input Seal Drive and Protection Sleeve Retention Block and Screw Oil Injection Adapter Tool Output Seal Driver Bearing Driver Adjustable Jack Bearing Driver Marine Transmission Operator s Manual 1021629 253 Special Tools Twin Disc Incorporated 254 Marine Transmission Operator s Manual 1021629 DRILL amp TAP Mle X15 20mm DEEP 30 Fz CHAMFER HAMFER LMM 2 0 0148 222 m CHAMFER IM HAMFER 5 NICO TOOL AM814A a DATE BY o SUMM lomm 221 4 mm 10mm 100mm B 15 D a 3Umm v c IP THREA 14mm DIA THRU 1 REQ DRILL 8 5mm THRU Q gt REQ MIO x 15 THREAD 2 X AD CAP SCR E Cc EB B SE Ge 4x9 AT MS BIS ne E a NG N ALL 21482 6 PUR MG 6557 MG 6619 amp MG 6600 TEL PART
57. 1021629 65 Preventative Maintenance Twin Disc Incorporated Overhaul Interval complete overhaul of the unit should be made at the same time that the engine is overhauled Periodic Visual Inspection Ll Check the mounting for tightness or damage such as cracks Tighten loose mounting and replace damaged parts Check pressure and temperature gauge where applicable Inspect the oil lines and heat exchanger for leaky connections cracks or other damage Replace damaged lines Ll Periodically inspect the drive line and the input and output shaft oil seals for leakage Replace parts as required 66 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Troubleshooting Troubleshooting of Mechanical and Electric Control Valves General Note Some of the troubleshooting procedures vary depending on the type of control valve that is installed on the transmission A thorough understanding of the valve operation is important to properly troubleshooting the problem that is occurring The following charts are intended as a guide for determining the cause of problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered w
58. 6557 SC IN SEA BALI eA TING Nowe Vis Ra ade ee WITH SPACER 91226 Wee NOTE VR WES SPECIF TED BREAK ALL SHARP CURNER CCARB amp HDNO 1 1 eS DRIVER BEARING ees DIA x 725 LG Nae DIAS amp SUJEBEADCES DET JREG MAT DESCRIPTIUN STUCK SIZE Date 2 23 98 By JPL RPN Scale FULL STAMP TOOL NO 21482 45 BE WUA E amp C NC L N R C NAME 8 2 Gro MS 6937 SC WITHIN 005 OF EACH OTHER Bees BEARING 1 ae E SPECIFIED FOR MG CES C SHEE 1 F 1 O10 UN FRACTIONAL AND Two PLACE mE a DENEN CAD E 21482 45 CHANGE DESCRIPTION DATE BY TWIN DISC INC RACINE WIS 2148 45
59. AR281 Figure 183 Seal and Install Pump Suction Adapter Plate 1 Marine Transmission Service Manual 1021629 193 Assembly Twin Disc Incorporated 3 Lubricate the pump suction jumper tube bore 2 4 Install O rings on each end of the pump jumper tube 3 Lubricate the O rings AAR288 AAR289 Figure 184 Jumper Tube 3 Lubrication 5 Install the jumper tube into the pump suction adapter plate re Install the jumper tube 5 and the pump 6 It may be necessary to rotate the primary shaft to allow the pump shaft to align during installation Torque the screws to 46 34 Ibeft 194 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Figure 185 Pump 6 Installation 8 Install the suction strainer 7 Install the suction strainer O ring and cover 8 Torque the screws to 45 Nem 33 Ib ft Note Do notcrush the suction strainer AAR295 AAR296 Figure 186 Suction Strainer 7 and Cover 8 Installation Marine Transmission Service Manual 1021629 195 Assembly Twin Disc Incorporated Trailing Pump Cover Installation 1 Install the trailing pump cover 1 and gasket 2 Torque the screws 3 to 46 Nem 34 Ib ft Note If the transmission is equipped with a trailing pump install the suction screen into the housing AAR298 DCP 0165 Figure 187 Trailing Pump Cover 1 and Gasket 2 Installation 196 Marine Transmission Service Manual 1021629
60. Control Valve upper body half 1 Install one dowel pin large diameter into each of the two bores of the valve body 2 Install one spring into each of the two bores of the valve body Figure 195 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 Nem 63 Ibeft 6 Apply lubricant such as Dow Corning 200 30 000 cSt 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 Nem 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 202 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Assembly of Electrical Control Valve lower body half 1 Install the steel shuttle ball into its bore in the valve body 2 Install the O ring onto the shuttle ball seat Apply lubricant such as Dow Corning 200 30 000 cSt fluid to the O ring and install the seat into the valve body Be
61. Disassembly Twin Disc Incorporated Disassembly of GP Control Valve with Electronic Interface The GP Valve is made up of a non serviceable electronic interface and two valve bodies with plugs and cartridges O ring kits are available for servicing the plugs and cartridges however none of the cartridges are field serviceable beyond replacement of the o rings The later version Assembly 1021658 of the hydraulic pressure regulator valve is serviceable and contains an orifice filter plug and a ball check valve assembly that are replaceable E Figure 96 GP Valve Assembly mounted on Marine Transmission 126 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Disassembly 1 Disconnect the connectors at the proportional valves the neutral switch and the temperature sensor if equipped and loosen the four M6 1 0 capscrews that retain the Electronic Interface Module to the Hydraulic portion of the valve assembly If the Electronic Interface is not being replaced it can be set aside without disconnecting the remaining wires from the installation Figure 97 Electronic Profile Module typical 2 Remove the six M10 1 50 x 70 capscrews that retain the top valve body assembly to the transmission and remove the top valve body assembly with gasket if not previously removed Marine Transmission Service Manual 1021629 127 Disassembly Twin Disc Incorporated Proportional Valves Ma
62. E T TERMINAL 4 BLACK lt B N n p AY ze SUL B POWER 10 12124075 MP Ly L 1 lc GND zs m A NE NEN s 3 xt Ky CUST R SUPPLIED SOL A POWER PEE T RED p SULENUID B BLUE mu iu WIRE 18 AWG XLPE SAE 1128 GX SOLENOID A ON BLACK 200 mA MAXIMUM a 300 USE 1020282 SOLDER SHRINK CRED LED WHITE 27 CONNECTORS AS REQUIRED 0 p 290 E BLACK _ 872 SOLENOID SWITCH is CUSTOMER SUPPLIED 150 START eee 6 SEE MOUDULE POWER CIRCUIT E CONNEC CHART pep LUG RING 2 CER TRANSMISSION MA nee 1201 2 E VERRIDE SWITCHES o i SOLENOID RETURN MODULE POWER CUNNECTIUN CHART C d USE OPTION 1 CONNECTIONS WHEN THE ULE IS CONNECTE NON ELECTRONIC LEVER HEADS USE 2 CONNECTIONS WHEN ULE IS CONNECTED ELEC IC GEAR CONI LERS 38 1 USE 3 CONNECTIONS WHEN ULE IS CONNECTED ELEC IC CONI SOLENOID IVE UTPUTS THE ELECT CONT S SOLENOID AND B RETURNS NEGATIVE SIGNALS 125 0 1 SHOU BE CONNECTED TOGETHER AND CONNECTED 1 HE E TROLL ULE RETURN ELEC IC LED INDICATORS GR x pet box 622 i H nee Wen ue 7 PORE EEE E e D n M SN T 3 i RED LED ILLUMINATED INDICATES VALVE COIL COMMANDED ON DNE RED FLASHING INDICATES AN OPEN CIRCUIT IN AN ENERGIZED VALVE COIL CIRCUIT 381 WIRE HUN 1 WIRING OPTION e WIRING INN 3 VALVE COIL LEADS SHORTED TOG
63. FOR RAILING PUM MG6557 amp MG6619 GEAR SHAFT amp BEARINGS BREAK ALL SHARP CORNERS E MC6557 619 010 ON FRACTIONAL AND TWO PLACE ME TRIC 3c a A CRE W Se Sori lela I DRILL 1025mm 6403 DIA x 36mm DEEP LAF Ji
64. Input Flange Shims 3 Heat the input flange to 200 C 392 F Push the input flange onto the input shaft until the flange contacts the shims WARNING Handle the input flange with care The input flange is HOT 4 Position the input flange plate Torque the screws 235 N m 173 Ib ft DCP5787 Figure 227 Install Input Flange Plate Marine Transmission Service Manual 1021629 225 Assembly Twin Disc Incorporated A IMPORTANT Liquid sealant must cure for a minimum of 24 hours prior to contact with oil AAR164R Figure 228 Install Input Flange Plate 52 Fill the transmission with oil 2 before operation 226 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Installation Installation General Alignment Information Proper alignment of an engine marine transmission and propeller is critical both during the initial installation and at frequent intervals during the life of the boat Itis 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 Alignment measurements should always be made with the vessel in the water The remote mounted v drive transmission must first be aligned to the propeller shaft and then the engine aligned to the remote mounted transmission Note The transmission output flange and companion flange bolts or screws must be torqued to the pro
65. Pan 2 Removal Remove the Output Shaft 1 Place the transmission in an upright position Be sure the transmission is supported securely Remove the output seal carrier screws This will allow the output shaft to slide a couple of inches rearward with the rear output shaft bearing 2 Rotate the transmission to place the rear of the output shaft 4 at the top output drive flange downward Be sure transmission is supported securely with the output shaft in as vertical position as possible Allow clearance below the output flange to allow approximately three inches of additional movement DCP 5692 Figure 53 Output Shaft 4 98 Marine Transmission Service Manual 1021629 Twin Disc Incorporated 3 Disassembly Install the special tool oil injection adapter tool T 21482 8 into the end of the output shaft a Identify the location of the oil injection port 5 The proper port is the threaded hole in the end of the shaft that contains a continuing passage through the shaft to the shaft tapered surface at the output gear Figure 54 Oil Injection Port 5 Location and Oil Injection Adapter Tool 6 Installation b Fill the shaft passage with SAE 40W oll Wrap the threads of the oil injection adapter 6 with teflon sealing tape Thread the oil injection adapter into the oil injection port in the end of the shaft Fill the oil injection adapter with SAE 40W oil Lightly tap the oil injection adapter to
66. Trolling Valve Optional Equipment 132 Cleaning and Inspection 137 VUNG eR 137 1 1 ete n 139 143 O eh A nea E E E 143 Primary Clutch Shaft Assembly 145 Secondary Clutch Shaft Assembly 153 Primary and Secondary Shaft Seal Ring Insert Installation 161 Trailing Pump Driven Gear Installation 162 Quipu Shall eas 164 Output Shaft Bearing 2 21 164 Assembling the Output Shaft Subassembly 167 Preliminary Output Shaft Gear Advancement Verification 172 Gear Pan and Bottom Cover Installation 184 Installing Primary and Secondary Shafts 185 Mmcte 187 Adjust Primary Shaft Bearing Clearance 189 Primary Shaft Cover Installation 190 Set Secondary Shaft Bearing Clearance 191 Pump Mount Installatio
67. Twin Disc Incorporated Assembly Heat Exchanger Installation Heat exchangers furnished by Twin Disc to be used salt water applications have zinc anode rods installed at the heat exchanger 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 anode rod indicates electrolytic action Acareful inspection should be made to determine if this action is caused by a short circuit or externally grounded electrical current If these conditions do not exist itis evident the corrosion is due to local electrolysis If the zinc anode rods are corroded with foreign materials they should be cleaned with a wire brush P Gasket Location P Yat TIT 24 T ep NI PA Zinc Anode Plug sd lil y D Front Cover 4 3 kgf m JIS 8 8 DJ Spacer and O Rings 7 BOLTS HEXAGON SOCKET HEAD 549607 Figure 188 Heat Exchang
68. an existing installation for proper alignment The marine transmission input shaft centerline will be fixed as it is located by and bolted to the propeller shaft The engine must be adjusted so that the angle between the engine crankshaft centerline and the transmission input shaft centerline are equal and the offset angle is within the proper limits 1 Fabricate pointer plates that be mounted to the same transmission input flange adapter that the driveline will connect to and to the engine flywheel mounted coupling that the driveline will connect to 2 Fabricate inner hollow tubes and outer hollow tubes and weld pointers indicator ends onto inner shafts 3 Drill a hole in same length outer tube and then weld a nut to the tube This will be used as the retention device for the inner tube once the inner tube is slid into the outer tube 4 Weld the tube assemblies to the plates making sure that the tube to plate runout is zero This will allow for adjustment of both shafts to identical lengths Make sure there is a tight fit between the outer tube and inner tube the closer the fit the more accurate the alignment will be Marine Transmission Operator s Manual 1021629 Installation Twin Disc Incorporated Bolt pointer onto the transmission input shaft flange Bolt the other pointer onto the engine flywheel mounted coupling output flange These pointers are an extension of the shaft centerlines on which the
69. and short screws Rotate the handle to the minimum trolling pressure position and install the last screw Torque the cover attaching screws to 9 5 Nm 7 ft lb Figure 208 Install screws 210 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 10 Place the small diameter spring into the pocket of the end cover Use a small amount of grease to retain the spring in the cover Figure 209 Install spring and rear cover 11 Install the cover being careful not to drop the small spring and gasket Install the hex head capscrews and torque them to 23 Nm 24 5 ft lb Marine Transmission Service Manual 1021629 211 Assembly Twin Disc Incorporated Trolling valve installation 1 2 Install the gasket and lower valve body half onto the transmission Install the ditch plates and gaskets onto the lower valve body half Install the socket head capscrews through the ditch plates valve body and into the transmission Torque the screws to the specification listed on the valve installation drawing Install the upper valve body half and gasket onto the ditch plates Torque the screws to the specification listed on the valve installation drawing Install the trolling valve and gasket onto the ditch plate and torque the screws to specification see Torque Chart Figure 210 Install trolling valve onto ditch plate 212 Marine Transmission Service Manual 1021629 Twin Disc Incorpora
70. 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 1021629 33 Operation Twin Disc Incorporated Hydraulic System with Electric Control Valve 34 The oil pump draws oil through the strainer from the oil sump and discharges it through the oil filter Filtered oil enters the control valve through the inlet port The incoming oil forces the pressure regulator piston against the springs to open the path to the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the heat exchanger to the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings There is a lubrication oil pressure relief valve to limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leaking oil from affecting the pressure regulation Marine Tran
71. b Place the tapered roller bearing cone onto the output shaft with the small diameter end of the bearing toward the bearing cup Slide the bearing onto the shaft until it contacts the shoulder of the output shaft seal sleeve 8 Install the output shaft spherical roller bearing cone 7 a Heat the output shaft spherical roller bearing cone to 120 C 250 F b Place the spherical roller bearing cone onto the output shaft with the large diameter of the bearing toward the bearing installed previously Slide the bearing onto the shaft until it contacts the rear tapered roller bearing cone 9 Install the bearing spacer 8 a Heat the bearing spacer to 120 C 250 F b Place the bearing spacer onto the output shaft with the small diameter end towards the spherical bearing cone Slide the bearing spacer onto the shaft until it contacts the spherical roller bearing race AAR222 AAR222 Figure 153 Tapered Bearing Cup 5 Tapered Bearing Cone 6 Spherical Roller Bearing Cone 7 and Bearing Spacer 8 Installation Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 10 Ensure the components are properly seated on the shaft Use a pressing sleeve and press to ensure the components are properly placed on the shaft 11 Install threaded rods and spacers 9 to the output flange and seal carrier The tool is used to maintain the position of the output shaft seal carrier during installation in the tran
72. consult the Product Service Engineering Department at Twin Disc Install the spacer over the shaft with the smaller diameter end toward the gear Marine Transmission Service Manual 1021629 Assembly Twin Disc Incorporated 28 Install the spherical roller bearing on the end of the output shaft Carefully align the components to ease installation Gently tap the inner bearing race If necessary to align the assembly during installation Make sure the snap ring is installed retaining the bearing to the shaft Note If the spherical bearing becomes out of alignment the assembly will become impossible DCP 0991 DCP 0992 Figure 166 Spherical Bearing 3 Installation in Transmission Housing DCP 0995 Figure 167 Snap Ring Installation Marine Transmission Service Manual 1021629 183 Assembly Twin Disc Incorporated Gear Pan and Bottom Cover Installation 1 Install the gear pan 5 into the main transmission housing around the lower portion of the output gear 2 of M10 1 5 x 25mm Torque the bolts to 46 Nem 34 lb ft 2 Place MA1015 sealer on the sealing surface of the bottom cover 6 Place enough sealant on the housing to adequately seal the transmission bottom cover 17 of M10 1 5 x 30mm 5 of M10 1 5 x 50mm 4 of M101 5 x 60mm Note Apply nickel anti seize compound to threads before torquing the screws stainless steel to 34 Nem 25 Ib ft A IMPORTANT Be sure to seal the surfaces around the two
73. e n 9 707BD AS 8 2 99 242 THREAD DOG POINT INT 10180 D 14 018688 e XM2759FL 12 VDC A2702BC gt 704 2415 3505 1017129 MA1038EXMe7 X 20 69 2451 Igal MG 6848SC ALC DAS DETENT GROOVE UNTIL SNUG 1018084 15 018688 e 2759 4 VDC 704p 2415 350 10171298 MAfDSBEXMe7 X 2 0 6H B2451B MG 6848SC ALC DAS BACK OFF 1 2 TURN 1B0BAAF 118 1017133 1017134 B1337F 1018688 xM2759F VDC XA2707Z 427077 A2703 25 250 1017129B MA1038E e7 x 2 0 6 B2451B f 1052 2 MA1058K 2 5202 81539 018084AG 41163 018688 2 XMe759F VDC XA2707AD A2707AD A2703AB 2000 2902 10171298 MA1038E e7 x 2 0 6H B2451B G 5805DC 112428 oe ee Sew 2 018094 41171 018688 2 xM2759FM 24 VDC 7072 A270 A2703 25 250 gt 10171298 1038 7 x 20 64 B24518 AS G 5170DC 1 19 99 H lE C Lx E C i _ 0180848 41172 018688 e XMe759F VIC XA2707Z A270 A2703 25 250 gt 10171998 MA1038E Me7 x 2 0 6H B2451B G 5170DC 47442 e GOGA W 1018084 244 1018584 1018594 B3117A 1018688 e XMe759F VDC xA2707Z 427077 A2703 25 250 gt 10171294 MA1038E e7 x 0 6 2451 4 1732 2 1732 MG 540 22 00 SPRING A2702BQ 2 963 0 101808441 250 018688 2 XM2759FM 24 VDC 70 270 2703 25 250 1017
74. each spring is firmly held in its bore within the housing Install the spherical bearing cup into the transmission housing next to the springs The spherical bearing cup is a slip fit in the transmission housing Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly AAR229 AAR228 Figure 159 Output Shaft Bearing Spring 8 and Bearing Cup 9 Installation 14 Ensure the surface of the shaft taper is clean and free of grease and other contaminants Lightly grease the output bore 1 of the transmission housing and the O ring 2 of the seal retainer on the output shaft subassembly Slowly lower the shaft subassembly into the transmission housing through the shims and the output gear assembly A CAUTION Carefully lower the shaft into the transmission housing as the seal carrier is installed into the housing Damage to the shaft seals could result if appropriate care is not taken during the installation process Marine Transmission Service Manual 1021629 177 Assembly Twin Disc Incorporated 15 Gently tap the end of the output shaft with a dead blow hammer if necessary to guide the seal retainer into the housing Note There will be a slight interference fit between the main housing and the seal retainer Note When the shaft is installed a small gap 3 will be present between the transmission housing and the seal retainer This gap is a result of the springs installed between the transmissi
75. ensure all measurements calculations are correct If no errors are found it will be necessary to change parts Contact the Product Service Department of Twin Disc Incorporated Marine Transmission Service Manual 1021629 175 Assembly 176 Twin Disc Incorporated Ensure the output gear bore is clean and free of grease and other contaminants Install two M10 1 5 eyebolts into the output gear 4 and place it in the transmission housing with the trailing pump drive gear 5 towards the rear side of the transmission housing Align the output gear with the output shaft bore in the transmission housing A CAUTION The tapered surface of the shaft and matching tapered gear bore must be completely free of grease oil dirt and solvent residue Failure to properly clean mating parts could prevent proper advance of the gear on the shaft and adversely effect torque carrying capacity of the assembled joint 10 Place the shim pack 6 on top of the output gear bore 7 Ensure the shims are centered on the bore of the output gear MVC886F AAR228 Figure 158 Output Gear 4 Placement in Transmission and Shim Installation 11 12 13 Fill the nine spring pockets in the bearing bore of the transmission housing with grease Note The grease will be used to retain the springs in the spring pockets while the transmission housing is rotated Install a spring in each of the spring pockets of the transmission housing Ensure
76. exchanger rear cover The heat exchanger positioning can be verified by viewing the heat exchanger through the inlet outlet ports 1 The divider should not be out of position when viewed through the inlet outlet ports Torque the screws evenly 38 Nem 28 Ib ft 6 of M8 x 50mm no Washer Note Improper tightening of the heat exchanger rear cover could cause damage to the cover DCP 0116 AAR313 Figure 192 Heat Exchanger Cover and Gasket Installation D Place the transmission housing in the upright position a Lubricate then install an O ring 2 over the front of the heat exchanger 3 6 Place the screws into the front cover 4 of the heat exchanger Install the front cover over the heat exchanger Tighten the heat exchanger cover screws evenly to a torque of 38 Nem 28 lbeft 6 of M8 1 5 x 55mm no washer Marine Transmission Service Manual 1021629 199 Assembly Twin Disc Incorporated Note Tighten the six screws evenly to prevent damage DCP 0107 DCP 0105 Figure 193 Heat Exchanger Front Seals 2 and Front Cover 4 200 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Cold Oil Relief Valve Installation 1 Install the cold oil relief valve DCP 0129 DCP 0130 Figure 194 Cold Oil Relief Valve Marine Transmission Service Manual 1021629 201 Assembly Twin Disc Incorporated Assembly and Installation of Control Valve Assembly of Electrical
