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Service Manual Marine

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2. Ya E GE OA BALL 4 1034 RING 2915 ASSEMBLE TAPERED EDGE 84 4 4 4 4 4 4 4 SIDE AWAY FROM BEARING 2 o RING 1048 edem BEARING 1014856 RING M19044Q 2 R da Ae 96m SEAL ds T P UMP 1001349 S 6 SHIM 1014884 5
3. PINION ASS Y 1015213 2 ASSEMBLY UNS TRUCIOS 6 961 RA ESSE ASSEMBLE AND TEST PER 570 NOTES 1 THRU 7 ARE IN S570AE PINION ASS Y 1015215 2 6 551 RATIO 20 PINION ASS Y 1015217 2 CREEN MA993 rH FANDARDS APPLY 101 RATIO 574 FASTENER TORQUE REQUIREMENTS 5692 BEARING SHIMMING PINION ASS Y 1015219 2 lt 765 TAPERED JUINT ASSEMBLY 5 04 1 RATIO 25 2 L C SOO PINION ASS 1015220 4 591 RATIO 2 GASKET 1000874 PINION ASS Y 1015223 2 5 UG MA1038C ZO TNT DNUS BEARING 1014857 25 PER HOUSING 929 HOUSING 1015018 2 THIS SPACER USED BALL MA1034C SAE 805 GASKET 1001076 WITH 6 961 6 554 AND 6101 RATI NL Y CARRIER 1000063 eee IMPO DI Se 1001380 GASKET 1001109 ETAINER B3616A 2 WASHER MALUSIA RING M2693E 2 1016215 MENT RING A2706AC GASKET 1001218 BEARING Co Lx v Sue A Seb
4. P d d s A N 0 gt re veras cy es re 9 Se Nm NE XZ N N NT 920265 N 5250 22 S 2590 P 6 Xx lt xo 252 090 050 px gt lt gt 505 LN EN EN n ee SERE 7 de cub E S N A N Nm M X Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 13 13 SECTION 13 MG5202DC ion View Sect ission Transm 13 6a non uols 1 2026 uonnquisip 0 JeureJis UIOS ees puiueq 2102 abueg sees yeys pue wys Ajquiasse yeys yeys 19402 49A00 pjojiueuJ 5 5 eys eec dol 13409 peau xeu do jexXserc Buisnoy peau xeu qnH
5. N E id eS PER TEST NE Seu MA960F amp DINE D TN VALVE SFECI TOS DEIN 6 4 DRILL end CLUTCH ENGAGED SEE CHART _ 3 Foe S a INSTALLATION DATA SEE CHART E 12 VALVE SUITABLE FOR UP 95 L min 20001 2 CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 207 AND 621 kPa PMe306D M12 1 5 THREAD P703P DEPENDING UPON SPRING ASS Y USED L min THRU VALVE AND MA960A PRESSURE GAUGE LINE lt INTERMEDIATE PRESSURE MAI038B LOCATION HF 1999 Em 5 18 62 AT THE 55 9 LOCATION OF THE 6 4 HOLE IS REQUIRED 46 0 2 8 OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST MA1038B _ Xem ce gt PROVIDE 35 8 LINEAR TRAVEL FROM NEUTRAL AT THE 6 4 HOLE s 55 6 LOCATION WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT 5 292 6 4 DRILL E SPRING AND PIN BE OMITTED THEN THE FORCE WILL BECOME 13 31 S N EE SEE NOTES amp 6 TER E T THE DETENT FEATURE IS PROVIDED IN THE FULL FORWARD FULL REVERSE NEE RRA A n AND NEUTRAL LEVER POSITIONS 1990 M Y WWW 4 TORQUE MOUNTING BOLTS 41 49 AS RECEIVED PER 5574 OR gt a N 34 39 _ LUBRICATED PER 5574 AFTER TORQUING MOUNTING 835746 i
6. 7 95 25 19 09 N 13 5 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC SECTION 13 13 3 Suction Strainer Qty Description O ring suction strainer cover Cover suction strainer Plate clamp manifold suction strainer cover Strainer suction 13 6 SECTION 13 Illustrations 13 4 Filter Description Filter assembly Fitting threaded filter to manifold Gasket ditch plate Screw socket head filter bypass valve Ring retaining filter bypass valve Seat valve filter bypass Cone filter bypass Ball Spring filter bypass valve Nut filter bypass valve Plug MG5202DC only MG5202DC Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC Illustrations 13 7 SECTION 13 MG5202SC MG5203SC MG5204SC ission Rear Vi Transm 13 5 HO DZS S opoui uo p sn jou Aew ey sued SHUN 10 SI puooes pue 10 1 151 34 USAG suoisueuiip JO 5195 OM ueuM Josues
7. 1014862 1 1531 RATIO 36 T 82415 1014850 HARE M488B 8 I INI x CU Sana at 1 M1990C x a STEEL BALL i A2916BY A Jo 4 8 1014889 D ii gt BENT A 702E isa ML A K x 2916 1014850 Y 9500 22222 lt AH STEEL BALL J 1 5 222 o SST SSS 1014876 A 2 15 5 Z LEES ZA RA 0 0 4 x 1 2 1019883 CLM IE Hess N V 7 i 2 ET 1 ii 7 d OZ 4 gt 22 ET NM 7 1 77 CLL P amp ACNIISNIBIES NNN NNN S 2 N gt a ____ 50 rdi ZING BS gt Z L Beasep 9 2 _ 888 _ 8 2 Ili 75 S MALLA L LLALL x D 5 Z 1 amp LAARA 048 8 2888 8 T 7 SN S HOUSING EET OPTIONAL EXTRA SUPPLIED x 1015120 1 1 DF AND PART NUMBERS 1015119 1
8. 1018493 1331 RATIO 5 1016194 1171 RATIO 1016108 2 921 RATIO 1016110 2 481 RATIO 1016113 2 03 1 RATIO 1016116 1761 RATIO 1016119 153 1 RATIO 1016106 OIL TEMPERATURE INDICATING SWITCH 83424 FOR INST LOCATION SEE HYDRAULIC DIAGRAM AND SHEET SEE NOTE 6 22 72 87 2 UI 222 7 2 1016109 MA961C M268 o BALANCING REQUIRED FOR SURVEY SOCIETY APPLICATIONS SEE PARTS DRAWINGS NOT SERVICEABLE SEPARATELY REMOVE BEFORE OPERATING 2 PLACES THREAD PROTECTORS L Emi Bir EE ALLATION OPTIONAL EXTRA SUPPLIED WHEN 0 SPECIFIED ASSEMBLY i Jonas _ 4 28958 1 21 99 Eg SUCTION SCREEN L 29957 12 15 98 4 AD 29648 i i 99 12 x 28834 10 6 98 225 29222 329 99 1 w 4 28657 7 21 98 sarno zone Sarna rev ze 101610 ASSEMBLY 1016103 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 1 ED IN ANY T TO BE US MANNER DETRIMENTAL TO THE IN
9. n S A E J620 MARINE A TRANSMISSION FLYWHEEL 11 9 Lo d 339 HATI Se uS EZ 466 725 43815 409 4 25 4 E Z Lekra Oke Sd E er qu DD 460 18 67945 ES Tio 42 92 498 3 Leg Les Le o9 3794 ELS ee TRANSMISSILN CLIUPLING ASSEMBLY ENGINE INSTALL COUPLING AND HUB ENGINE FLYWHEEL ADVANCE MARINE TRANSMISSION INTO POSITION WITH ENGINE FLYWHEEL HOUSING MOUNTING FLANGE LINE UP INPUT SHAFT EXTERNAL SPLINE WITH INTERNAL SPLINE IN COUPLING HUB AND MUVE ENGINE AND MARINE TRANSMISSION TOGETHER MAINTAINING ENGINE FLYWHEEL HOUSING AND MARINE TRANSMISSION FLYWHEEL HUUSING MOUNTING FACES IN PARALLEL RELATIONSHIP ENGAGE FLYWHEEL HOUSING PILOTS AND INSTALL ALL MUUNTING CAPSCREWS USING 8 8 PRUPERTY CLASS QUALITY PER ISU 898 1 GRADE QUALITY CAPSCREWS PER SAE J429 THRQUED 5574 HR SERVICE MANUAL VALUES 12 8 6 3 304 8 6 0 SEE SHEET 1 FOR MAXIMUM TRANSMISSION R P M 16 13 5 6 16 7 304 8 18 0 Io FD Sel Oo THE WR OF THE INNER SECONDARY PARTS INCLUDES HUB AND 1 4 Ce OTHER TRANSMISSION MASS ELASTIC DATA REFER B35044E POR TRANSMISSION INSTALLATION REFER TH 1016249 SHEET ALL COUPLINGS ABOVE HAVE TORSIONAL STUP INCLUDED NOTIC
10. RN FIRST USE X XX 0 13 ASSY ALL ANGULAR TOLERANCES ANG GEOMETRIC TOLERANCING MODEL PER ANSI Y14 5M 1982 2 1015c0 A4 SURFACE TREATMENT NAME MG S202 DC MARINE TRANSMISSION APPD FLEXIBLE COUPLING INPUTS SHEET 5 DF 7 0 B A qe TUN DUSE N CDR P AT D 53403 USA Di ARES VALVE ASS Y wz IRULLING VALVE MEM END VIEW gt 600000000 ETCH HO A 2 1 AUUSING cad file 115207 6 SIMILAR ROPRIE TARY INFORMATION SARD s TUN 213 PROPRIETARY INFORMATION AND IS DIMENSIONS ARE mm 19 28 97 D 1032 SCALE I BE USED IN ANY MANNER Nn DETRIMENTAL THE INTERESTS FIRSTUHSE X X 0 25 25 1 00 RACINE WI 53403 USA TWIN DISC INCORPORATED X X ASSY ALL ANGULAR TOLERANCES 1 DRN THIS NOTICE IS INTENDED PER ANSI 14 5 1982 CHIS TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NOME M G 2 2 D DAS GRANTED TO THE U S GOVERNMENT APPD DR OTHERS BY CONTRACT MARINE TRANSMISSION DAS SHEET 6 Z REV DE qd CUNTRUL VALVE gt 7 wW TRULLING VALVE END VIEW TUP VIEW SIDE VIEW 2 e
11. d 4 1 E a 4 1 F Tupa Recommended id dedi 4 2 a m E A AE e T T TM 4 2 H VIBE RIES MEN T EN T 4 4 l Mitan Cite TO Tie 4 4 RR ERU igtur 4 5 4 2 rr 4 6 Table of Contents Table of Contents 4 3 iL Ice a 4 6 A 4 6 EE EE T PE E AAE 4 6 Bg 4 7 D ae neran a 4 8 E u u u Susu ny 4 9 Section 5 Troubleshooting 5 1 CORE 5 1 Section 6 Disassembly 6 1 Prepare Transmission tor Disassembly uu l LLULLU ani a 6 1 6 2 Remove L EET 6 2 6 3 Z t l l __ 6 3 6 4 Remove and Disassemble Manifold and Bearing Carrier 6 4 6 5 Remove Primary and Secondary SHAMS 6 5 6 6 p aaah 6 6 6 7 Disassembly or Primary Shaft or Secondary Shall u u uususssaussssaqssasswshasss 6 11 Section 7 Cleaning and Inspection TA uU M E E 7 1 A ecce 7 1 B Preventing Dirt from Entering into Bearings 7 1 C Previously Seale Jolie DET 7 2 7 2 isl b ee 7 2 Housings Cast Parts and Ma
12. Sk PPYPPP 11 moo SAE 0 HUUSING 2 2 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT MATERIAL HEAT TREAT CO cad file 11520 THIRD ANGLE PROJECTION SIMILAR TO UNLESS OTHERWISE DATE SP Er ITIN DISE MACHINED DIMENSIONS X 0 75 255 100 RATE X X 0 25 1 poe USA FIRST USE 0 13 ASSY ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING MODEL PER ANSI Y14 5M 1982 SURFACE TREATMENT NAME 1015207 MG 5202DC MARINE TRANSMISSION LUBE TUBE 6 RELEASED ho m Ec EEEE Bae k F n A A lt A ME CLUTCH E e cc EE gt L I AU 22 Z 222777 8 PRIMARY amp SECUNDARY a x La ales 2 ut m 5 t4 G CUSTOMER TO INSTALL 32 22 22 JZ 22 PRESSURE GAUGE LINE HERE RE 285 ED PRESSURE GAUGE BE MDUNTED 25 sb Zu IN PILOT HOUSE 4 uw BEARING MARINE TRANSMISSIDN 2 CUSTOMER
13. peau xau pjojiueu edid edid qn 0 51615400 io A quu sse eqn Ajquiasse io I A snes uoneognuepi uoneoynuepi 9 eqni MOIS eqni 1914 Huiusng uoup peeu xeu peau xeu 0 ureup edid apno ansoja anno dund Aoq 3 pjojyiueuJ peau xau peau xeu pjojyiueuJ peau xau jewop pue peau xau 00 uonduoseg 40 uonduoseq 15 OS vOZSDIN OS 05691 OS Z0ZSDIN SECTION 13 Illustrations 19 8 E 53 1 SS o oaa BN PEN oy 22 L o X Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC Illustrations 13 9 uo p sn eq ey sued s lou d SHUN 10 S
14. m 711QY 9 40 Ist CLUTCH ENGAGED FOR 3 POSITION SECONDARY ENGAGED FOR 2 POSITION ENGAGED amp DISENGAGED USE PRIMARY NEUTRAL 5 16 18U UNC 2B TH D USE 0 0 THREAD S HDLES TO PROTECTOR WHEN IT 6 IS SPECIFIED 2 70 NEUTRAL FOR 3 POSITION PRIMARY 20 1 15 EU NEUTRAL SECONDARY USE WITH T L VS DISENGAGED FOR e 2 POSITION ENGAGED 2 amp DISENGAGE D gt USE CONTROL LEVER 40 1 4 DRILL SEE 3 end CLUTCH ENGAGED FOR 3 POSITION CPRIMARY NEUTRAL SECONDARY USE FOR 512 amp 7512 MG516 PORT 1 IS ENGAGED AND NEUTRAL IS DISENGAGED 2013410 M1990E 3574 208 2086 7 78 X lt S a WS lt F gt SS Z 4347 1927 PORT FOR end CLUTCH 31 MIN HOLE MUST LUCATED IN THIS AREA IN MATING PART CLUTCH DRAIN DATUM u Jo Oe III V V V SECTION section section 7361B VALVE BODY AS XA7361B VALVE BODY AS Ist CLUTCH USED FOR FACE PORTED USED FOR HOSE INLET VALVE INLET HERE THRU PORT X XA7361B CONSISTS OF A7361B 7 16 DRILL VALVE BODY AND 19454 Q e HO
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16. NO INCORPORATED RACINE WI 53403 USA A 119R PRIMARY SECONDARY SSS eto 5 CLUTCH CLUTCH LUBE TUBE SSS SPRING RELEASED 6 d d lt ado lt 41 M SS NY EON CLUTCH dac Z SHAFT LUBE lt Z 2ZZZZZZZZZZZZZZzzZz Z 1 gt T A a a z 2222 2 4 WA aly P gt E SSSSY E 55 ofS d we Sue P SL SM GAUGE MOUNTED are BEARING emu mmm s SEES lt MARINE TRANSMISSION Ee de ce vm CUSTOMER TO LUBE SH S INSTALLATION DRAWING m INSTALL NN 0 PRESSURE PRIMARY SHAFT SINI e te B LINE HERE FRONT amp REAR BEARING PINION el SHOWN ENGAGED LUBE RELIEF VALVE MARINE mm 100 PSI TRANSMISSION CONTROL VALVE E SHOWN IN NEUTRAL 4 S wass NING 9 ALN ORN KEH gt SNS VAN SS
17. BURT CONFORMS FLYWHEEL DUTLINE HOUSING ADAPTER eA Les Y ear es TO ISD 6149 55 MUST CONFORM CONTROL LEVER P AUXILIARY LUBE SUPPLY S AE 620 ees ig nies 6 35 1 4 7 HYDRAULIC 55 ND 355 1141 o DIAGRAM e s AE N 4 VALVE MOUNTING BOLTS e i AHEAD gt ER TO METRIC PORT CONFORMS cU GAGE IS FLEXIBLE AND es REMOVE THREAD o NECESSARY PROTECTOR BEFORE O 00 DPERATING UNIT In DIL OUT TO HEAT EXCHANGER M33 X 2 THREAD x METRIC PORT CONFORMS TO ISO 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT Em _ _ E e6 8 1 06 1016103B E f MET _ a NE gu us ID Po PLUG SPEED LON 1 PICK UP PORT T i 5 lt a l 4 0 do QJ E RS Bos 2 0 zuo z 21 3 ES x 841 T 5 CLEARANCE REMOVE PUMP ELLERT m 1 18 X 15 THREAD PRIMARY m METRIC PORT CONFORMS CLUTCH CENTER 130 6149 uw 5276 AUXILIARY LUBE SUPPLY Neos mE C INET SEE HYDRAULIC 52 09 om 20 77 DIAGRAM om N FILTER DRAIN NO a n
18. OIL DRAIN PLUG M33 X 2 THREAD 8 00 266 7 10 50 V THIRD ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIDNS X 0 75 INCH DIMENSIONS AND POUNDS SHOWN IN BRACKETS L 1 MATERIAL WEIGHT wr kg Nm 5 FIRST USE XXX ASSY ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING MODEL PER ANSI 14 5 1982 SURFACE TREATMENT NAME MG5203 SC transmiss TRANSMISSION 9 14 95 SCALE 201 DRN 1016249 TUIN p SC INC R AT E D RACINE WI 53403 USA THIRD ANGLE PROJECTION OURS NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT SIMILAR TO UNLESS OTHERWISE SPECIFIED NDE ALL ANGULAR TOLERANCES 1 HEAT TREAT SURFACE TREATMENT NAME ROLES T S SHEET 4 oF 49 4 49 Y Y 542 MARINE TRANSMISSION 1015361 1 ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 5570 NOTES 1 THRU 8 ARE IN 5570 F e e EN Em Ea e EA OIL PRESSURE GAGE B1703D PR
19. C puppe 0 NES UN VALVES PER TEST SP Eb INI CLINTAINED IN VALVE SPECIFICATION INSTALLATION DATA 12 VALVE SUITABLE FOR UP 95 2 CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 207 AND 621 kPa DEPENDING SPRING ASS Y USED L min THRU VALVE AND INTERMEDIATE PRESSURE 3 18 62 AT THE 55 9 R LOCATION OF THE 6 4 HOLE IS REQUIRED TO OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 55 8 LINEAR TRAVEL FROM NEUTRAL AT THE 6 4 HOLE LOCATION WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT SPRING AND PIN MAY BE OMITTED THEN THE FORCE WILL BECOME 13 31 THE DETENT FEATURE IS PROVIDED IN THE FULL FORWARD FULL REVERSE AND NEUTRAL LEVER POSITIONS 4 AS RECEIVED PER SS574 LUBRICATED PER 5574 AFTER TORQUING MOUNTING 4 TORQUE MOUNTING BOLTS TO 41 49 om 34 39 BOLTS INSTALL M2067Q PLUGS IN MOUNTING BOLT 3 SECTILIN ib B SECTION ESE GASKET ORIFICE PLATE GENERAL NOTES JY REMOVE BEFORE OPERATING UNIT THIRD ANGLE A ATMOSPHERIC PRESSURE PRBJECTIDN ATMOSPHERIC PRESSURE SMEAR TA ILP INTERMEDIATE PRESSURE C P CLUTCH PRESSURE XA7371 SERIES WEIGHT UNLESS
20. DISENGAGED FOR POSITION ENGAGED amp DISENGAGED USE CONTROL LEVER 40 2nd CLUTCH ENGAGED FOR 3 POSITION 4 RE USE 1038 2013410 M1990E 3574 M2087K 2086 778 B186 7 3 POSITION 25 2297 T 2 Si HR 22223 2 POSITION 2916 4347 M1927B B1334A SEE CHART SECTION C C 1001138 VALVE BODY AS USED FOR FACE PORTED VALVE INLET HERE SECTION VALVE BODY AS USED FOR HOSE INLET THRU PORT X CONSISTS OF VALVE BODY AND 1945 CORE PLUG 1001138 EE x 2040878 1 PM2306D 1 MA960A 4 MAI038B 1 2 S 51 82 y cc SG 7 9 MIN HOLE MUST LUCATED IN THIS AREA IN MATING PART CLUTCH DRAIN 72 3 96 206 DRILL V e il 9 GASKET SURFACE 85 7 2 46 21 8 end CLUTCH SI VALVE VALVE 238 9 ASSEMBLY _ BODY NUMBER ISEE SECT C C xX M27 X 2 THREAD OIL INLET WHEN Lp B PROTECTOR IS SPECIFIED 553 8 m 1 12 1 5 THREAD PRESSURE GAUGE LINE LOCATION meos __ M2067X 4 ES SE SSO ANOS at N 813990 1 2 w lt lt AN NGA 20
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22. 8 7 8 9 TAP 150 DEEP EQ SPACED 1 loi 4 5 d 1 7 00 no amp SPLIT 3 N 5 49 R HDN 45 49 Rc 100 LENGTH 50 Re THIS HIN 45 1 1 2 1 8 THREAD a lt a 5 23 DWG 200 AUTOCAD FILE T Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 21 SM _ 950 aiva aanva FEET Y 6 9968 3 0 8 6 9 1 5 zin SZOQZ L amis 7183 2005 Wika s Bi Zimoo s NGLLSISOS3T Twn 500 5310 0 X 05 71 2 figs 335 51 SO ONV 0135082 0 2 X 201 qos Z BION Ovds3N3 CUZ sw i HL 8 gt 5 5017 EG 5 6 8 1 622 X _ 80 20 QuvHaEd 6 8 6 8 2 ASSY 2 5 N S X 50 ELS SECTION 11 Details for Puller T 20023 Sh 3 of 4 11 22 u Ir c 0 02 060 i E _ E 31439
23. ON lt N ME INC OR POR ATE D RACINE WI 53403 USA 1016103 180083 3 of 5 AD FLYWHEEL DUTLINE MUST CONFORM SAE 620 No 3551141 J THRU HOLES EQUALLY SPACED USE 88 PRUPERTY CLASS THRU HOLES EQUALLY SPACED USE 8 8 PRUPERTY CLASS H QUALITY PER 150898 1 H QUALITY PER 150898 1 GRADE 5 QUALITY CLASS GRADE 5 QUALITY CLASS THRU PER SAE J429 CAPSCREWS 5 PER SAE J429 CAPSCREWS HOLES EQUALLY SPACED AND TORQUE 5574 DR AND TORQUE 5574 DR USE 8 8 PROPERTY CLASS SERVICE MANUAL VALUES SAE 1 HOUSING FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 35514 SERVICE MANUAL VALUES SAE 1 HOUSING FLYWHEEL OUTLINE MUST CONFORM QUALITY PER 150898 1 GRADE 5 QUALITY CLASS PER SAE J429 CAPSCREWS AND TORQUE TO S5574 OR SERVICE MANUAL VALUES SAE J620 No 355 14 35 0 S A E 1 HOUSING N SNN 55525255529 xx KKK 28 1016217 1 1017871 1 A 1016217 1 1017871 1019695 1 2 55 25 59 lt x SSS 555 25629 525529 5900 Oe 55 55529 5 555 COUPLING SRN C SS S S NN X 00 x x 9 22 x 0 lt 5 00009200 22040062000 2 4 050506595252 2222222222 2 55 SS 555 5 5 5 5 COUPLING C xx lt gt 810480
24. REPLACES IT P T H 2 S amp COOLING CLUTCH 5 REMOVE 10380 MI8 X 15 SECONDARY CC NN u er f PLUG FROM MANIFOLD PER FRONT amp REAR BEARING PINION cc s MARINE TRANSMISSION SHOWN x x INSTALLATION DRAWING INSTALL LUBE LINE ECC CK 5 CONNECTION LINES DIRECT LUBE FLOW INTO REFER TH TRANSMISSION HYDRAULIC e gt INSTALLATION CIRCUIT 2015 DRAWING gc s s CSHOWND FILTER PORTION ENCLOSED WITHIN KPa SR 7 CHECK THESE LINES IS REQ D FOR OPTIONAL HYD ONLY r s VALVE 15 8 DIA MIN FILTER BIN MT LI HOSE N lt HH MN 138 KPa E e 25 MICRON ws FILTER NN OPTIONAL N 6 ET nce ELECTRIC MOTOR SS NN ______ __________ _ _ lige DRIVE PUMP SY ee a a Su CLUTCH pra KA CUSTOMER SUPPLIED HEAT EXCHANGER INSTALLATION OPTIONAL 19 0 DI MIN COOLING
25. i x usu REF 7600 ENS s n u SN ajaj S SS 4 27 Z1Z Z Z ZJZ Z Z Z Z Z Z Z Z IN aS S 2 OPTIONAL AUXILIARY LUBE SYSTEM USER Ww innn PORTION ENCLOSED WITHIN T SUPPLY COMPONENTS AND INSTALL EN 5 X 250 e OPTIONAL HYD P T O ONLY LUBE HOSES TO MEET REQUIREMENTS OF N XA7540C OPTIONAL TROLLING SAE J517 FOR 10081 HOSE SELF NN NN NS feu MARINE TRANSMISSION VALVE B EXTINGUISHING AND FIRE RESISTANT I C S CONTROL VALVE REF XA7600B p pec ssec os deg apes REQUIREMENTS ALSO IDENTIFICATION Crore SY REQUIRED BY THE U S COAST GUARD VANS y lt E 2 KI AS SPECIFIED IN CUDE DF FEDERAL qute n dz Y I E 222 AM IS NOT REQ D W O gt Y THIS LINE SS P T D LUBE P TD CA REPLACES TT RN A AS SUO ESI eee iret Le CLUTCH MA1038D MI8 x 15 SECDNDARY SHAFT PLUG FROM MANIFOLD PER FRONT amp REAR BEARING PINION pae oe mc rae MARINE TRANSMISSION 3 SHOWN DISENGAGED poire x x a x INSTA
26. iv 1095 02 0 maJOS as ye 1 8 Ajepuooes JUIOd 8 5 deus Z Buueeq L S Buueeq yeys 9 Buue q yeys 9 020 200 800 Buneaq wys jexsec L L HE 195 05 ye yeys 5 uolsid r 6c yeys pjojiueuu Buiusng L 482 sButusnq peeu MaS v G 9915 L L Sslsisuo5 L 92 pjopuew edid r Gz wys JeurejeH L 10 sisisuoo Buueeq seas yeys 9 ullus Ajquiesse vc uonduoseq uonduoseg SECTION 13 Illustrations 13 2 Illustrations Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 13 3 SECTION 13