77. heat exchanger rear cover Marine Transmission Service Manual 1021629 79 Disassembly Twin Disc Incorporated Remove Transmission External Components Supply Cover and Output Shaft Cover 1 Remove 8 capscrews and remove the supply cover a Gently tap the cover 1 to break the sealer bond from the transmission housing b Remove the 2 O rings located on the transmission housing Remove the four seal rings 2 Tag the seal rings with identifying information DCP 0072 Figure 28 Supply Cover and Output Shaft Cover Removal 2 Remove nine capscrews and remove front output shaft cover 80 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Selector Valve Remove the selector valve 4 of M10 1 5 x 150mm with washer DCP 0108 110 Figure 29 Selector Valve Removal There is nothing holding the top half of the valve to the bottom half once the four screws are removed Be careful not to drop the valve Marine Transmission Service Manual 1021629 81 Disassembly Twin Disc Incorporated Heat Exchanger P Gasket Location ET Zinc Anode Plug Front Cover 4 3 kgf m JIS 8 8 7 BOLTS HEXAGON SOCKET HEAD Spacer and O Rings 549607 Figure 30 Heat Exchanger Component Identification and Location Remove the front cover 1 and gasket from the heat exchanger 6 of M8 1 5 x 55mm 2 Remove the O ring 2 and place i
78. in the bore of the steel insert with an arc welder 3 Heat the aluminum cover to 120 C 250 F 4 Pull the insert from the cover Figure 81 Clutch Shaft Insert 6 16 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Output Shaft Disassembly 1 Slide the oil seal carrier away from the output shaft bearings 7 until it contacts the output flange 2 Place a split bearing puller 8 around the shaft between the output shaft seal carrier and the tapered roller bearing on the shaft assembly The puller will remove both bearings simultaneously from the shaft Place a shaft protector 9 between the puller assembly and the end of the shaft to protect the shaft end during disassembly 3 Ensure the bearing puller is properly placed to prevent damage to the bearings and other components of the shaft during disassembly AR214 R213 Figure 82 Output Shaft Bearing 7 Removal 4 Tag the components 1 with identifying information Remove the output shaft seal sleeve 2 from the shaft AR215 AR220 Figure 83 Output Shaft Components 1 and Seal Sleeve 2 Marine Transmission Service Manual 1021629 117 Disassembly Twin Disc Incorporated 9 The seal sleeve 2 uses an O ring on the inner surface sealing the sleeve to the shaft It may be necessary to destroy the seal sleeve to remove it AR216 ARMVCOO7FGS Figure 84 Output Shaft Seal Sleeve 2 6 Hemove the bearin
79. manner 2 Remove the manifold from the transmission housing A CAUTION Use caution in removing the manifold from the transmission housing The forward and reverse shaft bearing cups could fall out of the manifold as it is being removed ARO72 DCP 0147 Figure 47 Manifold 2 Removal 3 Remove the primary shaft and secondary shaft rear bearing cups 4 from the manifold Marine Transmission Service Manual 1021629 93 Disassembly Twin Disc Incorporated Note The primary and secondary shaft bearing cups are different from each other Tag the components with identifying information 4 Remove the O rings located in the transmission housing behind the manifold J AR079 DCP 0149 Figure 48 Primary and Secondary Clutch Shaft Bearing Cup 4 and Housing O ring Removal 94 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Remove Secondary and Primary Clutch Shafts 1 Install two lifting eyes M10 1 5 into the secondary shaft transfer gear 5 and lift the shaft out of the transmission housing using the lift chain 2 Install lifting eyes M10 1 5 into the primary shaft transfer gear 6 and the shaft out of the transmission housing using the lift chain or use an appropriate lifting bracket Note Set the Primary and Secondary clutch shaft assemblies aside until further disassembly is required DCP 0151 DCP 0153 DCP 0154 Figure 49 Lifting Secondary 5 and Pr
80. otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment Only aTwin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge
81. piston stuck Orifice plate ball in control valve not seating properly Blown gasket on either side of orifice plate Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Marine Transmission Service Manual 1021629 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 T1 Troubleshooting Twin Disc Incorporated Troubleshooting of GP Control Valve with Electronic Interface 72 The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Electronic Interface LED Indicators The electronic interface control modules have one green and two red led indicator lights The green power light is illuminated only when the transmission is in gear The following table lists the
82. reasons for the various conditions where lights are illuminated This should guide in troubleshooting problems See the wiring schematics in the Installation Section Troubleshooting Tables begin on the next page Table 10 LED Light Status Light Status Profile Generator E troll Module Non trolling Green light on Supply Voltage gt 9 0 Volts Supply Voltage gt 9 0 Volts Red light on Valve coil commanded on Valve coil commanded on One red light flashing Open circuit in in energized valve coil circuit energized valve coil circuit or Valve coil leads shorted MG Units only together or Low coil current Valve coil leads shorted together or Low current Both red lights flashing MG Units After entering troll from simultaneously Power is applied to neutral with both voltage Solenoid A and B switch and current troll speed inputs at the same time signals present or power MGX Units Not Applicable 5 applied to Solenoid and B switch inputs at the same time Both red lights flashing Not applicable Either or both speed alternatel signals missing Marine Transmission Service Manual 1021629 Twin Disc Incorporated Table 11 Troubleshooting Chart GP Manual Control Valve with Electronic Interface 1 Low main oil pressure 2 Nooil pressure or erratic low pressure at control valve tap 3 High main oil pressure Partially clogged oil strainer Con
83. remove air entrapped in the passage Refill the passage with oil as required until the passage is filled and all traces of air are removed Wrap the threads of the injection adapter screw 7 with teflon sealing tape and install the screw into the oil injection adapter Hold the oil injection adapter to prevent rotation during operation and use an impact wrench to drive the screw into the oil injection adapter until the output shaft and output gear tapered surfaces separate If the shaft and gear do not separate during the initial injection repeat steps 4 through 6 Marine Transmission Service Manual 1021629 99 Disassembly Twin Disc Incorporated The gear and shaft will separate with extreme force potentially causing great physical harm Use EXTRA CAUTION and proper safety procedures Place a support at the bottom of the output shaft to avoid the shaft from sliding further down DCP 0950 Figure 55 Filling Oil Injection Adapter with Oil 7 Remove tool T4482 8 from the end of the shaft 8 Remove the snap ring 8 from the shaft Install special tool T21482 8 to the port that intersects the bearing inner diameter MVC 846F Figure 56 Internal Snap Ring Removal Marine Transmission Service Manual 1021629 Twin Disc Incorporated 10 11 12 13 14 Disassembly Repeat steps 3b through 6 which causes the bearing to expand allowing the shaft assembly to drop free of the bearing bore
84. screws that pass through the center of the bottom cover Leaks will result if the bottom cover is not properly sealed DCP 0162 DCP 0160 Figure 168 Gear Pan 5 and Bottom Cover 6 Installation 3 Rotate the transmission and place it with the output side at the top Be sure transmission is supported securely 184 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Installing Primary and Secondary Shafts 1 Install lifting eyes M10 1 5 into the primary shaft clutch housing Install the front bearing for the primary and secondary shaft DCP 0157 DCP 0156 Figure 169 Installing front bearing for the Primary and Secondary Clutch Shaft into Transmission Housing 2 Install the primary shaft assembly into the transmission housing with a hoist DCP 5704 Figure 170 Lowering Primary Clutch Shaft into Transmission Housing Marine Transmission Service Manual 1021629 185 Assembly Twin Disc Incorporated 3 Install the front bearing cone 3 for the secondary shaft if not already done Apply a thin film of grease to the inner bore of the bearing cone 4 Apply a thin film of grease to the front bearing carrier on the secondary shaft Install the secondary shaft assembly 4 into the transmission housing The bearing carrier of the secondary shaft is a slip fit into the bore of the front bearing cone Note Assembly will be difficult if the clutch shaft assembly is not perfectly aligned
85. the gasket and cover without the adjustment screw to the valve body with four M8 x 20 capscrews and torque to 23 Nm 17 Ft Ib Install the spool with washer and spring into the bore Install the gasket and cover with the adjustment screw using four M8 x 25 capscrews Evenly tighten the capscrews and torque to 23 Nm 17 Ft Ib Install the cap onto the adjusting screw finger tight as the main pressure must be set at the time of installation or testing no Fillur Chach Yaira Cover with Adjustment Figure 212 Assemble Main Pressure Regulator Components 214 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 2 Assemble the Top Valve Body Install the two proportional valve assemblies into the valve body install the retaining plate and torque the M6 1 00 x 16 socket head capscrew to 9 5 Nm 7 Ft Ib Install the Manual Direction Control Valve into the valve body and torque to 27 Nm 20 Ft Ib Install the M12 x 1 50 o ring plug into the valve body and torque to 16 Nm 12 Ft Ib Connect the wires for the Neutral Switch E EL Proportional _ M12x 1 50 amp o ring plug 3 am Valves Top Valve Body Figure 213 Assemble Top Valve Body Components 3 Install a new gasket and the Main Regulator Valve Assembly to the transmission or ditch plate using the four twelve point capscrews Torque the capscrews to the level specified for the appropriate sized cap
86. the output gear bore depth dimension including pump drive gear Place the output gear on a flat uniform surface such as a layout table Measure from the edge 1 of the output gear to the surface of the layout table Include the thickness of the trailing pump drive gear Measure in three locations around the circumference of the output gear bore The three readings should be identical Record this distance as dimension C reference drawing Gear Thickness Dimension C AAR234 Figure 156 Output Gear Thickness Measurement 1 Marine Transmission Service Manual 1021629 173 Assembly 174 Twin Disc Incorporated Measure the output shaft shoulder to spacer dimension as follows Measure from the shaft shoulder to the front edge of the spacer located next to the spherical roller bearing Measure in three locations around the circumference of the shaft The three readings should be identical Record this distance as dimension E reference drawing Dimension E Measure the output shaft end to shoulder dimension as follows Measure from the front end of the output shaft to the front edge of the shoulder 2 on the shaft Measure in three locations around the circumference of the shaft The three readings should be identical Record this distance as dimension G reference drawing Dimension G Calculate the correct shim pack reference drawing dimension B required to set the output gear advance on the out
87. to be parallel to each other When the two splined together yokes or forks of the driveline are in the same plane parallel to each other the universal joints are considered to be in phase It is very important to maintain the two yoke ends in phase when reassembling the driveline after service 246 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation Transmission Controls Transmission controls must be checked for proper function and alignment after any transmission selector valve is properly indexed in relation to the operator s control lever Failure to do so could cause control system malfunction resulting in personal injury and or damage to equipment and property 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 WIRING DIAGRAM CONNECTOR CONNECTOR 5 7 SECONDARY CLUTCH SOLENOID 5 PRIMARY CLUTCH SOLENOID NEUTRAL SOLENOID 5 SECONDARY CLUTCH SOLENOID T a D o L3 a Dp lt 7 gt PRIMARY CLUTCH SOLENOID OPTIONAL MATING WIRING HARNESS 1017404 OPTIONAL SERIES TH MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH NOTE LEVER MAY BE LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTAL ROTATION amp 11 4mm AXIAL
88. transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing Cup Measure in three locations around the circumference of the bearing bore The three readings should be identical If the dimensions are not identical realign the bearing cup Record this dimension Bearing Bore Depth 2 Insert the bearing spacer in the bore of the pump mount Measure the length of the spacer that is beyond the mounting surface of the cover Measure in three locations around the circumference of the pump mount The three readings should be identical Record this dimension Pump Mount Pilot Dimension si Calculate the correct shim pack required to set the secondary clutch shaft rear bearings a Subtract the secondary clutch shaft rear cover dimension from the transmission housing to rear bearing cup dimension Bearing Bore Dimension Cover Dimension Pinion Shaft Clearance b Calculate the shim pack thickness required to obtain 0 05 preload to 0 05 mm 0 002 preload to 0 002 inches clutch shaft clearance when the shim pack is installed 4 The calculated shim pack will be installed on the secondary clutch shaft between the bearing cup and the spacer 1049BE 1045BE Figure 179 Measuring Components to Determine Secondary Clutch Shaft Bearing Adjustment Marine Transmission Service Manual 1021629 191 Assembly Twin Disc Incorporated Pump Mount Installation
89. valve 1281b Figure 113 Remove end cover Marine Transmission Service Manual 1021629 135 Disassembly Twin Disc Incorporated 12 Remove the two bushings and internal retaining ring from the valve only if replacement of parts is necessary The bushings are a tight fit in the bore of the valve Note that the bushing with one groove in the outside diameter is adjacent to the retaining ring in the valve body bore 13 Remove the PT pipe plugs from the valve to clean the oil passages inside the valve c 1288b Figure 114 Valve parts 136 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Cleaning and Inspection Cleaning Note Replace all oil seals gaskets O rings piston rings seal rings and snap rings as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly Clean all parts using EPA OSHA approved solvents or by steam cleaning Parts must be dried and oiled immediately to prevent corrosion Examine all parts carefully for grit dirt and abrasives and reclean them if necessary Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent Use clean solvent to flush oil pumps and valves Flush all hoses tubing and coolers particularly if the unit is being disassembled because of an internal failure De burr the housing and bea
90. worn splines Cracked parts Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found 64 Marine Transmission Service Manual 1021629 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 determine if this action is caused by a short circuit or external grounded electric current If these conditions do not exist it is evident that the corrosion is due to local electrolysis If rods are corroded with foreign materials they should be cleaned with a wire brush In boat Repair Certain transmission maintenance repair procedures can be accomplished in the boat provided sufficient space exists to work These procedures are 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 and bearing carrier Removing and installing the clutch shaft assemblies for overhaul Marine Transmission Service Manual
91. 000 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 1021629 63 Preventative Maintenance Twin Disc Incorporated When inspecting the flexible coupling look for evidence or conditions identified in the following steps Cracks the surface of the rubber May be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques Separation of rubber from flex plate on coupling plate or deterioration of the rubber to metal bond See above 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 Ll Cracked bent or otherwise damaged flex plate or coupling plate Ll 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
92. 000 in 0 05 mm 0 002 in Note A negative end play indicates a pre load condition Table 3 Output Flange Runout Limits Feature Maximum allowable total indicator reading Output flange face near O D 0 10mm 004 in Output flange pilot diameter 0 10mm 004 in This note applies to a continuous 270 arc if the pilot is negative in readings otherwise it means all 360 Marine Transmission Service Manual 1021629 Description and Specifications Twin Disc Incorporated Torque Values for Fasteners Note Lubricate all threads and bearing face with light oil film prior to assembly Use SAE grade 5 and Property Class 8 8 torque value for all screws that are threaded into aluminum Table 4 Metric Coarse Thread Capscrews Bolts and Nuts Property Class 8 8 Property Class 10 9 Property Class 12 9 Size Loo m m m w i 65 75 12 14 10 12 14 16 70 80 121 139 298 342 581 669 1000 1150 2000 2301 28 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Description and Specifications Table 5 Tapered Pipe Plugs with thread lubricant Torque Valuesfor Lubricated Pipe Plugs Recommended Torque N m Size Installed in Cast Iron or Steel Installed in Aluminum Notes The lubricant is to be John Crane insoluble plastic lead seal No 2 or equivalent or Loctite No 92 or equivalent and plugs are to be capable of removal without damage Overti
93. 02 Install washer Marine Transmission Service Manual 1021629 207 Assembly Twin Disc Incorporated 4 Install the large diameter spring over the washer in the valve Figure 203 Install spring 5 Place the shim s into the bore of the piston assembly Install the piston assembly into the bore of the valve Figure 204 Install piston assembly 208 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 6 Install a new O ring into the groove of the shaft Apply grease to the bore of the cover and the shaft and insert the shaft through the cover Install the E retaining clip onto the shaft Figure 205 Install o ring and clip T Place the detent ball into the pocket in the cover of the shaft cover assembly Apply grease to help keep the ball in place and prevent corrosion during service Apply grease to the detent spring and place it into the pocket over the detent ball Figure 206 Assemble detent ball and spring 8 Install the cover and shaft assembly and gasket onto the valve Be sure to align the keyway in the shaft with the pin in the piston assembly Also be sure to align the detent spring hole in the cover and gasket with the detent spring pocket in the valve Marine Transmission Service Manual 1021629 Assembly Twin Disc Incorporated Figure 207 Install shaft assembly with cover Install the three loose cover socket head capscrews into the proper locations long
94. 1021629 111 Disassembly Twin Disc Incorporated 3 Remove the pinion bushing assembly 4 Tag the pinion assembly with identifying information This will ensure the gear will be installed in the same location where it was removed 1006BE 1007BE Figure 73 Bearing Carrier 2 Pinion 4 and Thrust Washer 3 Removal 4 Install two clamps 7 on the transfer gear and backing plate to compress the clutch wave springs Compress the clutch until the internal retaining snap ring in the clutch can be removed AR183 1009 Figure 74 Pinion Assembly 6 and Clamping 7 Clutch Backing Plate Twin Disc Incorporated Disassembly Remove the internal snap ring 8 from the clutch retains the clutch backing plate Remove the bar clamps from the clutch assembly 6 Remove the clutch backing plate 9 from the clutch 1012BE 1013BE Figure 75 Internal Snap Ring 8 and Clutch Backing Plate Removal Remove the steel clutch plates quantity 12 the friction clutch plates quantity 11 and the wave springs 1 quantity 22 Note Some early units use only a single wave spring between clutch plates ARMVCO26FGS ARMVCO28FGS Figure 76 Clutch Wave Springs 1 and 2 8 Remove the Clutch plates 3 and then remove the steel thrust washer 4 and needle bearing Marine Transmission Service Manual 1021629 113 Disassembly Twin Disc Incorporated 1014BE 1016BE Figure 77 Clutch Plates 3
95. 1294 MA1038E Me7 2 0 6H B2451B MG 520 1HP 22 0 HYDRAULIC LOCK ONLY F ET AS 2711 00 CCD 1 10180844 251 018688 xMe759rili VDC 270 A270 A2703 25 250 29 10 7 X 2 0 6H 2451 MG 5e0 1HP a c bas 2 2 2 0180844 196 017179 e xMe759FMe4 VDC A2707AD A2703BA 1860 2702 10171294 MAI038E e7 x 2 0 6 Be451B 95 MG 5141SC 2721000 PIN 2711 SPOOL 1017432 2 at E EN N AS 3 21 00 HYDRAULIC LOCK ONLY EN 8084 195 017179 2 XMe759FL 18 VDC A2707AD 70 1860 270 71894 1038 lt 7 x e0 6n 2451 6 51415 v NENNT zio Q018084AQ 41337 1017383 017179 YES 3 2759 24 VDC 270B 078D BU 2550 3702 1017129B MA1038E Me7 x 2 0 6 B2451B 4 MG 6557 42470 EINE A A D 2707 c MG 6600 6 21 00 ITS SHAFT THA PERMITS FREE RACE M2086DF PISTON SEE CHART 8084 146 1017383 017179 YE 3 XM8e759FM 24 VDC 2702 RC A2704BU 2450 6355 7129B 1038 7 x 2 0 6H 2451 5 MG 6619 DJM ALC e ua e suu E e 0180844S 41718 018688 YES 3 75 24 VDC XA27072 a2707z A2703T 1725 eso 10171298 1038 7 x 20 61 Be451B 85 MG 5170DC 4416 0 ROTATION amp 114mm AXIAL MOT BEARING M
96. 149 2 v7 BODY 1020519 UL x VALVE SEE CHART TORQUE TO 36 N m Eor nv 10210004 SHOWN mE t SEE NOTE C Uv or SEENOTE B lS N N 222 QM ol x N TO PLATE 1018175 SCREW MA 10GB GASKET 102053 FILTER P10786 PROPORTIONAL VALVE SEE CHART 21 SEE NOTE A PLUG 2 CLUTCH PRESSURE PORT MI2x1 5 THD CONFORMS m TO ISO 6149 GASKET 1021643 COVER 1021662 A PROPORTIONAL CONTROL VALVE OPERATION 1 WARNING DO NOT CONNECT VALVE COIL DIRECTLY TO BATTERY POWER SUPPLY VOLTAGE 2 OPFRATION TO PERFORMED WITH GNI Y TWIN DISC CONTROL SYSTEMS OR MODULES B MANUAL DIRECTIONAL CONTROL VALVE OPERATION 1 WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PUSH TO ENGAGE PORT 2 WITH MANUAL DIRECTIONAL CONTROL VALVE IN CENTERED POSITION PULL TO ENGAGE PORT C MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH SWITCH IS NORMALLY CLOSED WHEN MANUAL DIRECTIONAL CONTROL VALVE IS IN THE CENTERED POSITION AND OPEN WHEN LEVER 15 ACTUATED FROM CENTERED POSITION 2 CURRENT 20 AMPS 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE DRAWING C PRESSURE REGULATOR ADJUSTMENT 1 REMOVE 1002144 CAP AND LOOSEN 1002145 NUT 2 CLOCKWISE ROTATION OF 10209394 PISTON INCREASES PRESSURE COUNTER CLOCKWISE DECREASES PRESSURE A LOCK PISTON IN PI AF USING JAM NUT AND RFPIACEF CAP E REFER M