27. CIRCULAR RUNOUT CAZ DATUM FEATURE 3 010 ON FRACTIONAL AND TWO PLACE ZY TOTAL RUNOUT 1 4 ON ANGULAR DIMENSION POSITION 9 DIAMETER 47 7 7 7 7 VYYYYYYYY YY uOEKXXXXXXXXXXXXXXXXXXXXXXYX EXXXXXXXXXXXXXXXA XXXXXXXXXXXXXXY AUTOCAD FILE 19987 DXX YYYYYYYYYYYY E 4 gt HOLD DRILLED C BORED AND OR TAPPED HOLES 005 7 4 stk sHcs 5 8 11 X 1 25 SHCS 5 8 11 X 1 5 LG 4 2 GRIPPER 1 RH amp 1 L H 1 5 X 1 8 X 4 13 2 1 ms HANGER CROSS PLATE 5 8 X 7 X 11 8 1H t us HANGER ARM 1 5 SQ X 41 5 TUBING 16 us BOTTOM GUSSET TOP X 4 X 7 1F 1 us VERTICAL 1 5 SQ X 13 5 TUBING LiE 1 us GUSSET TOP AR 3 8 X 2 X 7 1 1 EYE BOLT ARM 1 5 SQ X 24 5 TUBING 1 stk SHOULDER FORGED EYE BOLT 3 4 10 1 ms EYE PAD 5 8X53 4 us CLAMP PLATE 5 8 X 5 0 X 15 40 1 WELDMENT DETS 1 1 amp 1J DESCRIPTIDN STOCK SIZE Date 10 2 84 SPATH Scole HALF NAME OUT PUT GEAR LIFTING FIXTURE FOR ASSEMBLY DEPT 344 FOR XA7470 A7496A A7491A D REDRAWN TO AuTOCAD14 12 3 99 TMV A7486A 1002580 A7501A 12193987 Torque Charts Section 12 Torque Charts 12 1 Metric Coarse Thread Capscrews Bolts and Nuts Refer to t
28. DIL TEMPERATURE INDICATING SWITCH B3424 FOR INSTALLATION RACINE WI 53403 USA GEDMETRIC TULERANCING LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 2 SERVICEABLE SEPARATELY e9eee s e9 99 1 V 85 28657 7 21 98 THIS NOTICE IS NOT INTENDED TO NULLIFY DR LIMIT RIGHTS SURFACE TREATMENT NAME DAS 1 6 2 gt REMOVE BEFORE OPERATING 2 PLACES THREAD PROTECTORS 28958 1 21 99 1 u 1 28544 5 4 98_ GRANTED TD THE US GOVERNMENT 2 MARINE zoe ce wo UR OTHERS BY CONTRACT MG S204SC TRANSMISSION E D A VALVE WIRING DIAGRAM 6 42 CONNECTOR 631 0 PRIMARY CLUTCH SOLENOID SECONDARY CLUTCH SOLENOID 2478 NEUTRAL SDLENDID MANUAL OVERRIDE 27 POSITION OPTIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH 543 9 EE ELECTRIC CONTROL 16 1 5 POSITION x CONFORMS ISO 6149 REFER CHART FOR REQUIRED PICK UP DEPTH 3432 Es 247 9 EYEBOLT t MANUAL OVERRIDE NEUTRAL START DRAIN amp OIL IN FROM HEAT EXCHANGER SWITCH CLOSED ONLY WHEN MANUAL DVERRIDE IS IN USE amp 247 9 1778 TRANSMISSION IS IN NEUTRAL EYEBOLT 4 PRIMARY CLUTCH ACTUATING PRESSURE M10 x 10 THREAD METRIC PORT CONFORMS ISO 6149 X MAIN PRESSURE PICKUP EN X
29. N TEMPERATURE PICK UP PORT MIO X LO THREAD METRIC CONFORMS TO ISU 6149 378 16 Gino 75 DEEP SUCTION SCREEN TRANSFER GEAR DIM X FROM PORT 4 03 1 824775247 OPTIONAL TEMPERATURE INDICATING SWITCH CUS TEMER INS TALL IN A PIPE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSION PUMP HEAT EXCHANGER INDE T REFER TO HYDRAULIC DIAGRAM NOTE ALL POINTS AVAILABLE FOR TESTING ARE CODED C x i 7T DRIVING THRU A SECONDARY CLUTCH ___ 24 5 9 THRU 12 HOLES EQUALLY SPACED Z illl Lil k VA EN iN 4 Z EN OIL DRAIN PLUG M33 X THREAD 406 4 elo CODO 346 71 2 PRDJECTIDN SIMILAR TD SPS 406 4 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS X 0 75 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF MATERIAL WEIGHT WR kg N HEAT TREAT FIRST USE DATE 12 1 93 3 SCALE X X 0 25 S 1mm X XX 0 13 DRN ALL ANGULAR TOLERANCES ANG KS TM GEOMETRIC TOLERANCING PER ANSI Y14 SM 1982 CHK JS DAS CDU MARINE TRANSMISSION TWIN DISC INCDRPDRATED RACINE WI 53403 USA ASSY MODEL SURFACE TREATMENT NAME THIS
30. g 11 25 Output Gear amp Shaft Puller for Assembly T 20023 2 Sh 2 of 2 11 25 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC Sleeve for Check 21302 1 20512 SI 3NIOVS INI OSIC NUIIdIS2S30 am 2n2 ar es ez v 2 130 2026 94 ERES MOSHO 110 204 3A33 dyl 91 8 5 3 91995 ar 8 96 91 N 0119189 34 16 obe now En L Y B aoa 5 1 2 Vid 9 Vite 14 115 205 91 T ES 5 0 1 L I MIT 1 1 i 91 us 1 9 cs V e D 8 VIC v NEX 62169 91 5 MMAM 20 i i 1 90 5 VIT D i 8 5 170 S lt OTC 710 cee Gr io LOAN 8 INN 26 07 dyl b Sa OL Ps heo 4 TN 002 o 5 my 1034 D SECTION 11 Special Tools 11 11 26 114 1
31. xu e Dalle iens T 18050 120 Bearing Seat Driver T 18050 152 Bearing Driver T 18050 606 Bearing Driver yu sat wisa ee eee T 18050 607 Driver o usunta awaqa aaa usha T 18050 609 Bearing Driver T 18050 610 612 Seal Driver Sh 1 of 2 T 18050 696 Seal Protector Sh 2 of 2 T 18050 696 Seal Sleeve e E a exa Pee T 21347 Seal Driver elei ve RAI E a T 21347 1 Seal Driver 18050 722 Output Shaft Seal Driver T 18050 716 Output Shaft and Gear Assembly Fixture Sh 1012 T 18196 6 Output Shaft and Gear Assembly Fixture Sh 2012 T 18196 6 Spring Retainer Hold Down T 19998 Output Gear and Shaft Puller Sh 1 of 4 T 20023 Output Gear and Shaft Puller Sh 2 of 4 T 20023 Output Gear and Shaft Puller Sh 3 of 4 T 20023 Output Gear and Shaft Puller Sh 4 of 4 T 20023 Output Gear to Shaft Puller Sh 1 of 2 T 20023 2 Output Gear to Shaft Puller Sh 2 of 2 T 20023 2 Sleeve for Runout Check T 21302 1 Output Flange Press
32. 1 ak om A proe lt lt lt Z AAA A ee NI 7 ZZ e ZZZA SEE 6 L Ak 2 aT 7 24 1014884 o lt MA1039E 19 A RS lt 1 2 lt 22 o SESS 1 E D A S LAG TEIZ i LL x Z RS a SSR 1 1945 1016251 1 SESS WE A 422 ____ ASSEMBLY 1016250 1016256 SHEET CROSS SECTIDNS 1 OF 5 AND PART NUMBERS ASSEMBLY 1016250 EE MA10644 N VA x HELI CDIL LIE Ge ug y uy S Bu t A A NEN Bi AS x lt e UF DRAWING ASSEMBLY 1016250A UTE INSTALLATIUN DRAWING SHEET FLEXIBLE 4 5 COUPLING INPUTS SHEET _ S EET MASS ELASTIC MAX INPUT SPEED 2300 CHNSULT SALES DEPT APPLICATIDN B3649K ENGINEERS F R LIMITING CONDITIONS oe HYDRAULIC DIAGRAM THIRD ANGLE PROJECTION 2 28985 12 14 98 NOTICE THIS PRINT CONTAINS GEAR RATIOS WEIGHT wR SPEC IEIED TYIN DISE PROPRIETARY INFORMATION AND IS 17 1 mm 8 1 95 gt 1 2 Y ceci 28834 10 6 98 NOT TO BE USED IN A
33. SECTION 11 Special Tools 114 Special Tools Seal Driver T 18050 120 11 5 0 1 05081 1 JHS A8 114142530 39NVH2 0 060811 AJALA 1995 AWYN 114142530 2 Kg LVW 038 AJAA 1 66 82 01 19300 INVE SW 1 c I cH 3 dV Mn CNV dad Bos 1n9830Nn vVVN 2003 000992 N 34 092 32914 DA NV 719 0 19 9 NDISN3N1 2 IR OW 7c SS3INn 3ONV3 l 081 ON 7001 divs V3S 203 lt SN 0 aL RRR IKKS 4 2505 25 25555 5 5 os LS 255252525250525055050505060 5 50 lt lt lt lt gt 555262 lt lt 5 11 5 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 11 6 Bearing Seat Driver 18050 152 STAMP 18050 152 229945 2 50 KNURL 6 76 6 74 JA FOR BEARING 271 CONE ONLY MATERIAL M S BEARING SEAT DRIVER 10 05 99 TWIN DISC INCORPRATED KJB 18050 152 11 6 SECTION 11 Special Tools Special Tools Bearing Driver T 18050 606 11 7 AA
34. 266 7 ASSEMBLY 1016c2504 METRIC THIRD ANGLE PROJECTION SIMILAR TO UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS 0 75 MATERIAL WEIGHT Nem HEAT TREAT FIRST USE AUN X XX ASSY ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING MODEL PER ANSI Y14 5M 1982 SURFACE TREATMENT NAME MARINE MG 3204SC TRANSMISSION SECONDARY CLUTCH SOLENOID ELECTRIC CONTROL MODE SWITCH CCLUSED WHEN MANUAL VALVE 194 2 FLYWHEEL HUTLINE MUST CONFORM TO SAE J620 355114 CREE gt H C CREF gt H C 5 FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 No 4601181 lat l ee TENS SAE J620 FLYWHEEL SIZE NO NO 355 VKE 4911 14 4000 14 COUPLING COUPLING MAX COUPLING rpm x x x x x NOMINAL TORQUE TORQUE kN m lf in 0 50 19 4 44001 172000 1 25 11100 IN T NS J DRILL THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY PER 150898 1 LGRADE 5 QUALITY CLASS PER SAE J429 CAPSCREWS AND TORQUE TO 574 OR SERVICE MANUAL VALUES SAE 1 HOUSING _ lt N was NJ XX RECS AA KS SAE 0 HOUSING 595 2 2343 TO HUTPUT FLANGE COUPLING WR Kg m2 Ib in2 DYNAMIC TORSIONAL STIFFNESS STIFFNESS kN m rad Llof in
35. 55388 1 SJAISG A 3 9590 0 944 1 9 566 1 1 gp SECTION 11 Special Tools 11 16 Special Tools 11 17 Output Shaft amp Gear Assembly Fixture T 18196 6 Sh 1 of 2 1 lo x la L fuf o E 2119 48 o 2 ah 9 Ely L 5 B a 2 E u 5 013 BEES zu Z E mE LL l 11 2 152 8 14 gt 00 SEE MERKE E 8 DIA 4 6 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 17 11 11 18 Output Shaft and Gear Assembly Fixture 18196 6 Sh 2 of 2 11 18 8 DRILL amp CT BORE FOR 3 4 SACS x L RID oa s 18 P B sx lt 55 2 gt T lt I z e 5 2 a o V lt I UI us N oA N 9 7 o N N gt N E D lt 2 Xg gt N N 1 1 X Ub we N 2 lt N N lt N Su N N gt N 27 NUN NC Y v si N o N N Lo E
36. 7119 ayers Na 01 3400 dAVHS TIY 3715 4901 2S v02S5 9N ON 2 22002 91 Gee oos n ery erv x os A2 18Ddans vid 298 51709 119 vit 296 Ive 60661 LAN 39NV14 SN3533C 9 8 x vid OW 108 2 1708 LOTHS uns 335 TJ 6 2 5 ovty 9 335 5 A3ONS 492 Y xis e er Sv 2112 HS 338 B7 3 D31S 629 SNOL 19v 18704 WV3l JJM 1 1 20 Ja E 532 74 v C E A Uy 9 p 7 dra p SZ 11 24 Output Gear amp Shaft Puller for Assembly T 20023 2 Sh 1 of 2 SECTION 11 SECTION 11 Special Tools 11 24 Special Tools SI 3 NDOILdTS2S30 39NvH2 v2 2 3314 ent 330 1 SED SCR 4559318 YW x
37. VALVE 7540 E37 PLATE 44800 lt 8 EE HX NS NE HDUSING 1017824 2 lt X NN PLATE A4481A 7 4 gt S OQ j PLATE 20124 lt D lt SN jc 1 BACKPLATE 1017822 4 q 4 E a 2 dr EA 2 Ve Z AA dedu ok SSS UWA nmi 7 ys TED 22 SUS P 72 22221 ao HE 22 UY amp 77 AE ae 15 2 EX N 24 09254 d SS NSS PALM sess 22521 Lor lt 1742 No 187 4 42 E MANIFOLD FACE PISTON 1017825A BEARING 208 RING M1904C NUT 94 4 STUD MA1049B 4 ADAPTER 101 834 SCREW MAl beL RING M1904L PIN MA1039B 5 12 REMOVE 42 PLUGS FROM MANIFOLD TOWER APPLY Me828 SERIES SEALANT THE 4 INSTALLATION INSTRUCTIONS 0 0 PLUG M194SAE AND PRESS INTO MANIFOLD AS SHOWN SA PRES gt TRE Geo Ere FINS IN TAE SST PEE FINS PRUTROUDE S0 FROM END OF SARAFI gt 5 SO THAT FASTEN WITH 55 4 SERVICE MANUAL VALUES qur VOS nl e BEARING M2898 of TSN RING 1017826 RING B1048E
38. sTa sezez e acss L L is EP 299 DETRIMENTAL THE merus i NOT INTERNALLY SUPPLIED E _on_ 2 ALL ANGULAR TOLERANCES 1 i THREAD SIZE AT PORT KNEES 29515 8 20 99 PACINE wd aeque n s PER ANSI YIASM 1985 B 10 1 8 4 1 4 18 WHEN 2052 22 29272 5 13 94 NOTICE IS INTENDED ea NAME Ex NC MA N 4 esese 4 319 99 TD THE US GOVERNME _ BOTTON VEW 4 29232 4 15 99 GRANTED TU THE U S GOVERNMENT VALVE ASS Y CIUNTRLU L REV 2 CH DATE REV zone CH NO WITHOUT TROLLING VAL VE DAS SHEET 1 nr 1 REv S xX STR TH D RING 1506149 MAIN PRESSURE DIL INLET WHEN MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL 78 8 BOTH SIDES 309 9 PLUG M2051K 2 MAX TROLLING PRESSURE RATE OF RISE FUNCTIONS DETENT SETSCREW MA1037D SCREW IN UNTIL BOTTOMS THEN LOOSEN 1 2 TURN INSTALL USING MA908 LOCTITE 242 CAPSCREW M2000H OO VALVE BOM DITCH See ASS Y No caches TRANSMISSION SOLENOID VANE oe TF ORIFICE SHIMS MOUNTING SCREWS 1018440 1017153 1017134 B1337F
39. 242 224 TER TENTER NER Q X TH D DRYSEAL DIL INLET THREAD SIZE AT PORT 1 4 18 WHEN 2052 REDUCER BUSHING IS SPECIFIED iA BOLT SYMBOL FOR XA7371J amp XA7371W ONLY USE AS REQUIRED 2 18 TEPE M2051CD 87078D 2704BU Ae708 BC gE xa7371U 7361 31387 970 958 44 0 LXa7371V 7 559 B397D 058 v A2707BD A2704BU 42702 JTER CENTER INNER A2707BD 2704 2708 BC 1 39 TEST VALVES TES DES 2 00 INSTALLATION DATA 1 VALVE SUITABLE FUR UP TO 25 1 4 18 N P T F eocess L Bb NZ xd 7 st Ole V era TL NI 75 HOLE MUST BE LOCATED IN THIS AREA IN MATING PART TORQUE CONVERTER DR BEARING LUBE NOT TO EXCEED 80 e a ur c section GASKET V V zt E 12 MIN DIA HOLE MUST LUCATED IN THIS AREA IN MATING PART FUR VALVE DRAIN 13732 DRILL THRU 4 HOLES FOR MOUNTING BOLTS WITHIN 008R OF TRUE POSITION ATMOSPHERIC PRESSURE MMC IN RELATION DATUM Ae ATMOSPHERIC PRESSURE LP INTERMEDIATE PRESSURE SIMILAR TD OIL INLET A7361B VALVE BODY ONLY CLUTCH PRESSURE XA7360 SEE SECTION Ca MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED MACHINED DIM
40. 5 435 FLAT PRINGLE 30 _ AUXILIARY PUMP DRIVE AND AUXILIARY PUMP INSTALLATION INSTRUCTIONS CIR NUMBER 17 12 24 12 REMOVE PLUG FROM DRAIN HOLE IN MANIFOLD pia 14167 FORM 1504 2 PRESS THE 22 DOWEL PINS IN THE SHAFT UNTILL THE PINS PROTRUDE 9 0 FROM END OF SHAFT MAJUR DIAMETER MAX 1535 32 ASSEMBLE THE PISTON RING INTO THE GROOVE THE DRIVE ADAPTER AND AND INSTALL THE ADAPTER OVER THE DOWEL PINS IN THE SHAFT 327 FASTEN THE ADAPTER THE SHAFT WITH 22 CAPSCREWS AND 34516 MEASUREMENT BETWEEN MIN ACT REF 4144 DIA PINS WITH mE NONE 9D ETIN ACT 1 2078 gt CIRCULAR SPACE WIDTH 4 2 ASSEMBLE THE NEW D RING AND THE AUXILIARY PUMP CARRIER ONTO THE MANIFOLD SO THAT THE SLOT IN THE CARRIER BORE ALIGNS WITH THE DRAIN HOLE IN THE MANIFOLD 6 MAKE SURE THAT THE PLUG IS NOT INSTALLED IN DRAIN HOLE STEP 12 FASTEN WITH 4 CAPSCREWS AND TORQUE PER 574 OR SERVICE MANUAL VALUES 5 ASSEMBLE THE SNAP RING INTO ADAPTER AND INSTALL THE ADAPTER DNTD THE DRIVE ADAPTI 62 INSTALL APPROPRIATE GASKET AND PUMP ONTO AUXILIARY PUMP CARRIER AND INTO SPLINED ADAPTER TORQUE FASTENERS PER 5574 SERVICE MANUAL TORQUE PER 5574 SERVICE MANUAL VALUES INTERNAL SPLINE DATA SEE S FLAT 30 NUMBER OF 14
41. FLEXIBLE COUPLING INPUTS SEE SHEET 3 i NUT SERVICEABLE SEPARATEL Y 1 6 27790 26826 2 15 96 THIS NDTICE IS INTENDED CER 1986 8 4 4 K BUM 1096 METRIC NPTF ADAPTER KIT T 127750 4 30 97 REMOVE BEFORE OPERATING 2 PLACES THREAD PROTECTORS SHT ND REV CH ND D SURFACE TREATMENT NAME 15 6 26820 2 14 96 TD THE US GOVERMENT MARINE OR OTHERS CONTRACT 05202 lt 5 TRANSMISSION COPTIONAL TROLLING VALVE INSTALLATION AND OPERATING NOTES 1 REFER VALVE ASSEMBLY DRAWING ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION DURING MANEUVERING DUCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TD THE PROPELLER 02 MAXIMUM ENGINE SPEED WHILE TROLLING 1100 RPM DR 602 OF FULL LDAD ENGINE SPEED WHICHEVER IS SMALLER 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUUCTION BY MOVING TROLLING CONTROL LEVER OUT OF LOCKED DETENTED POSITION TO MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION OF TRAVEL BY MOVING CONTROL VALVE LEVER TO THE PRIMARY CLUTCH OR SECONDARY CLUTCH POSITION MOVE TROLLING CONTROL LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED CLOSE TO DETENTED NE TRELL POSITION THE TROLLING CLUTCH MAY ENGAGE FUL
42. 1015108 a b G a 1 5574 FASTENER REQUIREMENTS THIS SPACER USED 2 E LA 1001138 692 BEARING SHIMMING WITH 1014905 P N 5 5765 TAPERED JOINT ASSEMBLY ONLY 4 M 2 4 MA1052B_ 2 5774 SEALANT APPLICATIUN Z M2795 1052 USED with 2 2040878 DOO PLASTIC CLOSURE 1016333 ONLY NNN A2702 BP ya yea 813971 T 2039 1 O 1 2999222 2 22 2 1399 EN NON 7 82334 gt N B1334A ve Cm E J 9 M1990E 813330 SAAS SERRA Ws S EAN AY MA960A 60 2 E Z SS NY B1867 AHHH EHH At K PETAD ISS t Z M1927B MINA 9 TAO AN 3574 212 DOE Y 07224 Tlx Soo WT NE SS 1014883 P m ol INSS SN Fes 1014884 20 NOTE 6 559 SIE MOUNT LUBE INSTRUCTION PLATE REPLACED BY OBSOLETE SX SRY 1014885 1 4 aN N OJ OJ CI J Ilala lololol 1014905 gt lt gt gt lt gt m lt 1016533 m E 3 481 RATIO 8 S qww w NN NN NNNN NS LLL ZR 3 M
43. 15 2 120 165 295 434 320 468 345 691 510 746 550 1051 775 1132 835 190 140 a 244 180 264 195 400 d I 390 637 470 969 715 Do not use moly disulfide white lead copper filled or other such filled lubricants with these torque values Such lubricants require special torque values Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 12 5 SECTION 12 12 3 Tapered Pipe Plugs Torque Valuesfor Lubricated Pipe Plugs Recommended Torque N m NPTF Size Installed in Cast Iron or Steel Installed in Aluminum 1 16 27 11 5 1 3 8 5 1 0 7 5 0 9 5 5 0 7 1 8 27 14 2 1 8 10 5 1 3 8 8 1 1 6 5 0 8 1 11 1 2 109 13 80 10 68 8 50 6 1 1 4 11 1 2 115 13 85 10 75 9 55 7 1 1 2 11 1 2 115 13 85 10 75 9 55 7 Notes The lubricant is to be John Crane insoluble plastic lead seal No 2 or equivalent or Loctite No 92 or equivalent and plugs are to be capable of removal without damage Overtightening may cause initial leakage plus potential removal damage An option of a maximum of two full turns after finger tightening the plug may be used if required and if removal conditions are met 12 6 SECTION 12 Torque Charts Torque Charts 12 4 Tube Fittings Hose Fittings Plugs with O Rings 37 45
44. a ho STOCK BORE SIZE S LC Z a CUSTOMER TO FINISH BORE e E s NE GREASE EUM sce 3 FITTING 0 525 6 20 69 Bob SECONDARY iN 2 LUBE P S I PORT x P BED Ga LUBE d IN SUPPLY INLET m Q DRIVING THRU 2 PRIMARY CLUTCH b I PLL T EE CO 2 0 2 ecd 9 5 Y oo d OM SG o OQ Bb Ti t I 1 24 5 96 THRU to DRIVING THRU 8 HOLES EQUALLY SPACED 3 SECONDARY CLUTCH E TENES FLYWHEEL OUTLINE MUST CONFORM TO a S A E 620 S A E 0 E sm 460 18 HOUSING Seca OUTPUT 138 7 5 46 4 CLUTCH ACTUATING 101 6 4 00 101 6 4 00 amp 101 6 4 00 6 096 aie 6 350 Ep m E 52101 150 6149 250 5 FE 22 4 V 3 8 16UNC THREAD UMP 6 4 88 7 6 1301 DEEP THRU SUCTIUN SCREEN USE 8 8 PROPERTY CLASS 16 HOLES 8 EACH SIDE CLEARANCE TO REMOVE 3 95 QUALITY PER 150 898 1 USE ALL 16 HOLES FOR MOUNTING UNIT CLEARANCE 190 50 7 50 MEM 0 USE 88 PROPERTY CLASS QUALITY CAPSCREWS TO REMOVE TEMPERATURE ASSEMBLY 1016103 WR PRAGUE ant O Ne PER ISO 898 1 AND TORQUE TO SAN 196 1 7 78 S QUY Ob 574 SERVICE MANUAL VALUES 136 4 5 37 Q9 203 2 8 00 ME 190 50 EZ SD 2 211 01 8 343 203 2 8 001
45. 4 7540 z ema SS lt CONTROL VALVE ASSEMBLY uo O O0 Ql Qu No n lt 112 21 2 M2943 lt lt u gt Z lt gt gt 5 gt ura Wu MA1038B M2067X Xt Y 8040878 N N CRASS 2 996 oe __ ___ _ __ N SSS S SSS M990 t THES 2 23062 1 S PANY a 88746 1014983 5 SSS S 1014884 98 e sae SSS 77 1014865 amp oi 1016330 2 NI gt lt 2 921 RATIO 24 T E SS NE s ez SS SN S SERES Re eu 4 eee o lt E emi m r 111222224 SS C SESS ess Eo mI 1 AN S M Bii NNN 1761 RATIO 33 T 8 1 2 EUIS SA MANN E NSS w ERIS 1001349 2 _ SET SPRING LENGTH N REO sss st r sss PY TH 302 mm ratio 42 7 FILTER BY PASS NE HOUSING 1018462 1 Pr 1 MA1038C 1 W MA961 16 NaS ER Xr a S 2702 1
46. EXC 6 925 59 PRIMARY amp SECONDARY PRESSURE HOLES 947 82 PRIMARY amp SECONDARY LUBE P ST 650 250 INE TE RE 090 99 OL OD NOTICE THIS PRINT CONTAINS MATERIAL PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERMENT OR OTHERS BY CONTRACT HEAT TREAT TWIN DISC SURFACE TREATMENT NAME 254 0 Nt STUEK BERE SIZE CUSTOMER TO FINISH BURE CSE INGLES 1052 FIRST USE ASSY MODEL SOOO 40 342 835 FLANGE MAX BORES 96 6 t WITH 22 2 SQUARE KEY 117 5 t WITH 25 4 SQUARE KEY 139 WITH 31 8 SQUARE KEY Sl 222 2 KET 169 WIG SS X Zo4 RECT RET TAPER cad file 11520743 THIRD ANGLE PROJECTION a UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS X 0 75 X X 0 25 0 13 ALL ANGULAR TOLERANCES ANG GEDMETRIC TDLERANCING PER ANSI 14 5 1982 Sele MARINE TRANSMISSION 12 e 97 290156 SCALE INC RP D D 50 1 00 WI 53403 USA DRN 10152074 CHK DAS CONNECT OIL PRESSURE GAGE LINE M12 X 15 INTERNAL JE METRIC PORT CONFORMS TO ISO 6149 AT VALVE MOUNT GAGE