97. 2087AD 2570790 ZALE REQUIRED FOR CONTR THESE SOLENOID CONNECTIONS 018084AT 42206 018688 3 XM2759FM24 VDC ae7oedt 078 2415 3502 1017129 Mat038E we7 x 20 6 B24518 AS MG 6848SC dO A 1 _ L E RAGE SAMENG TA 01808441 42964 10171334 1017134 B1337F 1017179 YES 3 759 24 VDC A2707AD 1585 2305 1017129 MA1O38ECM27 x 20 6 B2451B 25 10528 2 MA1052B 2 wc su4 SOLENOID ASS SEE CHART E oco SEE PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND PORT A PORT COVER ASSY 1017336 NEUTRAL SPRING 2705 2 a Na a TORQUE TO 33 9 N m UB MEIN ENS CMS OLENDID SOLENOID A CARRIER 1017335 SOLENOID 250 lbf ft d PIN A2711R 2 BALL 1990L 9 BALL M1990Y WITH OR WITHOUT 0 WIRING DIAGRAM PTIDNAL 5 HYDRAULIC LOCK BALL 1990 SCREEN 221336 MATING WIRING HARNESS 1017404 M8 X 125 6H TH D CONNECTOR SERIES SPECIFY LENGTH gt HOLES pL SPRING ASSY PORT SOLENOID RUE MANUAL OVERRIDE VALVE BODY ASS Y 1017444 p rii POSITI E NE E S EE PISTUN B1399H BODY 1017443 D Ic er EE 846 TERNI CONTR BALL MA1034A 11 a P SITI N OZ 6 a 7 SITI SEE CHAR BAL s M1990Y 6 HESE S LEN 1D 8 N 5 ARE NOT POLARITY SENSITIVE mel SEAL MA778 SHIM SEE CHART D p OW VALVE GASKET 1017136B
98. 5 6 PUR TEFLON BACK UP RING P230 OMA P E ARD RC mio D OF DETAL 1 WITH MINIMUM 174 INCH HIGH LETERING DU IT SING 5235 C OTETE 4 16 STK SUC HD CAP SCREW METRIC M6x1 0x20mm LG NOTE U SS HERWISE SPECIFIED 3 4140 PISTON RETAINTER 1125 DIA 50 BREAK ALL SHARP CORNERS 2 2 stk PIPE PLUG M2051K gt 1 4 18 NPTF 1 4140 RAM BODY 1L85 DIA x 325 NOTE Al GRD DIA S amp SURFACES MUST BE DET REG MAT DESCRIPTIUN STUCK SIZE SQUARE amp CONCENTRIC WITHIN Date 8 19 97 JPL EPN Scale FULL Sei aa Dealt sec 001 F EACH HER NAME RAM GEAR 1 SHAF 1 E SPECIFIED FOR SHEET OF 1 PID CACTI MAD TWD PLACE CAD FILE T 2148e e DWG UPDATE PRINT PER ENG REQUEST 11 20 2000 TMV G 6000 T 21482 2 1 4 ON ANGULAR DIMENSION REV DESCRIPTION DATE BY TWIN DISC INC RACINE WIS 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 168753G Valve Assembly Trolling E 349460 Hydraulic Schematic Transmission 350178 Output Shaft Assembly
99. 65 Retaining Ring 4 and Bronze Thrust Washer 5 6 Remove the pinion assembly 6 Tag the pinion assembly with identifying information This will ensure the gear will be installed in the same location where it was removed Install two clamps 7 on the transfer gear and backing plate to compress the clutch wave springs Compress the clutch until the internal retaining snap ring in the clutch can be removed AR183 6557 AR186 6557 Figure 66 Pinion Assembly 6 and Clamping 7 Clutch Backing Plate Marine Transmission Service Manual 1021629 107 Disassembly Twin Disc Incorporated 8 Remove the internal snap ring 8 from the clutch retains the clutch backing plate Remove the bar clamps from the clutch assembly 9 Remove the clutch backing plate 9 from the clutch AR187 AR188 Figure 67 Internal Snap Ring 8 and Clutch Backing Plate Removal 10 Remove the steel clutch plates quantity 12 the friction clutch plates quantity 11 and the wave springs 1 quantity 22 Note Some early units use only a single wave spring between clutch plates There are only 11 wave springs on these units ARMVCO26FGS ARMVCO28FGS Figure 68 Clutch Wave Springs 1 and 2 108 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly 11 Remove the inner steel thrust washer and needle bearing AR188C AR188D Figure 69 Clutch Plates 3 and Bronze Thrust Washer 4 12 Remove the steel t
100. 729 DATED 8 9 02 POSITI PEN WHEN LEVER IS ACTUATED FROM 1020525 CENTERED POSITION CURRENT 20 AMPS N _DQ_ L MATERIAL WEIGHT wR UNLESS OTHERWISE SPECIFIED DATE Ae IECN12561 7 88 04 B6 CN11978 11 18 03 NOTICE THIS PRINT CONTAINS V 3 FOR WIRING SCHEMATIC REFER TO CONTROL MODULE PROPRIETARY INFORMATION AND IS DIMENSIONSS CEU 8 9 Uc I DRAWING L BS 12457 5 28 04 E B6 1 61 8 14 03 T TO BE USED ANY MANNER dis PE 22 5 N D SS K Fe IECN12413 5 7 04 D 1170317 30 03 is a eee HEAT TREAT FIRST USE xut 2 1 RO ECN12314 3 24 04 C ECN11589 5 2 03 dup ASSY _ DM UES 0207289 O P 2 IN 7 aL MGX 5114A PER ANSI 14 5 1982 CHK xx CN1205812 18 03 B ECN11368 4 08 03 IS CE IS N NTENDED 5 CN12015 A 321 NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME ALC wal G E 4 0 12 03 03 EC Ll 1 30 03 GRANTED THE U S GOVERNMENT MP L APPD F X NUT SERVICEABLE SEPARATELY REV sheet Zone CH NU DATE REV sHeeT ZONE CH DATE R OTHERS BY CONTRACT 2 GAM SHEET 1 of 1 SCREW 961 6 PLUG MA1038B O RING A291 6JT 2 MAIN PRESSURE CHECK 2 PM M12x1 5 THD CONFORMS PORT 45 2 TO ISO 6
101. 9 9 Table of Contents Twin Disc Incorporated 1 227 General Alignment 227 228 Marine Transmission to Propeller Shaft Alignment 229 ONG m 234 Torsional Input Coupling Alignment Free Standing Units 235 Engine Flywheel Measurements reference SAE 236 Engine to Marine Transmission Alignment 240 s nn miucirimMee a 246 Transmission Controls ECL NDNN UN 247 Wiring Connections for Optional GP Control Valve 249 LOOMS E 253 GISI OF xeu UN 253 hi gr n H M 255 AMO TAA P 256 T 21482 6 Retention Block and Screw 257 T 21482 8 Oil Injection Adapter Tool 258 T 21482 17 Output Seal Driver 259 T 21482 26 Bearing usu reuera 260 T 21482 44 Adjustable Jack e 261 T 21482 45 Bearing Driver
102. A eU T 1021658 43196 AEN a34 1C 10210004 1016122A NONE NONE 1018528 K1418 vo 4 1D21658F F 43197 uas awe 10210004 1016122A 038 NONE 1020520 1420 a 10216880 43198 TES aoc 1020542 NONE 20515 1018528 1419 I021658H 43199 as 34C 10210004 M20515 MATIBSA NONE 1018528 K1418 y 1021658 J 43200 Nosy 1020542 M20515 MATOSSQ NONE 1018528 K1418 BOTTOM VIEW TWIN DISC s nae vet epe GM tA Rei T IOWI METRIC 1 METERS BC 2 ECNI2561 7 28 04 us 1021658 A BP 2537 8 28 04 002 PEERS MERDA a7 Seo Na VALVE ASS Y eap tn quiim ME 4 1 1021629 04 05 TW POWER TRANSMISSION EQUIPMENT TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
103. AD A2703AB 2000 290 1017129 1 8 7 x 20 6 B24518 MG 6650SC DAS AZ STEM IS LOCKED IN ELECTRIC 2 0 10180840 40842 1017133 1017134 B1337F 1018688 2 XM2759FM 24 VDC XA270 A270 A2703T 1725 250 1017129 MA1038E we7 x 2 0 64 2451 8 1052 2 MA1058K MG 5808SC 52298 MODE MAX I 20 A PLATE 1018318 m z See C A t 10 9 98 1018084R 40935 017383 017179 YES 3 xMe759FM 24 VDC A2707BD A2704BU 2415 350 10171298 1038 27 x 20 6 B2451B 92 MG 6557 Heese m z TA am SCREW MA1052P 4 1 10180845 40954 1018584 8594 B3117 8688 2 2759 24 VDC XA270 270 A27031 1725 250 29A 10 8 7 x 2 0 64 B2451B 1732 2 M1732AH 2 MG 540 TORQUE TO 54 2 0180847 40955 C17 see 017179 e XM2759FM24 VDC A2702 270780 2655 3853 1017129B MA1038EX M 7 X 20 6 B2451B 5 MG 6449 15 98 400 lbf ft Q1018094U 40956 0 017179 2 759 24 VDC aovoop l BB Apu 2550 370 1017129 10 27 X 20 6 Be451B 4 MG 6557 here SECURE LEVER IN THE DEPRESSED Tipe 018084V 40957 017383 017179 2 75 4 VDC A27028 7A 2450 lt 355 1017129B 1038 7 x 20 6 B2451B B eee UU E ELEC ES as
104. ARINE TRANSMISSION ASSEMBLY DRAWING OR BILL OF MATERIAL FOR VALVE MOUNTING AND SCREWS F APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS AROUND CORE PLUG JUST BEFORE FINAL ASSEMBLY REFER TQ 774 FOR FURTHER INFORMATION GC MODIFICATION KIT TO UPGRADE EXISTING 1020729 1020696 PLUG SEE CHART 7 SERIES VALVE ASSEMBLIES TO 1021658 SERIES VALVE ASSEMBLY OPTIONAL INLET PORT 22 mo E M27x2 0 THD CONFORMS Lop SCREW 4 B TO ISO 6149 2 3 n COVER 1021661 enn cee SPOOL 1021660 senem f GA s SCREW MA960A 4 5 Fe s X a ML i toe d IH 0 1 2 TEILE jd M Sc 0 amp 7 VALVE 1020942 77 a WASHER 2782 BODY 1021659 CAP 10021 44 SPRING S SEE CHART SEE NOTE D SEE CHART STAMP VALVE ASSEMBLY IDENTIFIER HERE NUT 1002145 RING PISTON 10209394 A B VALVE VALVE PRESSURE 2E DEM MODIFICATION ASSEMBLY ASSEMBLY BOM kPa SPRINGS HG PROPORTIONAL PART NO IDENTIHER dps Bi VALVE SENSOR PLUG PLUG ee YA SEE NOTE C Lh 10216584 A 43110 10210008 NCINE M20515 MA 1038E 1020520 E 210216588 AMI XL amare 10210004 NONE 20515 NONE 1018528 K1418 ee 10218820 C 43112 HHH IMUC 1001000 NONE 20515 NONE 1020520 K1429 PORT A PORTE 02165880 D 4395 028900 1021000 1016122A NONE 1 8 NONE 1020520 K1417 ORT
105. CE TREATMENT C 3 GOVERNMENT NTRACT MG ET 1 OF REVEL TWIN DISC PART NUMBER
106. DAS BJE PORT SOLENOID Sc 224 C 1018084 40752 1017133 1017134 B1337F 1017179 XM2759FM 24 VDC 707 585 2302 10171294 051 20524 0930 B2451B 5 M2089F 2 514 IS D T mg PLUG M2051K 2 1018084 0753 017133 1017134 B1337F 017179 2 XM2759FM 24 VDC XA2707BZ A2707BwW A2703BA 1380 200 1017129 VP09IL c 1036 go451g Meog9v 1 Meogsr DD S16V 22 EUTRAL SOLENUID E 0180840 40754 1017133 1017134 B1337F 1017179 2 JXMe759rl 12 VDC A2707AD 585 230 10171294 MEL qsa B2451B y Meogor 2 Meo89 G DD 514V m e 2 SCREEN 1020479 9 1018084E 40755 1017133 1017134 B1337F 1017179 XM2759FL 12 VDC xA2707BZ 2707BW A2703BA 1380 200 1017129 M20SIL 10530 B2451B 1 Meog9r pp siev 2517598 bad PTIONAL 18 AN rm BN 018084F 40756 10171334 1017134 B1337F 1018688 2 XM2759FM 24 VDC XA2707Z A2707Z A2703 25 2505 10171294 1038 27 x 2 0 6 B2451B Me089F 2 2 6 1 ey 2 Y n SE DERON da oe 2 7 0 ae ae 1 018084G 40757 10171334 1017134 B1337F 1018688 xMe759FL 19 VDC x42707Z 4270 A2703 25 250 10171294 1038 27 x 20 6 2451 2089F 2 M2089F 2 G 5111 UNE am T 1 x SEES 5 D H 3 T i E EDIT 2
107. EATHER OR LOW COIL CURRE SOLENOID B CONNEC LIE NNFCT TH THE BUTPU CONNECT TO THE RED LEDS FLASH SIMUTAINIOUSLY WHEN POWER IS APPLIED TO SOLENOID AND SWITC POSITIVE TERMINAL IN THE GEAR CONTR R CONTROL S SOLENOID SWITCH INPUTS AT THE SAME TIME AY F THE INE THAT IS USED ERGIZE POSITIVE DRIVE YZ BATTERY THROUGH THE SOLENOID B UTPUI M SWITCH CONTACTS OTE 1 TEMPERATURE SENSOR MUST BE TWIN DISC SUPPLIED PART 51 2 NOTE 2 WHEN THE NOT IN NEUTRAL CIRCUIT IS NOT USED INSULATE AND SECURE THE 1 BLUE AND BLACK WIRES SOLENOID CONNECT 1 E CONNECT HE SAME CONNECT 1 HE ETUR EGATIVE TERMINAL GROUND POINT USED BY CONTROL S SOLENOID HE ENGINE F GEAR LE EGATIVE OUTPUT BATTERY F ENGINE CONTR CIRCUI 3 2 SOLENOID A CONNECT HE CONNECT THE OUTPUT CONNECT 1 PLACES POSITIVE TERMINAL IN THE GEAR CONTROLLER CONTROL S SOLENUID des F THE ENGINE THAT IS TO ENERGI POSITIVE DRIVER BATTERY UGH THE SOLENOID 4 UTPUT SWITCH CONTACTS 24 0 USED TO ENERGIZE SOLENOID A PART FACTORY SETTINGS 1 Fi FOR USE ON INAL 12 24 VDC SYSTEMS EON 21 0 1020585 DY TT THIRD ANGLE 10205854 SEE PAGE 2 SE eed SIMILAR L 1020585B eve CAVITY FILLED WITH ENCAPSULANT HIC THIS PRINT CONTAINS MATERIAL WEIGHT WR AS 03 N gt Se EAE ECNi2521 6 30 04 NUT BE USED IN ANY MANNER See NEE ui 22 19 CUVER DETRIMENTAL TO THE INTE
108. ER aE s N9B5710035_ SCREW BEHEAD oad TORQUE Z N mM 77 PIPING AS A ETheeebond 1 300 77 78492 PIPING AG EE INSTALLATIE WORK SHOULD HE MADE AS PER THE FDLLOWING BSTRUCT IONS TORQUE ASM ra Theeebond 132 1327 clk 1 OEMS 1 BO Al INSTALLATION WORE me eee LEE F RATS EHDICATE TEE ADDICIONAL PARP FOR WORK 00 42 17 ALPHABCTS INGIGATE PRE FITTFO GN THI 3EABRHOX 3 23 RFFFR TO TRE ATRACHED FIGURES TGR IMS OM LAT HON PE CARR JO HARLH THE PATTERNS OF GASECTS GF THE PARTS To BE COMPLETED VIEW 7 62 AR CAR TS 31 EFF ORF Tel GMSTALL ATION RLMOYE CH3 OMS SROM THF PARTS Br OLL WASHING AIF BLORIALG 5 47 WHEN ARL HABD TO INSTALL TR AGAIN ARACH ADJUSTEMS TAE LOGCAT CH TERQUE AN GARE PARTO Y Peo NG RF IR SCRLWS 2 REMOVALS OF HE PROTESTED PARIS REMOVE AO C AND Pou KEEP SCR Ws 5 AT THE RIION OF IBA amp I PUMP FEIT TORQUE EA m INSTALLATION OF TRA FUP 2 INSTALL ATLON OF FRAILIHE FHP A ATTACH masi OY GASKET UB SCREWS HB ATTACHE GLOWAN COLPLING 4 Tf THF SHAFT BF USING GREASE DURING Ol UHAM COUPLIKG AHO THE PREFER MIC COUPL IAG ALL C
109. GHTS TO NULEIFY OF LIH OR OTHERS BY CONTRACT BOL ES HEXAGON SOCKET MEAD 42 1 INFORMATION 15 DETRIMENTAL TO THE INTERESTS OF INCORPORATED GRANTED TO THE U S GOVERNMENT DETER DIA SECTION FOR TROCHOID PUMP NOTES 1 AD3uUuSi SPACES AND B SHOULD BE 0 05 0 05 mm SPACE f 9 SHOULD BE 0 05 mm CE I FO A 2 FIGURES IN THE DRAWING SHOW TIGHTENED TORQUE FOR HAIN 1 LHPOR TANT B l T5 m M ee ASSEMBLE THEM SPACES C AND DIFOR EACH SHAFT WITH SHIMS MATERIAL 0 E HEAT TREAT FIRST W ee ee HEL NG 6449 00 R SURFACE TREATHEMT SECTIONAL VIEW 100 WAVE SPRING COOUSLE 22 15 8 8 2 5 HEXAGON HEAD 4 42 6415 8 8 LE BOLTS HEXAGON SOCKET HEAD MEDEE CIER NT E BOLTS HEXAGON SOCKET HEAD JCKET HEAD N Bee Som Wi il a Lo 3 EN SECTION FOR REVERSE SHAFT 235 M mtJ15 8 8 B B 3 B TS HEXAGON SOCKET HEAD 42 N mtJ E CIE T S BOLTS HEXAGON SOCKET HEAD B BO 15 HEXAGON SOCKET HEAD 4 2 SECTION FOR ATTACHING OIL LEVEL GAUGE c uw RD ANGLE 1 CTIOM T8 ur gyro TR ASBO A REY UML ESS MACRO
110. GREATER THAN 1 59MM 0625 INCH BOTH SIDES PRIOR TO ALIGNMENT ROTATE BOTH SHAFTS TO TRANSMISSION INPUT SHAFT DRIVELINE Figure 237 Remote or Island Mounted Alignment Tool Shafts Parallel 242 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation A C ee ER ER Eee D i i LA ANGLE B DRIVE S HAE TRANSMISSION INPUT SHAFT Figure 238 Engine Crankshaft Centerline Parallel to Transmission Input Shaft Note that Angle A must equal Angle B within 1 2 degree ANGLE A ANGLE B Seh DRIVE FT e N INPUT SHA CRANK TRANS STERLINE Figure 239 Engine Crankshaft Centerline Not Parallel to Transmission Input Shaft Note that Angle A must equal Angle B within 1 2 degree Marine Transmission Operator s Manual 1021629 243 Installation Twin Disc Incorporated TOP VIEW Ss _ QU LI dd g eed CORRECT ALIGNMENT USING PARALLEL PLANES BETWEEN ENGINE AND TRANSMISSION CENTERLINES A VARIABLE LENGTH UNIVERSAL SHAFT MUST BE USED CORRECT ALIGNMENT BETWEEN ENGINE AND TRANSMISSION CENTERLINES THE ENGINE AND TRANSMISSION CENTERLINES USE THE SAME PLANE IN THIS TOP VIEW A VARIABLE LENGTH UNIVERSAL SHAFT MUST BE USED IMPROPER ALIGNMENT BETWEEN ENGINE AND TRANSMISSION SHAFT CENTERLINES NOTE THE ENGINE AND TRANSMISSIN CENTERLINES ARE NOT ON PARALLEL PLANES Figure 240 Examples of Proper a
111. I s Mese UIE TAREN BUI GRADE 88 METRIC 2 1 STK METRIC HEX BOLI M12x1 75 73mm LG Mile x 172 summ LUNG 1 MS KNECK DUT 7 ied DIA x 678 LG i 2 5 R Q Q 1 y DET IREQ MAT DESCRIPTIUN STOCK SI MG 6557 SC amp MG 6557 d 1 9 98 By JPL FPN Scale FULL M HYDRAULIC KNOCK OUT TOO SPECIFIED FOR MG 699756 amp MG 69976 SPEE i G 6600 MG 6619 SERIES Tende ea ARSE DIMENSTEIN CAD ILE 21482 8 CHANGE ESCRIPTION DATE BY TWIN DISC INC RACINE WIS ed SUCUS 6 0 THREAD m an 1 102 COSS e 2 WELDMENT 1 REQ D dee e vue OO ROE AR MERITE cum IN Eee SIS a NT 4 HI DME AME E E Cae lie ea des 17mm 669 DIA 11 6433 DIA 1 HOI HRU c2 HULE HRU 17mm 5 6692 DIA THRU lt 1
112. ILEeTLOeLIOJeI c RENIMaSS ee tem A Ud DIS L Ld Eme OT TS HAME PAR INED DUE RSS hesa 0000 EHTA TO THE LATERESTS OF PAETI Kx in x ut sued DISC INCORPORATED MAIS MOUNIS 1 ees co LL Ll el laus THIS KOTE 15 NOT INTENDED gt ter eel ee ce 251 amp pe we pes rev me cu mo meme cw wx 08 TS SHEET 1 OF 1 REY ____ 2
113. INSTALL PUMP SD WITH GASKET 2 BY SCREWS C3 TH THIS WORK MARC SURE THAI HE HOLE OF THE GASKFT MFETS HMI OF TRE PLU 22 ern Y OF BONERE TURE VAL WL A INSERT NOMHRPTIURN VALVE 3 ro Gace PEUS 4 SEPUBLY 0 R RA MFR Z T0 THE AND INSTALL TI ANGI 8 WITH is 2 C INSTALL PIPING ASSCMaLY 19 G2 ANC 8 DN GFASHOX JORSUE ASH m Tree baer TE WORE S COMPLP E LS THE SIHA MER SHALE EVERY TMF Al CHANGING DIL 9 zi r 3 r zt Z3 In u AIQNQUE ASN 4 Threesband 1327 METRIC THIRD ANGLE PROJECTION FIG 2 amp IHILAR TO BOM NO 5703776 SIE pun At crc TWIN DE HOT BE USED EM ANY HANNER X xp uu Mem mes ia TE DETRIHENTAL TO THE INTERESTS YF XE x AACIWE W 53403 TWIN DISC INCORPORATED HEAT TREAT xXx ALL TOLERANCES 41 TOLERANC ING uS AMSL Y14 5M 1992 RACINE Wi 53403 USA m MG B44B0 OO0 A THIS HOTICE 1 HOT 1HIENHDED ie VENE Pe OPTION KIT cies 5 49402 GRANT u s OR OTHERS BY CONTRACT TRAILING PUMP SHEET 1 OF 1 REY _ D C D r 1 1 i 1 1
114. LEVEL GAUGE OF ROTATION CLOGGING INDICATOR OUTLET TO LUBE OIL PRESSURE FILTER DIFFERENTIAL NPTF 1 4 PLUG PRESSURE SWITCH 1 4 PLUG FOR TEMPERATURE PICK UP B COOLING WATER OUTLET FLANGE COOLING WATER INLET FLANGE OUTLET TO REVERSE LUBE OIL PRESSURE R 1 4 PLUG OIL DRAIN PLUG FOR HEAT EXCHANGER R 3 8 ZINC STICK FOR CORROSION PREVENTION MAIN PUMP STRAINER 17 a n X LU LJ Le 6909977 OUTPUT SHAFT DIRECTION S S 5 S DRAIN PLUG WITH MAGNET GREASE NIPPLE R 3 8 FOR OUTPUT SHAFT SEALS 738165A Figure 27 MG 6449RV Component Identification and Location 78 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Drain Oil Transmission Sump Drain the oil from the transmission sump by removing the square head 3 8 PT pipe plug with magnet from the bottom rear side of the transmission bottom housing Heat Exchanger Drain the oil from the heat exchanger by removing the pipe plug from the bottom of the
115. MOTION MANUAL OVERRIDE NEUTRAL START REQUIRED FOR CONTROL SWITCH CLOSED ONLY WHEN ENGAGES MANUAL OVERRIDE IS IN USE amp SECONDARY 6 4 THRU TRANSMISSION IS IN NEUTRAL SHAFT CLUTCH ENGAGES PRIMARY SHAFT CLUTCH 50 MANUAL OVERRIDE 36 1 i 8 1 25 6H THREAD POSITION 2 HOLES FOR REMOTE CONTROL ELECTRIC BRACKET CONTROL 24 7 POSITION mm GION310S 093S Advd ELECTRIC CONTROL MODE SWITCH 1866 CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE Figure 241 Electric Control Valve Installation Specifications Marine Transmission Operator s Manual 1021629 247 Installation 248 Twin Disc Incorporated Mechanical Controls lf the manual override valve is connected to a control cable or device 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 selec
116. Note This must be done with the transmission in Neutral 4 Turn the slotted adjustment stem clockwise to achieve the main pressure setting See the specifications in Description and Specifications 5 Tighten the jam nut to a torque of 20 Nm 15 Ft Ib install the protective cap and torque it to 14 Nm 10 Ft Ib 218 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Oil Filter Housing Installation 1 Install the oil filter assembly 1 Push the 2 O Rings sealed tube which is holding the filter into the housing hole 2 2 Install the bracket above the filter 4 x M10 X 24mm at 3 and 4 x M10 x 90mm at 4 S Install the piping assemblies on the transmission a Pump to filter 5 Banjo fitting with copper washer Note See specification section for tubing and banjo fitting torque values DCP 0121 DCP 0120 DCP 0117 Figure 219 Oil Filter 1 Installation Marine Transmission Service Manual 1021629 219 Assembly Twin Disc Incorporated Transmission Top Cover and Oil Level Gauge Installation 1 The top cover 7 of the transmission housing should be installed with the oil baffle 8 towards the rear of the transmission housing Note The oil baffle attaching studs are sealed with Loctite Threadlocker 277 or equivalent The oil baffle retaining nuts are retained with Loctite 242 or equivalent 2 Place MA1015 sealant on the sealing surface 9 of the transmission housing and
117. Operation Power Take off Optional There are two types of power take offs available for this marine transmission Both are designed to drive hydraulic pumps meeting SAE J 744 with flange size 127 and shaft size 32 4 Live Pump Mount Power Take off The live pump mount power take off drives accessories using engine horsepower Since the live power take off connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven when the engine is running Hydraulic Clutched Pump Mount Power Take off The hydraulic clutched power take off also allows accessories to be driven using engine horsepower Since the power take off is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The power take off is engaged by the power take off electric control valve that can be engaged manually if necessary The hydraulic clutched power take off operates with oil pressure supplied by the transmission s hydraulic system Marine Transmission Service Manual 1021629 55 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 as windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller The tra
118. RESTS OF XX 30 25 1 1 STAINLESS STE D 1 amp 2 LCN11890 10 15 03 TWIN DISC INCORP RAT HEAT TREAT FIRST USE X XX 013 T RACINES WI SEAS USA D Fr n2 z C ALL ANGULAR TOLERANCES 1 06 5mm THICK WIRE SPLIC AR 1020282 11590 6 03 03 RACINE WI 53403 USA ib GEOMETRIC TOLERANCING Russell E J DH DEUTSCH EGI B 1 Ft IECNIISSS 4 29 03 IS CE IS NTENDED MADE ANSI 14 5 1982 CHK o z SURFACE TREATMENT NAME R N Schenk 1 FS ecNii4is 4 22 03 THE Ux GOVERNMENT CUNT ROI seen REV SHEET ZONE CH NB DATE REV SHEET ZONE CH NO DATE R OTHERS BY CONTRACT CMG PRUF ILE JULE M B Gee SHEET 1 OF 2 REV EL 230 E VALVE VALVE 2 a O asst MBLY ASSEMBLY VALVE os 7 Wr AR icm E ME TORQUE TO 33 N m PART NU IDENTIF TE 1 T er 10207894 42223 021000 038 1020520 350 H H 10161224 4c eb 10161225 N 1038E E LOLS D238
119. SURFACE 4 S zi C ps ATMOSPHERIC PRESSURE RE Roan L 2 37 PLUF RTC PRE n m CO 2 AND SERVIC 12 47 1j D d LP INTERMEDIATE PRESSURE FC THIRD ANGLE o Q M CLUTCH PRESSURE PROJECTION on Tq E Der E 6 NOT SERVICEABLE SEPARA VEL T N E 2 SIMILAR TO CN Er ee THESE PARTS ARE TO BE PACKAGED LEVER Pil Ru CANTE J SEPARATELY AND SHIPPED WITH UNIT CIZDI TZI II I 2 1 i i non AL E 2514 6 23 04 NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE DV N PROPRIETARY DATION ANS fe aren 3723 98 UY OLN DISS 5 1492 5 28 03 NOT BE USED IN ANY MANNER kg x 0 75 SCALE INCORPORATED STR TH D U RING 1516149 DETRIMENTAL TO THE INTERESTS OF XX 0 25 MAIN PRESSURE OIL INLET WHEN HEAT TREAT FIRST USE XXX 0 13 a Ed NOT INTERNALLY SUPPLIED Eno ae E go o2 WIN DISC INCORPORATE Ric A ALL ANGULAR TOLERANCES 289 oy THREAD SIZE AT PORT a RACINE 53403 USA MODEL MG S202DC Boe NCE see 8 gt 9 S 4 1 4 18 WHEN M20524 3 VE um 2 10415 1 11 02 15 IS NOT INTENDED PER ANSE Tea Lane REDUCER BUSHING IS SPECIFIED ULLIFY OR LIMIT RIGHTS TREATMENT NANE RM BJE ERIE BOTT VIEW 4 4 5 10553 12 3 01 GRANTED THE U S GOVERNMENT VALVE Wa
120. Thousandths i M Indicator 1 Ml Crankshaft Engine Flywheel IL 11 RD Checking the Flywheel Pilot Ring Bore Eccentricity Marine Transmission Operator s Manual 1021629 Installation Twin Disc Incorporated Engine to Marine Transmission Alignment 240 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 or excessive noise and vibration The transmission must be aligned to the propeller shaft and mounted in its final location prior to the alignment of the engine and driveline to the transmission The engine can be mounted in the vessel such that the engine crankshaft centerline is parallel to the transmission input centerline or with proper placement for equal u joint angles in a position where the located in a position that the engine crankshaft centerline is not parallel to the transmission input centerline The angular offset between the transmission input shaft and the driveshaft must not exceed the driveline manufacturer s recommendation Typically the maximum allowable angle is seven 7 degrees and the angle between the transmission input shaft and the driveline must be within one half 0 5 degrees of the angle between the engine crankshaft centerline and the driveline A method of alignment is listed here to aid in proper alignment or checking
121. a cE COVER 1017128 927 225 1 4 DIA THRU 36 6 sy O ee x oue em e 50 L SIE T RM Spree e HT E 19 455 He R SHROUD 1001434 25 LAN CB eae DITCH PLATE GASKET 649 e xr er SEE CHART RING MA379CP CUENTE a TRANSMISSION GASKET H rx 2 e TEN da d GASKET 1017334 E HL RING A2916FT Lig GASKET 1017130 PLUG 1017389 mE SNAP RING A2915S PORT B E BALL M1990H R Sere el SCREW 1042 4 SPRING 2702 SECTION SECTION C000 W A SHIM 1020005 AS REQ D SPRING 1801 BER AROS GE D m c o SETSCREW A2870K 0 RING A2916DK VALVE BODY ASSY 1018095 0 RING 2916 BODY 1018094 E PIN M1927AX BALL MAIOSAN SPRING A2705AK WASHER A2782AS SCREW SEE CHART Boa Vig SEAT 1017524 MALOS4D 2 gt SECTION BA Sx M1990H E A e BALL MI990Y Sy 34 28 72 64 MAIN PRESSURE PICKUP POR SWITCH lt 2 L PIRT 1 4 18 N P T F DRYSEAL TH D APPLY MA895 THREAD SEALANT SPOOL 1017433 2 WITH TEFLON gt TO THREADS co TT NOTE nen 30 0 lof ft NUT 2027 SCREW 1042 4 NSTALL USING MA908 LOCTITE HYDRAULIC DIAGRAM A7119W SHEET 1 DF e zd SCREW M2000L 7 242 SCREW MUST P FLUSH WITH
122. aft rear bearing cup 4 Install the secondary shaft rear bearing cup 5 7 Lightly press the primary and secondary shaft rear bearing cups into position on the bearing cones with tool T 21482 31 AAR273 AAR271 Figure 175 Install Dowel Pins 3 and Bearing Cups 4 and 5 188 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Adjust Primary Shaft Bearing Clearance 1 Measure the depth 6 of the primary shaft tapered roller bearing cup in the transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing Cup Measure in three locations around the circumference of the bearing bore The three readings should be identical If the dimensions are not identical realign the bearing cup Record this dimension Bearing Bore Depth Measure the length of the primary shaft rear cover pilot 7 and bearing spacer Measure from the bearing contact point to the rear mounting surface of the cover Measure in three locations around the circumference of the rear cover The three readings should be identical Record this dimension Hear Cover Pilot Dimension Calculate the correct shim pack required to set the primary shaft rear bearings a oubtract the primary shaft rear cover and spacer dimension from the transmission housing to rear bearing cup dimension Bearing Bore Dimension Cover Spacer Dimension Pinion Shaf
123. al Control Valve continued 7 Harsh engagement 8 Low lube pressure 9 Oil spilling out of breather 10 Low Clutch Apply Pressure Faulty Proportional Valve Faulty Temperature Sensor if equipped Profile Generator defective or out of adjustment Pump flow output too low Pump suction strainer plugged Air leak on suction side of pump Lube relief valve malfunction Broken piston rings Oil level too high Wrong type of oil Low Main Pressure Defective Proportional Valve Low voltage to Profile Generator Marine Transmission Service Manual 1021629 Replace Proportional Valve Replace Temperature Sensor Replace Profile Generator Adjust if proper equipment is available Replace pump Remove clean inspect and install the suction screen Inspect and correct cause of suction leaks Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil See Paragraph 1 Replace Proportional Valve Verify that green voltage supply light and red clutch energized lights are bright 75 Troubleshooting Twin Disc Incorporated NOTES 76 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Disassembly Prepare Transmission for Disassembly Note During the service of this unit all O rings gaskets and seals must be replaced It is good practice
124. amaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Clutch plates warped Control valve incorrectly indexed Solenoid malfunction units equipped with electric selector valve Hydraulic lock piston stuck units equipped withelectric selector valve Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch Overhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve Overhaul marine transmission Remove marine transmission Replace a worn or damaged coupling Select proper torsional coupling Overhaul marine transmission Check alignment of engine transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine Remove clutch plates Overhaul unit Check and adjust control linkage Replace defective solenoid Inspect repair or replace hydraulic lock spool Marine Transmission Service Manual 1021629 Twin Disc Incorporated Table 9 Troubleshooting Chart Mechanical and Electric Control Valves continued 7 Harsh engagement 8 Oil spilling out of breather 9 Oil spilling out of breather Regulating piston or rate of rise
125. arately The trailing pump drive gear and shaft are serviced as an assembly as a single part number AR151 AR153 Figure 61 Trailing Pump Shaft Removal Bearing Removal Pull the trailing pump shaft bearings and spacer 3 out the back of the transmission housing The spacer is located between the two ball bearings R156 AR157 Figure 62 Trailing Pump Shaft Bearing and Spacer 3 Removal 104 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Front Bearing Cup Removal NOTE It may be possible to remove the bearing cups using a slide hammer puller To remove the Primary and Secondary shaft front bearing cup 3 if replacement is required weld a bead midway around the circumference of the bearing cup with an electric welder causing it to shrink for removal AR145 WELD BEARING CUP Figure 63 Input Shaft Front Bearing Cup 3 Marine Transmission Service Manual 1021629 105 Disassembly Twin Disc Incorporated Primary and Secondary Clutch Shaft Output Shaft Disassembly Primary Clutch Shaft Disassembly
126. as a one piece main housing A top cover bottom cover and manifold sealed with silicone sealer are bolted onto the housing An end cover is located on the primary shaft and a pump mount and pump are located on the secondary shaft completing the housing enclosure Bearings The primary and secondary clutch shafts are supported and located by tapered roller bearings The pinions are supported on bushings and the end movement limited by thrust washers Bearing clearances for each clutch shaft are set by using a single shim pack at the rear tapered roller bearing on each shaft Tapered roller bearings and a spherical roller bearing support the output shaft and have bearing clearance adjusted by using shims at the rear bearing retainer Oil Pump and Drive The oil pump is spline driven by the secondary clutch shaft Marine Transmission Service Manual 1021629 21 Description and Specifications Twin Disc Incorporated Lubrication Features 22 The MG 6449RV transmission bearings and clutches on the primary and secondary shafts are lubricated through oil passages drilled in the shafts The output shaft bearings transfer gears primary and secondary pinions and their bearings are gravity and splash lubricated Suction Screen The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and oil pump in the hydraulic circuit The strainer can be replaced if necessary F
127. ated 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 1021629 37 Operation Twin Disc Incorporated 38 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 6 Pilot Spool Passages Marine Transmission Service Manual 1021629 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 7 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
128. aturally undergoes some bending Therefore it is always good practice to unbolt the marine transmission output coupling to prevent bending of the shaft Two reamed dowel pin holes are located on each of the transmission side mounting surfaces It is required that the mounting brackets be dowelled to the transmission to maintain proper alignment and to prevent movement of the mounting bolts in their clearance holes due to the propeller thrust Marine Transmission Operator s Manual 1021629 229 Installation 230 Twin Disc Incorporated With the transmission in position on the mounting bed arrangements must be made to have a controlled lifting or lowering of each of the four corners of the transmission If threaded holes are provided in each of the transmission mounts jacking screws can be used in them The transmission position can be adjusted with the jacking screws to obtain the desired alignment oteel plates must be inserted under the jacking screws so that the bolts will not damage the mounting 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 transmission to one side or the other on the mounting bed to obtain horizontal alignment This can be done with a jack placed horizontally between the transmission and the foundation At the same time a
129. basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit January 16 2002 TDW P2004 M Ets TWIN DISC INCORPORATED em pisc FLAT RATE HOUR ALLOWANCE ecd ms MARINE PLEASURE CRAFT Hourly Labor Rates Must Be Acceptable to Twin Disc Incorporated MODEL SERIES R amp R UNIT REBUILD MG340 MG 360 0 0 0 0 MG502 MG5010 MG5011 MG5005A MG5015A 10 0 8 0 MG506 MG5050 MG5061 MG5062 MG5055A 10 0 11 0 MG507 MG5081 MG5085 MG5090 MG5091 10 0 12 0 MG509 MG5111 MG5112 MG5114 10 0 17 0 MG514C MG5141 10 0 25 0 MG5202 MG5203 MG5204 MG5222 10 0 32 0 MG5225 MG6000 10 0 32 0 MGN 80 MGN 232 MGN 233 MGN272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN472 MGN 493 10 0 32 0 PUMP ALL MODELS EXCEPT MG340 amp MG360 1 0 VALVE ALL MODELS EXCEPT MG340 amp MG360 1 0 55 January 16 2002 TDW P2004A Qu ACS Twin Disc Incorporated Table of Contents Contents Introduction OPI T TT 13 General Information e nennen nnn nnn nnns 13 Safety and General Precautions 13 Preventative 15 csp sears ros ee cept 15 Ordering Parts and Obtaining Services
130. carrier should contact the shaft stop shoulder as it is installed Marine Transmission Service Manual 1021629 159 Assembly Twin Disc Incorporated AAR200 Figure 138 Bronze Thrust Washer 5 Rear Bearing Carrier 6 Installation 13 Verify the pinion has measurable end float 14 Invertthe shaft assembly positioning the sealing ring end of the shaft up Install the rear tapered roller bearing if removed Heat the clutch shaft rear bearing cone 7 to a temperature of 120 C 250 F Place the bearing on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing against the clutch housing as the bearing cools Handle the bearing with care The bearing is HOT AAR193 Figure 139 Rear Bearing Cone 7 Installation 160 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Primary and Secondary Shaft Seal Ring Insert Installation Heat the aluminum cover 8 to 120 C 250 Cool the cast iron insert 9 to 20 C 5 F Handle the components heated and cooled with care The cast iron insert will be located with three capscrews Use three guide studs to index the insert in the cover correctly 2 Install the new insert into the aluminum cover Remove the guide studs and install the two M8 screws and torque them to 23 Nem 17 Ib ft AAR283 Figure 140 Shaft Seal Ring Insert 9 Marine Transmission Service Manua
131. ch backing plate 1 Press the backing plate firmly into the clutch housing to ensure the splines of the clutch are aligned Place the internal snap 2 ring next to the clutch backing plate AARO69 1012BE Figure 136 Clutch Backing Plate 1 and Internal Snap Ring 2 158 Marine Transmission Service Manual 1021629 Twin Disc Incorporated 10 11 12 Assembly Install two clamps 3 on the clutch housing and backing plate Use the clamps to evenly compress the clutch until the internal snap ring can be installed properly into the clutch housing Install the snap ring Remove the clamps Lubricate the area of the clutch shaft that will contact the pinion bushing Install the pinion assembly 4 Gently rotate the pinion as the pinion is lowered into the clutch plates until the splines are fully engaged in all of the clutch plates 1009 AR1008BE Figure 137 Clutch Backing Plate and Pinion Assembly 4 Install the bronze 5 thrust washer with 18 radial grooves next to the pinion Note that the bronze thrust washer for the secondary shaft has a slightly larger O D than the primary shaft thrust washer Heat the secondary clutch shaft front bearing carrier 6 to a temperature of 120 C 250 F Install the bearing carrier on the clutch shaft and push it firmly into position against the shaft shoulder as it cools Handle the bearing carrier with care The bearing carrier is HOT Note The bearing
132. clutch actuation When the primary or secondary clutch is selected by the operator the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate of rise profile is controlled electronically by the GP Control Valve Electronic Interface Profile or E Troll Module to provide a rapid smooth oil pressure increase in the clutch hydraulic passages during engagement i C AU TION The proportional valve coils are low resistance devices that are current driven The use of an uncontrolled power source may supply too much current and damage the proportional valve Note Installations with this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 2 75 or better Besides the valve s requirement on filtration the filter must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1021629 45 Operation Twin Disc Incorporated ELE Proportional mizas Top Valve Body Figure 13 Top Hydraulic Valve Body Assembly P Temperature Sensor Regulator spool Figure 15 Main Regulator Assembly 1021658 46 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Operation GP Control Valve Electronic Control Interface Profile or E Troll Module Note Some installations will consist of t
133. cts used to energize Solenoid B Connect to the negative terminal of the engine battery Connect to the positive terminal of the engine battery Connect to the same ground point used by the gear controller or the engine control Connecxt to the output in the gear controller that is used to energize Solenoid B Connect to the same ground point used by the gear controller or the engine control Connect to the output in the gear controller that is used to Connect to the same point as the control s power ground signal Connect to the controls Solenoid B positive driver output to the solenoid Output Connect control s negative circuit Connect to the control s Solenoid A positive driver output through the switch contacts used to energize Solenoid A energize Solenoid A The customer supplied normally closed not in neutral relay must be located in a position to not be affected by vibrations The coil must have a 200 ma maximum current draw The coil must be connected to the two not in neutral wires of the Profile Generator The contacts of the manual direction control switch closed in neutral must be wired in series with the energizing coil of the not in neutral relay Plug the appropriate connectors from the Profile Generator into the appropriate Proportional Valves and Temperature sensor Plug the appropriate connectors from the Profile Generator into the Engine Speed sensor and the Pro
134. d 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 Dowel pin Return spring Figure 9 Neutral Solenoid Engaged Marine Transmission Service Manual 1021629 41 Operation Twin Disc Incorporated Manual Override Operation The control valve has a manual override feature which is a lever operated selector When the manual override lever is rotated counterclockwise and pulled outwards the upper portion of the valve is disabled because the connecting slots in the manual override stem are no longer aligned with the oil passages in the valve body Oil pressure from the solenoid operated pilot valve controlled spools cannot reach the clutch pressure passages in the transmission The main oil pressure regulator shuttle ball neutral pressure regulator and rate of rise functions remain exactly the same as when the valve is in the electric mode In the manual override position shifting is controlled by rotating the lever on the manual override stem In the Neutral position both clutches are vented to sump by two pockets in the stem w g Fa 6 1 SE T GPTL T Figure 10 Stem Pocket or Passage Main pressure oil can flow throug
135. d measure again Bearing Bore Depth 6 Measure the length of the output seal carrier pilot Record the dimension Output Seal Cover Pilot Dimension AAR221 AAR222 Figure 146 Measuring Components to Determine Output Shaft Bearing Adjustment 5 Calculate the shim pack required to set the output shaft bearing clearance a oubtract the output seal carrier dimension from the bearing bore dimension Bearing Bore Dimension Seal Carrier Dimension Output Bearing Clearance b Calculate the shim pack thickness required to obtain 0 00 0 05 mm 0 000 0 002 inches bearing clearance when the shim pack is installed Label the shim pack for use when assembling the output shaft subassembly Marine Transmission Service Manual 1021629 165 Assembly Twin Disc Incorporated 8 Remove the output shaft rear bearings from the main transmission housing to allow for assembly of the output shaft a Place the housing with the input side on top b Use the output shaft spacer 177277 and tool T 21482 38 to press the bearings from the main housing Note The tapered output bearing cup is a slight interference fit in the main housing Removing the bearing assemblies will require some force Output Shaft Rear Bearing Removal Tool 71 21482 8 Space 178291 Note Slight Interference Fit Cup To Mai
136. e 242 E Troll Wiring Diagram SOLENOID B ON RED LED WIRING SCHEMATIC GREEN p TEMPERATURE SENSOR 222 24 POWER OK GREEN LED BLACK id fF Y x NORMALLY CLOSED BLACK lt lt SOLENOID NOT IN NEUTRAL RELAY men _ up O CLOSED IN NEUTRAL A SOLENOID 25 CUSTOMER SUPPLIED BLUE SOLENOID ON BLACK 200 mA MAXIMUM 46 RED LED WHITE e EH SWITCH ro YELLOW CUSTOMER SUPPLIED Lee SEE MODULE POWER CIRCUIT CONNECTION CHART SOLENOID A SWITCH T TRANSMISSION MANUAL CUSTOMER SUPPLIED OVERRIDE SWITCHES pills SOLENOID RETURN Figure 243 Profile Module Wiring Diagram Final Checks Be sure the transmission is filled with oil before starting See Description and specifications and Preventative Maintenance for proper oil and filling Marine Transmission Operator s Manual 1021629 251 Installation Twin Disc Incorporated 252 Marine Transmission Operator s Manual 1021629 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 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 AM814 AM814A T 21482 2 1 21482 6
137. e lever to the detent position 1256b 1257b Figure 107 Remove cover screws 132 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly 5 Remove the three remaining cover attaching socket head capscrews Note the long capscrews are used in the bottom screw holes 6 Remove the cover and shaft assembly and cover gasket The shaft will be removed with the cover because of the shoulder in the shaft Remove the detent spring and detent ball from the pocket in the cover assembly 1261b 1263b Figure 108 Remove cover and detent spring f Remove the E retaining clip from the shaft Slide the shaft out of the cover Remove the O ring from the groove in the shaft 1268b 1270b Figure 109 Remove clip and o ring Marine Transmission Service Manual 1021629 133 Disassembly Twin Disc Incorporated 8 Remove the piston assembly and large diameter spring from the bore of the valve Remove the shim s from the bore of the piston assembly 1273 12740 Figure 110 Remove piston springs and shims Remove the washer from the bore of the valve 1277b Figure 111 Remove washer 134 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly 10 Remove the flow control piston and spring from the valve bore 1278b Figure 112 Remove flow control piston and spring 11 Remove the end cover attached with four hex head capscrews and gasket from the
138. e life of any torsionally resilient coupling that may be mounted to it 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 pm Thousandths Indicator Engine F L mpa 1 IL E A Fiun Flywheel Engine i Crankshaft Engine gt Flywheel Housing Figure 232 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 15 236 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation Table 12 Total Indicator Readings for Engine Flywheel Housing Flange SAE Housing Number Face Deviations Eccentricity 0 48 0 019 048 09 26 04100 0 0 36 014 eco i 000 e onom 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 EE Thousandths Engine a d i 1 Flywheel Engine Ad 21 addi Crankshaft im _ 2 Engine Fl
139. ect with a soft stone replace the gear Inspect gear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear Inspect thrust faces of gears for scores scratches and burrs If you cannot remove these defects with a soft stone replace the gear oplined 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 1021620 141 Disassembly Twin Disc Incorporated NOTES 142 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly General Assembly Note Photos are for illustration purpose of the procedure and may not appear to be consistent with the previous assembly steps During service of this unit all O rings gaskets and seals must be replaced Refer to cleaning and inspection information in this manual prior to assembly It is good practice to com
140. er Component Identification and Location Marine Transmission Service Manual 1021629 197 Assembly Twin Disc Incorporated 1 Install the heat exchanger base 1 and gasket if removed Torque the mounting screws to a value of 46 Nem 34 Ibeft E i jM uy 4 Fu per Jj n BE 74 Ey eM 1 E 4 a AAR302 AAR305 Figure 189 Heat Exchanger Adapter Plate Housing 1 2 Install the gasket 2 and heat exchanger 3 The gasket is placed between the flange 4 on the heat exchanger and the base 5 AAR306 AAR308 Figure 190 Heat Exchanger Gasket 2 and Core 3 Installation 3 Install the heat exchanger 6 with the mark made during disassembly at the top Place the heat exchanger into the transmission housing with the divider 7 located horizontally in the housing The divider in the heat exchanger along with the rear cover 8 separates the inlet from the outlet of the heat exchanger Note If the heat exchanger is not properly installed in the transmission housing the transmission could overheat 198 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Figure 191 Heat Exchanger Core 6 Placement 4 Apply grease between the rear cover and gasket of the heat exchanger The heat exchanger gasket 9 is attached to the rear cover mounting of the heat exchanger Install the heat