47. I N R P D R T LP INTERMEDIATE DETRIMENTAL TH THE INTERESTS OF Xx 75 100 PRESS LUBED 0 D FIRST USE Y xx j mn RACINE WI 53403 USA ASSY ALL ANGULAR TOLERANCES 1 M MAIN PRESS NOMEN C EMEN GEOMETRIC TOLERANCING BJE MODEL PER ANSI Y14 5M 1982 _ b THWS notice 15 INTENDED TH NULLIFY LIMIT RIGHTS SURFACE TREATMENT NAME GRANTED TU THE US GOVERNMENT DIAGRAM HYDRAULI m prev ZUNE CH DATE REV zone CH DATE DR DTHERS BY CDNTRACT DAS SHEET 1 2 A B Er E T 26 Eh WA E Section 5 NEUTRAL START Section B B SWITCH Sump 4 CLUTCH ENGAGED H sss 00 3 Z d Kor C MANUAL CONTROL VALVE FOR HYDRAULIC PTOS z CE a VALVE Y PROJECTION SIMILAR TO 1002456 dC Per cms ues quent scr LP INTERMEDIATE USED IN ANY MANNER Ke DUX p s 0 acne w sama tsa MODEL PER ANSI Y14 5M 1982 S SUNP 1774 Mm x TN 241 TO NULLIFY OR LIMIT RIGHTS 5 a mw co no nate zog ca wo 08 OTHERS BY CONTRACT P pas 2 2 B TWIN DISC INCORPORATED u
48. INPUT SPEED 2500 B P M N 1552 E GEAR 1015240 CONSULT SALES DEPT APPLICATION B3649K 4 THIS UNIT CAN EE USED WEB CER E EE BA 131 ENGINEERS FOR OTHER HAND ENGINE I LIMITING CONDITIONS 7119R HYDRAULIC cO OPTIONAL EQUIPMENT GEAR 1015241 DIAGKA COMPANI FLANGE ASSEMBLY 1002312 E 12S CONTROL TROLLING VALVE XA7600 wane IVE P T O 1017177 AUXILIARY PUMP DRIVE GEAR 1015242 HYDRAULIC CLUTCHED P T O 1017820 504 1 RAI 126 aN THIRD ANGLE TRAILING PUMP 1016473 GEAR RATIOS LLL PROJECTION FLEXIBLE CDUPLING INPUTS SEE SHEET 5 5 GEAR 1015243 0a SIMILAR TD KIT B 1090 METRIC TO NPTF ADAPTER KIT Zee SEAT 124 ps 7 IL TEMPERATURE INDICATING SWITCH 83424 FOR INSTALLATION i Eno CATION SEE HYDRAULIC DIAGRAM AND SHEET 3 e GEAR 1015244 5 04 S SE eu RA 12 HIS PRIN CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE N BALANCING REQUIRED FOR SURVEY SOCIETY APPLICATIONS NUI TO BE USED IN ANY MANNER 1032 7 W D SS SEE PARTS DRAWINGS DETRIMENTAL TO THE INTERESTS OF 3 pd 50 21 00 a Aa d RE UE 1 7 G 1 22644 10 12 99 2 2 ALL ANGULAR TOLERANCES 2 REMOVE BEFORE OPERATING 2 PLACES PLUGS P 29289 4 20 99 IS NOTICE IS NOT INTENDED k p IEEE M AN GRE DU GRA TED E Tee TEE SHTND REV ZONE CH ND DATE
49. g 8 PAE gt WAODAINN 8 9 19N31 SIHL 05 Gp 25 d n K ott HY X 8 k 24 101 ld d X Hl191 8 8 X 1 295 Z 2 5214 68 08 dALZSTy SECTION 11 Special Tools 11 22 Special Tools 11 23 Spacer for SKF Hydraulic Assembly T 20023 Sh 4 of 4 Im e MN aja gt in 4 QJ O M lt i 1 lt al a s N lt 5 m c 2 Ww Bo LL 5 41 g d 25 1 d c 1 lt 5 5 a os ry 2 amp gt o n m P 12 E 5 4 z ou Sis gt gt _ a 2 ir Tu alolmiait 5 QA e 5 Ll L e m Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 23 SI ONI NIAL 11150534 3DNVH2 NDISN3WIQ ND d Jogan i 22002 1 2709101 2 220 37113 advo NIISN3WIQ vHI23 2 3 I 133HS JS v0gS ONe w Stee 3388 ND o 13985 OL NV39 SN 345 3SIAH3HlD SS37Nn 3ONVE37D
50. x IXI S2 90 SUS Se S ZZ 02 e Go SECTION 11 Special Tools 11 14 Special Tools Seal Driver T 18050 722 11 15 3190 1 4145530 39NVHJ 114 06081 1 SYM SIM 3NIOV3 INI 2511 22 05081 1 1 I JHS 5 lt 43 011 418435 30 29 VAS MD 404 5 IV v3s8 2345 SSIMSSHLO SSd Nn 088 E 08 56 x ED a 7 00 b 1 v 30H IN NAHL 62 11 15 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 Output Shaft Driver 18050 716 11 16 I ET xm auva 1 4182530 JONVHO 912 060 3314 092 2SE026 3S202S OW ans SJAIBU 7935 SGHIO dU S GAB i v I311VNVd 38 LSAW S39V 3875 31UN SHE3NBUO 119 9358 131510345 FSIMSSHIO SS33ND 310 1935 SS 38d L 55 NALE JONY 1d N 2S v026 DN 25 5005 OW 25 5 838 Wf ASEWNN 1935 BGHADN B3INHVO _ 1001 dWVIS 5 SV 3DNV 13 XJA 193 HI aglaya OLNI 1935
51. 2 Assemble and install filter bypass valve Assemble parts in maifold oil inlet port in the following order Check ball B Spring C Plug 3 Install assembled manifold over alignment studs and dowels Use a soft ham mer near the dowels to seat manifold against gasket and over dowels Install manifold attaching screws and torque to specification see Torque Chart Models MG5203SC and MG5204SC Apply 908 to the threads of the two MA960C see transmission assembly drawing manifold attaching screws and torque to specification see Torque Chart Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 23 SECTION 9 9 10 Primary and Secondary Shaft Bearing Adjustment NOTE Procedure for setting and checking endplay for primary and secondary shafts is the same Procedure described and illustrated is for the secondary shaft Repeat same procedure for the primary shaft 1 With a felt tip pen make a mark across the rear end of the secondary shaft 2 Install a dial indicator on a machined surface on the manifold with the probe resting on the mark made on the secondary shaft 3 Install an eyebolt into the end of the shaft and exert 890 200 16 downward force while rotating the shaft several revolutions in each direction Stop so that the dial indicator probe is resting on the mark Zero the dial indicator Remove downward pressure and exert 1334 N to 1557 300 16 to 350 Ibs li
52. 31 CLIP CONNECTOR a 33 5 4 CAUTION 35 BAL 1 36 BALL 2 39 SETSCREW _________________ _ SOENOD 2 S3REQD FORUNTSWITHHYD LOCK M BAL 1 O RING 1 48 SCREEN 46 VAVEBODY 1 47 SOME MODELS 49 GASKET 1 80 VAVEBODY at 51 screw 1 HEXHED oo SCREW SOCKET HEAD 53 NUT _55 CONNECTOR SHROUD 1 UNITS WITHOUT HYD LOCK ________ 56 ORNG 1 UNITSWITHOUTHYD LOCK PLUG 1 UNITS WITHOUT HYD LOCK 59 SPOOL UNITS WITHOUT HYD LOCK a d LLI lt lt s lt lt N OO SENS DETENT HEX 13 09 TROLLING VALVE GROUP NAME NUT PRING PISTON 23 2 GASKET 4 ______ 3 PLATE ORIFICE 5 5 7 ADAPTER 000400000000 _8 SETSCREW 14 00 LLI SECTION SP TC ec 99 NNN NIN NJ N NA NANS N im 8 SECTION B B Engineering Drawings Section 14 Engineering Drawings MG5202SC MG5203SC MG5204SC and MG5202DC transmissions NOTE foldout drawings appear after this page in the order listed below 14 1 1014841 MG5202SC 14 2 1015389 MG5202SC 14 3 1016103 MG5202SC
53. Cracked bent or otherwise damaged flex plate or coupling plate Bolt holes in flex plate or coupling plate elongated oval shaped not round This could be caused by improperly assembled parts loose parts vibration or improperly torqued parts If defects are found replace defective parts Bolts nuts bent worn or stripped threads Replace defective fasteners 2 Inspect hub Look for A B C Damaged or worn splines Cracked parts Oil seal surface for wear or damage Replace defective parts D Heat Exchanger Check Heat exchangers furnished by Twin Disc to be used for salt water applications have zinc rods installed at the inlet and outlet heads These rods must be checked every 90 days If over 5096 of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded elec tric 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 SECTION 4 Specifications and Maintenance Specifications and Maintenance E Overhaul Interval A complete overhaul of the unit should be made at the same time that the engine is over hauled Periodic Visual Inspection 1 Checkthe mountings for tigh
54. DRAIN PLUG 525 6 20 69 Ses 22 41 595 27 esu NOTE WHEN MOUNTING ENGINE ZTRANSMISSION IN BOAT ALL THE MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW THE 1016249 CONFIGURATION IS NOT SUITABLE FOR REMOTE MOUNTING RECOMMENDED NOT RECOMMENDED CLEARANCE TO REMOVE S A E J620 S A E 0 NO 460 181 HOUSING 138 7 5 46 101 6 4 00 101 6 4 00 101 6 4 00 H M20 X 2 5 TH D 32 0 1 261 DEEP 16 HOLES 48 EACH SIDE DRILL THRU USE ALL 16 HOLES FOR MOUNTING UNIT HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS 15 0 0 59 V TROLLING RANGE MAX TROLLING PRESSURE THE TRDLLING LEVER NB DETENT ANGULAR LOCATION MAY BE RATE RISE ADJUSTED SO THAT THE 90 FUNCTIONS DETENT LEVER ROTATION REQUIRED FOR 6 35 DRILL THRU 238 5 9 39 SAE 1 2 36 STRAIGHT 111 0 4 371 SIDED SERRATION MIN TROLLING PRESSURE N DETENT p 1 41 CONTROL HEAT EXCHANGER REQUIREMENTS REFER TO B3649K HEAT EXCHANGER DATA CONTROL VALVE 18 62 4 14 052 AT THE 36 0 2 200 R LOCATION OF THE 6 35 1 4 DIA HOLE IS REQUIRED OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE FULL PRIMARY CLUTCH FULL SECONDARY CLUTCH AND NEUTRAL LEVER POSITIONS THE DETENT SPRING TROLLING LEVER
55. MANUAL OVERRIDE MODE SHOWN IN NEUTRAL MANUAL OVERRIDE NEUTRAL START SWITCH MANUAL OVERRIDE NEUTRAL START SWITCH 721 F 22 7 A lt lt LONG VA E lt ailla zzz Lay WA A qc 2774 S Eiern ges Section C C Section Section ELECTRIC CONTROL MODE ELECTRIC CONTROL MODE SWITCH SWITCH lt S Section rar CLUTCH ENGAGED Trolling eae ea oe B Trolling Volve FDR ELECTRIC Volve H C OPERATION H A AA WAV 1 1 H Orifice 221 T 7 EU 3 JS ur I ERE MR NS pd ROR Orifice 4 JN b ISS I e A M gt CLUTCH ENGAGE D 16733 T IM I Fn e METRIC ELECTRIC MODE 1 Flectric Monuol valve for MG 509 thru MG 61849 REFERENCE VALVE ASSEMBLY 1018085 MANUAL MODE ELECTRIC MANUAL VALVE FOR MG 509 THRU MG 61242 wey Gaal VUES X 0 75 100 100 2 REFERENCE VALVE ASSEMBLY 1018085 Um 53403 USA MODEL PER ANSI YIASM 15857 MAIN PRESS THIS NOTICE 15 INTENDED me DIAGRAM HYDRAULIC F4 1 1 9 W 0
56. OBE INSTALLATION DRAWING INSTALL 2223228 PRIMARY Ml LINE HERE FRONT amp REAR BEARING PINION BN 7540 amp CLUTCH LUBE SHOWN ENGAGED LUBE RUE bs a E CONTROL VALVE 6 NEUTRAL 1 lt 4 NN A WW NL ge 2 2 2 mme SY TL NNI m w i S sS ss js eee 2 DPTIDNAL TRDLLING VALVE S OIRO IR EH E PO lt 4 sess RSS T Q1 REF XA7600 SSS ISIS i N I 2499 24 M EINE NN WO PORTION ENCLOSED WITHIN OPTIONAL AUXILIARY LUBE SYSTEM USER lt THESE LINES IS REQ D FOR TD SUPPLY COMPONENTS AND TO INSTALL EN KX 1586 OPTIONAL TROLLING OPTIONAL HYD 0 ONLY LUBE MEET REQUIREMENTS IN XA7540 VALVE p SAE J517 FOR 100R1 HOSE SELF NS SSS T MARINE TRANSMISSIUN REF 7600 Satria sets Neen en Sone be EXTINGUISHING FIRE RESISTANT e Q CONTROL VALVE AND XA 601 REQUIRED BY THE U S COAST GUARD EN Nd 4 AS SPECIFIED IN CODE FEDERAL NC 7 REGULATIONS 46 CFR 56 60 25 lt AN 2 M V IS REQ D W O era Z LUBE
57. RACINE WI 53403 USA qe ALL ANGULAR TOLERANCES aM T PER ANSI Y14 5M 19828 2 7 A Ma e De TJ T J 6 THRU HOLES EQUALLY SPACED USE 8 8 CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE 5574 OR SERVICE MANUAL VALUES SIZE CHUPLING SAE 620 FLYWHEEL K THRU HOLES USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS 50 898 1 AND TORQUE 55 MANUAL VALUES OUPLING COUPLING C NO 6 0 24 H FLYWHEEL OUTLINE MUST CONFORM TO J620 um B1048X SNAP RING 1 FLYWHEEL OUTLINE MUST CONFORM TO S A E J620 iub oo EQUALLY SPACED srQyP 4 OR SERVICE DYNAMIC NOMINAL TORQUE Tua bre 7 lt TORSIONAL STIFFNESS COUPLINGS A amp ONLY DYNAMIC TORSIONAL STIFFNESS kN m rad TORQUE S A E 0 HOUSING COUPLING 1016215 ELEMENI MA1041E CAPSCREW 16 MA94 D 16 1016520 HUB SPLINED 1018742 RING 5 49802 RING COUPLING B 1016217 ELEMENT COUPLING WR kg m 2 PARIS INNER PARTS ND 460 277 PER CHART 6 os mes 2750 PER CHART Co ms S A E J620 MARINE TRANSMISSION ee FLYWHEEL 127 460 2800 PER CHART 0 290 0 166 3000 PER CHART 0 206 0 166 06 5 Soe 467 7 43815 EO ALL COUPLINGS ABOVE HAVE TORSI
58. Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 1 SECTION 3 3 3 Manual Control Valve Assembly A General The control valve assembly contains passages and ports to direct pressurized oil within the transmission s hydraulic system The pressure rate control piston within the control valve assembly provides a rapid smooth oil pressure increase in the hydraulic system during clutch engagement B Manual Control Valve Neutral Oil enters the control valve body through passage A and fills chamber B The oil causes the pressure regulating piston to partially compress the piston outer and inner springs against the pressure rate control piston This pressurizes the oil in chamber B This pressure varies with engine speed The movement of the pressure regulation piston against the springs exposes port C in the valve body Port C directs overage oil to the lubrication oil circuit Passage D which is the engaging outlet to the primary clutch and Passage E which is the engaging outlet to the secondary clutch are interconnected by slot F in the control valve stem when in the neutral position The slot is aligned with a drilled hole and cored cavity in the face of the valve body The drilled hole and cored cavity are aligned and drilled holes that pass through the main housing to sump Therefore passages D and E are at atmospheric pressure at this time Also passage J is at atmospheric pressure be cause port H interc
59. WASHER 2782 5 SECTION B m NUT 2027 SCREW 2000 INSTRUCTION PLATE 2464 co some INSTRUCTION TAG B2385 e D l LEVER 2103 ml i STR TH D RING 1506149 MAIN PRESSURE DIL INLET WHEN NOT INTERNALLY SUPPLIED THREAD SIZE AT PORT 1 4 18 NP T F WHEN 2052 REDUCER BUSHING IS SPECIFIED BOTTOM VIEW GASKET 1017553 PLATE SEE CHART PISTUN P 10491 Q GASKET 1017130 BALL M1990H SPRING 2702 DITCH PLATE SEE CHART SCREW SEE CHART PORT x lt MAIN PRESSURE PICKUP 1 4 18 NP T F CDRYSEAL TH D SCREW 1042 2 Q INSERT SPRING A2701BN OVER ROLLPIN PM 3036 M UNTIL FIRST SPRING COIL REMAINS LOCATED AGAINST STEM FACE SPRING 1801 SETSCREW A2870K NOTE EN He 7 SECTIDN E E TRANSMISSIUN GASKET SEE CHART SECTION D m BALL 1990 0 RING 2916 PIN M1927AX SEAT 1017524 DITCH PLATE GASKET SEE CHART VALVE BODY ASSY 1018095 A BODY 1018094 BALL 1034 BALL MA1034D BALL M1990H BALL M1990Y lt 52 INSTALL USING MA908 LOCTITE 242 SCREW MUST FLUSH WITH SURFACE ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE INTERMEDIATE PRESSURE CLUTCH PRESSURE A gt LP C P SERVICEAB
60. u x 54 5 lt LJ SECTION 11 Special Tools Special Tools Spring Retainer Hold Down T 19998 11 19 56 531 1 01 08 934 95 JU 500 OL JIBMIN3ONDO 3 3919 38 1504 54294415 8 3514 IV SSANAOD 11 AVANT 131412345 ASIMYSHLO 31UN DN 86661 3114 0492 YU e 4 yi Vet ha apud L e 9 i 204000 poi 2 4 kes ies T th 0 5 11 19 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 11 20 Output Gear amp Shaft Puller for Assembly 20023 Sh 1 of 4 p S 22 SS N L mM TNNT EN Lic JA H wu 1 2002 AUTOCAD FILE 4 222 11 20 SECTION 11 Special Tools Special Tools 11 21 Details for Puller T 20023 Sh 2 of 4 5 x lt D
61. 20 69 Ses 22 41 595 27 esu NOTE WHEN MOUNTING ENGINE ZTRANSMISSION IN BOAT ALL THE MOUNTING PADS ON THE ENGINE MUST BE USED PLUS THE TRANSMISSION SIDE MOUNTING PADS FAILURE TO DO SO MAY RESULT IN DAMAGE TO TRANSMISSION SEE BELOW THE 1016249 CONFIGURATION IS NOT SUITABLE FOR REMOTE MOUNTING RECOMMENDED NOT RECOMMENDED CLEARANCE TO REMOVE S A E J620 S A E 0 NO 460 181 HOUSING 138 7 5 46 101 6 4 00 101 6 4 00 101 6 4 00 H M20 X 2 5 TH D 32 0 1 261 DEEP 16 HOLES 48 EACH SIDE DRILL THRU USE ALL 16 HOLES FOR MOUNTING UNIT HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS 15 0 0 59 V TROLLING RANGE MAX TROLLING PRESSURE THE TRDLLING LEVER NB DETENT ANGULAR LOCATION MAY BE RATE RISE ADJUSTED SO THAT THE 90 FUNCTIONS DETENT LEVER ROTATION REQUIRED FOR 6 35 DRILL THRU 238 5 9 39 SAE 1 2 36 STRAIGHT 111 0 4 371 SIDED SERRATION MIN TROLLING PRESSURE N DETENT p 1 41 CONTROL HEAT EXCHANGER REQUIREMENTS REFER TO B3649K HEAT EXCHANGER DATA CONTROL VALVE 18 62 4 14 052 AT THE 36 0 2 200 R LOCATION OF THE 6 35 1 4 DIA HOLE IS REQUIRED OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE FULL PRIMARY CLUTCH FULL SECONDARY CLUTCH AND NEUTRAL LEVER POSITIONS THE DETENT SPRING TROLLING LEVER AND PIN MAY BE OMITTED
62. ALL COUPLINGS ABOVE HAVE TORSIONAL STOP INCLUDED FOR OTHER TRANSMISSION INSTALLATION DIMENSIONS REFER TO 1015207 SHEETS 3 AND 4 FOR TRANSMISSION SHIPMENT SECURE FLEXIBLE COUPLING TO HOUSING SAE FLANGE HOLES USING STANDARD METHOD BEFORE SHIPMENT OF UNIT NDTICE THIS PRINT CDNTAINS PROPRIETARY INFORMATION AND IS NOT TD BE USED IN ANY MANNER DETRIMENTAL THE INTERESTS DF TWIN DISC INCORPORATED MATERIAL HEAT TREAT FIRST USE ASSY MODEL SURFACE TREATMENT NAME RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED THE U S GOVERMENT OR OTHERS BY CONTRACT MG5202 DC MARINE TRANSMISSION DIMENSIONS ARE mm MACHINED DIMENSIDNS X 0 75 WO DISE INCORPORATED RACINE WI 53403 USA XX 0 25 0 13 ALL ANGULAR TOLERANCES KS GEOMETRIC TOLERANCING PER ANSI 14 5 1982 AOIS m DAS APPD SHEET 5 of 7 FLEXIBLE COUPLING INPUTS WAS 849 7 3 MATERIAL NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS ED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED HEAT TREAT RACINE WI 53403 USA M SAL 1 HUUSING SIMILAR WR UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm 4 12 94 DISE Nem MACHINED DIMENSIONS INCORPORATED FIRST USE 0 25 29 1 00 RACINE WI 53403 USA ASSY MODEL
63. AND PIN MAY BE OMITTED WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY NEUTRAL ne o ra edis AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS LEVER MAY BE LOCATED uj FORCE AT THE LEVER HOLE TO OPERATE THE VALVE THEN REDUCES TO 13 31N 3 7 0 THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 35 8 1 41 LINEAR TRAVEL N 2 CO FROM NEUTRAL AT THE 6 35 1 4 DIA HOLE LOCATION ROTATIONAL STOPS THE saq In Di STATED VALVE TRAVEL LIMITS HAVE A MAXIMUM CAPACITY OF 445N 100 LBS AT THE uin 6 35 1 4 DIA HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES SO CAPACITY THE VALVE 4 U ROTATIONAL STOPS IS NOT EXCEEDED EXCEEDING THE CAPACITY 7 THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS CONTROL CONTROL TROLLING oe TROLLING FEATURE OPTIONAL A _ 343 7 18 51 BAv OIL DRAIN amp DIL IN FROM HEAT EXCHANGER 247 9 9 76 5 DIL PRESSURE GAGE EYEBOLT t LINE HERE 2 X 15 THREAD 144 8 5 70 DIL FILLER HDLE AT VALVE E 139 7 5 50 E MOUNT GAGE IN PILOT HOUSE 111 3 4 38 1 8 27 NPTF EXTERNAL NEUTRAL 109 7 4 32 TH D DRYSEAL GAGE OO CONNECT GAGE INTO OIL 50 8 2 00 LINE BETWEEN AND 76 8 R CONTROL VALVE x 3 00 R FACE USED FOR CONTROL MOUNTING BRACKET 16 7L21 321 DRILL THRU 2 HOLES FOR 5 8 1
64. N N N SECTION B bul B1398E A 19 0 HOLE MUST BE LOCATED IN THIS AREA IN MATING PART FOR TORQUE CUNVERTER BEARING LUBE NOT TO EXCEED 53532 kPa SEE CHART VALVE BODY GASKET ORIFICE VALVE SPRINGS 5 5 SOCKET HD SCREWS unser PLATE X SPRING CONSISTS DF kPa PART FIRST QTY QTY Q QTY USE APPR QTY PART SIZE ASS Y DUTER INNER DATE AND Ba Ea SEE NOTE 4 SEE CHART SEE CHART 02 SEE CHART 1 MATERIAL HEAT TREAT LO j 3 0 MIN HOLE MUST BE LOCATED IN THIS AREA IN MATING i lt lt PART FOR VALVE DRAIN DRILL THIS PORT FOR 4 HOLES st CLUTCH FOR MOUNTING BOLTS 0 410 B e HOLES INLET 2001188 VALVE BODY ONLY 102 s SECTIUN DP 104 14 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS 111 5 NOT TO BE USED IN ANY MANNER 26267 8 15 95 DETRIMENTAL THE INTERESTS TWIN DISC INCORPORATED 26246 8 1 95 RACINE i 53493 2222 tpe 5 16 94 THIS IS INTENDED NULLIFY DR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT zssss 7 21 99 lt 24635 u 3 93 zme cm wo pam D SURFACE TREATMENT NAME t pq L3 4
65. O RING 1 O RING 1 UNITS WITHOUT HYD LOCK PLUG 1 UNITS WITHOUT HYD LOCK 53 SPOOL UNITS WITHOUT HYD LOCK PORT SOLENOID PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND HYDRAULIC LOCK OPTIONAL CONDITION Yje 2 y ESI AAAT 13 08 CONTROL VALVE GROUP qe SS N ANN D _ NS SN ZN S EN SSS N x MY 2 NASM u 426 DN ME Z 40 2 s 2 vv a d G sn Ay G gn O 9 4 SECTION SECTION D D 1 1 DOGPON 0 0000000 2 2 o 3 SPOUL 2 UNTSWTHHYDLOCK F U PISTON 1 e L6 PN Pe Tb SPRING 1 OUTER PRESS REGULATING 8 PISTON 0 1 9 PLATEORFICE ORIFICE __ D 10 sum MI COER 13 GASKET BALL T 18 SPRING 1 NEUTRAL PRESS REGULATING O RING 488 spring 1 19 snap 1 22 cower 1 GASKET 1 25 PLUGASSEMBLY _ PN 2 SCREW SOCKET HEAD
66. SPRINGS AND BALL MAY BE OMITTED THEN THE FORCE WILL BECOME 3 7 LBS VV WA Se THE DETENT FEATURE IS PROVIDED IN THE FULL 15 CLUTCH ENGAGED FULL SU 4 28 2001 end CLUTCH ENGAGED AND NEUTRAL LEVER POSITIONS SSS aS B1399C 42 TORQUE MOUNTING BOLTS TO 30 36 LB FT AS RECEIVED PER 5574 LUBRICATED PER 5574 AFTER TORQUING MOUNTING BOLTS INSTALL M2 026Q PLUGS IN MOUNTING BOLT CDHUNTERBDRES eui SECTION E ORIFICE PL 5 GENERAL THIRD ANGLE PROJECTION G DATE 9 3 80 SCALE 7 1 00 DRN KS SERIES CHK REB JS ATE REMOVE BEFORE OPERATING UNIT ALUMINUM THREAD PROTECTOR TUN louse INC DL R POR ATE D RACINE WI 53403 USA X5 3 1 SERIES APPD SHEET 1 oF 1 REV Z_ file name XA7371 VALVE BDDY GASKET VALVE VALVE ASSEMBLY UT NUMBER G G 15 CLUTCH ENGAGED X TH D lt DRYSEAL DIL INLET 5 16 18UNC 2B TH D THREAD SIZE AT PORT o 5 HOLES 1 4 18 N P T F WHEN 2052 REDUCER BUSHING IS SPECIFIED 2 70 XA7372F 7 VIT e sai A7361B 5275 552 GASKET 1 437 FOR XA7S72H amp xa7a720 A73618 P277 siao7r ES 5 27 d AT361B B1397F mac 2 NEUTRAL USE Ek SER VIER REPLACED BY 7600 FOR PRODUCTION e SEE CHART ___ meor Tab SEE
67. SQUARE KEY 120 6 4 75 WITH 31 8 1 1 4 SQUARE KEY 139 7 5 50 e WITH 31 8 1 1 4 x 22 2 7 8 KEY amp 1251 X150IN FT TAPER 2 OPTIONAL TEMPERATURE INDICATING SWITCH CUSTOMER INSTALL IN 3 4 X 3 4 X 3 41 PIPE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSION PUMP THE HEAT EXCHANGER INLET REFER HYDRAULIC DIAGRAM NLITE ALL POINTS AVAILABLE FUR TESTING ARE CODED V b MARINE C a TRANSMISSION 22200 10000 0 FLYWHEEL 000 005 gt 006 004 gt 460 187 711 2 679 45 647 70 571 50 498 3 157 35 0 484 PEU 6 0 8 00 26 750 25 500 22 500 21 375 19 62 1 38 gt 24 gt 1 355 1471 222 4 530 20 511 17 466 72 438 15 409 4 25 4 25 7 1e UF BF 12 0 lt 21 75 gt 20 875 gt lt 20 125 gt lt 18 375 gt lt 17 250 gt lt 16 12 gt lt 1 00 gt 1 012 48732 Ces 32 9 131 3 48 1 100 5 4 01 HOLE AT THIS LOCATION OMITTED SAE 0 HSG ENGAGES CLUTCH ON SHAFT t CALLED SECONDARY CONTROL LEVER 6 35 1 4 DRILL TROLLING SECONDARY CLUTCH 228 600 9 000 REF S N 203 2 8 00 211 91 8 343 BASIC 245 1 L9 65 332 6 u3 09 374 7 14 75 42 92 GEAR IDIM FROM PORT SETS ISFACE
68. Selector Valve 13 2 EL HO 2028 uo p sn eq jou Jeu sued 1snuu p u eg A 8A WIYS 9SIJ JO 9 81 peeu xau aye d aures eje d pue arejd ayse sels 6uuds Apog ainsseid 6uuds 6uuds sejou onse d 9218902 uo Buipuedep yos 10 peau 192 uolsid Buu O Buuds a10 1 A09 peeu xau 19497 peau 1 206 MAINS dois elon 1 1 snuu QI N N lt uonduoseg SECTION 13 Illustrations 13 4 Illustrations Z d jh Z s 4 m hays 7 om lt N A de N Pn e w G
69. 1 2089 10180840 40754 1017133 1017134 BI337F 1017179 75 12 4270740 565 1017129 510 2 0536 451 2 sae 6 OPTIONAL USE AS REQUIRED e a l s dod 18 5 da 10180846 40757 1017133 1017134 B1337F 1018688 XMe759FL i8 VDC XA2707Z 27072 703 1725 250 1017129 1 8 7 x 451 2 2 5 1018084 40758 1017583 1017569 1017613 1018688 2 xMe759FM 24 VDC XA27072 427077 2703 2000 290 1017129 MAio38E we7 x 20 6 2451 0 1062 2 10626 2 5600 MN ae EN Hs 1018084 40761 1017583 1017569 1017613 1018688 XMe7S9FL i VDC XAe707 427072 Ae703T 2000 290 1017129 MAi038E Me7 B2451B 0 2 MAi06eG 2 6 560 CUNNECTUR SHRDUD 1001825 1018084 40762 10171334 1017134 B1337F 1017179 ND 2 2759 24 vDC A2707AD_ 585 230 1017129 7 x 20 68 BP451B Ld 20585 10180841 40763 1017133A 1017134 B1337F 1017179 870740 1585 2302 1017129 1038 27 x 20 6 BP451B 5 ES 1018084M 40764 1017383 1018688
70. 1011 SEE SHEET 1 FOR MAXIMUM TRANSMISSION R P M THE WR THE INNER PARTS INCLUDES HUB AND 1 4 FOR OTHER TRANSMISSION MASS ELASTIC DATA REFER B35044E FOR OTHER TRANSMISSION INSTALLATION DIMENSIONS REFER TO 1014841 SHEET 2 Ru PEHR REPLACED NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER kg DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA HEAT TREAT FIRST USE ASSY MODEL METRIC O E age SIMILAR INCH DIMENSIONS AND POUNDS SHOWN BRACKETS L 1 WR UNLESS OTHERWISE SPECIFIED DATE DIMENSIONS ARE mm 6 3 94 P N 15 4 MACHINED DIMENSTENS SCALE INCORPORATED 0 25 RACINE WI 53403 USA 0 13 DRN ALL ANGULAR TOLERANCES 1 EDME TRIC TOLERAN ING 1982 THIS NOTICE IS NOT INTENDED ID NULLIFY DR LIMIT RIGHTS SURFACE TREATMENT M G5202 SC MARINE GRANTED TO THE US GOVERNMENT APPD OR OTHERS BY CONTRACT TRANSMISSION DAS 3 409 NU sasa FOR PRODUCTION REPLACED BY 1016103 THIRD ANGLE PROJECTION PROPRIETARY INFORMATION AND IS MACHINED DIMENSIONS NOT TO BE USED IN ANY MANNER LBS LBS IN 0 050 DETRIMENTAL THE INTERESTS HEAT TREAT FIRST USE TWIN DISC INCORPORATED
71. 81048 1 7 D H C REF 810480 2 H C REF gj HF Do qj REF REF REF 5 D 5 D 8 2 lt kN ABS CHC i MAI041E 16 E 1016215 1 SSS MALO4IE 16 MA947D 16 1016215 1 AI SS emm COUPLING D 555555525559 0609000500 THRU 020050 1019696 1 HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 A 2905 5255552 6006060600600 5 QUALIIY CLASS 777772 5 4 PER SAE J429 CAPSCREWS AND TORQUE 5574 H SERVICE MANUAL VALUES a SRS THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY PER ISU 898 1 LGRADE 5 QUALITY CLASS PER SAE J429 CAPSCREWS AND TORQUE TU 5574 UR SERVICE MANUAL VALUES K THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 GRADE 5 QUALITY CLASS PER SAE J429 CAPSCREWS AND TORQUE 5574 OR SERVICE MANUAL VALUES FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 No 460 18 FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 No 460 18 7 HOUSING S A E 0 HOUSING FLYWHEEL OUTLINE MUST CONFORM TO SAE J620 No 460 18 H 634 3 94 97 T OUTPUT FLANGE FACE 2952 2343 TO OUTPUT FLANGE FACE S A E 0 G s DYNAMIC TORSIONAL STIFFNESS
72. B3649k HEAT EXCHANGER CONSULT SALES DEPT APPLICATION B3649K oto gioco ct ge us ENGINEERS FDR DTHER SEE FOR PRODUCTION LIMITING CONDITIONS HYDRAULIC lt 9 lt lt QJ SESS PY dq IUS x Mie x o2 DIL CAPACITY 265 L 7 GALS LESS HOSES AND HEAT EXCHANGER WHEN IT AVAILABLE ELM b THIS UNIT CAN NOT BE USED WITH LEFT HAND ENGINE OPTIONAL EQUIPMENT CLIMPANILIN FLANGE ASSEMBLY 1015378 WEIGHT UNLESS OTHERWISE SPECIFIED DATE Ei AT DA DIL TEMPERATURE INDICATING SWITCH B3424 FOR INSTALLATION 2 s 27632 3 13 97 THIS PRINT CONTAINS MATERIAL i73 2031 3484 ARE mn DISE LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 28657 7 21 98 1 R 27354 10 22 96 TU BE USED IN ANY MANNER S341 2 481 MACHINED DIMENSIONS SCALE INCORPORATED LIVE EL XB628434A CAUXILIARY PUMP DRIVE SUCTION SCREEN DETRIMENTAL TO THE INTERESTS OF i 92 1 X 0 75 HYDRAULIC CLUTCHED P T O XA7554 SHAFT DRIVE AND XA7554A PUMP DRIVE 28544 5 4 98 1 4 27113 6 12 96 us FIRST USE TRAILING PUMP 1016473 0 actly lesea7 5 57 PUS P 70 0 5 7 96 TWIN DISC INCORPORA assy I E
73. COLLAR B1867 STEM A4347J SCREW 960 4 RACE 2086 lt 2 SCREW MAQS6F 4 COVER 3574 O RING 2916 PLUG GASKET B13344 SCREW 532 BALL MA1034C SCREW MA996D 42 PIN MA103SA SCREW SG lt 2 E PLUG MA1040A x cz La 2 gt gt L 2 SPRING 2 06 FITTING MA927 PIETER ASS Ys FILTER 3614 LABEL 950 SCREW 996 lt Ws A2916JT mE 75 COVER 2502 s LLL LIP PLATE 212754 f 2 STRAINER Be130B cad file 115207428 ews a PROPRIETARY INFORMATION AND IS 1032 DIMENSIONS ARE mn 12 22 97 D Rei E EE METUIT X X 0 25 l RACINE WI 53403 USA HEAT TREAT FIRST USE X XX 0 13 TWIN DISC INCORPORATED ASSY ALL ANGULAR TOLERANCES ANG DRN AZ RACINE WI 53403 USA det GEUMETRIC TOLERANCING 1 0 1 5 2 0 7 A THIS NOTICE IS NOT INTENDED CHR DAS TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME GRANTED THE 0 5 GUVERMENT APPD OR OTHERS BY CONTRACT MARINE TRANSMISSION DAS SHEET 2 OF 7 REV 0 M16 x 15 METRIC THREAD CONFORMS ISU 6149 REFER CHART REQUIRED PICK UP DEPTH RANA rm 04 gee BN ee e es eee MU SAE 620 460 NEUTRAL N 419 75
74. MDUNT LUBE INSTRUCTIUN PLATE WITH WORDS MARINE TRANSMISSION MOUNT INSTRUCTION PLATE WITH LUBRICANT AWAY FROM BREATHER WORDS MARINE TRANSMISSION TOWARDS BREATHER PER TE BEALS SCREW M4eeB lt o CAPSCREW MA996A 24 GASKET 1398 25 WASHER MA1039B 24 BALL M1990H SPRING A2703P 204098 GAUGE LINK 2007 6 BREATHER B12851A CHAIN M1072 GAUGE B1703D CLIP 1 6 PLUG MA1038E 1047 2 CAPSCREW 1052 4 gt CLOSURE 2067 4 SPRING A2707BD PLUG MA1038B 3 SPRING 2039 SPRING A2704BU G SPRING A2702BP SPRING A2702BC 5 BALL MI79UE BUDY 1001138 ME BEARING M2087K 7540 i CONTROL VALVE ASSEMBLY PLATE B1397D LEVER 204087 SS B1333D 2 PIN M1927B PISTON B1399C m STUN ass da SHIM B2334 45 REQ DD 22 TAG MA656C IN 02022020200090004 VY CAPSCREW 960 4 TUBE ASS Y XB2301N 22 APLUG M2702F lt 2 TUBE 82301 PISTON B1400B B1337F COLLAR 81867 STEM 4347 CAPSCREW 40 RACE M2086AV 2 CAPSCREW MA226F 4 COVER 3574 D RING 916 BALL 1034 CAPSCREW MA996B 3 GASKET 813348 PIN 1035 2 CAPSCREW MA996A 4 CAPSCREW MA996C 2 NWS LL 5 S SPRING A2706W CAPSCREW MA
75. RACINE WI 53403 USA GEDMETRIC TDLERANCING MDDEL PER ANSI Y14 5M 1982 ji J 1 A ji THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME 5202 GRANTED TO THE U S GOVERNMENT APPD OR OTHERS BY CONTRACT MARINE TRANSMISSION DAS SHEET 4 OF 4 B 24 4 9 E ASSEMBLY INSTRUCTIONS wall ASSEMBLY INSTRUCTIONS RAJ addio MOUNT INSTRUCTION PLATE WITH 1014878 1 D zr mmm mes 2 50 CONTROL VALVE ASSEMBLY 517035 M1990E oe a STEEL BALL SII M2051CD STANDARDS APPLY 1014851 mes gt lt Sas aS eel 574 FASTENER TORQUE REQUIREMENTS THIS SPACER USED 2 E 7361B S692 BEARING SHIMMING HUB WITH 3 48 2089 5765 TAPERED JOINT ASSEMBLY 19506 1 5785 S774 ANAEROBIC SEALANT APPLICATION STEEL BALL 2916 I 2067 1014962 2 204087 TAIN PLASTIC CLOSURE 1014849 UM MESS P 708 BP CE V CN Se 2039 1 220 B1399C 1 _ ____ _ ___ 23 65 SS B1334 GG E io NN 1 2 B1333D EN M2001P HB 2001 1990 SINC 55 7 M1
76. TWIN DISC INCORPORATED Service Manual Marine Transmission Components 52025 MG 5203SC MG 5204SC MG 5202DC Document Number 1017462 Twin Disc Incorporated makes 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 Table of Contents 1017462 Marine Transmission Service and Installation Manual Models MG 5202SC MG 5202DC MG 5203SC MG 5204SC Original Issue May 1997 Revision B March 2003 Twin Disc Incorporated 1328 Racine Street Racine Wisconsin 53403 U S A Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC Table of Contents ii Table of Contents TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE TRANSMISSION Twin Disc Incorporated warrants all assembled products and parts except component products or parts which written warranties issued by the respective manufacturers thereof are furni
77. Vv 1 VIC tf 00 2 li _ yr Sb X 1 S300H n j38 ND 05 90 0 944 OST see WI _ SECTION 11 Special Tools 11 10 Special Tools 11 11 Seal Driver T 18050 696 Sh 1 of 2 in 4 OO c3 4 JS Oo CO i i 4 Pe x 0 s L9 U L CU E In 5 NI a z OU ii In NI 25 19 x IN a ML gt S Y lt I lt EN N lt 8 52 Mb e D USED CAD 1016111 SHAFI OU Br 0 69 1 180 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC Z O PART NO a mG 6 p EK L DRI SEA N DISC IN 11 11 11 Protector 18050 696 Sh 2 of 2 11 12 9689 06081 26 d s e e ON 149 40 5 908 2 g 959 06 ala LJVHS Lavd a 60 x S 02S 9W 0350 BEARS x N 3 gt a i SI ONIAUHS 40 o B v 5222 S A j LO d 8v Q ES 91405 lt 4 50 d ey
78. XMe7S9rMo4 P ern e415 350 1017129 7 x 20 6 45 1780 ELMO war CLOSED WHEN MANUAL VALVE 10180 4 40775 1017583 1017569 1017613 1018688 75 24 VDC XAe7072 427072 4270 2000 290 1017129 1 20 6 B2451B 0 62 2 1062 2 22 2 PLATE 1018312 1018084 40817 1017569 1018688 2759 24 707 2707 D 4270348 000 290 10171298 mat038E we7 x B2451B 0 222 10180848 40842 1017133 1017134 B1337F 1018688 2 2759 24 VDC 27077 427072 A2703T 1017129 MA1038E e7 x 2 0 6H 2451 TORQUE TD 542 NOTE 10180847 40955 1017383 1017179 no xme759FM 24 VDC 2655 385 10171294 1038 027 x 0 6 24518 MG 6449 SECURE LEVER IN THE DEPRESSED VIEW 1 180840 40956 1017383 1017179 no 2 2759 24 77 2550 370 10171294 038 x 20 68 2451 MG 6557 ELECTRIC CONTROL MODE POSITION 40957 147363 1017179 DMe759FM24 voel zo 2450 c355 101712
79. e 5 SHAFT q seine OE 16 1 5 METRIC THREAD m CONFORMS TO ISO 6149 PRIMARI REFER CHART REQUIRED PICK UP DEPTH I N In NS OO ON D 0 PLACES CUTOUTS X DRIVING THRU SECUNDARY CLUTCH 32 t THRU OLES EQUALLY SPACED 1 1 8 H ee 2 PLACES 228 600 9 000 t CUTOUTS CREF OUTPUT SHAFT q b p 2 PLACES CUTOUTS IX OIL DRAIN PLUG M33 X THREAD e11 91 8 343 BASIC 245 1 9 65 8 001 UBSULETE 266 7 10 50 FOR PRODUCTION REPLACED BY 1016103 METRIC SIMILAR TO 332 6 13 09 355 6 14 00 374 7 14 75 INCH DIMENSIONS AND POUNDS SHOWN IN BRACKETS WR UNLESS OTHERWISE SPECIFIED DATE NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT TAJUN DISE PROPRIETARY INFORMATION AND 1 DIMENSIONS mn 3 25 93 USED MANNER Nn MACHINED DIMENSIUNS INCORPORATED DETRIMENTAL TO THE INTERESTS OF RST USE 35 50 PACING Wi 53403 USA 0 13 TwIN DISC INCORPORATED ASSY ALL ANGULAR TOLERANCES ANG DMETRIC TOLERANCING 1982 RACINE WI 53403 USA GE ER ANSI Y14 5M MODEL NAME 3 0 TRA SURFACE THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERMENT OR OTHERS BY CONTRACT CHK 1014841 THRU HOLES EQUALLY
80. kN m rad Ibf in rad UP TILIN ARRANGEMENT WHERE ASSEMBLY 1016103 REPLACES ASSEMBLY 1014841 5052 2343 s TO OUTPUT FLANGE FACE STANDARD 1016103 ASSEMBLY ARRANGEMENT 2 2 0 DYNAMIC TORSIONAL STIFFNESS kN m rad Uo in rad1 TORQUE kN m lbf in 0 50 4400 COUPLING WR COUPLING WEIGHT kg m lb in 1 kg lb WITHOUT WITH 0 24 0 40 23 7 36 7 820 1383 52 2 76 6 0 40 27 7 40 7 85 41 0 61 2084 13831 611 DYNAMIC TORSIONAL STIFFNESS SAE J620 MAX COUPLING SIZE NO h NOMINAL TORQUE kN m Clb in1 CLIUPL ING 355 VKE 49115 5 00 2750 44250 1 25 2 90 22100 3 75 5 00 COUPLING WEIGHT kg Ib COUPLING WR2 kg m 16 2 kN m Em rpm lbf in OUTER PARTS INNER PARTS 5 00 0 206 0 166 25 3000 di row 567 5 0 166 27 567 5 00 0 290 508 018 DYNAMIC TORSIONAL STIFFNESS SAE J620 FLYWHEEL SIZE NOMINAL COUPLING 0 OBSOLETE COUPLINGS REFER TO DRAWING SAE J620 w COUPLING WEIGHT COUPLING BELOW FOR FLYWHEEL kg m lb in kg Ib SIZE PRIMARY SECONDARY 5 INFORMATION 5 620 CF DS 59 7 3 NO 355 0 16 0 61 24 4 DS 59 7 0 24 0 61 275 253922 820 2081 14 552 4 530 20 511 17 466728 438 15 409 4 25 4 25 7 mus ERR 3 304 8 355 141 51751 20 8751 20 1251 18 3751 17 2501 16121 11001 95 133
81. 0 13 5 111 51 28982 12 2 98 TWIN DISC INCORPOURATED f Lss ASSY ALL ANGULAR TOLERANCES 1 ILP INTERMEDIATE PRESSURE x S RACINE WI 53403 USA SEE CHART GEDMETRIC JOLERANCING X A 6 0 0 RD CHK CLUTCH PRESSURE Be 27243 8 23 96 NOTICE IS NOT INTENDED wer SERIES 24983 GRANTED TO THE US GOVERNMENT INR I i 5 I UR OTHERS BY CONTRACT TBC File name 7600 MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL 23 8 A CLUTCH ENGAGED FOR 3 POSITION amp FWD NEU REV USE ENGAGED FOR 2 POSITION ENGAGED amp DISENGAGED USE NOTE LEVER MAY BE LOCATED ANYWHERE ON ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 TOTAL ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL BALL M1990Y SEAL MA778 STEM SEE CHART SNAP RING A2915W M8 X 1 25 6H 2 HOLES 23 3 OR 36 3 SCREW 10424 42 CLUTCH ENGAGED FOR POSITION FWD NEU REV USE NEUTRAL 3 POSITION CF WD NEU REV USE DISENGAGED FOR POSITION CENGAGED amp DISENGAGED USE CORJ APPLY MA895 THREAD SEALANT WITH TEFLON 2 TO THREADS TORQUE TO 300 lbf ft 407 N m S PLUG 2080 NUT Me027C WASHER 1017522 GASKET B1334C COVER ASSY 1017336 A CARRIER 1017335 35
82. 100 1851 AT THE E 713 2 28 08 Gu d Am 6 35 1 41 DIA HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING 40 PS aa THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES SO CAPACITY OF THE VALVE E 670 1 26 38 ROTATIONAL STOPS IS EXCEEDED EXCEEDING THE CAPACITY THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS OF CONTROL Sse ADVERT CONTROL TROLLING ET VALVE 5629 ES TROLLING FEATURE OPTIONAL B M EYEBOLT t 575 6 22 82 2 13 51 k 247 9 9 76 DRAIN 8 OIL IN FROM HEAT EXCHANGER 570 4 22 46 297 9 11 73 177 8 7 00 564 6 122 231 247 9 9 76 546 0 21 50 w EYEBOLT t HIL PRESSURE GAGE 150 8 5 94 144 8 5 70 4826 9 00 LINE HERE s DRILL THRU 1 4 18 NPTFJ INTERNAL TH D 139 7 5 50 HOLES EQUALLY SPACED 459 5 18 09 4 DRYSEAL AT VALVE _ _ USE 8 8 CLASS QUALITY eee 111 3 4 38 150 898 1 393 7 15 50 1 8 27 NPTF EXTERNAL 109 7 4 32 GRADE 5 QUALITY CAPSCREWS eed AS M n NEUTRAL PER S AE J429 AND TOQUE 330 2 03 00 EYEBOUT t _ QU CONNECT GAGE INTO DIL 50 8 2 00 5574 SERVICE MANUAL zi OTHER SIDE LINE BETWEEN H E AND
83. 12 24 11667 FORM 1 254 CIRCULAR mer 1317 IDEEN eD S PLINE D A IN INCHE S I SAE J744 No 127 4 4 I I N I s A D d I I I I REFERENCE ONLY THIS IS 1038 PLUG DRAIN HOLE LOCATION I I 161 9 CREF I SAE J744 No 127 4 2 1810 2 CREF X 20 THRU APPLICATION ENGINEERS FOR OTHER LIMITING CONDITIONS MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED 1 xs 5 LO0 1mm imm RACINE WI 53403 USA DETRIMENTAL THE INTERESTS DF FIRST USE ALL ANGULAR TOLERANCES 31 DRN 742 46 EEE egg Ass 1017020 ae manaa 222 DIMENSIDN TD SAE 00 HOUSING B 3 29757 12 1 99 1 99 ll THIS NOTICE IS INTENDED me PER ANSI Y145M 1908 1 0 1 7 1 Us AS NULLIFY DR LIMIT RIGHTS SURFACE TREATMENT GROUP MOUNTING FACE 22128159 10 21 9 GRANTED THE US GOVERNMENT uv wt OTHERS BY CONTRACT AUXILIARY PUMP DRIVE DAS 1 oF L F E D PLUG 1945 SEE NOTE 2 B1337D P T O ENGAGED PLATE B3576C RING M1904E See FITTING M2483BR 2 PACE M2086CV FITTING MA1053L N 17 LE LOCATION OF PLUGS a DISENGAGE D IN MANIFOLD TOWER x SPRING B1783N 75