141. er through the heat exchanger The heat exchanger is located in the transmission housing Replaceable zincs for corrosion protection are located on the heat exchanger end caps Marine Transmission Service Manual 1021629 23 Description and Specifications Twin Disc Incorporated Specifications Maximum operating speed 2500 rom Operating oil sump temperature 65 70 C 149 158 F when using SAE 40 oil Oil type and viscosity See data plate below Oil capacity 18 liters 4 8 gal Approximate Dry weight 325 kg 716 Ibs Oil pressure See Table 1 Oil temperature to be in normal operating range REPLACE AFTER 100 OUR OF THE FIRST OPERATION e Figure 2 Oil Specification Data Plate 24 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Description and Specifications Table 1 2551 2758 kPa 370 400 psi Transmission Oil Pressure Specifications Mechanical Valve 2551 2758 kPa 370 400 psi Springs Speed Position Inlet Clutch Min Clutch Min MEM NENNEN ETE MINUM NN ide Neutral 2530 3745 o o fo o 19min 28mi Ide Primary 7862758 114400 76 114 o o 19 28min Ide Secondary 786 2758 114400 o o 786 114 19 28min Rated Neutral 4901179 o o 0 0 193 690 2840 Rated Primary 2551 2758 370400 2561 370 o 0 199 586 28 65 Rated Secondary 2551 2758 37040 0 0 2551 370 193 586 2885
142. ervice Manual 1021629 Twin Disc Incorporated Assembly Primary and Output Shaft End Cover Installation Note Be sure sealing rings are installed on primary shaft before installing cover 1 Place 1015 sealer on the sealing surface of the primary end cover 2 Install the O rings 1 in the counterbore of the transmission housing 3 Install the primary end cover 2 Torque the M10 capscrews to 46 Nm 34 Ib ft DCP0069 DCP0075 Figure 224 Install O rings 1 and Primary End Cover 2 4 Place MA1015 sealer on the sealing surfaces of the output shaft front cover 5 Install the output shaft front cover Torque the M10 capscrews to 46 Nm 34 Ib ft Marine Transmission Service Manual 1021629 223 Assembly Twin Disc Incorporated Install Input Flange and Fill Transmission with Oil 1 Determine the thickness of shims required to properly locate the input flange a Thoroughly clean the taper of the input flange and the input shaft b Measure distances A B and C e Use the following formula to determine the correct thickness of shims B C A 1 2 0 05 mm 0 048 0 005 in Advance Thickness of Shims 2 ADVANCE 1 220 5 mm 0 048 0 005 in INPUT ADVANCE Figure 225 Determine Input Flange Shim Thickness 224 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 2 Position the correct thickness O D shims on the input shaft DCP5782 Figure 226 Position
143. g shims 3 and output seal carrier 4 Tag the components with identifying information AR218 Figure 85 Output Shaft Bearing Shims and Seal Carrier 4 8 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Selector Valve Assembly Electric Valve The steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of the steel ball 1 Loosen and remove four of M8 x 25 socket head capscrews and remove orifice plate cover and gasket Figure 86 Removing Orifice Plate Cover Gasket 2 Remove orifice plate 3 Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket Marine Transmission Service Manual 1021629 119 Disassembly Twin Disc Incorporated 9 Hemove the screen form the pocket and then remove rate of rise piston Note that shims are located between the piston and springs Figure 87 Screen Left Rate of Rise Piston Middle and Regulator Springs right 6 Remove pressure regulating springs 7 Remove pressure regulating piston with an external retaining ring pliers b E Figure 88 Removing Regulating Piston with Pliers 120 Marine Transmission Service Manual 1021629 Twin Disc Incorporated 10 11 12 13 Disassembly Remove external retaining ring from the lever end of the stem Loosen the clamping nut and remove the control lever from the ste
144. ge 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 Operator s Manual 1021629 Twin Disc Incorporated Installation 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 mounted coupling flange to the transmission input hub Marine Transmission Operator s Manual 1021629 235 Installation Twin Disc Incorporated Engine Flywheel Measurements also reference SAE J 1033 and J 617 Note Since the remotely mounted v drive transmission is not attached directly to the engine flywheel housing common sense should be used regarding any measurements taken during these procedures The detailed instructions are included here because any engine installation should include these measurements The flywheel runout dimensions are important to th
145. gh 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 This additional spring compression further resists the movement of the pressure regulating piston resulting in a force balance between the area at the pressure regulator the springs and the area behind the rate of rise piston Neutral main pressure of approximately 40 psi is maintained by relieving excess oil behind the rate of rise piston through the ball and spring regulator Regu lator Ball and Spring Figure 4 Neutral Regulator and Rate of Rise Orifice Marine Transmission Service Manual 1021629 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
146. ghten the capscrews to a torque of 440 Nem 325 lbeft 23 Connect a hydraulic power 2 supply to tool T 21482 2 24 Seat the output gear on the output shaft taper with 50 000 kPa 7 250 psi Hold the pressure on the assembly for a minimum of five minutes 180 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly MVC898E MVC899E Figure 164 Using Tool AM814 and T21482 2 1 to seat the Output Gear on the Output Shaft 29 Remove the tools DCP 0998 Figure 165 Removal Tools Marine Transmission Service Manual 1021629 181 Assembly 182 26 27 Twin Disc Incorporated Verify the output gear advancement on the output shaft a Measure the distance from the shaft shoulder near the output gear to the end of the shaft Record this dimension as dimension D Dimension D Measure the distance from the edge of the output gear to the end of the output shaft Record this dimension as dimension E Dimension E The differences between these two dimensions E D should be 0 00 0 05 mm 0 00 0 002 inches If the output gear requires further advancement reinstall the tools and reapply pressure to advance the output gear If the gear cannot be advanced the proper distance the shim pack thickness should be checked Checking the shim pack dimension will require disassembly If the shim pack thickness is correct and the output gear cannot be advanced the proper distance
147. ghtening may cause initial leakage plus potential removal damage An option of a maximum of two full turns after finger tightening the plug may be used if required and if removal conditions are met Marine Transmission Service Manual 1021629 29 Description and Specifications Twin Disc Incorporated Table 6 Straight Threaded Tube Fittings Hose Fittings and O ring Plugs Nominal Nominal Nm Ib ft lb ft Thread or 5 or 5 or 5 96 or 596 Diameter Diameter Lam ow o Lm ow 9 ow e o 30 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Description and Specifications Table 7 Tubing Nuts Torque Values for Tubing Nuts Nominal Tube Size Torque Lb ft Table 8 Banjo Fittings and Sealing Plugs with Copper Washers Torque Values for Banjo Fittings amp Sealing Plugs with Copper Washers Thread Size Recommended Torque N m Lb ft M24 x 1 5 186 137 Marine Transmission Service Manual 1021629 31 Description and Specifications Twin Disc Incorporated Clutch Plate Wear Limits Clutch steel plates Minimum thickness 2 10 mm 0 083 inch Clutch friction plates Minimum thickness 3 15 mm 0 124 inch 32 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Operation Operation General The control valve obtains primary neutral and secondary positions When these positions
148. h 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 42 Marine Transmission Service Manual 1021629 Operation Twin Disc Incorporated SAT HS 331738 21 1113 mm Pahna Hyde 43 JIBIJSTS Haiti av Pos Figure 11 Hydraulic Schematic electric control valve Marine Transmission Service Manual 1021629 Operation Twin Disc Incorporated General Overview of GP Control Valve with Electronic Interface The General Purpose GP control valve is a hydraulic valve assembly for use with Twin Disc Marine Transmissions that may include an integral electronic interface control module The valve assembly contains current controlled proportional cartridges d i 4 rem Figure 12 GP Valve Assembly mounted on Marine Transmissio
149. he hydraulic portion of this valve and the Electronic Control Interface will be replaced by an appropriate electronic control system The electronic portion of the GP Control Valve fastens to the hydraulic portion of the GP Control Valve and is located on the top surface This module contains the electronic circuitry to control the proportional cartridges that are used to engage the clutches based on the commands from the operator Clutch apply pressure rate of rise profile is factory set with the use of internal circuitry The initial fill level is factory set with an adjustment screw that is embedded in the bottom surface of the Profile or E Troll Module and sealed This can be field adjusted if necessary by authorized personnel with the proper instrumentation There are two different types of control modules for the MG6449RV marine transmission with and without the trolling E Troll feature All electrical wiring for the marine transmission system controls are routed through this interface module The vessel battery power 12 vdc or 24 vdc is supplied to the electronic interface only and never directly to the hydraulic proportional valves Two red led lights are used to identify the proportional cartridge valve that is energized and a green led is used to identify when power is provided to energize one of the clutches Signals are provided to power a customer supplied relay to allow engine starting only when in neutral Atransmission oil tem
150. he optimum relative mating location will be where the measured runout dimensions of the transmission flange and the shaft coupling flange compliment each other to result in the least relative out of true parallel measurement Figure 230 Checking Output Flange Face Runout Marine Transmission Operator s Manual 1021629 231 Installation Twin Disc Incorporated L DiAL INDICATOR s OI Figure 231 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 transmission 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 transmission in place Then recheck the alignment and if satisfactory bolt the coupling together See Description and Specifications for proper bolt torque 232 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation There are many types of flexible output shaft couplings in the market today that solve a variety of problems Couplings t
151. hen problems are encountered Marine Transmission Service Manual 1021629 67 Troubleshooting Twin Disc Incorporated Pressure Test Kit The Digital Pressure Transducer Kit BOM 42168 provides two pressure transducers 0 to 500 psi with hydraulic quick couplings a power supply box for the transducers and cables needed to connect the transducers to the power supply box and the signals out of the power supply box to a customer supplied digital volt meter Contact the Twin Disc Service Department Racine Wisconsin for specific information concerning this test kit One principle of troubleshooting is to start with the simple and move to the more difficult Check the simple items first Run the simple test first Then move to the more difficult Figure 26 Test kit 42168 68 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Table 9 Troubleshooting Chart Mechanical and Electric Control Valves 1 Low main oil pressure 2 Nooil pressure or erratic low pressure at control valve tap 3 High main oil pressure Partially clogged oil strainer Stuck pressure regulation piston Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Incorrect linkage adjustment to control valve assembly Clogged or plugged orifice in orifice plate of control valve assembly Shimming required between regulator springs and rate of rise piston Engine idle speed too low Oi
152. hrust race from the clutch 13 Remove the clutch piston from the clutch Note If the clutch piston does not have threaded holes compressed air can be used to remove the piston 191 6557066BE Figure 70 Steel Thrust Race 7 and Clutch Piston 6 Removal Marine Transmission Service Manual 1021629 109 Disassembly Twin Disc Incorporated 14 Invertthe shaft placing the input end of the shaft upward Remove the shim and seal race if they have not already been removed 15 Removal of the rear tapered roller bearing 1 requires destruction of the bearing to facilitate removal DO NOT remove the rear bearing unless replacement is required RV SHAFT AND GEAR Figure 71 RV Shaft and Gear 110 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Secondary Clutch Shaft Disassembly 1 Position the shaft with the clutch sealing rings downward BACKING PLATE WAVE SPRINGS BRONZE THRUST WASHER 18 GROOVES 1 0mm ORIFICE PLUG WITH DUMP
153. i DRILL Smm 19680 DIA 5 BEOGESJ 1 i x 62 DEEP See M6x10 x 6e DEEP i I 2 PLACES 5 167 5 CYRO 1 1 4 774 bs CTE 7 0 276 0 039 11024 0020 1977 9 6455 DIA Set 0020 Jal n 6 4960 DIA DIA DIA Y Y DIA 0020 0020 0805 0000 5 551 9 083 7 087 86 4965 DIA DIA DIA DIA 04 x 45 04 x 45 1 eas Y 04 x 45741 Pn s DR omm 1968 2 015 R TYP DRILL 8 5mm 03346 DIA sede Tp Xx mg JEEP M6x10 x 81 04 x TAP M10x1 5 x 59 DEE 2 PLACES N PM PLACES 9 O31 R 0078 R CT YP 2 DRILL 7 16 64375 DIA THRU E I PIPE TAP 174 18 NPTF 08 x ZB ar 9 PLACES 1 7028 2 D 580 40 DRILL 37 64 S781 DIA x 122 DP RING C15 REBR m EAT EE WE D 2 L IPE TAP 378 18 NPTF 1 PLACE 5 MEE PBEHART m 08 2 s 5 167 Sn 0 2 4 044 A S La 5 167 REF 4 774 gt 3 654 0 1977 C DNE 11 084 DIA Y Y Y 9 639 9146 DIA DIA Y 03 x 45 Y 08 x 45 4 DRILL THRU amp 11 25 1 06 x 30 DEPTH SH WN FOR M6 S C HD e 9 4140 PISTON RAM 9 75 DIA x 150 THK CAP SCREW 16 PLACES 8 PUR TEFLON BACK UP RING P165 3 z LING RE OR eS MAXIMUM OPERATING PRESSURE 7250 PSI 7 1 PUR t RING 016
154. ifying information 5 Remove O ring 90 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Remove Primary and Secondary Shaft Manifold 1 Remove the screws with washers retaining the manifold at the rear of the transmission housing 4 of M10 1 5 x 90mm 5 of M10 1 5 x 65mm 110f M10 1 5 x 45mm 2 Hemove the dowel pins 9 located at the side of the primary and secondary shaft The Dowel Pins locate the bores concentric with the gear Tighten the nut on the dowel pin 9 to pull the dowel out of the transmission housing Tighten the nuts until they bottom on the end of threads Pulling the dowel pin from the transmission housing will assist in removal of the manifold TL LAN m ARO69 AR7026BE Figure 45 Dowel Pins 9 Marine Transmission Service Manual 1021629 91 Disassembly Twin Disc Incorporated AR6557025BE AR6557029BE Figure 46 Dowel Pin Removal 92 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Remove Manifold 1 The manifold 2 is equipped with two pusher screw 1 locations near the dowel pins to assist in the removal of the oil manifold Thread two M10 1 5 x 60 mm fully threaded cap screws lubricated into the pusher screw locations to push the oil manifold away from the transmission housing A IMPORTANT Always lubricate the pusher screw 1 threads before use Always tighten pusher screws in an even
155. iling pump is driven by the output shaft and oil flow from the trailing pump flows through a check valve into the transmission s lubrication circuit below the heat exchanger 56 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Operation Power Flow Input power to the transmission is through a driveline connected to the engine flywheel The driveline is connected to the engine 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 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 1021629 57 Operation Twin Disc Incorporated Neutral
156. ilter Assembly A canister style filter is located between the oil pump outlet and the selector valve in the hydraulic circuit The replacement element should be replaced at 1000 hour or six month intervals whichever comes first The replacement filter part number is 178363 All gears are helical carburized hardened and skived or ground for smooth quiet operation All gears are in constant mesh The primary and secondary transfer gears clutch spiders are shrunk fit onto the primary and secondary shafts Do not remove these gears during service The output gear is mounted on a keyless taper Marine Transmission Service Manual 1021629 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 flexible 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 E Absorb shock and reduce noise Minimize gear rattle There is no flexible input coupling provided with this transmission The engine supplier may provide a coupling as a part of the engine package Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh wat
157. imary 6 Clutch Shafts From Transmission Housing Marine Transmission Service Manual 1021629 95 Disassembly Twin Disc Incorporated Remove Primary and Secondary Shaft Front Bearing 1 Remove the Secondary and the primary tapered roller bearing after removing the shafts 2 Remove the front bearing cups if they are to be replaced a ig j DCP 0156 DCP 0157 Figure 50 Primary and Secondary Shaft Front Bearing 96 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Remove Output Shaft Remove the transmission bottom cover Remove the retaining screws from the bottom cover 1 of the transmission housing 17 of M10 1 5 x 30mm 5 of M10 1 5 x 50mm 4 of M10 1 5 x 60mm All with washers Be sure to remove the screws near the center of the cover A IMPORTANT The screws used to retain the bottom cover of the transmission are stainless steel 2 The transmission housing bottom cover is equipped with pusher screw to assist in the removal Thread a M10 1 5 x 60 mm fully threaded cap screw lubricated into a pusher screw location to push the bottom cover away from the transmission housing DCP 0159 DCP 0161 Figure 51 Transmission Bottom Cover 1 Removal Marine Transmission Service Manual 1021629 97 Disassembly Twin Disc Incorporated 3 Remove the retaining screws from the gear pan 2 2 of M10 1 5 x 25mm Remove the gear pan DCP 0162 DCP 0163 Figure 52 Gear
158. intenance 61 Marine Transmission Service Manual 1021629 7 Table of Contents Twin Disc Incorporated Troubleshooting 67 Troubleshooting of Mechanical and Electric Control Valves 67 GENET 67 SSS TOST KI ec 68 Troubleshooting of GP Control Valve with Electronic Interface 72 Clg RR RR E OE 72 Electronic Interface LED Indicators 72 ISAS uosaeo E E I IERENMFIAYERKERERECH ER EER DUE 77 Prepare Transmission for Disassembly 77 Component Identification 78 Bg pl 79 Remove Transmission External Components 80 Supply Cover and Output Shaft Cover 80 i i lero RE L e ccc c 81 Meat OD T 82 Top Cover with Oil Baffle amp Cold Oil Relief Valve 84 leue T REEL mU ak 85 OIl Filer ahd bellico Tm 87 Remove Primary and Secondary Clutch Shaft Assemblies 89 Remove Clutch Shaft Covers 4 4 44 89 Remove Primary and Secondary Shaft Manifold 91 PAPI 93 Remo
159. into a suction adapter plate 6 on the rear side of the transmission 6 Remove the gasket if it did not remain with the pump Remove the oil pump suction adapter plate 6 Note the orientation the suction adapter plate if removed to assist in the re assembly process CUm P lt EB E a rM DCP 0126 DCP 0128 Figure 41 Oil Pump Removal 88 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Remove Primary and Secondary Clutch Shaft Assemblies Remove Clutch Shaft Covers Remove the screws retaining the secondary clutch shaft cover 1 4 of M10 1 5 x 115mm 1 of M10 1 5 x 100mm 1 of M10 1 5 x 35mm 1 of M10 1 5 x 60mm 1 of M10 1 5 x 45mm All with washers a Gently tap the shaft cover to break the sealer bond from the transmission housing b Remove the cover 1 the shims and the bearing spacer 2 Tag the components with identifying information EIE DCP 0133 DCP 5775 DCPO136 Figure 42 Secondary Clutch Shaft Cover Removal Marine Transmission Service Manual 1021629 89 Disassembly Twin Disc Incorporated 2 Remove the 2 O rings 3 located in the manifold counterbores DCP 0139 Figure 43 O ring Removal From Manifold DCP 5768 Figure 44 Primary Shaft Manifold Cover Removal 3 Remove the primary shaft manifold cover 4 Remove bearing shims and tag with ident
160. ion Service Manual 1021629 Twin Disc Incorporated Introduction Preventative Maintenance Towing Frequent reference to the information provided in the Marine Transmission Owner s Manual 1016313 regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for recommended maintenance of the equipment WARNING Under the conditions described below the propeller shaft must be locked in place to prevent backdriving or an optional trailing pump must be added 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 lubrication Conditions where backdriving may occur Vessel is being towed One or more engines on a multiple transmission vessel are shut down while under way 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 6449RV transmissions if any of the above conditions are present Lock the propeller shaft to prevent rotation Add an optional trailing oil pump into the lubrication circuit Hefer to the hydraulic s
161. is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Note Installations with this valve must include an oil filter with the proper filtering characteristics This valve requires a filtration level of 16 micron at an efficiency of 98 beta ratio 2 75 or better Besides the valve s requirement on filtration the filter must meet the requirements of the transmission operating pressure flow etc Marine Transmission Service Manual 1021629 49 Operation Twin Disc Incorporated RUP BI MANIFOLD a 4 PROPORTIONAL VALVE MANIFDI EN gt A a lt uu Ht N LC SUMP UR E GUL ATUR HY DRAUI A RAM CGRAPHII YMBLIL 5 Figure 18 Hydraulic Sche
162. 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 4 With the oil at operating temperature transmission in neutral and the engine running at low idle check the oil level with the oil gauge Add or remove oil if necessary to bring the oil level to FULL mark on the oil gauge 5 Allow the oil temperature to cool to normal cold oil conditions 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 62 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Preventative Maintenance Torsional Coupling Note The torsional coupling is not supplied with the MG6449RV marine transmission This information is included for the operators use in the event that no other information is available for the torsional coupling that may be mounted on the engine flywheel 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 2