84. 2 0 6H B2451B 52052 4132 1017133 1017134 1018668 e pwtezssrMe4 27072 47072 725 esol 1017125 x 45 VG Seossc 22 ansa a 759 245 050 10171298 x 51 e seee te sc 22222 USE AS REQUIRED 2 MG 5600DR PRELIMINARY 1176 98 DAS BJE 1176 98 DAS BJE ELECTRIC CONTROL POSITION ME viw uU QM M 1017179 Ng 2 jeeerserwes voci 725 17429 Uu n M 2 _ 77 147569 101866 kwe7S9FM24 Vpcjxagzozap A2707aD 7 2000 ces 1071295 x 24518 XS HOLE BEHIND PULL TIGHT TRIM LINEAR TRAVEL AT THE 64mm Q 4 DIA HOLE pom 121211121 ee sr Mum 0184407 j j j j j j j STRAP M2942B INSTALL USING MA908 LOCTITE WIRING DIAGRAM 4 4 j j j j 242 THREAD DOG POINT INTO T T T L j T BACK DFF 1 2 TURN CONNECTOR porsasoac L L L L L L op
85. 235 20 143 64 109 73 S AE 0 HLIUSING DUTLINE LUBE P S I 0 MIB X 15 THREAD METRIC PORT CONFORMS ISO 6149 k AT THIS LUCATIUN OMITTED UN SAE 0 RSG 7 2 5 1 REFER TO VALVE ASSEMBLY DRAWING FOR ADDITIONAL INSTALLATION NOTES I CUNTRUL HEAD FUR TRULLING VALVE MUST INCLUDE DEVICE LUCK E FILTER DRAIN PLUG O Ho aa ho REA Eu N v 8 FULL POWER THE PROPELLER O Q lt o TH ISD 6149 2 MAXIMUM ENGINE SPEED WHILE TROLLING 1100 R P M OR 60 DF FULL ex d ws me 40 zs ud LOAD ENGINE SPEED WHICHEVER IS SMALLER HE oe E e 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUNCTION BY n O D MOVING TROLLING CONTROL LEVER OUT OF COCKED DETENTED POSITION MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION OF TRAVEL BY MOVING CONTROL VALVE LEVER TO FORWARD OR REVERSE MOVE TROLLING CONTROL LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED CLOSE DETENTED NO TROLL POSITION THE TROLLING CLUTCH MAY ENGAGE FULL Y m CONTROL VALVE pa PRIMARY 444 133 N AT THE 560 LOCATION OF THE 6 35 DIA HOLE CLUTCH IS REQUIRED TO OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE T ES FULL PRIMARY CLUTCH FULL SECONDARY CLUT
86. 251 12 18 60 6 O 2 2 2 2 L 6 0 304 8 13 5 16 7 THIRD ANGLE PROJECTION MACHINED DIMENSIONS LBS LBS IN XX 0 030 0 010 HEAT TREAT FIRST USE ASSY MDDEL R ANSI Y14 5M 1982 CHK SURFACE TREATMENT NAME MARINE gt gt Transmission A 460 18 711 2 679 45 647 70 571 50 542 92 498 3 15 7 35 0 22 5001 21 375 19 62 L62 C1 38 17732 SEE SHEET 1 FUR MAXIMUM TRANSMISSION FUR TRANSMISSIUN CDIUPLING ASSEMBLY TU ENGINE INSTALL COUPLING AND ENGINE FLYWHEEL ADVANCE MARINE TRANSMISSION INTO POSITION WITH ENGINE FLYWHEEL HUUSING MUUNTING FLANGE LINE UP INPUT SHAFT EXTERNAL SPLINE WITH INTERNAL SPLINE IN CDUPLING HUB AND MUVE ENGINE AND MARINE TRANSMISSION TOGETHER MAINTAINING ENGINE FLYWHEEL HOUSING AND MARINE TRANSMISSION FLYWHEEL HOUSING MOUNTING FACES IN PARALLEL RELATIONSHIP ENGAGE FLYWHEEL HOUSING PILOTS AND INSTALL ALL MOUNTING CAPSCREWS USING 8 8 PROPERTY CLASS QUALITY PER ISU 898 1 LGRADE QUALITY CAPSCREWS PER SAE J429 TOURQUED 5574 SERVICE MANUAL VALUES d L THE WR OF THE INNER SECONDARY PARTS INCLUDES HUB AND 1 4 SHAFT FOR OTHER TRANSMISSION MASS ELASTIC DATA REFER 3504 POR OTHER TRANSMISSION INSTALLATION DIMENSIONS REFER TH 1086105 SHEET ALL COUPLINGS ABOVE HAVE TORSIONAL STOP INCLUDED IN UR TRANSM
87. 343 2 DIL DRAIN amp OIL IN FROM HEAT EXCHANGER EYEBOLT 762 HOLE AT THIS LOCATION OMITTED S AE 0 HSG ENGAGES PRIMARY SHAFT CLUTCH INCH ENGAGES SECUNDARY SHAFT CLUTCH SECONDARY 4 CLUTCH SHAFT t 228 600 332 6 DOO 374 7 PROPRIETARY INFORMATION AND IS USED ANY MANNER DETRIMENTAL THE INTERESTS TWIN DISC INCORPORATED RACINE WI 53403 USA THIS PRINT CONTAINS THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT SE LEG S VALVE WIRING DIAGRAM PRIMARY CLUTCH SDLENDID NEUTRAL SOLENOID UP TIONAL MATING WIRING HARNESS 1017403 SERIES SPECIFY LENGTH 2479 EYEBOLT 2479 778 5 76 2 RA STEM IS LOCKED IN ELECTRIC 0 HOUSING MODE OUTLINE M8 X 125 6 THREAD HOLES SUITABLE FOR CONTROL MOUNTING BRACKETS PRIMARY CLUTCH ACTUATING PRESSURE 10 x 10 THREAD METRIC PORT CONFORMS TO 1 0 6149 LUBE PRESSURE 5 M18 x 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 AUXILIARY LUBE SUPPLY INLET SEE HYDRAULIC je DIAGRAM 136 6 2 CLUTCH O KO GREASE 1 5 FITTING 24 5 THRU DRIVING THRU 8 HOLES EQUALLY SPACED SECONDARY CLUTCH OUTPUT SHAFT
88. 4 10 5 11 16 12 beo es won sm se m sm wer bs nm o m e 17489 12569 136 100 165 122 191 141 205 151 219 162 M6 17903 1920142 205 152 256 189 294 217 298 219 320 236 342 253 2909 254099 283 209 348 257 400 295 409 302 440 325 471 347 Neo 3857 374 276 400 295 493 364 567 418 581 429 625 461 669 493 0645 exe a78 693 511 848 626 1000 737 1075 793 1150 848 1674 1926 2000 2301 967 713 1040 767 1113 821 35 1421 1475 1697 Use these torque values for all capscrews bolts and nuts whose threads and washer face are lubricated Also for screws or nuts whose washer face is assembled against a hardened washer or smooth finished part Rc 40 or above and 40AA max Also usefor plated screws except zinc plated Lubricating the threads and screw or nut face with SAE 20 or 30 oil is recommended for best results for all the property class 10 9 screws and is required for all the universal joint bearing capscrews Do not use moly disulfide white lead copper filled or other such filled lubricants with these torque values Such lubricants require special torque values Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 12 3 SECTION 12 12 2 US Standard Unit Capscrews Bolts and Nuts 1 of 2 Torque Values for U S Standard Uni
89. Apply grease to the adapter and bore of the valve body and install the adapter and stem assembly with piston into the valve body Be sure to align the set screw holes in the adapter with those in the valve body Rotate the stem if necessary to bring the helical slot into alignment with the dog point setscrew hole Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 15 8 10 11 12 13 8 16 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn The end of the setscrew should protrude approximately 3mm from the valve body when the dog point of the setscrew is fully engaged in the helical slot 1017555 6 Check the action of the stem in the trolling valve If the stem does not rotate 90 smoothly loosen the dog point setscrew 1 8 turn and recheck the action of the stem Install the detent ball and spring into the remaining setscrew hole Apply 908 threadlocker to the threads of the detent setscrew and install until flush with the valve body x Me 1017555 5 Check the torque required to overcome the detent The torque should be 1 1 1 7 N m 10 15 in Ib Adjust the detent setscrew if necessary to achieve the proper torque to rotate the lever out of the detent position Install the lever on the stem It may be necessary to splay the lever to be able to install it DO NOT apply an
90. Check pilot runout by rotating output flange Total indicated runout must not exceed 0 10 mm 0 004 in NOTE Should total dial indicator runout exceed 0 10 mm 0 004 in proceed as follows A With a felt tip pen draw a line across the end of the output shaft and face of output shaft counterbore to mark original installed position of the output flange versus the output shaft B Remove the output flange as described in Section 6 and reinstall 90 from original position Recheck runout of flange face and flange pilot using procedures in steps 6 and 7 above If runout is within specification do nothing more C If runout continues to exceed tolerance repeat procedure in B above at positions 180 and 270 from originally installed output flange position Stop at whatever position output flange runout is no more than 0 10 mm 0 004 in D If output flange runout cannot be reduced to acceptable tolerances contact the Product Service Department at Twin Disc Incorporated for informa tion recommendations If your output shaft is tapered follow these instructions 1 Clean tapered surface of output shaft and tapered bore of output gear Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Wipe surface with clean paper towel Do not touch cleaned surfaces CAUTION Tapered surface of shaft and matching tapered bore of flange must be completely free of grease oil dirt or solvent residue Failure
91. F 29550 917 99 5 20 99 2 2 99 15 11 5529 10 20 98 1223 97 LOCATION DRAIN IN MANIFOLD SEE NOTE 6 CLUTCH ACTUATING A PRESSURE Mie x 1 75 THREAD PURT CONFURMS TU ISU 6149 FITTING MA10S3K lt 2 CME SURE M2067B lt 2 u OIL DRAIN TH ISO 6149 Mc X das cub 4 HULES EQUALLY SPACE START THE PLUG INTO THE COVER BORE INTERNAL SPLINE DATA SEE S 435 _ oor 307 _ AES PITCH 1 4167 1 504 MAJUR DIAMETER 1 535 CIRCULAR SPACE 1327 1345 MEASUREMENT BETWEEN MIN ACT 1 2052 4 DIA PINS WITH NONE FLAT eD 1 2078 MAJOR DIAMETER 1283 CIRCULAR SPACE 1317 WIDTH T ACT MEASUREMENT BETWEEN 144 DIA PINS WITH NONE FLA X 175 THREAD METRIC PERT cud c ds 180 APPLY THIN BEAD ANERUBIC SEALANT 8 8 THE PLUG UD PER 5774 AND INSTALL TE AE GUESS SURFACE Br IDEE Ss MG 5208DC 1015207 MG 5170DC 1017463 MG 516 74700 SAE TO SAE J744 No PUMP ADAPTER IS 592 CONSULT SALES DEPT s J744 No PUMP ADAPTER IS 1186 MAX APPROVED INPUT TORQUE 32 4 SIZ APPLICATIDN ENGINEERS OTHER LIMITING CONDITI NOTICE
92. Incorpo rated To prevent accidental starting of the engine when servicing Twin Disc marine transmissions disconnect battery cables and remove ignition key from the switch Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 1 1 SECTION 1 1 2 CAUTION 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 CAUTION Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing Bolts should be near but should not contact bottom of bolt hole 1 3 Preventative Maintenance Frequent reference to the information provided in the operator s manual regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are provided for the recommended maintenance of the equipment and if ob served minimum repairs aside from normal wear will result See Section 4 Maintenance and Specifications 1 4 Replacement Parts replacement parts or products including tubes 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
93. 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 Be sure to inspect the housing in the vicinity of all pusher screw locations If you cannot remove defects with crocus cloth or a soft stone replace the part Inspect threaded openings for damaged threads Chase damaged threads with a tap of the correct size Inspect studs for damaged threads and looseness Replace defective studs Inspect dowel pins for wear or damage Replace defective dowels This applies where a matched set of parts is not involved Inspect dowel pin holes for wear due to movement between mating parts If a dowel pin hole is worn re bore and sleeve the hole when possible Otherwise replace the parts This applies where a matched set of parts is not involved Check Ball Seats Inspect check ball seats for burrs nicks and scratches If you cannot remove these defects with a crocus cloth replace the part Check to see that the check ball is seating properly after reworking the check ball seat SECTION 7 Cleaning and Inspection Cleaning and Inspection C Bearings 1 Inspect bearings for roughness of rotation Replace the bearing if the rotation is rough 2 Inspect bearings for corrosion and for indication of wear of balls or rollers Inspect for scored scratch
94. Keel cooler water 60 C 140 F State min also max L Min gpm of water flow to H E HEAT EXCHANGER INSTALLATION amp SERVICE REQUIREMENTS Oil Lines Transmission to H E and Return 1 Max Velocity in Fittings Pipe Hose and Tubes 7 6 m sec 25 ft sec 2 Burst Pressure Min 10 X Peak Oil Pressure at H E 3 Hose SAE 4517 10081 Meeting USCG 46CFR 56 60 25 C 135 C 275 F Temperature Rating 4 Protect lines from mechanical damage Zinc anodes protect H E raw water passages from corrosion Check amp replace them frequently 5205 05 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 4 5 SECTION 4 4 6 4 2 In boat Maintenance 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 e Removing cleaning and installing the suction strainer e Removing and installing the control valve Removing and installing the manifold or top cover bearing carrier and lube tube Removing and installing the primary and secondary shaft assemblies NOTE See special tools section for lifting bracket to aid in clutch removal e Changing primary and secondary clutch plates NOTE Further disassembly reassembly of the primary or secondary shafts will require use of tools and equipment normally not available on board the vessel
95. M27 X 2 0 THREAD METRIC PORT CONFORMS 16 7 DRILL THRU 2 HOLES ENGAGES ISO 6149 FOR 3 8 11UNC STANDARD WITH NUTS THESE HOLES MAY USED LIFTING MARINE TRANSMISSION ONLY PRIMARY SHAFT CLUTCH Z hs c 4 NOTE GES ELECTRIC CONTROL MODE SWITCH OU 1 4 18 CDRYSEAL TH D LEVER BE LHCATED ANYWHERE CLOSED WHEN MANUAL VALVE MOUNT GAGE IN PILOT HOUSE IN ITS SHAFT THAT PERMITS FREE 562 R 5 0 HOUSING STEM IS LOCKED IN ELECTRIC I MOVEMENT WITHIN THE 50 TOTAL MODE 64 2911 SIDE x ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL Se det am asa M8 X 1 25 6 THREAD usd OMITTED ON SAE 0 HSG 2 HOLES SUITABLE FOR 189 4 t CONTROL MOUNTING x 127 i OUTLINE OPTIONAL 1 SAE 0 HOUSING ADAPTER LUBE PRESSURE 0 M18 x 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 SAE 1 HOUSING AUXILIARY LUBE SUPPLY INCH INLET SEE HYDRAULIC OIL IN FROM HEAT EXCHANGER 1 4 DIA THRU DIAGRAM M33 X 20 THREAD METRIC PORT CONFORMS TO ISO 6149 5 THREAD e BEFDRE ENGAGES OPERATING UNIT SECUNDARY 0 C015 CLUTCH DIL OUT TO HEAT EXCHANGER M33 X 2 THREAD METRIC PORT CONFORMS ISU
96. PINION giae 92 8 3 7 2 48 1 85 3 3 4 2 031 73 0 3 0 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 1 NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE 15 NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT C s SZ PLACES eeo L88 Ge PRIMARY CLUTCH ACTUATING PRESSURE M10 x 10 THREAD METRIC PORT CONFORMS TO ISO 6149 0 HOUSING OUTLINE 5 16 180 TAP THRU EN 2 HOLES SUITABLE FUR CONTROL MOUNTING LUBE P S I 6 LL x 15 THREAD ENGAGES CLUTCH EN eS SHAFT CALLED AUXILIARY LUBE SUPPLY 2 PRIMARY C INLET SEE HYDRAULIC DIAGRAM DISTANCE REQUIRED REMOVE DIL GAGE GAGE IS FLEXIBLE AND CAN BE BENT IF NECESSARY DIL FILLER HOLE 535 6 21 09 0 ou n v Y ed 5 lt 4 IN D QI x T gt LI Oe aJ gt ND JD u D CJ 9 V 915 ER CLUTCH DS SHAFT Na Ms Duc N I nado 1 NA 5 GREASE e FITTING lt al I DRIVING THRU PRIMARY CLUTCH b L Ir CO UU SE D 0 SF 24 5 1961 9 THRU 8 HOLES EQUALLY SPACED DRIVING THRU SECONDARY CLUTCH OUTPUT SHAFT t
97. RAV 3574 ES m NI 3 V S SN B BOLTS INSTALL M20670 PLUGS IN MOUNTING BOLT CDOUNTERBDRES 00 M2087K 1 RACs INF EN S NN NSNN SN 5 52 TROLLING VALVE REQUIRES 89 156 N AT THE 46 0 R LOCATION DF THE S O Me086A V AAT LESS gt ey GS Wes 6 4 HOLE TO OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR ug 778 SOUL SSN 2 2 INS M2038AD 1 MUST PROVIDE 65 0 LINEAR TRAVEL FROM DETENT THE 6 4 4 S d HOLE LOCATION THE DETENT FEATURE IS PROVIDED IN B1139 THE RATE RISE POSITION ONLY 2297 X SW SS ISS SS 5 CHESS 1 6 CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK gt position ENN 20 20020 220 2 2 2 ASAE HN B6115A TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION P CRT SE vm meme n Eee Se NN Well 2 AE DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS 2916 SIS STEEN Z THAT REQUIRE FULL POWER TO THE PROPELLER 2X S Ll ONSE NW IL EISE PS VN Ee 2870k 7 INSTALL EACH D RING FROM ITS RESPECTIVE SIDE OF TROLLING 4 7 Mh ES VALVE COVER DO NOT PASS 6 THROUGH CENTRAL CAM SLOT 4347 GASKET
98. SEE CHART 3 H 0 DATUM io FIELD Coma 2 2 u um fi INSTRUCTIONS V V MIN DIA HOLE MUST BE 2 gt LOCATED IN THIS AREA IN MATING E Ey PART F R VALVE DRAIN 13 32 DRILL THRU PORT FOR 4 HOLES 1st CLUTCH FOR MOUNTING BOLTS WITHIN 008R DF TRUE POSITION es MMC IN RELATION TO DATUM 3105 z OIL INLET A7361B 4 02 VALVE BODY ONLY NOW OBSOLETE k PISTON DESIGN 4 100 4 390 SECTION D D ADJUSTS TROLLING PRESSURE ADJUSTS CONTROL PRESSURE SECTION ORIFICE PLATE SECTION F ss F GASKET GASKET THIRD ANGLE PROJECTION SIMILAR TO XA7362 SERIES UNLESS OTHERWISE SPECIFIED MACHINED DIMENSIONS X X 0 050 WEIGHT wr DATE 8 24 90 SCALE 2 1 00 DRN KS HK I NC R E D RACINE WI 53403 USA LBS LBS IN 0 010 0 005 ALL ANGULAR TOLERANCES 1 FIRST USE ASSY SEE CHART MODEL XA 3 2 GEOMETRIC TOLERANCING PER ANSI 14 5 1982 SERIES C SURFACE TREATMENT NAME B A file name XA7372 Ist CLUTCH ENGAGED FOR 3 POSITION SE USE ENGAGED POSITION ENGAGED amp DISENGAGED USE CORI 8 1 25 TAP THRU ROLES 68 6 NEUTRAL FOR 3 29 2 Tr 55 9 z WITH POSITION FWD GASKET 36 50 NEU REV USE 22 222222 2
99. THIS PRINT CONTAINS y PROPRIETARY INFORMATION AND IS IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA IS NOT INTENDED TS THIS NOTICE T NULLIFY LIMIT RIGH GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT MAX APPROVED INPUT TORQUE 38 4 SIZE METRIC PROJECTION WO Ul 2 6 UNLESS OTHERWISE SPECIFIED DATE 11 18 97 SCALE 589 CENTER LABEL 1018729 CAUTION MAX TEMP 100 REDUCE SHAFT SPEED IF EXCEEDED w C RATURE 100 SHAFT RPM t REDUCE 22222222222222222222222222222222222222222 365 QZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZ 4 PART 1016473 ON MOTOR NAMEPLATE RED PILOT LIGHT LIT WHEN MOTOR IS OPERATING OIL OUT 1 2 14 N P T THREAD INSTALL PLUGS FOR SHIPPING FILTER REPLACEMENT ELEMENT FILTER PRODUCTS CORPORATION 30 25 PARKER 925023 CROSS 119023 2 150 INSTALL PLUGS FOR SHIPPING OIL IN 3 4 14 N P T THREAD FEMALE PIPE SWIVEL 100 MESH INLET STRAINER REMOVABLE SCREEN LARGE HEX PLUG REMOVE THIS ENDCAP TO SMALL PIPE PLUG EXTRACT SCREEN FOR CLEANING REMOVE TO CLEAN D SINGLE PHASE CAPACITOR THERMALLY PROTECTED DUAL VOLTAGE DUAL ROTATION 8 LEAD REMOVE PLUG TO
100. WITH 31 8 1 1 4 SQUARE KEY UE 608 37 e395 139 7 5 50 WITH 31 8 1 1 4 X 22 2 7 8 t PROJECTION RECT KEY amp 1251 lt bS0INZET 5 TAPER m amp NOTICE THIS PRINT CONTAINS WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE 2 SAE 620 C D TEMPERATURE INDICATING SWITCH PROPRIETARY INFORMATION AND IS 1 17 94 C G H PIPE TE x dei eas c 006 605 ce 006 004 IN THE HYDRAULIC LINE LEADING FROM THE MARINE 50 1 00 RACINE VI 53403 USA 711 2 679 45 647 70 571 50 542 92 4953 15 7 318 6 60 SE NE 460 1181 TRANSMISSIDN PUMP THE HEAT EXCHANGER INLET ME TRIC TWIN DISC INCORPORATED ALL ANGULAR TOLERANCES 1 5 9 1355 558 4 530 20 51117 466 725 43815 409 4 25 4 224 EXCEPT FOR INCH DIMENSIONS AND 2 PER ANST YI4SN 1982 CHR 1 D e 5 gt 21 75 20 875 20 125 gt 18 375 gt 17 250 16 122 lt 1 00 gt 88 gt 93 133 _EXCEPT FUR INCH DIMENSIONS AND THIS NOTICE IS NOT INTENDED NOTE POUNDS SHOWN IN BRACKETS 1 NULLIFY DR LIMIT RIGHTS SURF ACE IRE LENT kus MARINE gt APPD ALL POINTS AVAILABLE FOR TESTING ARE CODED V OTHERS BY CONTRACT 5 TRANSMISSION SHEET 2 2 REV O 2 Ed 3 B1048BB e ee eJ adeste um JE
101. X X X XX 0 13 DRN ALL ANGULAR TOLERANCES 1 PER ANSI 14 5 1982 1 2 THIS ACTICE 15 NOT INTENDED w 202 GRANTED TO THE U S GOVERNMENT DR DTHERS BY CUNTRACT MARINE TRANSMISSION DAS SHEET 6 79 REV Le SAE 0 HUUSING WAS EX8587 48 wies NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED PROPRIETARY INFORMATION AND IS DIMENSIONS 4 12 94 Tod ul DISE NOT TO BE USED IN ANY MANNER CBS CBS N 0 050 SCALE INCORPORATED DETRIMENTAL TO THE INTERESTS OF X XX 20 010 FIRST USE XXXX 50 005 25 1 00 RACINE WT 293405 USA TWIN DISC INCORPORATED me ALL ANGULAR TOLERANCES 1 DRN RACINE WI 93403 USA GEOMETRIC TDLERANCING MODEL PER ANSI Y14 5M 1982 THIS NOTICE IS NOT INTENDED AZ TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME M 3 5 e 2 i Q ORA IR OTHERS BY CONTRACT MARINE TRANSMISSION 7 pr T
102. ing NOTE This bearing is a slip fit and will not require special tools for installation 12 Assembly of pinion A Use special tool T18050 607 to install chilled tapered roller bearing cup into rear of pinion for secondary shaft Bearing cup is installed with small I D of 9 18 SECTION 9 Assembly Assembly taper toward the front and seated against shoulder of bore in clutch hub Fig 9 20 B Install chilled roller bearing into bore at front of pinion C Install internal retaining ring into groove in pinion bore LAGAN Fig 9 21 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 19 SECTION 9 9 20 13 14 D Some 1014841 assemblies only Press front tapered roller bearing cone for secondary pinion onto bearing spacer Install bearing with large diam eter pressed to shoulder of bearing spacer Refer to Bill of Material to deter mine if a spacer is to be used and also Tech Talk 98 005 for more information about pinion spacer usage E Align plates in clutch pack and install pinion on secondary shaft so that external teeth on clutch hub mesh with internal teeth of steel plates in clutch pack Assure that clutch hub is in mesh with all plates E Install external retaining ring to retain pinion on shaft B Fig 9 22 Install two piston rings into grooves at rear end of shaft Assemble primary shaft Assembly procedure for primary shaft is exactly the sa
103. 1016666 ves 3 2759 424 Voc 7072 A2707Z ae70aT 725 eso 1017129 x 20 68 52451 hoisa4on 1017133 1017134 31337F 1017179 e we7ssrMe4 585 a aa MARS5G p4513 i033 1017134 31337F 1017179 VDC xAP7078Z AB7075v a2703BA eom 1017109 PT c oa M 824518 1018440 1017133 1017134 31337F 1017179 e werssrt ie 70782 827078 en 1017169 EE sa 1018440F 1017133A 1017134 31337r 018688 e 2769 24 7072 27072 7 725 lt 250 1017129 steer x 21 BP4513 hoieaaoc 1017133A 1017134 7 1 e 75 vacl xae7o7z A2707Z 7 725 ceso 17129 _ x ELECTRIC CONTROL MODE SWITCH CLOSED WHEN MANUAL VALVE STEM IS LOCKED IN ELECTRIC MODE PLATE 1018312 SECURE LEVER IN THE DEPRESSED 70 75 TROLLING 90 RANGE 4175 1017583 1017569 1017613 1019688 e 759 24 2 427072 eros 2000 2905 1017129 x e0 lt w Be4518 9 MAI062B 1164400 4176 _ 1017583 1017569 1017613 1018688 e jwwezseri ie vpc xae7o7z 627072 AP703T 2000 290 1017129 pateseteer x ex em Re4
104. 14 4 3 1016249 MG5203SC 14 5 1016250 amp 1016250A MG5204SC 14 6 1015207 MG5202DC 14 7 1015207 MG5202DC 14 8 A7119R Hydraulic Diagram 14 9 A7119Q Hydraulic Diagram 14 10 A7119W Hydraulic Diagram 14 11 A7119Y Hydraulic Diagram 14 12 XA7371 Control Valve 14 13 7372 Control Valve with Trolling 14 14 XA7540 Control Valve 14 15 XA7600 Control Valve with Trolling 14 16 1017172 Control Valve 14 17 1017555 Trolling Valve 14 18 1018084 Control Valve list continued on page 14 2 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 14 1 SECTION 14 14 2 14 19 14 20 14 21 14 22 1018440 Control Valve with Trolling 1017177 Live PTO 1017820 Clutchable PTO 1016473 Electric Trailing Pump remote mounted SECTION 14 Engineering Drawings ASSEMBLY INSTRUCTIONS O 2693 5 1 THRU 8 ARE IN 570 1015361 1015360 ZIS lt CONTROL VALVE ASSEMBLY B1703D es 2510 SIR S 9 99S ea 39 l 2 2 sj lee THESE STANDARDS APPLY aul ai so lt lt olx 8 lt lt 1
105. 16 lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 300 16 lifting force on bearing Zero the dial indicator and mark the spot where the reading was taken D Using a hoist exert 2225 N to 4000 500 Ibs to 900 Ibs of lifting force onto the shaft Rotate shaft several revolutions with lifting force applied Stop rotation with dial indicator finger on mark previously made continuing to hold Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 11 SECTION 9 lifting force Read shaft endplay dial indicator E Make a shim pack to decrease endplay to 0 05 mm to 0 15 mm 0 002 in to 0 006 in Install shim pack between seal carrier and housing E Repeat steps B through D until endplay is between 0 05 mm to 0 15 mm 0 002 in to 0 006 in 2 Remove lifting fixture Remove capscrews and remove output seal carrier 3 Install O ring in groove in O D of output seal carrier 4 Install oil seals into output seal carrier using driver T18050 120 Note Coat O D of seals with M2828 anaerobic sealant prior to installation Remove ex cess sealant that is wiped off as seals are pressed into position A Install forward seal with spring loaded lip toward the inside of the trans mission Install flush with inner face of seal carrier B Install rear seal with spring loaded lip of seal toward rear of the transmis sion Install flush with outer face of s
106. 2 PLACES i CUTOUTS N d N 26 2 1 1 32 THRU N DRIVING THRU 8 HDLES EQUALLY SPACED p 520 SECONDARY CLUTCH 4 Se ___ lt FLYWHEEL DUTLINE HOUSING MUST CONFORM TO T 2 PLACES 1620 ND 460 18 2 CUTOUTS SECONDARY de CLUTCH ACTUATING 5 00 R 177 8 er XD 101 6 4 00 101 6 4 00 9 101 6 4 00 j 6 096 PRESSURE 1 2 20UNF TH D 2 PLACES Jus 6 350 PER SAE J514 O RING OUTPUT CUTOUTS n 540 CONNECTION t iux 2507 S 4 45 22 gt y lt d B 3 8 16UNC THREAD E 4 DIL DRAIN PLUG DRILL THRU ds 1 5 16 12UNF THREAD HULES EQUALLY SPACED 3 4 10UNC1 TH D 318 1 251 DEEP 15 0 0 59 e ___ 100 3 203 2 4084 E x E CLASS QUALITY 16 HOLES 8 EACH SIDES CLEARANCE TO REMOVE 3 95 GRADE 5 QUALITY CAPSCREWS USE ALL 16 HOLES FOR MOUNTING UNIT DRAIN PLUG CLEARANCE 211 91 8 343 USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS TO REMOVE BASIC PER SAE 24291 AND TORQUE PER ISO 898 1 GRADE 5 QUALITY SUCTION ee UR SERVICE MANUAL CAPSCREWS PER SAF 4291 AND TORQUE SCREEN 245 1 2 65 2667 10 50 574 SERVICE MANUAL VALUES N 332 6 13 09 ses S 228 6 3 00 355 6 14 00 564 6 22 23 Gd Ae COMPANION FLANGE MAX BORES 114 3 4 50 WITH 25 4 1 00 SQUARE KEY 120 6 4 75
107. 22 4 23 00 26 7501 25 5001122 5001 21 3751 19 501 2 621 ELLOS Tes NOTE UNITS WITH THIS FLEXIBLE CDUPLING ARE APPROVED FOR RIGHT HAND ENGINE ROTATION ONLY DUE TO COUPLING RESTRICTION ADVANCE MARINE TRANSMISSION INTO POSITION WITH ENGINE FLYWHEEL HOUSING MOUNTING FLANGE LINE UP INPUT SHAFT EXTERNAL SPLINE WITH INTERNAL SPLINE IN COUPLING HUB AND MOVE ENGINE AND MARINE TRANSMISSION TOGETHER MAINTAINING ENGINE FLYWHEEL HOUSING AND MARINE TRANSMISSION FLYWHEEL HOUSING MOUNTING FACES IN PARALLEL RELATIONSHIP ENGAGE FLYWHEEL HOUSING PILOTS AND INSTALL ALL MOUNTING CAPSCREWS USING 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 LGRADE QUALITY CAPSCREWS PER S AE J429 TORQUED TO 574 DR SERVICE MANUAL VALUES E ties 999000 5182171 466725 A BSAA dv A 7345 9179 90S 7 emteodig 75 SERVICEABLE SEPARATELY SECURE FLEXIBLE COUPLING HOUSING S AE FLANGE HOLES USING STANDARD METHOD BEFORE SHIPMENT OF UNIT COUPLING I COUPLING SIZE NOMINAL TORQUE TORSIONAL REF 5x STIFFNESS WR WITHOUT TORSIONAL STOP WR WITH TORSIONAL STOP C DUTER PARTS INNER PARTS DUTER PARTS INNER PARTS 38 6 kN 0 76 0 30 kg m LS14E 2500 6 24 kN m 38 6 kN 0 98 kg m 0 30 4400 55 2 x 103 342 x 10 lbf in rad 3169 lb in
108. 5 p 22 SCREW 2000 28 45 58 93 51 82 LEVER B2103 xX STR TH D D RING 1506149 MAIN PRESSURE DIL INLET WHEN NOT INTERNALLY SUPPLIED THREAD SIZE AT PORT 1 4 18 NP T F WHEN 2052 REDUCER BUSHING IS SPECIFIED MEG ASSY 1017172 40770 1017133 1017134 B1337F 1018163 1018688 427072 A2703T 1725 250 gt 1017129 10 8 7 20 6 _ 052 2 1052 2 MG seoepnc 32798 1071724 40772 1017383 iot8163 1017179 AB7075D AP704BU pars 3505 I017129A 0 x oyec anes 1017983 1016163 1017179 2655 x eo em 54518 00 6 6449 nase uJ x m 2 PLUG M2051K 2 1 1017172D 1017383 1018163 1017179 _ 2550 370 10171294 0 27 x 20 6 51 3 MG 6557 ama 1017172 AVAILARE 1017383 1018163 1017179 _ 2450 355 10171294 1038 7 x BP451B Reo ase e x A 1017172 41085 1017133 101
109. 6149 e REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT 2 la 3 I RARE J 5 9 D 28 p _7 PRIMARY O SHAFT t LUBE PRESSUR X 15 THREAD A 5 METRIC PORT CONFORMS PRIMARY D j ISO 6149 CLUTCH Oe AUXILIARY LUBE SUPPLY 49 zs 0 M INLET HYDRAULIC FILTER DRAIN TR DIAGRAM lt N 57 P STOCK BORE SIZE ON EUST TIMER TE NN BORE 4 2 Z ee GREASE YA CENTER se FITTING GRAVITY 6125 SECONDARY CLUTCH H R H ENGINE 2 N DRIVING THRU PRIMARY CLUTCH ON e NF NE JD V e o V 24 5 THRU ON ENGINE 8 HOLES EQUALLY SPACED i DRIVING THRU _ SECUNDARY CLUTCH H H HOUSING 2298 60 OUTPUT SECONDARY REF t 1387 CLUTCH ACTUATING 101 6 Le 101 6 PRESSURE 10 X 10 TH D _ 6 223 0127 METRIC PORT CONFORMS 5 6149 lt m M20 X 2 3 TH D 300 DEEP 16 HOLES 8 EACH SIDE USE ALL 16 HOLES FOR MOUNTING UNIT 3 8 16UNC THREAD 7 6 S DEEP SUCTION SCREEN USE 88 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE TO 55 4 UR SERVICE MANUAL VALUES 266 7 TEMPERATURE 1 4 18 NPTF DRYSEAL 525 6 355 6 R
110. AND HEAT EXCHANGER b gt THIS UNIT CAN NOT BE USED WITH LEFT HAND ENGINE c OPTIONAL EQUIPMENT COMPANION FLANGE ASSEMBLY 1002312 CONTROL TROLLING VALVE XA7600 LIVE P T O XB6243A AUXILIARY PUMP DRIVE FLEXIBLE COUPLING INPUTS SEE SHEET 5 OF 5 KIT BOM 1090 METRIC TO NPTF ADAPTER KIT 4 gt 007 J SON 1 2 HCHLEHLETHA TT 222 RSS Z UE 7 85 Z SNC SON ON SEE 3 S IN gt Isi awa ACN 422222242224 lt lt 777 lt SEE NOTE Uo 7 lt XXX EXAM GEAR GEAR Sool GEAR 6 101 GEAR 52 041 GEAR 4 591 4 031 OIL TEMPERATURE INDICATING SWITCH 83424 FUR INSTALLATION LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 3 SERVICEABLE SEPARATELY REMOVE BEFORE OPERATING 2 PLACES PLUGS E 4 LOOT 1015240 RATIO 1311 1015241 I 1015242 RATIH leet 1015243 RATIO 1241 1015244 RATIO 12
111. ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERMENT OR OTHERS BY CONTRACT PRIMARY CLUTTER SHAFT GREASE FITTING LUBE A 18 X 15 IHREAD METRIC TEL ISBE 6145 AUXILIARY LUBE SUPPLY NLET SEE HYDRAULIC DIAGRAM CZ HEAT EXCHANGER CHE REQUIREMENTS REFER B3649K HEAT EXCHANGER DATA Go PRIMARY CLUTCH ACTUATING PRESSURE 6 M18 X 15 THREAD METRIC PURT CONFORMS ISU 6149 GAGE IS FLEXIBLE AND CAN BE BENT IF NECESSARY aT SHAFI 24 5 THRU UIL DRAIN PLUG M33 THREAD 406 4 MATERIAL HEAT TREAT SURFACE TREATMENT DRIVING THRU SECONDARY CLUTCH 12 HOLES EQUALLY SPACED 9 lt 9 J LJ gt L1 go C lt v L I t NE LO Cr Y 3D Oon QU a A 50 se E e S 0 tv 9 M L I O C lt N lt V V V V V C ARS 5 DRIVING THRU PRIMARY CLUTCH 3 gt cad file 11520744 MT a WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE pr TWIN DISE 1032 SCALE INCORPORATED Nm MACHINED DIMENSIDNS X 0 75 50 1 00 FIRST USE X X
112. APPD SUMP WITH TROLLING VALVE SHOWN WITH CLUTCH Clutch ENGAGED Clutch Solenoiq Solenoid Solenoid 6 ASCO SHOWN WITH CLUTCH A ENGAGED Neutral Clutch Clutch Solenoid B A Solenoid Solenoid ASCO Neutral Solenoid WITH HYDRAULIC LOCK MANUAL OVERRIDE MODE SHOWN IN NEUTRAL MANUAL OVERRIDE NEUTRAL START SWITCH MANUAL OVERRIDE NEUTRAL START SWITCH 71 m u r 41 lt 2 es x CU ptt dy 2271 r I 22 17 AA OQ SIE SEHE Ji Section C C Section Section ELECTRIC CONTROL MODE SWITCH RATE OF RISE FUNCTIONS DETENT TROLLING PRESSUR ELECTRIC CONTROL MODE SWITCH Section A A LEVER LOCKED s FUR ELECTRIC ch Dub icio OPERATION Value EET TZ K Bw EA H T DEA p j S z l N Ji 4 LA 15 aod i 4 j a METRIC ELECTRIC MODE Electric Manual valve MG 509 thru 6124 2 REFERENCE VALVE ASSEMBLY 1018440 A ENGAGED Filter NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED ay fe INTERMEDIATE HEAT TREAT FIRST USE xx 0 25 00 1 RACINE WI 53403 USA MANU
113. Assembly Assembly 5 Install cups for rear tapered roller bearings on primary and secondary shafts into bores in bearing carrier Tap cups down gently with soft hammer or brass drift to seat against bearing cones on shafts 6 Install manifold gasket over alignment studs and against bearing carrier Install with silicone beaded side up 7 Push tapered roller bearing cups with shim retainers firmly against roller bear ing cones on rear of primary and secondary shafts Use a depth micrometer to measure from manifold gasket face to shim retainers Measured distance is shaft endplay Use necessary shims to develop a shim pack for each shaft to reduce shaft endplay to 0 05 mm to 0 15 mm 0 002 in to 0 006 in 8 Install calculated shim pack at each shaft location On units without roll pins in the shim retainers install thickest shim against bearing cup install remaining shims then retainer agaist shims at each shaft On units with roll pins in the shim retainers place the shim retainers against the bearing cup and the shims over the roll pins Orient the shim retain ers of both clutch shafts such that the roll pins are all in a single line This is required to ensure the roll pins fit into the cast pockets of the manifold 9 9 Assembly and Installation of Manifold 1 Install new O rings onto the plugs used for the clutch and lube pressure test ports Lubricate and install the plugs torquing them to specification see Torque Chart
114. CENTERLINE 78 00 ADAPTER 1017834 RING M1904L 25 00 SA f RING A2669FV ULL E E 3 7 2 yess SSS 2222 2 cce 2 LE aT u NN L Z VETERA u 5 WY 22 CCC BAR CU lt Sis J744 No 127 2 127 4 FLANGE AND 744 32 4 DRIVE ADAPTER SHOWN BELOW CENTERLINE SECTION A RING A2669DG CARRIER 1015532 O RING 2916 CAPSCREW 1062 A PLUG 1945 CAPSCREW 10625 42 VALUES WHEN MOUNTING 4 BDLT PUMP REPLACE THESE SCREWS WITH STUDS ADEQUATE LENGTH MOUNT BOTH THE PUMP AND CARRIER SECURE PUMP AND CARRIER WITH NUTS ADAPTER 1017836 SAE J744 No 38 4 0 03 127 06 9 ADAPTER 1017835 SAE J744 No 32 4 MAX APPROVED INPUT TORQUE E S 22 lt 4 HOLES SAE 744 38 4 SIZE PUMP ADAPTER 1 1187 N m c mmm ANGLE PROJECTION A THIS PLUG IS USED ONLY FOR FACTORY INSTALLATIONS OF AN AUXILIARY WAX APPROVED Se ES Se PUMP DRIVE WITHOUT AUXILIARY PUMP INSTALLED PUMP ADAPTER IS 592 N m START M1945T CUP PLUG INTO CARRIER BORE APPLY A THIN BEAD OF CONSULT SALES DEPT ANEROBIC SEALANT M2828 TO PLUG 0 0 PER 774 AND INSTALL PLUG FLUSH WITH REAR SURFACE OF CARRIER LI jJ L THS PRINT contains Nu BE IN ANY MANNER INTERNAL SPLINE DATA
115. CHART 2 00 1 4 DRILL SEE NOTE 3 ORIFICE SPACER M VALVE SPRINGS 12 PT SCREWS INSTR DATE CLUTCH eerie PLATE Y Parlar SPRING consists P S a PRATE FIRST QTY PART ND SIZE ASS Y INNER QTY APPR A7361B 8575 Ses ee wo vaszyrca AP7078X 200 weossr 5 2 waste 7 8597 960 Heme wo wemwee 230 weneoma pessa APE Fee bases PRP wa wemer eso 2 WER A7361B 8575 1860 eie wo A27078V aa7oacx 160 2 2 nessa mesis 6 A7361p 1877 96 wo 4 707 150 weossr weoesr e pessa Fee s ___ A27078X ae7osaT 200 1 3 2464 516 VALVES FER LES NE CONTAINED IN VALVE BILL MATERIAL INSTALLATIDN DATA 1 2 3 3 VALVE SUITABLE FOR UP TO 85 GPM CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 30 AND 90 P SI DEPENDING UPON SPRING ASS Y USED THRU VALVE AND INTERMEDIATE PRESSURE CO
116. Directional Port L Oil Pressure Chamber Control Valve L ever Control Valve Stem Control Valve Body Atmospheric Pressure Engaging Pressure Fig 3 4 Control Valve Primary Cutaway View Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 5 SECTION 3 3 6 Manual Control Valve Secondary When shift to the secondary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 3 5 and 3 6 The pressurized oil in chamber B is directed through ports G and K to passages E and J E is aligned with a passage directing main pressure to the secondary clutch Pressurized oil from port G travels through passage J and enters chamber L through an orifice in the orifice plate The orifice in the pate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against springs until the piston is stopped by a shoulder in the valve body The causes the pressure in chamber B to rise to clutch engaging pressure When in secondary passage D remains at atmospheric pressure because slot F re mains open to sump When a shift is made from secondary to neutral the valve stem is rotated to the position illustrated by Figures 3 1 and 3 2 Under these conditions passage E is connected to the sump by slot F Passage J is also con
117. INSTALL CUSTOMER SUPPLIED PRESSURE ALARM SWITCH 13 8 41 4 kPa SETTING SEE TOP VIEW FOR TENES NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NDT T BE USED IN ANY_MANNER 3 65M POWER CORD D 2 5 29860 1 26 00 DETRIMENTAL THE INTERESTS P 3 PRONG GROUNDING PLUG E TWIN DISC INCORPORATED H 115 V AC 29423 7 6 99 53403 USA Me COILED AND TIE WRAPPED 1 29078 1 19 99 THIS IS INTENDED FOR SHIPMENT 29003 12 4 98 GRANTED TU THE US GOVERNMENT d OR OTHERS BY CONTRACT GAUGE 1379 kPa MATERIAL HEAT TREAT SURFACE TREATMENT FILTER WITH 172 kPa BYPASS 25 MICRON WEIGHT ASSY MODEL SECONDARY LUBE TEST PORT 27 0 FIRST USE HEAT EXCH FAN ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING PER ANSI 14 5 1982 PUMP ASSEMBLY TRAILING SHEET _1 oF 1 RELIEF VALVE 483 kPa 3 4 NPT QUICK DISCONNECT 6 3 OIL TO AIR HEAT EXCHANGER pil 4 3 DRAIN PORT 2 PUMP FLOW RATE IS 110 l min 102 C SIMILAR UNLESS DTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIDNS X 0 75 24 2 TJIN DISE INCORPORATED DRN 0 25 0 13 RACINE WI 53403 USA 1016473 1017462 03 03 TWIW DISC POWER TRANSMISSION EQUIPMENT NN TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWI
118. L 1 o E E E THESE SULENUID CONNECTIONS PORT SOLENOID f C i i ees ARE NOT POLARITY SENSITIVE na E C C p j 22 220 25 E p UEt OPTIONAL n HYDRAULIC LOCK ON MATING WIRING HARNESS 107403 _ ee 22 22 3 jg une po 22 2 5 22 24221 2711 2 SPOOL 1017432 2 NOTE HYDRAULIC LOCK ONLY Z HYDRAULIC LOCK ONLY LEVER MAY LOCATED ANYWHERE T as ITS SHAFT THAT PERMITS FREE E PISTON SEE CHART ADJUST SETSCREW 0 THAT MOVEMENT WITHIN THE 50 TOTAL ROTATION amp 11 4mm AXIAL MOTION WASHER 1017522 SPRING 27 2 DVERCUME DETENT IS SOLENOID ASS Y SEE CHART REQUIRED CONTROL PIN A2711R 2 11 17 Nm 10 15 lbf in TORQUE TO 33 9 VALVE BODY ASS Y 1017444 GASKET B1334C FEE E INSTALL USING MA908 27 PARTS UNITS WITHOUT NEUTRAL SOLENOID AND E TIERS LOCTITE 242 BALL MA1034A 10 OR 11 UR a qp SPRING ASSY BALL M1990Y 6 HYDRAULIC LOCK DPTIUNAL CONDITION SOLENOID A CARRIER 1017335 SOLENOID SEE on BALL 19900 2 OPTIONAL BALL 1990 PISTUN B1399H BALL M1990E 2 VALVE GASKET 1017136B OVES E EXEUNT d SHIM SEE CHART connec
119. LZ NN LH LA E 2 SIRVA AR LILA PLP ALLL a 1014884 1014885 R N 1014883 ae lt y 7 __ 1 7 2 MASI fa ZZ EE 52300 3 MA1038C 1 ee 2 r 90999 1015343 o o lt L1 MA996D _ 8 e lt lt lt NEN 5509 Wx zT E Ma996r 8 e888Cv 8 Z EY ss A 7 SZ S u AV AV AV AV AV AV AV AV AV N 2772 le 5 AWE ALAA E A Z 2 II NZ S s OPTIONAL EXTRA SUPPLIED ONLY WHEN SO SPECIFIED SHEET CROSS SECTIONS L AND PART NUMBERS a SHEET INSTALLATION 2 OF 3 DRAWING 484 8 FLEXIBLE use Een 3 3 COUPLING INPUTS i Q B3504AE MASS ELASTIC SYSTEM MAX INPUT SPEED 2500 R P M B E E
120. Lubricated 12 3 122 US Standard Unit Capserews Bolts and Nuts a ener e e nnn ain 12 4 Tapered Pine uu ein i enit e Etude eis Eee 12 6 124 Tubs Fittings Hose Fittings Plugs with OTINgS JULI ttt 12 7 12 8 Section 13 Illustrations 13 2 13 4 139 13 6 DE ete 13 7 13 5 Transmission Rear View MG5202SC MG5203SC MG5204S0O 13 8 Transmission Rear View I MGS5202DO ad nae Md dea 13 10 13 6 Transmission Section View MG5202SC MG5203SC 952045 13 12 13 6 Transmission Section View NIG5202DQO 13 14 GOO 13 17 We Conto yao uuu Su aap eraser 13 19 129 13 21 Section 14 Engineering Drawings TES DESWITWQO anane 14 1 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC Table of Contents THIS PAGE INTENTIONALLY LEFT BLANK x Table of Contents Introduction Section 1 Introduction 1 1 General Information This publication provides oper
121. MG 5204SC SECTION 9 9 5 Output Shaft Tapered Roller Bearing Adjustment 1 Tosetoutput shaft bearing clearance proceed as follows Model MG5202SC MG5203SC and MG5204SC A Develop an estimated shim pack 1 Use a depth micrometer and measure the distance from the rear face of housing to the cup of output shaft rear tapered roller bearing Record this reading as dimension Fig 9 10 2 Use a depth micrometer and measure the distance from the pilot of the seal carrier to the mounting flange Record this reading as dimension B Fig 9 11 3 A B Bearing clearance without shims 9 10 SECTION 9 Assembly Assembly 4 Use necessary shims to develop a shim pack that will reduce the endplay to 0 05 mm to 0 15 mm 0 002 in to 0 006 in B Install shim pack and seal carrier without seals or O ring Installthe seal carrier attaching screws and torque to specification see Torque Chart C Install lifting fixture T21397 onto rear of output shaft Apply 1340 N to 4000 N 300 Ibs to 900 Ibs of downward force on rear end of output shaft Seat front bearing by rotating shaft several revolutions with weight applied D Install dial indicator onto the housing with finger resting on rear of output shaft or on lifting fixtures Minimum of 2224 500 16 lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 N 300 Ibs lifting force on bearing Zero the dial indic
122. ND 100 25 07 ens 20049553815 14 FEN 2SIA2MID SSTWNA 33NVSS DL 4939 1141100 0 034 622 104 6 SS3NS03 Tw ane PRIMIS M 25 025 04 24 gt 2 2002 1 18 UN 1001 devis i3 pos PE elc Sapaq E 9 4 vid n HIN 7 E INN TI 8 ER 930995 30088553815 LVW 66 26 2 E y ET vid 0001 6 NIH 009 1934 e 1 BvHS TIV ON 0 HLDN31 ud 24 0 6y i 1 CAD x EL 3 6 130 HIDE 2M 66 26 DILE P 1 934 lt 9 39 _ Jm 130 906900971 5 WYLS ong F lt aus CU NGH Obly LWW ae far NOH S W 190 D av 1103 9 D 1 ET 2 69 12 1 038 gt 32914 Q3 v3sHl 3111901 dvl 01108 8330 SZ x INN 9I 8 E dvl X 9 1075 A33 Tw2ldAL 0 2 2 1 491 001 vid lt 0102 gt 77180 MT I 081 NDIIVOD 09 N 0 038 lt gt x INN ET 3 d330 ler 9 2 71180
123. NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERMENT OR OTHERS BY CONTRACT DISTANCE REQUIRED REMDVE BREAYHER METRIC PORT CONFORMS ISO 6149 298 DISTANCE REQUIRED REMDVE GAGE GAGE IS FLEXIBLE AND CAN BE BENT IF NECESSARY TUN DISS INCORPORATED RACINE WI 53403 USA D 0 THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE 574 OR SERVICE MANUAL VALUES DYNAMIC TORSIONAL STIFFNESS kN m rad TORQUE kN m S A E J620 460 Lu ul lt E E 7 3 B1048X SNAP RING 1 c SAE J620 FLYWHEEL COUPLING COUPLING SIZE i NO EON NOMINAL TORQUE kN m 2750 PER CHART 2 S A E J620 C D MARINE TRANSMISSION 000 0 000 FLYWHEEL TORSIONAL STIFFNESS 12 7 SAE 0 HOUSING 6 4 M RING ADAPTER SAE 355 TO 460 on S A E 0 HOUSING FLYWHEEL OUTLINE MUST CONFORM TO 64 30 6 FLYWHEEL OUTLINE MUST CONFORM TO S A E 4620 NO 555 THRU HOLES EQUALLY SPACED USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER 150 898 1 AND TORQUE 5574 OR SERVICE MANUAL VALUES DYNAMIC COUPLING WR COUPLING WEIGHT kg m 2 WITHOUT WITH SEE SHEET 1 FOR MAXIMUM TRANSMISSION RPM THE 2 INNER PARTS INCLUDES HUB AND 1 4 SHAFT FOR OTHER TRANSMISSION MASS EL
124. REQ D 2 7 SHIM 1014885 SEE 6 IM 1014882 AS REQ D 1014884 IM 1014885 SEE it GEAR 1001116 PLUG A1038D 4 BEARING MEZZI KZ ING M1275 RING M1904DA 2 gt GREW MASIGA K123 EAL MA440 PISI IN B6232 1016217 PIATE UGIVGr ee T ATE 806107B 620 tocne UP SS LG MOUS Oi PLATE B6231 7 40 d E RING A2669AU 2 RING 2031908 2 gt RING ASS Y XA2703BD 32 E RING 49701BG JR PRING ws m FLANGE ASS Y 1002312 SHAFT 1000798 gt 2 5 gt gt T 1048 12 z PTI INA FAT TEA SUPPLIED GR D LY WHEN use D CREW MA1041C O FIELD 100142 RING A2916LF FLANGE 1001042 BEARING 1014858 BEARING MA43 CREW MA9964A 8 SHEE CROSS SECTIONS 1 OF AND PART NUMBERS RING SHE CROSS SECTIONS H U ING 3c HOT A 2 AND PAR UMBERS KAPUSTIN G sa SHE INSTALLATI LUBE gt SHIM 1018458 3 DRAWING SHIM 1018458 5 SEQ D SEE NOTE 6 SHE INSTALLAT SHIM 10184588 1 SHE LEXIBLE PLUG MA1040B 22 22 SHEE 6 SAE 1 HSG S A VIEW file 11520741 GEAR LO De ie _ MASS ELASTIC LM 6 961 RATID 160T SYSTE 4 ES EAT EXCHANGER
125. SHEET INSTALLATION 20057 sl e RE TS 4 Eu 79 T EN 28 63 T S8 T 55 m MASS ELASTIC 504 SYSTEM 5 INPUT SPEED 2500 R P M THIS INFORMATION BE ADDED HEAT EXCHANGER a olau slim slo als slog 1 lt CUNSULT SALES DEPT APPLICATIUN B3649K 1 ek 5 x WHEN IT BECDMES AVAILABLE ERE EE E REQUIREMENTS 55 5 O D w O y y O0 Ped LIMITING CUNDITIUNS HYDRAULIC S 9 2 z 2 80 DIAGRAM 9 QJ QJ QJ THIRD ANGLE CUSTOMER NOTES gt n o2 CAPACITY GALS LESS HOSES AND HEAT EXCHANGER 1171 2034 3484 1521 2481 b THIS UNIT CAN BE USED WITH LEFT 7 RRR 9e HAND ENGINE DIL TEMPERATURE INDICATING SWITCH B3424 FOR INSTALLATION AMI LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 2 D ________ 5 25730 7 95 nonce THIS print contains MATERIAL en TAJUN DISS c OPTIONAL EQUIPMENT Z PROPRIETARY INFORMATION AND IS MACHINED DIMENSIUNS COMPANION FLANGE ASSEMBLY 1015120 OIL PRESSURE GAUGE B1703D FOR INSTALLATION LOCATION j E 25854 1 27 95 NUT TQ USED IN ANY MANNER LBs XX 0020 SCALE INCORPORATED CONTROL TROLLING VALVE XA7372Q SEE HYDRAULIC DIAGRAM
126. SIDE 291 1 EYEBOLT t 185 4 THIS SIDE 7 Em JE OUTLINE OPTIONAL SAE 1 TO SAE 0 HOUSING ADAPTER gt 1 HOUSING SHAFT t 7 6 FILTER DRAIN lt a _ ED 99 CENTER GRAVITY HOUSING 138 7 fai 101 6 101 6 101 6 X 2 3 IH D 30 0 DEEP 6 HOLES SIDE SHOWN 8 HOLES SIDE OPPOSITE USE ALL 14 HOLES FOR MOUNTING UNIT USE 10 9 PROPERTY CLASS QUALITY CAPSCREWS PER ISU 898 1 AND TORQUE 55 4 SERVICE MANUAL VALUES 486 7 547 8 595 2 525 6 REF LUBE PRESSURE PURT MANUAL OVERRIDE NEUTRAL START SWITCH CLOSED ONLY WHEN MANUAL OVERRIDE IS IN USE amp TRANSMISSION IS IN NEUTRAL LEVER LUCATED ANYWHERE ITS SHAFT THAT PERMITS FREE MOVEMENT WITHIN THE 50 2 ROTATION amp 11 4mm AXIAL MOTION REQUIRED FOR CONTROL MAIN PRESSURE PICKUP PORTS 1 4 18 N P T F DRYSEAL TH D MOUNT GAGE IN PILOT HOUSE 36 1 gt MAIN PRESSURE PICKUP PORT M27 X 2 0 THREAD METRIC PORT CONFORMS TO ISO 6149 16 7 DRILL THRU HOLES FOR 5 8 11UNC STANDARD EYEBULTS WITH THESE HOLES MAY BE USED FUR LIFTING MARINE TRANSMISSION ONLY OIL IN FROM HEAT EXCHANGER M33 X 2 0 THREAD METRIC PORT CONFORMS TO ISO 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT 395 4 386 3 76 8 R gt OIL O
127. SPACED USE 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 GRADE 5 QUALITY CLASS PER SAE J429 CAPSCREWS AND TORQUE TO 574 OR SERVICE MANUAL VALUES 6 4 25 FLYWHEEL OUTLINE MUST CONFORM SAE 1 HOUSING 2048 162 TES J lt L 000 0051 000 0042 lt 2620 355 14 Bu M2002BW lt 8 AS REMOVE NUT M2027R 8 A 888CV 8 BEFORE INSTALLATION SANS 555 1002557 2 FLYWHEEL ESE RA TN XX 1015345 1 A N B 14 COUPLING A NOSES 55555 J 251 555525050 KKK ROSY eves 0 E 2 N 2272 a 2 r Z pss LMA c lots I T VA 18 COUPLING B MaS96p 8 MA1039B 8 Tak V S A E 0 D FLYWHEEL DUTLINE HOUSING rM MUST CONFORM TD SAE J620 460 1181 pal oe C THRU HDLES EQUALLY SPACED USE 8 8 PRUPERTY CLASS QUALITY 150 898 1 GRADE 5 QUALITY CLASS PER SAE J429 CAPSCREVS AND TORQUE 574 OR SERVICE MANUAL VALUES CHUPLING FLEXIBLE CHUPLING FLEXIBLE CHUPLING LS14E 4400 LS14E 4400 14 187 S A E J620 MARINE mss acd 67949 647 70 571 90 493 3 4557 1 8 iE E
128. TRANSMISSION TBC OR OTHERS BY CONTRACT CONNECT PRESSURE GAGE LINE HERE X 15 INTERNAL TH D METRIC PORT CONFORMS 150 6149 AT VALVE MOUNT GAGE IN PILOT HDUSE 1 8 27 NPTF EXTERNAL TH D CDRYSEAL AT GAGE CONNECT GAGE INTO LINE BETWEEN AND CONTROL VALVE CUNTROL TROLLING VALVE TROLLING FEATURE OPTIONAL A RATE RISE FUNCTIONS DETENT 6 4 DRILL THRU MAX TROLLING EE HEE REMOVE lt 4 PLASTIC PLUGS CONTROL VALVE TROLLING VALVE NO DETENT TO OBTAIN ACCESS TU 4 VALVE MOUNTING BOLTS 0 90 EN lt 0 DIL IN FROM HEAT EXCHANGER M33 X 2 THREAD E SE 705 METRIC PORT CONFORMS H AN 5 TO 150 6149 REMOVE THREAD PROTECTOR BEFORE UPERATING UNIT 3 MIN TROLLING 2 PRESSURE THE TROLLING LEVER ANGULAR LOCATION _ 55 6 _ DETENT MAY BE ADJUSTED SO THAT THE 90 LEVER ROTATION REQUIRED FOR CONTROL FALLS ANYWHERE WITHIN THE 360 RANGE IN WHICH THE LEVER BE LOCATED gt TROLLING VALVE INSTALLATION AND NOTES 382 53 SPEED PICK UP PORT 355 5 M16 X 1 5 THREAD 15 3 METRIC PORT CONFORMS iss TO ISO 6149 330 20 382 53 917 397 290 89 PRIMARY CLUTCH 9 7 ACTUATING PRESSURE lt 267 44 23495 M18 X 15 THREAD 237 74 FILTER q
129. WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY NEUTRAL ne o ra edis AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS LEVER MAY BE LOCATED uj FORCE AT THE LEVER HOLE TO OPERATE THE VALVE THEN REDUCES TO 13 31N 3 7 0 THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 35 8 1 41 LINEAR TRAVEL N 2 CO FROM NEUTRAL AT THE 6 35 1 4 DIA HOLE LOCATION ROTATIONAL STOPS THE saq In Di STATED VALVE TRAVEL LIMITS HAVE A MAXIMUM CAPACITY OF 445N 100 LBS AT THE uin 6 35 1 4 DIA HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES SO CAPACITY THE VALVE 4 U ROTATIONAL STOPS IS NOT EXCEEDED EXCEEDING THE CAPACITY 7 THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS CONTROL CONTROL TROLLING oe TROLLING FEATURE OPTIONAL A _ 343 7 18 51 BAv OIL DRAIN amp DIL IN FROM HEAT EXCHANGER 247 9 9 76 5 DIL PRESSURE GAGE EYEBOLT t LINE HERE 2 X 15 THREAD 144 8 5 70 DIL FILLER HDLE AT VALVE E 139 7 5 50 E MOUNT GAGE IN PILOT HOUSE 111 3 4 38 1 8 27 NPTF EXTERNAL NEUTRAL 109 7 4 32 TH D DRYSEAL GAGE OO CONNECT GAGE INTO OIL 50 8 2 00 LINE BETWEEN AND 76 8 R CONTROL VALVE x 3 00 R FACE USED FOR CONTROL MOUNTING BRACKET 16 7L21 321 DRILL THRU 2 HOLES FOR 5 8 11UNC STANDARD EYEBOLTS W
130. and adapter as an assembly Note that the inner spring will come out with the stem RevB0203 01 9 Slide the stem out of the adapter by pushing the lever end thru the adapter Remove the O ring from the groove in the end of the stem RevB0203 02 1017555 12 10 Remove the inner spring and roll pin from the stem only if replacement of parts is necessary Remove any paint from the large diameter of the stem Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 13 Subassemblies Install the roll pin and inner spring onto the end of the stem if removed sure the first coil of the inner spring is fully seated against the end of the stem Install a new O ring into the groove of the stem Apply grease to the stem from the O ring groove to the necked down diameter at the end Install the stem into the adapter insert lever end of stem first until the stem protrudes through the seal in the adapter Install the large diameter washer some models inside the bore of the adapter until it lays flat on the end of the stem Install the outer spring into the bore of the piston Install the small diameter washer s some models inside the spring in the piston keeping it centered within the spring Be sure the washer is at the bottom of the bore in the piston Place the inner spring stem and adapter assembly into the outer spring and invert the assembly with the piston pointing up 3 RevB0203 04
131. can be raised by screwing down or lowered by backing off the desired amount 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 particu larly for future realignment It will also be necessary to move the engine and transmission from one side or the other on the bed to obtain horizontal alignment This can be done with a jack placed horizontally between the engine and the foundation At the same time a straight edge is laid across the edges of the flanges at the top and side to check the parallel alignment of the coupling edges Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 10 7 Installation Fig 10 9 Checking output flange face runout Fig 10 10 Checking output flange pilot eccentricity Propeller Flange 19 10 10 10 Some boats are not structurally rigid and some carry their load in such way that they will hog or go out of normal shape with every loading and unloading Where this condition exists it may be necessary to make a compromise between the top and bottom coupling clearance by leaving a greater clearance at the bottom of the marine transmission output flange and propeller coupling This clearance might be 0 13 mm 0 005 in to 0 18 mm 0 007 in while the top would maintain the s
132. 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 specifications listed in Section 4 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 7 3 SECTION 7 7 4 THIS PAGE INTENTIONALLY LEFT SECTION 7 Cleaning and Inspection 8 1 Subassemblies Section 8 Subassemblies Mechanical Control Valve Disassembly A CAUTION Steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball Remove the orifice plate cover orifice plate gaskets check ball and spring e e Remove the rate of rise piston pressure regulating springs and pressure regulator piston The pressure regulator adjustment shims are in the spring pocket of the rate of rise piston Remove the O ring plug O ring detent spring s and detent Mark the lever and the stem to indicate the position the lever was installed on the stem Loosen the screw clamping the shift lever to the stem and remove the lever It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem lever or bearing might get damaged Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 1 8 8 2 oo Mark the stop and the stem to indicate
133. 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 specifica tion see Torque Chart Install external retaining ring onto stem if equipped Install the steel balls and electrical switches if equipped into the bores in the sides of the valve body Note that the small diameter ball is inboard of the large diameter ball at each side Install pressure regulating piston into valve body Install pressure regulating springs into valve body SECTION 8 Subassemblies 25 26 27 28 29 30 31 Subassemblies Install shims into the bore of the rate of rise piston Install the rate of rise piston into valve body Install neutral pressure regulating spring into the pocket of valve body 692 Install orifice plate gasket onto valve body Install orifice plate and steel ball onto valve body Install orifice plate cover and gasket onto valve body Install gasket over lower valve body half Set upper valve body half over lower valve body half Insert attaching screws through valve body halves to keep parts in alignment until installation onto the transmission When installing the valve onto the transmission be sure to torque the screws to the specification listed on the valve installation draw ing Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 11 SECTION 8 8 3 1017555 Trolling Valve A Disa
134. lubricant such as Dow Corning 2008 30 000cSt fluid to the O rings of the solenoids and plug plug used on units without hydraulic lock Install solenoids and plug if equipped into valve body and torque them to 34 N m 25 ft Ib 7 nsertthe 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 bogy E Assemble lower valve body half 1 Install steel shuttle ball into its bore in the valve body 2 Install the O ring onto the shuttle ball seat 8 8 SECTION 8 Subassemblies Subassemblies Apply lubricant such as Dow Corning 2009 30 000cSt fluid to the O ring and install the seat into the valve body Be sure to align the roll pin holes in the seat with the holes in the valve body AM8x1 25 screw threaded into the seat can be used to adjust the seat location in the valve body Install the roll pin to retain the shuttle ball seat Drive the roll pin in until itis flush with the gasket surface of the valve body 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 bogy Apply MA908 threadlocker to the threads of the dog poin
135. m ADAPTER 1017821 lt 5 0744 No 38 4 23 BEARING M1989 i RING 42915 ASSEMBLE ve DS DEIN PING UF DHWEL PINS TO THE SHAFT WITH CAPSCREWS AND TORQUE PER 55 4 SERVICE MANUAL VALUES INSTALL THE 42 STUDS INTO THE MANIFOLD INSTALL THE ASSEMBLY THE MANLF OLD WITA THE DRAIN IN THE MANIFOLD HOSE MA923AL HOSE MA923AP PLUG 1945 2 Tu ADAPTER 101 821 CSAE J744 32 4 RING A2 amp 669DG RING B10484K RING Ge olor PLUG 10 B D qu seb dp 4 HULES EACH SIDE NOTE X USE ALL 4 HOLES FOR MOUNTING CUSTOMER SUPPLIED SUPPORT BRACKET Pe Mr QUALITY CAPSUREWS ISU 898 1 AND TORQUE 5574 UR SERVICE MANUAL VALUES AND INSTALL IHE ADAPTER DIVER THE THE MANIFOLD TOWER WITH 49 SC FASTEN THE ADAPTER VALUES NA AND AS SHOWN SLET TN _ 1 29358 2910 29042 ________ 8 28863 4 23256 awe ce wa zone THE 4 NUTS AND TORQUE ASSEMBLE THE GASKET DITCH PLATE AND VALVE IE WS AND TORQUE PER 5574 SERVICE MANUAL VEZ UIE Ss e ASSEMBLE MHE TINGS