163. l 1021629 161 Assembly Twin Disc Incorporated Trailing Pump Driven Gear Installation TRAILING PUMP DRIVEN GEAR COVER FOR UNITS WITOUT TRAILING PUMP DRIVE PUMP AND GOVERNOR BEARINGS AND SPACER 738166 Figure 141 Trailing Pump Drive Component Identification and Location Note The housing should be placed with the front face down 1 Lubricate the bore 1 of the transmission housing Install the trailing pump drive shaft 2 through the bearing bore in the transmission housing AAR160 AAR204 Figure 142 Trailing Pump Driven Shaft 2 162 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 2 Position a spacer 3 below the shaft assembly inside the transmission housing to support the gear shaft 4 in the correct position during the bearing installation process Use tool T 111147 5 to press the first bearing onto the trailing pump drive shaft AAR204C AAR204 Figure 143 Trailing Pump Driven Gear Shaft 4 and Bearing Installation 3 Install the spacer and the second bearing into the bearing bore Press the spacer and bearing into position 4 Install a snap ring 6 to retain the bearing on the pump drive idler shaft If the snap ring 7 fits securely into position the bearings and spacer are properly positioned AAR206 AAR204 Figure 144 Trailing Pump Driven Shaft Snap Ring 7 Installation Marine Transmission Service Manual 1021629 163 Assembly Twin Disc Inc
164. l of the clutch plates the round snap ring groove will be visible above the bronze thrust washer 11 Install the round snap ring 3 onto the shaft to retain the bronze thrust washer AAR200 AAR182 Figure 125 Bronze Thrust Washer 2 and Round Snap Ring 3 Installation Marine Transmission Service Manual 1021629 151 Assembly Twin Disc Incorporated 12 Install the bearing carrier over the shaft with thrust flange towards the bronze thrust washer 13 Verify the pinion has measurable end float Invert the shaft assembly positioning the sealing ring end of the shaft down Install the rear tapered roller bearing if removed Heat the clutch shaft rear bearing cone 4 to a temperature of 120 C 250 Place the bearing on the clutch shaft and push it firmly into position against the clutch housing Note Be sure to seat the bearing against the clutch housing as the bearing cools Handle the bearing with care The bearing is HOT RV SHAFT AND GEAR Figure 126 RV Shaft and Gear 152 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Secondary Clutch Shaft Assembly BACKING PLATE WAVE SPRINGS BRONZE THRUST ir WASHER 18 GROOVES 1 0mm ORIFICE PLUG aan A PISTON WITH DUMP Apnea d BALL a CLUTCH PORT A 0 _ aa PUMP DRIVE ay 1 COUPLING LUBE PASSAGE PINION GEAR SEALING RING ASSEMBLY STEEL PLATES 12
165. l pump 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 Regulating valve stuck Improperly shimmed Lube relief valve malfunction Marine Transmission Service Manual 1021629 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 Adjust linkage so that valve stem is indexed properly by detent Remove orifice plate cover Clean parts Shim as required Raise engine speed Remove and clean strainer Check oil level and correct Correct cause of air leak Disassemble and repair as required Remove disassemble clean and repair the regulating valve Replace oil pump Replace heat exchanger Remove and clean regulating valve Shim as required Inspect repair or replace parts as necessary 69 Troubleshooting Table 9 Troubleshooting Chart Twin Disc Incorporated Mechanical and Electric Control Valves continued 4 High temperature 5 Excessive noise 6 No neutral 70 4 1 Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Worn or d
166. le danger to person s or property from accidents that may result from the use of machinery Twin Disc Inc will not be responsible for personal injury resulting from careless maintenance working practices Inspect as necessary to assure safe operations under prevailing conditions Proper guards and other safety devices that may be specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Inc WARNING Selecting NEUTRAL disengages transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a shaft brake or other shaft locking device must be used WARNING To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove ignition key from the switch WARNING Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the complete power unit Lifting excessive loads at these points could cause failure at the lift point or points and result in damage or personal injury Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole Marine Transmiss
167. lot Relief Valve Assembly Turn this adjustment stem counterclockwise until it reaches a positive stop This allows the engine transmission to be started and flush any debris past the relief valve Note This must be done with the transmission in Neutral 4 Start engine with controls in neutral Main pressure should be approximately 100 psi or less Allow the fluid to flush the valve for approximately 1 minute 5 Turn the 1 4 hex head adjustment stem clockwise to achieve the main pressure setting helpful practice is to turn the adjustment stem slightly beyond the desired setting approximately 5 psi and then adjust for the target pressure This aids in reducing variance in pressure setting due to torsional wind up of the spring Note If main pressure is to be set with cold oil adjust the main pressure approximately 5 to 10 psi higher than the desired value with hot oil 6 Tighten the jam nut to a torque of 20 Nm 15 Ft Ib install the protective cap and torque it to 14 Nm 10 Ft Ib Marine Transmission Service Manual 1021629 217 Assembly Twin Disc Incorporated Valve Assembly 1020729 1 Install a main pressure gauge into the port on top of the Top Valve body 2 Remove protective cover cap located at the end of the adjusting stem This will expose a slotted adjustment stem Loosen the jam nut on the stem Figure 218 Main Pressure Regulating Valve Assembly 1021658 3 Start engine with controls in neutral
168. low of main pressure oil to the engaged clutch which ultimately controls the pressure in the engaged clutch of the transmission The trolling feature is available when the selector valve is in the electric mode but is disabled when the selector valve is in the manual override mode Main pressure oil can flow into the trolling valve through a fixed orifice at all times Oil may exit the trolling valve through a variable orifice The size of the variable orifice depends on the trolling valve lever position When the trolling valve lever is in the detented position the variable orifice is closed Since oil can flow into the trolling valve through the inlet orifice and is not allowed to escape the oil pressure inside the trolling valve rises to match main oil pressure This oil pressure inside the trolling valve pushes the piston assembly over to compress the large diameter spring behind it The compressed spring pushes the flow control piston against its return spring allowing unrestricted flow of oil to the engaged clutch Unrestricted flow of oil to the engaged clutch results in full clutch apply pressure Detent position Inlet orifice Clutch behind cover Sump OH o
169. m 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 Remove the washer and spring from the stem Hemove four of M8 x 25 socket head capscrews Remove the cover assembly with the gasket from the valve body Remove the O ring and oil seal from the cover assembly Figure 89 Removing O ring from Cover 14 ES Remove the two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body some models Remove the detent setscrew spring and steel ball from the valve body Marine Transmission Service Manual 1021629 121 Disassembly Twin Disc Incorporated Figure 90 Removing Detent Setscrew and Spring 16 Remove the dog point setscrew Note that the setscrew is retained with MA908 threadlocker Figure 91 Removing Dog point Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem 122 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly m M2oB6OF Figure 92 Removing Thrust washer 19 Remove the stem from the valve body 20 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 93 Removing Roll Pin Retaining Shuttle Seat 21 Thread a M8 x 1 25 screw one of the cover screws works well into the seat and remove it from
170. matic GP control valve Assembly 1020729 50 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Operation CLUTCH CLUTCH PROPORTIONAL VALVE gt _ 4 q Ale 1 VY PROPORTIONAL VALVE lt a gt iF m Al 4 HREN ere x L SUMP EE e FROM PUMP RE SAL ECL Se TES ON MANUAL DIRECTIDNAI CONTROL VALVE 2 7 l L PTIUNAL TEMPERATURE SEN gt PORT M14 X 15 gt IMA es 7 JARY Marine Transmission Service Manual 1021629 Figure 19 Hydraulic Schematic GP control valve Assy 1021658 51 Operation Twin Disc Incorporated Manual Direction Control Valve Operation The manual directi
171. mm 7TOd1H I X AA X N e RACHIBED QIMENS SEE NENNEN TREAT FIRST USE rx uw ee ALL AKGULAA TOLERANCES 1 mE Te re TEE ST CF PER NOI II EM e 7 aA Aq 1 1 VO Ub DISE OF Pg AA Tren ACCME Wi SAF oim ol a 1 E Hrs A HEH 0156 INCORPORATED MEIE al Gin as SURFACE TREATMENT MHES MOM ICE 13 hir 3 AS9480 zc Se HYDRAULIC DIAGRAM F9 rev ib PROCESS OF GEAR ASSEMBLING BRGz 2 E E ag va iru 8 PROCESS OF GEAR ASSEMBLING au do c ois 7 AA ow Ei 1 Remove oil on the taper Location share amd gags wf Eee ug Fst te Hee te i ee Bec co 2 Negsure C and AR Go BEE c _ THEE Stamler 52 3 Thickness of khe E saina obka ned in aceerding te AMG O 40 05 mr wd eee C 32 ce do Fal lawi ha formura b SHIM ADJUSTMENT OF OUTPUT BEARING BEd 15 B E C 029 1 n aa L L Uo oe yare RL TAAT Hat adjustment shims before gear asserblinma ael ieee Me 4 Put Ehe gear on the outewk shaft ard ste ke it Lightly The clearance C C 0S mm wikain tha SRE FISHEL MBun E Dik REM AD xr B THOUSANOTHS INDICATOR GEAR uro 4 5 5 85 UM E SE 7 aam 1 mom ons sida
172. mounted unit that is driven by a driveline that attaches to the engine flywheel usually through a flywheel mounted torsional coupling The output shaft is angled downward from the input shaft by a 10 degree angle 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 ATE MA epa DDR i LN JAPAN 19m Figure 1 Nameplate for MG 6449RV Marine Transmission Marine Transmission Service Manual 1021629 19 Description and Specifications Twin Disc Incorporated Power Ratings The MG 6449RV 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 can 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 20 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Description and Specifications Construction Features Housings MG 6449RV series transmission h
173. n 44 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Operation GP Control Valve Hydraulic Portion The hydraulic portion of the GP Control Valve is made up of two blocks a lower main regulator valve body and an upper valve body The upper valve body contains two electrically actuated proportional valves and a manual direction control cartridge valve The lower valve body contains the hydraulic pressure regulating valve and a temperature sensor if the application requires it There are two different versions of the lower valve assembly The hydraulic pressure regulating valve in earlier versions Assembly 1020729 consist of two cartridge assemblies a pilot relief cartridge assembly and a main spool cartridge assembly The hydraulic pressure regulating valve in later versions Assembly 1021658 is not a cartridge assembly but is comprised of a spring and spool with an adjustment cover The regulating valve body contains a ball check valve assembly in parallel with an orifice with a filter that provides rapid fill and damping for the rear cavity of the regulator valve Akit is available to upgrade the earlier version to the later version temperature sensor is housed in the main regulator valve body on some applications The manual direction control cartridge valve contains a switch that is closed when the valve is in the neutral position Separate identical proportional cartridges are used for the primary and secondary
174. n Housing 12148238 Figure 147 Removing Output Shaft Rear Bearings i 166 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Assembling the Output Shaft Subassembly SINGLE LIP SEAL BEARING CUP AND SHIMS O RING DOUBLE LIP SPACER SEAL SPHERICAL ROLLER BEARING SEAL SLEEVE COVER SURFACE WITH LECTRICAL TAPE TAPERED ROLLER BEARING DURING ASSEMBLY 549607 Figure 148 Output Shaft Component Identification and Location 1 Install the oil seal sleeve onto the output shaft a Install an O ring into the groove in the inner bore of the oil seal sleeve Lubricate the surface of the O ring with grease Apply a thin film of grease to the output shaft surface from shaft midpoint to seal sleeve shoulder RMVC 007FGS Figure 149 Oil Seal Sleeve O ring Installation Marine Transmission Service Manual 1021629 167 Assembly Twin Disc Incorporated b Place the oil seal sleeve 1 onto the output shaft with the counterbored end toward the output flange Note The oil seal sleeve must contact the output shaft shoulder Lubricate the surface of the shaft between the output flange and the oil seal sleeve AAR220A1 Figure 150 Oil Sleeve Installation on Output Shaft 3 Install new output shaft seals into the seal carrier using a seal driver a Apply MA1015 or equivalent sealer to the outside diameter of the oil seals and the bore of the oil seal carrier
175. n s cassa uu ERERRRXRIKRUFAYMERKERNHREKN RIRESR 192 Transmission External Components 193 Pump and Suction Screen Installation 193 Trailing Pump Cover Installation 196 Heat Exchanger Installation 197 Cold Oil Relief Valve Installation 201 Assembly and Installation of Control Valve 202 Trolling Valve Optional Equipment 207 TCE valve 72 M DE NEM EDT 212 Assembly of GP Control Valve with Electronic Interface 213 Adjustment of Main Pressure 217 Oil Filter Housing Installation 22 22 221 219 Transmission Top Cover and Oil Level Gauge Installation 220 Grease Output Shaft Seals 2 2 2 21 222 Primary and Output Shaft End Cover Installation 223 Install Input Flange and Fill Transmission with Oil 224 Marine Transmission Service Manual 102162
176. nd Improper Installations Top View 244 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation With the 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 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 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 Marine Transmission Operator s Manual 1021629 245 Installation Twin Disc Incorporated Driveline Installation Both ends of a two piece driveline must be in phase with each other Many drivelines contain a slip spline between the two ends and the male and female sides of the slip spline may be capable of assembly at random angular positions The correct orientation of the yoke arms on each end of the driveline is for them
177. ns satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit Oil not used for clutch engagement flows past the regulator piston to become lubrication oil Lubrication oil flows through the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings Main pressure is supplied to the inlet of each proportional valve and to the inlet of the manual direction control valve In Neutral the inlet port of both clutches is connected to the sump Since the area behind the clutch pistons is open to sump the clutches are disengaged When one of the clutches is commanded to engage the proportional valve directs main pressure to engage the selected clutch pack The rate of rise is controlled electronically and prefills the engaging clutch at a predetermined level and then increases to full pressure following a predetermined timing sequence The initial prefill level is factory adjustable by means of an adjustment screw embedded in the bottom surface of the electronic interface Field adjustment of this feature should never be attempted without special equipment and knowledge of its use to prevent serious mechanical damage to the marine transmission or vessel The electronic interface portion of the control valve allows only one proportional valve to be energized at a time thus only one clutch can be engaged at a time and the oil from the disengaged clutch
178. nual Override Figure 98 Top Hydraulic Valve Body Assembly 3 Remove the four capscrews that retain the main regulator valve assembly to the transmission housing or ditch plate and remove the valve assembly and gasket Temperature Sensor Pilot Relief Valve M adn Regulator spool Figure 99 Main Regulator Hydraulic Valve Assembly 1020729 128 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Figure 100 Main Regulator Hydraulic Valve Assembly 1021658 4 Remove the Manual Direction Control Valve with switch or the Plug Assembly from the Top Valve Body Override Valve with Neutral Switch Locking Pin Plug if applicable Figure 101 Manual Direction Control Valve or Plug Marine Transmission Service Manual 1021629 129 Disassembly Twin Disc Incorporated 5 Remove the M6 1 00 x 16 Allen head capscrew the retaining plate and the proportional Valve Cartridges from the Top Valve Body A slight rotating motion while pulling will help to with the removal of the valves Figure 102 Remove Proportional Valve Cartridges 6 Valve Assembly 1020729 Remove the Main Pressure Regulator Pilot Relief Valve and Main Valve from the Main Regulator Valve body Regulater Valve Body Figure 103 Remove Main Pressure Regulator Valve Components 130 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly 6 Valve Assembly 1021658 Remo
179. o reduce noise and vibration Couplings to allow a permanent angular misalignment Ll Couplings that allow engines to be flexibly mounted and take out the momentary misalignment In some cases the proper alignment of these couplings requires an accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Marine Transmission Operator s Manual 1021629 233 Installation Twin Disc Incorporated Engine Preparation 234 Most Twin Disc products mount directly onto the flywheel of the engine or are attached to the flywheel through external shafting or adapters Flywheel to driven component interference is possible due to mismatch of components or other reasons Therefore engine crankshaft endplay as well as flywheel alignment checks must be made before the driven component is installed After installation of the driven component the crankshaft endplay should be measured again The endplay at the second measurement should be the same as the first A difference in these two endplay measurements could be an indication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage caused by engine to Twin Disc component interference regardless of the cause of interference This engine crankshaft endplay check is considered mandatory The transmission housing flan
180. 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 more Figure 5 Rate of Rise Piston in Neutral left and Rate of Rise Piston with Clutch Engaged right The travel rate of the rate of rise piston and resulting pressure rate of rise Is controlled by the orifice size regulator spring stiffness and the final main pressure after completion of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the rate of rise piston is against the stop pressure regulating springs are compressed the most the main oil pressure reaches approximately 370 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 regul
181. on because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when the unit is in the secondary position p m TURPE PR E gt pes Secondary Clutch Engaged SE Figure 25 MG 6449RV Power Flow with Secondary Clutch Engaged 60 Marine Transmission Service Manual 1021629 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
182. on control valve is locked in the NEUTRAL center position during normal operation There are three possible positions of the manual direction control valve stem If conditions exist that the operator wishes to manually operate the transmission for any reason the operator can remove the locking pin from the direction control valve and push the stem into the valve for engagement of clutch A or pull it out of the valve for the engagement of clutch B The manual direction control valve has an integral switch with contacts that are closed only when the manual direction control valve is in the NEUTRAL position This switch must be wired such that the engine cannot be started while clutch A or clutch B is engaged i C AU TION Engagement of a clutch with the Manual Direction Control Valve should only be done with the engine at idle speed Locking Pin Figure 20 Manual Direction Control Valve 52 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Operation Trolling Valve Optional The trolling valve is used to reduce and control propeller soeed below that normally attained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure to reduce the propeller speed The trolling valve for this transmission does not control the pressure in the rate of rise chamber when in the trolling mode it controls the flow of oil to the engaged clutch Trolling is achieved by restricting the f
183. on housing and the spherical bearing cup f T 1056BE MVC 891F MVC 893F Figure 160 Output Shaft Assembly Placement in Transmission Housing 16 Install the seal retainer screws and tighten them evenly Torque the nine screws to 80 Nem 59 Ib ft 17 Raise the transmission housing Support the output gear with a cylindrical support that will stop on the shoulder of the shaft 4 Lower the transmission housing until the output gear only the gear not the housing is supported firmly by the tool 178 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 18 Seat the shaft taper in the bore of the output gear Use a mallet to tap firmly on the end of the output shaft flange 5 seating the tapered joint A CAUTION Monitor the position of the trailing pump drive and driven gear during output shaft installation to pr AAR244 AAR251 Figure 161 Seating Output Gear on Output Shaft 19 Rotate the transmission with the input end up Install tool AM814A 6 onto the output shaft assembly 7 DCP 5681 MVC 895E Figure 162 Tool T 21482 5 Placement 20 Install tool T 21482 2 8 over tool AM814A Marine Transmission Service Manual 1021629 179 Assembly Twin Disc Incorporated 21 Install tool AM814 on top of tool T 21482 2 MVC896E MVC897E Figure 163 Installing Tool T 21482 2 8 22 Connect tool AM814 to the output shaft using four M18 x 1 5 socket head capscrews Ti
184. opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section Marine Transmission Service Manual 1021629 39 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 Meutral solenoid Hour m HYDRAULIC LOCK UNITS Figure 8 Hydraulic Lock Units The resulting reaction is a force on the spool that overcomes the spool s return spring force Should the solenoid become de energized while the spool has its clutch pressurized oil pressure will keep the spool in that position This keeps the transmission in gear as long as the engine is running 40 Marine Transmission Service Manual 1021629 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 use
185. orporated Output Shaft Installation Output Shaft Bearing Adjustment 1 If not previously done position the transmission housing with the output shaft end up Note Output shaft bearing adjustment is completed without springs installed in the pockets 1 of the transmission housing Apply a thin film of grease to the primary and secondary shaft front bearing bore inside the transmission housing Press the primary and secondary shaft bearing cups into the transmission housing bore with an appropriate driver The bearing cups should be a light slip fit Install the rear output shaft spherical roller bearing cup and cone into the transmission housing Install the rear output shaft tapered roller bearing cone next to the spherical roller bearing Install the tapered roller bearing cup 2 into the transmission housing Press the cup snugly against the rollers 164 AAR221 242 Figure 145 Output Shaft Bearing Spring Pockets 1 and Bearing 2 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Di Measure the depth of the tapered roller bearing cup into the transmission housing Measure from the machined surface of the transmission housing to the rear surface of the tapered roller bearing cup 3 Measure in three evenly spaced locations around the circumference of the bearing If all three readings are identical record the dimension If the readings are not identical adjust the bearings an
186. ot involved Marine Transmission Service Manual 1021629 139 Disassembly 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 Ll Inspect bearings for rotation roughness Replace the bearing if the rotation is rough Inspect bearings for corrosion and for wear indication on 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 140 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Gears Ll Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the def
187. pare the new parts with those being replaced during the assembly process to make sure you don t mistake the quantity or size Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces Pipe threads called out as PT on drawings and in this text are different from NPT threads PT threads and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Where grease is specified use a lithium based grease NLGI 2 Submerge all new clutch friction plates in clean transmission oil for a minimum of one hour prior to installation This transmission uses liquid sealer in many locations The approved sealant is Loctite 518 MA1015 applied per S774 a thin layer of sealant is all that is required with Loctite Primer N MA1012 Avoid getting sealant into the O ring counter bores This transmission uses thread lockers MA908 and 1007 at specified capscrew locations Marine Transmission Service Manual 1021629 143 Assembly Twin Disc Incorporated Note In the discussion that follows the input and output side of the transmission is the front Left and right sides are determined by facing the unit from the rear toward the front CAUTION Appropriate eye protection must be worn during tran
188. peller speed sensor if equipped Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation WIRING SCHEMATIC TROLL ENABLE SWITCH CLOSED TROLL MODE OPEN CRUISE MODE CUSTOMER SUPPLIED o 0 SEE MODULE POWER CONNECTION CHART RED 45V TROLL SPEED POTENTIOMETER 1K OHM ORANGE 00 TO 05 VOLT MINIMUM TROLL GREEN 4 75 TO 5 0 VOLT MAXIMUM TROLL SEE NOTES 2 amp 4 SOLENOID B ON O CUSTOMER SUPPLIED RED LED VIOLET TROLL SPEED CURRENT INPUT GREEN 4 20 MA SEE NOTE 1 GREEN TEMPERATURE SENSOR 2 TAN E Ai TAN ENGINE SPEED SENSOR RED dm iu AEZ POWER OK BROWN GREEN LED C PROPELLER SPEED SENSOR GREEN BLACK ee Fal A SVN NORMALLY CLOSED BLACK SOLENOID A NOT IN NEUTRAL RELAY RED gt CLOSED IN NEUTRAL A REN I SOLENOID B CUSTOMER SUPPLIED BLUE MP SOLENOID A ON O BLACK ys RED LED ae WHITE e O ii 87 BLACK o SOLENOID B SWITCH G9 YELLOW CUSTOMER SUPPLIED TO BEA START 5 a SEE MODULE POWER CIRCUIT CONNECTION CHART a LU DE TRANSMISSION MANUAL OVERRIDE SWITCHES 0 0 SOLENOID RETURN a Figur
189. per value as identified in Description and Specifications before alignment of the engine to the marine transmission Marine Transmission Operator s Manual 1021629 227 Installation Twin Disc Incorporated Propeller Shaft Before any attempt to align the engine and gearbox to the propeller shaft proper alignment of the propeller shaft must be determined This includes alignment of the propeller shaft through all struts and intermediate bearings Failure to properly align the propeller shaft may result in premature wear on bearings vibrations or possible 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 transmission to propeller shaft alignment 228 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation Marine Transmission to Propeller Shaft Alignment When mounting the transmission in the boat all of the mounting pads on the transmission must be used Failure to do so may result in damage to the transmission It is important to align the engine and transmission only when the boat is afloat and NOT in dry dock During this alignment period it is also advisable to fill the fuel tanks and load the boat in the typical manner that it is to be used Some boats are built with flexibility and may change shape as the loading varies When a heavy boat is dry docked it n
190. perature sensor is required for the MG6449RV marine transmission Engine speed and Propeller speed sensors are required for transmissions with E Troll The following figures show the various versions of Electronic Profile or E Troll Module WARNING Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System Marine Transmission Service Manual 1021629 47 Operation Twin Disc Incorporated Solenoid B on Red LED Power ok Green LED 4 Figure 16 Electronic Profile Module Solenoid Bon Red LED Power ok Green LED Solenoid on Red LED Figure 17 Electronic E Troll Module 48 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Operation Hydraulic System with GP Control Valve The oil pump draws oil through the strainer from the oil sump and discharges it through the heat exchanger to the oil filter Filtered oil enters the control valve through the inlet port The incoming oil Assembly 1020729 is supplied to the main pressure regulating relief pilot cartridge and the main regulating valve cartridge satisfying the main pressure requirements of the transmission cascading all remaining oil flow into the lubrication circuit The incoming oil Assembly 1021658 is supplied to the main pressure regulating valve and is supplied in parallel paths through a ball check valve and an orifice with filter to quickly regulate and dampen pressure oscillatio
191. put shaft as follows Calculate the shims Dimension E Dimension 0 00 0 1 mm Shims Dimension B Dimension E Dimension 0 00 0 004 in Shims Dimension B f The calculated shim pack 3 will be installed on the output shaft between the spacer and the output gear DO NOT install the shim pack at this time The shim pack will be installed Figure 157 Installation as the output shaft is lowered into the transmission housing AAR232 AAR233 Shaft End to Shoulder 2 Measurement and Shim Pack Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 88 Measure the expected gear advance to ensure it falls into the range as listed in the table below Table 9 Gear Advance Table GR Dimension mm 1 51 4 15 5 85 1 73 4 55 6 25 2 07 4 5 6 45 2 44 4 65 6 35 2 99 4 65 6 35 a Place the gear on the output shaft Seat the gear on the shaft by tapping it with a dead blow hammer to measure expected gear advance b Measure from the front end of the output shaft to the front edge of the output gear Record this distance as dimension F reference drawing Dimension F Calculate the expected gear advance dimension D reference drawing Dimension D Dimension G Dimension F Dimension D should fall into the range of as shown in the table above A CAUTION If the calculated advance falls outside the range given above check to
192. retaining pin is flush 7 with the shaft stake it in two locations at both ends of the pin AAR197 AAR170 Figure 129 Pump Drive Coupling 6 and 7 Installation 3 Replace the clutch piston seals 8 Lubricate the clutch piston sealing rings before installing the piston into the clutch housing 154 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly AAR200 AAR200 Figure 130 Installing Cutch Piston Seals 8 4 Lubricate the clutch piston bore with a thin film of grease Install the piston into the clutch housing Gently push the piston by hand until it is fully engaged into the clutch 9 Note Ifthe piston is difficult to install by hand remove the piston assembly and inspect the piston seals AAR188f AAR191 Figure 131 Clutch Piston Installation Marine Transmission Service Manual 1021629 Assembly Twin Disc Incorporated 5 Lubricate and insert the steel thrust race 3 thicker onto the shaft Ensure the steel thrust race is against the shaft shoulder Lubricate and install the needle thrust bearing followed by the 4 thinner steel thrust washer 1015BE 1016BE Figure 132 Installing Steel Thrust Race 3 and Bronze Thrust Washer 4 6 Install the clutch plates a Install a steel 5 clutch plate next to the piston b Install a friction plate Place two a pair wave springs 6 around the outer circumference of each friction plate Each pair of
193. ring carrier with a stone or file in the vicinity of all pusher screw locations Marine Transmission Service Manual 1021629 137 Disassembly Twin Disc Incorporated Cleaning Bearings DO NOT remove grease in which new bearings are packed Thoroughly wash bearings that have been in service Soak bearings in solvent if they are particularly dirty or filled with hardened grease Never dry bearings with compressed air DO NOT spin non lubricated bearings Oil bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently it is important to keep bearings clean DO NOT remove grease from new bearings Keep the wrapper on new bearings until they are installed DO NOT expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Sealed Joints For previously sealed joints scrape surfaces to remove old gasket material or silicone Clean surfaces with solvent to remove oil and grease residue Test for clean surfaces by applying a few drops of cool water to the surfaces Parts are sufficiently clean if water covers the surface in a film If the water puddles or forms beads use fresh solvent and reclean Marine Transmission Service Manual 1021629 Twin Disc Incorporated Inspection
194. rom 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 16 Marine Transmission Service Manual 1021629 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 1021629 17 Introduction Twin Disc Incorporated Warranty Equipment written about in this manual has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual or contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Racine Wisconsin U S A 18 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Description and Specifications Description and Specifications General The 7 37431 738165B and 738180 drawings identify the installation information for the MG 6449RV marine transmission This unit is only available as aremote
195. rounded edge is easier to install into the transfer gear splines when installed in this manner 067 068 Figure 122 Clutch Friction Plate 3 and Steel Plate 4 Installation Marine Transmission Service Manual 1021629 149 Assembly Twin Disc Incorporated 6 Install the clutch backing plate 5 Press the backing plate firmly into the clutch housing to ensure the splines of the clutch are aligned 7 Place the internal snap 6 ring next to the clutch backing plate 069 AAR187 Figure 123 Clutch Backing Plate 5 and Internal Snap Ring 6 8 Install two clamps 1 on the clutch housing and backing plate Use the clamps to evenly compress the clutch until the internal snap ring can be installed properly into the clutch housing Install the snap ring Remove the clamps Lubricate the area of the clutch shaft 8 that will contact the pinion bushing Install the pinion assembly 9 Gently rotate the pinion as the pinion is lowered into the clutch plates until the splines are fully engaged in all of the clutch plates Figure 124 Clutch Backing Plate 1 and Pinion Assembly 9 150 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 10 Install the bronze 2 thrust washer with 18 radial grooves next to the pinion Note that the bronze thrust washer for the primary shaft has a slightly smaller O D than the secondary shaft thrust washer Note If the pinion is fully engaged with al
196. s in lieu of an and all other warranties express or impliedincluding the given by T win Disc Incorporated T his warranty applies only to Bale non commercial non revenue earning marine pleasure craft applications delivered by Twin Disc Incorporated to the original customer on or after May 1 1995 The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated application engineering Twin Disc Incorporated is not responsible for any specific application installation of performance standard Any analysis program by Twin Disc Incorporated based upon customer supplied information is done solely as an accommodation to the customer and is not to be interpreted or construed as an approval for specific application or a guarantee of performance Twin Disc Incorporated cannot be held liable or responsible for incorrect information supplied or deviations from specifications provided by customer T he exclusive rem ovided T win Disc Incorporated whether arising out of warra Within the applicable be either the repair or replacement of any T win Disc Incorporated part or product found by T win Disc Incorporated to be defective For all models except MG 340 and MG 360 this include the labor to perform that work and to remove and reinstall or i it Inthiscontext labor is defined asthe flat rate labor hours established T win Disc reassemble reinstall and test the T win Disc
197. screw into aluminum threads See the torque specifications in Description and Specifications Figure 214 Install Regulator Valve Body to Transmission Marine Transmission Service Manual 1021629 215 Assembly Twin Disc Incorporated 4 Install a new gasket and the Top Valve Body Assembly on the Main Regulator Valve Assembly using six M10 1 50 x 70 hex head capscrews and torque to 46 Nm 34 Ft Ib Figure 215 Install Top Valve Body onto Regulator Valve Assembly 5 Install the Electronic Profile or E Troll Module on the top Valve Body and torque the four M6 1 0 capscrews to 9 5 Nm 7 Ft Ib lin Figure 216 Place Profile or E Troll Module onto Valve and tighten screws 6 Connect the electrical wires to the proportional valves and connect any other wires that were removed during disassembly 216 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Adjustment of Main Pressure Valve Assembly 1020729 It is recommended that following the servicing of the GP Valve Assembly off of the transmission that a procedure be followed to ensure the flushing of oil through the valve assembly followed by adjustment of the main pressure 1 Install a main pressure gauge into the port on top of the Top Valve body 2 Remove protective cover cap located at the end of the cartridge This will expose a 1 4 hex head adjustment stem Loosen the jam nut on the stem Ad4jsakeing crew Figure 217 Pi
198. sher 7 Marine Transmission Service Manual 1021629 147 Assembly Twin Disc Incorporated 9 Install the clutch plates a Install a steel 1 clutch plate next to the piston b Install a friction plate Place two a pair wave springs 2 around the outer circumference of each friction plate Each pair of wave springs is installed with the ends aligned The wave spring pairs are installed with their ends oriented in a random manner Note Some early units only have one wave spring per clutch RMVCO26FGS RMVCO28FGS Figure 120 Clutch Plate 1 and Wave Spring 2 Installation Install the remaining clutch plates and wave springs in an alternating fashion until all clutch plates have been installed 12 steel plates 11 friction plates 11 pairs of wave springs Note Asteel plate is located next to the piston and the backing plate Installation Note Friction Plates When installing clutch friction plates 3 install the plate with the rounded edge 5 away from the piston The rounded edge makes installation of the pinion gear splines easier to align as the pinion gear is installed into the transfer gear 148 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly AARMVC 029F AARMVC 001F Figure 121 Clutch Friction Plate Edge 5 Rounded Edge and Sharp Edge Shown Steel Plates When installing steel clutch plates 4 install the plate with the rounded edge toward the piston The
199. smission Service Manual 1021629 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 Ashuttle 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 3 Location of Shuttle Ball The electric control valve can be used in a manual override mode in the event of an electrical power failure When the control valve is energized or shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively increases the clutch engaging pressure causing the clutches to engage at a controlled rate The control valve allows only one clutch to be engaged at a time and the oil from the disengaged clutch is vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s piston to the disengaged position minimizing clutch plate drag Marine Transmission Service Manual 1021629 35 Operation 36 Twin Disc Incorporated Control Valve Assembly in Neutral Some of the main pressure oil from the oil inlet chamber flows throu
200. smission assembly To avoid personal injury proper safety equipment must be used during installation of any heated bushings bearings and other components 144 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Primary Clutch Shaft Assembly BACKING PLATE WAVE SPRINGS BRONZE THRUST WASHER 18 GROOVES ET AINING RING 1 0mm ORIFICE PLUG 5 PISTON WITH DUMP CLUTCH PORT i Ait i BALL lt j tT Tit ul LUBE PORT A 7 TNT Sn A SEALING RING PINION GEAR
201. smission housing Maintaining the seal carrier position protects the seal during assembly into the transmission housing 222A AR1052 Figure 154 Pressing Output Shaft Component with sleeve and Installing spacers 9 on Seal Carrier Marine Transmission Service Manual 1021629 171 Assembly Twin Disc Incorporated Preliminary Output Shaft Gear Advancement Verification 4 15 5 82 455 625 4 75 6 95 4 65 6 35 4 65 6 35 OF OUTPUT BEARING Input Advance Figure 155 Output Shaft Advancement Procedure 172 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly 1 Clean and inspect the output gear tapered bore a b Prepare the gear tapered bore surface for assembly by using a Scotchbrite pad to remove any burrs Clean the shaft tapered surface and the gear bore with an appropriate solvent Dry the shaft and clear all oil passages in the shaft with compressed air CAUTION If the gear or shaft is damaged and cannot be repaired without material removal replace the part CAUTION The tapered surface of the shaft and matching tapered gear bore must be completely free of grease oil dirt and solvent residue Failure to properly clean mating parts could prevent proper advance of the gear on the shaft and adversely effect torque carrying capacity of the assembled joint 2 Install the trailing pump drive gear if it was removed from the output gear 3 Measure
202. straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges 0 002 FEELER GAGE FEMALE d diis STRAIGHT EDGE Figure 229 Checking Parallel Alignment of the Coupling Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation As the marine transmission come into its 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 T
203. sure to align the roll pin holes in the seat with the holes in the valve body One of the valve s M8x1 25 cover screws threaded into the seat can be used to adjust the seat location in the valve body 4 Install the roll pin to retain the shuttle ball seat Drive the roll pin in until it is flush with the gasket surface of the valve body Figure 196 Installing Shuttle Ball Seat Roll Pin 9 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 1021629 203 Assembly Twin Disc Incorporated 6 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn Figure 197 Installing Dog point Setscrew rd Install the steel detent ball into the valve body 8 Install the detent spring over the detent ball Apply MA908 threadlocker to the threads of the hollow setscrew and install into the threaded hole Astepped Allen wrench or one wrapped with tape will ease the installation of the hollow setscrew Tighten the setscrew until it is flush with the gasket surface of the valve body Check the stem rotation and detent action Figure 198 Installing Detent Ball Setscrew 204 Marine Transmission Service Manual
204. t D B N S 1 lt i BS SUMP _ A ee NOTE X PLUG a SCREW MA961X 6 PRESSURE REGULATOR PLUG MA1038B lt 2 HYDRAULT DIAGRAM GRAPHIC SYMBOLS CLUTCH PRESSURE PORT E X D 12 1 5 HD CONFOR B PORT TO ISO 6149 12 15 THD CONFORM PLATE 1018175 TO ISO 6149 RING D A2916JT lt 2 SCREW 1100 PROPORTIONAL VALVE SEE CHART 2 M6X1 0 X 16 VALVE BODY 1020519 4 PLACES E s SEE NOTE
205. t Clearance b Calculate the shim pack thickness required to obtain 0 05 preload to 0 05 mm 0 002 preload to 0 002 inches clutch shaft clearance when the shim pack is installed The calculated shim pack will be installed on the primary shaft between the spacer and the rear cover DCP 5759 DCP 5762 Figure 176 Measuring Components to Determine Primary Clutch Shaft Bearing Adjustment Marine Transmission Service Manual 1021629 189 Assembly Twin Disc Incorporated Primary Shaft Cover Installation 1 Install O rings 2 clutch ports and lube ports into the counter bores in the manifold housing 2 Install the shim pack 3 on top of the Bearing Cup Place the thickest shims on the outside of the shim pack and the thinnest shims in the center of the shim pack DCP 5766 DCP 5765 Figure 177 Primary Clutch Shaft Bearing Spacer 1 O ring 2 and Shim 3 Installation 3 Lubricate the bore of the primary clutch shaft rear cover 4 Place MA1015 on the sealing surface of the primary clutch shaft rear cover 5 Install primary clutch shaft cover 6 8 of M10 1 5x32mm with washers Torque the screws to 46 N m 34 Ib ft DCP 5768 Figure 178 Seal 5 and Install Primary Clutch Shaft Cover 6 190 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Set Secondary Shaft Bearing Clearance 1 Measure the depth of the secondary clutch shaft tapered roller bearing cup in the
206. t and gear do not separate during the initial injection repeat steps 6 through 9 86 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly Oil Filter and Oil Pump 1 Remove the steel tube 1 between the pump and the filter There is a banjo fitting with a copper washer at the bottom and a compression fitting at the top DCP 0090 Figure 38 Steel Tube Removal DCP 0120 DCP 0121 Figure 39 Bracket and Oil Filter Removal 2 Hemove the bracket above the filter 4 of M 10 1 5 x 90mm at 2 and 4 of M10 1 5 x 24 at 3 Two O Rings seal the steel tube at the housing The assembly be removed by rotating and pulling the filter and tube with a slight force The O Rings are located at 4 4 Remove the suction strainer cover 5 from below the pump and remove the suction strainer 2 of M10 1 5 x 65mm The cover of the suction Strainer is sealed with an O ring The suction strainer is located inside a spring to hold the suction strainer into position Marine Transmission Service Manual 1021629 87 Disassembly Twin Disc Incorporated he 73 kPa ue NNI 3 L Ls 3 1 pymes i F DCP 0123 DCPO 124 Figure 40 Suction Strainer 5 Removal D Remove the oil pump and the jumper tube located behind the pump 2 x M10 x 130 3 x M10 x 105 and 1 x M10 x 185 A washer is needed under the head of the M10 x 185 The jumper tube is sealed at each end with an O ring and is fitted
207. t together with the front cover 3 Mark the heat exchanger core 3 at the top to ensure it will be replaced into the transmission housing correctly Note Place a container at the bottom of the rear cover to hold the lubricants DCP 0105 DCP 0107 Figure 31 Heat Exchanger Cover Removal 1 and Core Indexing 2 82 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly 4 Remove the rear cover from the heat exchanger 6 of M8 1 5 x 50mm Note Place acontainer at the bottom of the rear cover to hold the lubricants DCP 0112 Figure 32 Heat Exchanger Rear Cover Removal 5 Remove the heat exchanger core and the gasket is attached together with the heat exchanger rear cover mounting DCP 0115 DCP 0116 Figure 33 Heat Exchanger Core Removal Marine Transmission Service Manual 1021629 83 Disassembly Twin Disc Incorporated Top Cover with Oil Baffle amp Cold Oil Relief Valve 1 Remove the transmission top cover 7 The top cover contains the filler cap breather Note On the bottom surface of the top cover is an oil baffle 8 to prevent oil leakage through the breather Do not remove the baffle from the top cover unless replacement is necessary AR164 AR165 Figure 34 Top Cover Removal 2 Remove the Cold Oil Relief Valve located at the side of the transmission housing DCP 0129 DCP 0130 Figure 35 Cold Oil Relief Valve 84 Marine Transmission Service Man
208. table that follows No other electrical loads should be connected to this circuit Make the following Connections The following power connection chart lists the possible configurations for connecting Electronic Profile or E Troll Module to the power source for the three possible wiring options O Option 1 connections are used when the Profile or E Troll Module is connected to non electronic lever heads Option 2 connections are used when the Profile or E Troll Module is connected to electronic gear controllers Option 3 connections are used when the Profile or E Troll Module is connected to electronic control solenoid driver outputs The electronic control s Solenoid A and B returns or negative signals should be connected together and connected to the E Troll module return if equipped Electronic control solenoid drivers must have their solenoid return internally connected directly to ground If not the Profile or E Troll Module must be interfaced to the electronic control with relays Marine Transmission Operator s Manual 1021629 249 Installation Troll Enable Switch Return if equipped Solenoid B Switch Solenoid return Solenoid A Switch 250 Twin Disc Incorporated Table 13 Module Power Connection Chart Wiring Option 1 Wiring Option 2 Wiring Option 3 Connect to the negative terminal of the engine battery Connect to the positive terminal of the engine battery through the switch conta
209. tamination on Pilot Relief Valve seat Contamination in Main valve Cartridge Broken piston rings on clutch shaft s Damaged or worn oil pump assembly Engine idle speed too low Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Pilot Relief Valve or Main Regulating Valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost over board Pilot Relief Valve is out of adjustment Main Regulating Valve orifice missing Marine Transmission Service Manual 1021629 Remove and clean oil strainer Disassemble the Pilot Helief Valve and clean Service the transmission oil filter Clean or replace Main Valve cartridge and service the transmission oil filter Remove the collector and inspect the piston rings Replace damaged or worn oil pump assembly pump is not serviceable Raise engine speed Hemove and clean strainer Check oil level and correct Correct cause of air leak Disassemble and repair as required Hemove disassemble clean and repair the Pilot Relief Valve Remove clean or replace the Main Regulating Valve This valve cannot be disassembled Replace oil pump Replace heat exchanger Adjust Pilot Relief Valve Replace if necessary Replace Main Regulating Valve cartridge 73 Troubleshooting Twin Disc Incorporated Table 11 Tro
210. ted Assembly Assembly of GP Control Valve with Electronic Interface Prior to assembly all parts must be properly cleaned Carefully inspect all o rings for any damage and replace as necessary Lubricate all o rings and replace both gaskets 1 Valve Assembly 1020729 Assemble the Main Regulator Valve body A Install the Main Pressure pilot relief valve into the valve body and torque to 27 Nm 20 Ft Ib B Install the Main Valve into the valve body and torque to 33 Nm 24 Ft Ib C Install the 3 8 nptf pipe plug or optional temperature sensor into the valve body and torque to 23 Nm 17 Ft Ib D Install the M27x2 0 o ring plug into the valve body and torque to 75 Nm 55 Ft Ib Requlator Valve Body M27x2 0 o ring S a plug 3 8 plug or Temp Sengor Main Regulator Spool Pilot Relief Valve Figure 211 Main Pressure Regulator Components Assembly 1020729 Marine Transmission Service Manual 1021629 213 Assembly Twin Disc Incorporated 1 Valve Assembly 1021658 Assemble the Main Regulator Valve body A Install the filter into the threaded hole of the valve body and torque to 7 5 Nm 5 5 Ft Ib If removed install a new check valve assembly into the bore of the valve body and drive it with a drift until it is flush with the face of the body Install the 3 8 nptf pipe plug or optional temperature sensor into the valve body and torque to 23 Nm 17 Ft Ib Install
211. the valve body 22 Remove the shuttle ball from the valve body Marine Transmission Service Manual 1021629 123 Disassembly Twin Disc Incorporated Disassembly of Upper Valve Body Half electric section 1 Remove the Weatherpak connector from the valve body by sliding it in the direction of the opening in the shroud 2 Mark the wires with the location letters that are on the Weatherpak connector Open the end of the Weatherpak connector to allow removal of the pins and wires o Hemove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool The tool is Packard Electric P N 12014012 Figure 94 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them 9 Remove the third Neutral solenoid units with hydraulic lock or plug units without hydraulic lock 124 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Disassembly 6 Remove the filter screen from the valve body Figure 95 Removing Filter Screen ig 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 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 1021629 125
212. to keep the used components O rings gaskets and seals with the appropriate components for reference during the inspection and assembly process to make sure you don t forget the quantity size etc CAUTION Flat washers are used under all fasteners where the head of the fastener contacts an aluminum surface Pipe threads called out as PT BRITISH STANDARD PIPE TAPER on drawings and in this text are different from NPT threads PT threads and NPT threads are NOT interchangeable Adapters are available from several manufacturers to convert PT threads to NPT threads Most pusher screws used in the disassembly of this transmission are threaded through aluminum parts ALWAYS LUBRICATE the threads of the pusher screw before threading it into the mating part When installing pusher screws avoid rapid tightening with an impact wrench or similar device If an impact wrench is used with the pusher screws the threads may gall or seize in the aluminum part Tighten pusher screws in an even manner to avoid damaging components Marine Transmission Service Manual 1021629 77 Disassembly Twin Disc Incorporated Component Identification OIL LEVEL GAUGE OVERALL LENGTH 550 fF 5 ELECTRIC SELECTOR VALVE 0 2 Fw 8 016 2 0 as EQ SPACED NS DISTANCE REQUIRED TO INPUT SHAFT DIRECTION PEMO DIL
213. top cover Figure 220 Seal Top Cover 7 d Install the top cover 1 on the transmission housing Tighten the screws to 45 Nem 33 Ib ft 4 Lubricate the sealing ring of the oil filler cap 2 and install it in the top cover of the transmission AAR327 AAR164 Figure 221 Install Top Cover 1 and Filler Cap 2 220 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Di Install the oil level gauge tube into the housing if removed Place tool T 21578 2 3 over the top of the oil level gauge tube and gently tap the oil level gauge tube into the transmission housing 1038BE AAR316 DCP0096 Figure 222 Using Tool T 21578 2 to Install Oil Level Gauge Tube Marine Transmission Service Manual 1021629 221 Assembly Twin Disc Incorporated Grease Output Shaft Seals Fill the cavity between the two single lip and double lip output shaft seals with grease as follows a Remove the pipe plug 4 on the output shaft seal retainer housing The pipe plug is located on the opposite side 180 opposed of the grease zerk fitting 5 on the housing The pipe plug provides a place for air to escape while greasing the seal cavity b Use a grease gun 6 to fill the cavity with grease When grease escapes the seal retainer through the pipe plug opening the cavity is filled P Reinstall the pipe plug ED 1 AAR328 AAR329 Figure 223 Grease Output Shaft Seals 222 Marine Transmission S
214. tor 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 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation Wiring Connections for Optional GP Control Valve General The vessel wiring for the Profile or E Troll Module must be of sufficient size to prevent excessive voltage drop no greater than 0 5 Vdc between the battery connections positive voltage and ground and the Profile or E Troll Module The battery power connection must be protected by an electrical over current protection component fuse or circuit breaker as required by the vessel s approval agency The minimum current capacity should be 5 amps WARNING Do not connect valve coils directly to battery power supply voltage Use an approved Twin Disc Control System The customer supplied selector switches for each of the transmission clutches and for troll if equipped must be connected directly to the wires of the Profile or E Troll Module and connected to the power source as shown in the
215. ual 1021629 Twin Disc Incorporated Disassembly Input Flange 1 Position the transmission with the input flange facing up sure the transmission is supported securely Remove three socket head capscrews and the retainer plate DCP Figure 36 Input Flange Removal 2 Identify location of oil injection port 3 Install special tool T 21482 8 4 Fill the shaft passage with SAE 40W oil D Wrap the threads of the oil injection adapter with Teflon sealing tape 6 Fill the oil injection adapter with SAE 40W oil Lightly tap oil injection adapter to remove air entrapped in the passage Refill the passage with oil as required until the passage is filled and all traces of air are removed fe Wrap the threads of the injection adapter screw with Teflon sealing tape and install the screw into the oil injection adapter Marine Transmission Service Manual 1021629 85 Disassembly Twin Disc Incorporated 8 Install a retaining tool to stop the input flange from suddenly coming all the way off and causing damage Figure 37 Input Flange Removal WARNING The input flange will separate with extreme force potentially causing great physical harm Use EXTRA CAUTION and proper safety procedures 9 Hold the oil injection adapter to prevent rotation during operation and use an impact wrench to drive the screw into the oil injection adapter until the output shaft and output gear tapered surfaces separate If the shaf
216. ubleshooting Chart GP Manual Control Valve continued 4 High temperature Improper oil level Check and fill or drain with proper oil to the correct level Faulty heat exchanger Inspect repair or replace heat exchanger Clutches slipping Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch If pressure is low replace Proportional Valve and service the transmission oil filter Bearing failure Overhaul marine transmission Air leak on suction Inspect and correct side of pump cause of suction leak Control valve malfunction 6 Inspect repair or replace control valve 5 Excessive noise Bearing failure Overhaul marine transmission Worn or damaged input Remove marine coupling transmission Replace a worn or damaged coupling Excessive torsional Select proper torsional vibration coupling Worn or damaged gears Overhaul marine transmission Improper alignment Check alignment of engine transmission output flange to propeller shaft Correct as necessary Damaged propeller Repair propeller Misfiring engine Repair engine 6 Noneutral Clutch plates warped Remove clutch plates Overhaul unit Disengaged clutch has Replace Proportional Valve apply pressure Service Transmission oil filter 74 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Table 11 Troubleshooting Chart GP Manu
217. ve Secondary and Primary Clutch Shafts 95 Remove Primary and Secondary Shaft Front Bearing 96 Remove Output sescisiccpanps URN UNMNAUESNKMIN USUS LOGRETM sine 97 Remove the transmission bottom cover sees 97 Remove the Output SHOE o doin renee ters S tie AIR RUE A MEET KHOE 98 Remove Trailing Pump and Shaft 103 Remove Pump Cover and Shaft aan 103 RR TE TN 104 Front Bearing Cup 105 Clutch Shaft Output Shaft Disassembly 106 Primary Clutch Shaft Disassembly eee 106 Secondary Clutch Shaft Disassembly 111 Primary and Secondary Clutch Shaft Insert Removal 116 Ouip t SHOT DISASSEMDNY asssnieaxesuidaiskvaeusbs Cbku PEE FF NERO VENE UON PK EU IV ERI 117 Disassembly of Upper Valve Body Half electric section 124 Disassembly of GP Control Valve with Electronic Interface 126 8 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Table of Contents 872 27 770 e h ee 127
218. ve body and into piston spring pocket Install the shims that were removed into the bore of the rate of rise piston Install the rate of rise piston over the springs and into valve body Install screen into passage Install neutral pressure regulating spring into the pocket of valve body Figure 200 Neutral Pressure Regulating Spring Location 29 26 27 28 29 206 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 23 Nem 17 Ibeft 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 Nem 40 Ibeft Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Trolling Valve Optional Equipment 1 Install the pipe plugs bushings and internal retaining ring if removed into the valve 2 Install the piston into the bushings of the valve Note that the small diameter end of the piston will protrude past the bushing at the opposite end of the valve when installed properly Figure 201 Install piston 3 Install the washer over the shoulder of the piston in the valve Figure 2
219. ve the Main Pressure Regulator from the Main Regulator Valve body A Remove the regulator adjusting screw cap and loosen the jam nut B Turn the adjusting screw counter clockwise to reduce the spring load on the valve Evenly loosen the four 8 x 25 capscrews and remove the cover assembly and gasket followed by the spring s and spool D Remove the four M 8 x 20 capscrews and remove the cover and gasket E Remove the orifice and screen assembly for cleaning F Remove the ball check assembly only if necessary Removal will require destruction and replacement of the assembly F Temperaire m L Pot a Y 22 fiio w Chock Valve f P Figure 104 Remove Main Pressure Regulator Valve Components Cover with Adjustment Cover Figure 105 Remove Main Pressure Regulator Valve Components Marine Transmission Service Manual 1021629 131 Disassembly Twin Disc Incorporated Trolling Valve Optional Equipment Remove the trolling valve from the ditch plate HEP IRE NC p a 7 E 22 168753c3 Figure 106 Remove trolling valve 2 Remove upper valve body half from the ditch plates 3 Remove the ditch plates and lower valve body half from the transmission 4 Rotate the trolling valve lever to the minimum trolling pressure position Remove the upper right hand cover attaching screw Rotate the trolling valv
220. wave springs is installed with the ends aligned The wave spring pairs are installed with their ends oriented in a random manner Note Some early units only have one wave spring per clutch RMVCO26FGS RMVCO28FGS Figure 133 Clutch Plate 5 and Wave Spring 6 Installation 156 Marine Transmission Service Manual 1021629 Twin Disc Incorporated Assembly Install the remaining clutch plates and wave springs in an alternating fashion until all clutch plates have been installed 12 steel plates 11 friction plates 11 pairs of wave springs Note A steel plate is located next to the piston and the clutch backing plate Installation Note Friction Plates When installing clutch friction plates 8 install the plate with the rounded edge 7 away from the piston The rounded edge makes installation of the pinion gear splines easier to align as the pinion gear is installed into the transfer gear AARMVC 029F AARMVC 001F Figure 134 Clutch Friction Plate Edge 7 Rounded Edge and Sharp Edge Shown Marine Transmission Service Manual 1021629 157 Assembly Twin Disc Incorporated Steel Plates When installing steel clutch plates 9 install the plate with the rounded edge toward the piston The rounded edge is easier to install into the transfer gear splines when installed in this manner 067 068 Figure 135 Clutch Friction Plate 8 and Steel Plate 9 Installation 14 Install the clut
221. y are mounted If the installation requires that the transmission input shaft centerline is not parallel to the engine crankshaft centerline adjust both pointers to the same lengths so the pointed end indicator reference end of the inner shafts are in close proximity to each other Once this is completed use a dial indicator making sure that the run out on the pointers are no greater then 0625 inch 1 59mm It will be necessary to check runout on both shafts by turning them each 360 The engine position must be adjusted so that the pointer ends meet each other ADUSTABLE SHAFTS ON BOTH SIDES LENGTHS MUST BE SET EQUAL ADJUSTMENT LOCKING BOLTS M BOTH MUST BE LESS THAN 1 59MM RUNOUT IN THIS AREA IS NO GREATER THAN 1 59MM 0625 INCH BOTH SIDES PRIOR TO ALIGNMENT ROTATE BOTH SHAFTS TO Figure 236 Remote or Island Mounted Alignment Tool Shafts not Parallel Marine Transmission Operator s Manual 1021629 241 Installation Twin Disc Incorporated 6 If the engine position can be adjusted so that the transmission input shaft centerline will be parallel to the engine crankshaft centerline the engine must be adjusted so that the two rods are parallel to each other The rods can be lengthened as long as the runout is within the allowable limits to ease in the adjustments ADUSTABLE SHAFTS ON BOTH SIDES LENGTHS MUST BE SET EQUAL ADJUSTMENT LOCKING BOLTS ENGINE FLYWHEEL MOUNTED RUNOUT IN THIS AREA IS NO
222. y cere ROL REV ZONE CH NO pate REV ZONE CH NO DATE R OTHERS BY CONTRACT WITHOUT TROLLING VALVE DAS SHEET 1 OF 1 REV AL Wl C3 C2 A Ma Te ee 4c 52 Lal F HITICE Telg Toa AROPUHIETAaHY INF OARATOOM AM 5 MOT TO BE watt IH shi SETRIMEMTAL TO THE INTERESTS OF THIN 0 98 iNCORPORATED RACIME Wi 33405 USA WETICE SOT CT THLE O TO HILL FY OR LLMLT 3S 3HT7Z G TRE 1 2 R OTHERS HY CONTRACT 1 a Lf C 22 LAWLESS OTHERS LSE SEEC IF ES HUHI OIRN HS ALL TOLEXAKDERS 31 EAMG 14 PER 5 i m r3 13 Ta RE ANGLE TINDE cue Hts 27 4 z i ee pr REY LL ux PLN DU a T T woe 1 LE x B Y L 7 x B ES 5 E T
223. ystem prints for more details on the optional trailing pump specifications for the applicable transmission or contact your Twin Disc Authorized Distributor Marine Transmission Service Manual 1021629 15 Introduction Twin Disc Incorporated Ordering Parts and Obtaining Services WARNING All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Ordering Service Parts Renewal parts service parts kits optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you Note Do not order parts from the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material number on the units nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating f
224. ywheel Housing Figure 233 Checking Flywheel Housing Bore Eccentricity Marine Transmission Operator s Manual 1021629 237 Installation Twin Disc Incorporated 4 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore See the previous Table for allowable tolerances 5 Bolt a thousandths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the surface to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter j Flywheel ngine _ Engine Flywheel Engine Thousandths Crankshaft Indicator T Figure 234 Checking the Flywheel Face Runout 238 Marine Transmission Operator s Manual 1021629 Twin Disc Incorporated Installation 6 With the indicator mounted as in the paragraph above adjust the indicator tip so that it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot 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 Figure 235 p Engine Flywheel engine J Housing i p g d i i T 1

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