136. of the propeller shaft through all struts and intermediate bearings Failure to align the propeller shaft may result in premature wear on bearings vibration and a possible shaft or other machinery failure If the length of the shaft from the last support bearing to the gearbox is excessive or a flexible stuffing box is used the shaft must be centered prior to engine and gearbox propel ler shaft alignment SECTION 10 Installation Installation 10 4 Engine and Marine Transmission Alignment CAUTION When mounting the engine and 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 used Some boats are built with flexibility and may change shape as loading varies When a heavy boat is dry docked it naturally undergoes some bending Therefore it is always good practice to unbolt the marine transmission coupling to prevent bending of the shaft With the engine and transmission in position on the engine bed arrangements must be made to have a controlled lifting or lowering of each of the four corners of the engine If threaded holes are provided in each of the engine mounts jacking screws can be used in them The engine
137. product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement parts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit September 4 2001 TDW P2003 TWIN DISC INCORPORATED FLAT RATEHOUR ALLOWANCE Hourly Labor Rate Must be A cceptable to Twin Disc Incorporated COMMERCIAL MARINE TRANSMISSIONS ALL RATIOS MODEL SERIES R amp R UNIT REBUILD CLUTCH REPAIR BOTH PACKS MG 502 MG 5010 MG5011 MG5005A MG5015A 10 0 8 0 MG 506 MG5061 MG 5050 MG5055A MG 507 MG 5081 MG5085 MG5090 MG 5091 MG5112 MG5113 MG 509 MG 5111 MG5114 MG5114A MG5114RV MG 514C MG514M MG5141 MG514CHP MG 516 MG 5161 MG 518 1 MG520 1 MG 5202 MG5203 MG5204 MG5205 MG 530 MG530M MG5301 MG 540 MG5600 MG6000 MGN 80 MGN 232 MGN 233 MGN272 MGN 273 MGN 332 MGN 334 MGN 335 MGN 432 MGN 433 MGN 472 MGN 49
138. qu lt run mara A2703P SAE 1 M1990H 1 HOUSING 1398 MA1038C Wo N MA961P 16 ECCO nh N 1018461 FILTER BY PASS 1018462 1 D 1015110 1018470 11 jO N 44 270 i 2 LOL PSR 2 Z EO A Z 2775 HI 4 G 4 77 A 22 8 6 Z d e pp toes E a a gt lt lt wem 1 2 Z _ A e i COMER S Z x d 222222 7 MA1038C 5 lz MA1038A 7 4 e 7 7 2 7 f a INA S ATERIK S N I x S A E 0 wea HOUSING b NW 2 di TP ATA LH A ID os Q Ji MA1064A OPTIONAL EXTRA SUPPLIED WHEN 0 SPECIFIED SHEET CROSS SECTIONS 1 3 AND PART NUMBERS SHEET INSTALLATION e OF 3 DRAWING SHEET FLEXIBLE 3 OF 3 COUPLING INPUTS MASS ELASTIC 504 SYSTEM 1 EE se T ES 55 EN
139. rad 19 9 EHE EN 2 50 591 22100 204000 3 75 w 5 00 47 0 380 3000001 1015017 A CLIUPL ING 1016217 1 A OPTIONAL INERTIA RING COMPONENTS 3 49802 1041 0 53 kg m 1018742 WR 1017871 MA1041E MA947D 1016215 3 1 bi GR DRILL THRU FLYWHEEL OUTLINE MUST CONFORM TO S A E J620 NO 1048 SNAP RING COUPLING E L Ma S A E 0 HOUSING gt 36 0 LLL LL LL lt 1019719 COUPLING lt 57757 S K 7 S N 0 SNS N NY _ 55525252505 Y 0609 2 KKK 5 Q Q lt Q lt 2 Q lt Q 2 d 27 27 7 292 2 5 5 4 55 5 QS lt gt 4 KX X X X X X X X gt x gt 5045 A 5945 lt CSS OX 52 52 x 5 5 x x 5525 Z LEGA I 2 lb Maer seem t emer eee nes DYNAMIC TORSIONAL HOLES EQUALLY SPACED USE 8 8 PRUPERTY CLASS QUALITY PER ISU 898 1 GRADE 5 QUALITY CLASS PER SAE J429 CAPSCREWS AND TORQUE 5574 SERVICE MANUAL VALUES COUPLING WEIGHT k SAE J620 FLYWHEEL SIZE COUPLING TORQUE kN m O40 080 200 NOMINAL TORQUE DYNAMIC TORS
140. se T ES 1 INPUT SPEED 2500 REM _ CONSULT SALES DEPT APPLICATION o 0 lt B F eSt ENGINEERS OTHER 5 0 9110 OEC s 2157 ere Seres sp LIMITING CONDITIONS 471190 HYDRAULIC 0 4 9 0 o 101519 DIAGRAM 1 lt zz e Ssss ars S S SIS Rain gt METRIC ROSSI Fe INES DICERES o2 DIL CAPACITY 26 5 L 7 GALS LESS HOSES AND HEAT EXCHANGER Rd 1 b THIS UNIT CAN BE USED WITH LEFT HAND ENGINE c OPTIONAL EQUIPMENT COMPANION FLANGE ASSEMBLY 1015378 MATERIAL WEIGHT wr UNLESS OTHERWISE SPECIFIED DATE CONTROL TROLLING VALVE XA 600B DIL TEMPERATURE INDICATING SWITCH 83424 FOR INSTALLATION 4 4 s 1 21 99 171 1761 2 92 DIMENSIONS ARE mm 9 14 95 Tod uu DUSE LIVE P T O XB6243A AUXILIARY PUMP DRIVE LOCATION SEE HYDRAULIC DIAGRAM AND SHEET 2 V 28834 10 6 98 BE USED IN ANY MANNER MEO MACHINER DIES SCALE INCORPORATED HYDRAULIC CLUTCHED 554 SHAFT DRIVE 12 128728 8 11 98 DETRIMENTAL TH THE INTERESTS DF WERT TERT USE 0 25 RACINE VI 53403 USA e p j sens as S TRAILING PUMP 1016473 SERVI
141. the output shaft Retain the blocking to temporarily hold the gear and shaft assembly in position eS Fig 6 11 Fig 6 12 6 Connect oil injection equipment to the output shaft 6 10 SECTION 6 Disassembly Disassembly 7 Install eyebolts into the end of the output shaft and into the main housing mount ing pads 8 Thread a heavy strap through the eyebolts in the output shaft and the strap to the eyebolts in the main housing The strap will restrain the output shaft during disassembly Fig6 14 The parts separate with EXTREME force potentially causing great physical harm Use EXTRA CAUTION and proper safety procedures 9 Inject oil with a viscosity of 900 mm S 900 cSt at room temperature dismount ing fluid into the output shaft until the shaft and gear separate Remove the output shaft gear and front output bearing cone 10 Tapered roller bearing cups for front bearings on primary pinion secondary pinion and output shaft are an interference fit in their respective bearing bores Remove these bearing cups only if replacement is required To remove these bearing cups weld a light bead around the I D of the bearing cup with an elec tric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced 6 7 Disassembly of Primary Shaft or Secondary Shaft Disassembly of Secondary Shaft is Described 1 Remove two piston rings from rear end of shaft Twin D
142. the position the stop was installed the stem Drive the rollpin out of the stop with a drift punch and remove the stop Remove the valve cover and valve stem Slide the valve stem out of the valve cover Remove the gasket O ring and oil seal from the valve cover Remove the thrust bearing and races from the valve stem Cleaning and Inspection See Section 7 Assembly Install the thrust bearing and races onto the valve stem Install a new oil seal and O ring into the valve cover Coat the seal lip O ring and stem with light assembly grease Install the valve stem into the valve cover Use caution to prevent damage to the oil seal O ring and bearing Install the cover gasket and valve stem and cover assembly onto the valve body Install the cover capscrews Torque to specification see Torque Chart Install the stop and rollpin lining up the marks made at disassembly Use small punch to line up the rollpin hole in the stop with the corresponding hole in the stem Continue to hold the holes in alignment as the rollpin is driven into place Support the stop while driving in the roll pin to prevent damage to the stem and valve Install the shift lever onto the stem lining up the marks made at disassembly Torque the screw to specification see Torque Chart Install the pressure regulator piston regulating springs shims and rate of rise piston into the bore in the valve body SECTION 8 Subassemblies Subassemb
143. to the pressure regulating posi tion once the spring force is equal to force induced by the pressure at the rate of rise piston 3 10 SECTION 3 Operation Operation B Electric Control Valve Assembly Neutral Some of the main pressure oil from the inlet chamber flows through a passage to the orifice in the orifice plate The small flow of oil through this orifice fills and begins to pressurize the rate of rise chamber Ball and Spring Regulato Mvc 002a Both clutches are connected to sump when the control valve is in Neutral Since there is no pressure acting on the shuttle ball from either clutch the passage behind the ball and spring regulator is also connected to sump This allows the oil pressure in the rate of rise chamber to be regulated by the ball and spring since the overage oil can flow to sump The oil pressure in the rate of rise chamber acting on the rate of rise piston causes it to stroke over partially which compresses the pressure regulating springs additionally This additional spring compression further resists the movement of the pressure regu lating 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 C Electric Control Valve Assembly Primary or Secondar
144. valve malfunction Bearing failure Worn or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine Remove and clean regulating valve Shim as required Inspect repair or replace parts as necessary Check and fill or drain with proper oil to 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 worn or damaged coupling Select proper torsional coupling Overhaul transmission Check alignment of engine and transmission output flange to propeller shaft correct as necessary Repair propeller Repair engine T 5205 07 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC 5204 5 3 SECTION 5 neutral 6 1 6 2 6 3 Harsh engagement Low lube pressure Oil spilling out of breather Clutch plate warped Stuck shuttle spool Solenoid malfunction units equipped with electric selector valve Hydraulic lock piston stuck unit equipped with electric selector valve and hydraulic lock Regulating piston or rate of rise piston stuck Orifice plate ball in co
145. 0 APSISCK e MeoeoaD 1014861 1 90444 4 TAPERED EDGE SIDE AWAY BEARING o 2210 a m lt C lt 0 ON m SS Sls 65255985 CONTROL VALVE ASSEMBLY CZ T 16 RIA ISI GAUGE THESE STANDARDS APPLY lt ujuma lt jM lt gt gt gt MA1038E 1 5574 FASTENER TORQUE REQUIREMENTS 1001138 692 BEARING SHIMMING A NN ET WP 2 5765 TAPERED JOINT ASSEMBLY l a ES MA1038B NEES 1 2040878 SO Im Aa 5 32 el HESS 2013410P LU ee RIK Be SIX 2 2 IX o me MA960A NSS E DDL 5 y M PA AE eae enn BU lt no 69 Q AS MOUNT LUBE INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION LUBRICANT TOWARDS BREATHER MOUNT INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION TOWARDS BREATHER NM BEI Wt ZZ ZZ ZZ m 1016318 _ SET SPRING LENGTH 30 2 mm k 4 lt Y 7 gt gt NN NS NS
146. 016103 MACHINED DIMENSIDNS x 0 75 CHK 1016410 X ALL ANGULAR TOLERANCES 31 GEOMETRIC TOLERANCING PER ANSI 145 1982 TD SURFACE TREATMENT C OPTIONAL TROLLING VALVE INSTALLATION AND OPERATING NOTES 1 REFER TO VALVE ASSEMBLY DRAWING FOR ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE TROLLING RANGE 238 5 9 39 EE MUST INCLUDE DEVICE TO LOCK TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION DURING 90 MIN TROLLING 111 0 437 SIDED SERRATION MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TO THE PROPELLER ih at ain sas ea CONTROL VALVE i gt al DETENT 18 62 N AT THE 56 0 2 201 LOCATION OF THE 6 35 1 41 DIA HOLE 2 MAXIMUM ENGINE SPEED WHILE TROLLING 1100 RPM OR 60 FULL LOAD ENGINE SPEED WHICHEVER IS SMALLER ANGULAR LOCATION MAY BE mr s T 18 62 AT THE 560 220R LOCATION OF THE 635 41 DIA HOLE Tur 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUUCTION BY MOVING TROLLING CONTROL LEVER ADJUSTED SO THAT THE 90 FUNCTIONS DETENT DRILL THRU LEVER FULL PRIMARY CLUTCH FULL SECUNDARY CLUTCH AND NEUTRAL LEVER POSITIONS THE DETENT SPRING OUT OF LOCKED DETENTED POSITION MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION OF TRAVEL LEVER ROTATION REQUIRED TROLLING LEVER afi AND PIN MAY BE OMITTED WHEN REMOTE CONTROL
147. 09 kg 900 Ibs 52035 MG 5204SC DRAWING NUMBERS 1016249 1016250 10162504 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 4 1 SECTION 4 F Type Oil Recommended The recommended oil viscosity for this unit is SAE 40W or SAE 50W depending on operating temperature Use only SAE API service class CD engine oil certified by vendor to pass TO 2 or C 3 test specifications Also approved is SAE API service class CG engine oil MIL L 2104B NOTE Multi viscosity oils i e 10W 20 etc should not be used in Twin Disc marine transmissions 7G Cil Pressure The following tables give oil pressures at different speeds and ranges See the installa tion print for location of oil pressure checkpoints Oil Pressure Limits 1586 kPa 230 psi units 215 psi minimum pressure when cruising X Zrc Zsc Valve Inlet Primary Secondary Input RPM amp Collector Collector Shift Position kPa psi Kpa psi kPa psi min max min max min min min min min max min max 1800 Primary 1572 1634 228 237 97 234 Neutral 207 634 30 92 214 372 Secondary 1572 1634 228 237 97 234 600 Primary 1413 1620 205 235 Neutral 103 496 15 72 Secondary 1413 1620 205 235 5202 01 Oil Pressure Limits 1725 kPa 250 psi units 235 psi minimum pressure when cruising X Zrc Zsc Valve Inlet Primary Secondary Input RPM amp Collector Collector Shift Position kPa psi Kpa psi kPa psi min m
148. 0mm 2 inches clearance between housing and floor 3 Remove output shaft seal carrier Remove O ring and oil seals from seal carrier 4 Remove shims from output bearing bore of housing 6 6 SECTION 6 Disassembly Disassembly 5 Use ahoist to lift output shaft and gear assembly until gear contacts housing Place blocks under gear to support it in a position where a bearing puller can be used to remove the tapered roller bearing cone from the output shaft see fig 6 7 Remove the bearing cup from above the bearing cone Remove the bearing cone from the output shaft by pulling on the cone and pushing on the output shaft Retain the blocking to temporarily hold the gear and shaft assembly in position p JU a B all i V gt p 6 Fig 6 7 Fig 6 8 6 Install a round metal spacer 114 mm dia 4 5 in x 25mm 1 0 in thick at front end of output shaft inside cup plug 7 Support weight of output shaft and gear assembly and remove blocks installed in step 5 Lower shaft and gear assembly until weight is supported by spacer and cup plug Remove hoist Using a soft hammer drive the gear and shaft assem bly downward to remove cup plug Shaft and gear assembly will be supported by front tapered roller bearing when cup plug and spacer are driven out of hous ing bore 8 Block gear and shaft assembly against other s
149. 11 2222 77 7 522 lt EN lt 2 NI 2 NS SCREEN 9 CUVER ASS Yy 1000974 A COVER 1000276 ADAPTER 1966 GASKET 1000874 lE 0 8 e BEARING 1014857 2 SPACER 1015108 2 GASKET 1001026 THIS SPACER USED WITA AND GAUL RATIOS INE Y GASKET 1001109 TUBE 1001380 RETAINER 1002091 2 RETAINER B3616A RING M2693E 2 gt SPRING 7064 MANIFLILD 1002673 11 HI CRRRIRNUUUUU 7 MIMI XY 7 2 2 2 Sw lt RING A2916JZ Aan APR COVER 202347 SE SCREW 10 NG S N RING B1048BC RING ASSEMBLE TAPERED EDGE RING 2915 Ce SIDE away FROM BEARING PLUG 10 lt 6 BEARING 1014856 SHIM 1014883 SHIM 1014884 AS REQ D NN NS 6 SSS 27 r SHIM 1014833 2 Y N S N 6 S VN RSS e S NS AN 77 222227 2 SETZEN d I A ZZ LL GEAR 1001416 J N
150. 13 51 2257120871 gt DIL DRAIN amp DIL IN FROM HEAT EXCHANGER 8 1016103 506 9 9 96 247 9 9 76 CONNECT OIL PRESSURE GAGE EYEBOLT t 443 5 7 46 PHR t X L5 THREAD 144 8 5 70 eo OIL FILLER HOLE J THRU u 420 4 16 60 u AT VALVE 1016103 MDUNT GAGE IN 55 354 6 13 96 GAUGE t PILOT HOUSE 111 3 4 38 2 IN 16 7 21 321 DRILL THRU 2 HOLES GRADE 5 QUALITY CLASS 1 8 27 NPTF EXTERNAL FOR 5 8 11UNC STANDARD NEUTRAL 109 2 PER SAE 4291 CAPSCREWS prd QU GAGE 9 WITH NUTS THESE lt 50 8 2 001 AND TORQUE TO 574 283 5 1116 OIL GAUGE 1016103B LINE BETWEEN AND MARINE 76 2 R T SERVICE MANUAL VALUES ME CONTROL VALVE lt a 2718 10 70 DIL FILLER 3 00 6 63 5 2 50 i FACE USED FOR CONTROL amp 4 Les 240 3 12 46 nes TTE MOUNTING BRACKET HOLE AT THIS LOCATION PLACES EYEBOLT t Ds S A E 0 HOUSING 1 199 eme HUTLINE PRIMARY CLUTCH ACTUATING PRESSURE M10 x 1 0 THREAD 12 7 50 METRIC PORT CONFORMS Blea E DISTANCE REQUIRED m ENGAGES CLUTCH DN 2 HOLES SUITABLE FOR REMOVE GAGE ES un SHAFT t CALLED CONTROL MOUNTING G 1 GAGE IS FLEXIBLE AND SECONDARY BRACKETS LUBE P S I SAE AM TO 0
151. 16 SECTION 3 Operation Operation 3 9 Power Flow A Neutral When in neutral the primary and secondary shatts transfer gears and clutch friction plates rotate at engine speed Other parts including the output shaft do not turn Driving Gear r Piniana a Primary Shaft Secondary Shaft a ut Gear Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 17 SECTION 3 3 18 Primary When the primary position is selected hydraulic pressure is applied to the primary clutch piston clamping the friction and steel clutch plates together The primary input pinion will then rotate at engine speed and direction because the steel plates are spline connected through the clutch hub assembly to the pinion Because the primary input pinion is in mesh with the output gear the output gear and shaft will rotate in anti engine direction The secondary input pinion will be backdriven engine direction when the unit is in the primary position Primary Glutch Engaged SECTION 3 Operation Operation C Secondary In secondary the same pans are turning that were turning in neutral When the sec ondary position is selected hydraulic pressure is applied to the secondary clutch piston clamping the friction and steel plates together The secondary input pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to
152. 1UNC STANDARD EYEBOLTS WITH NUTS THESE HOLES MAY BE USED FOR LIFTING MARINE T Bis TRANSMISSION ONLY OIL IN FROM HEAT EXCHANGER M33 X 20 THREAD METRIC PORT CONFORMS TO ISO 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT DIL OUT TO HEAT EXCHANGER M33 X 2 THREAD METRIC PORT CONFORMS TO ISO 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT tout 82 5 3 25 50 37698 Det oot 21 3 84 CLEARANCE DIL PUMP LUBE P S I M18 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 AUXILIARY LUBE SUPPLY 1 INLET SEE HYDRAULIC DIAGRAM BASIC 2 119 48 4 704 O E 70 E 62 gt s 152 349 5 998 152 400 6 0001 190 5 7 50 4 228 6 9 00 aye ec 57221251 STUCK SIZE CUSTOMER FINISH BORE SEE 279273 10 995 279 400 11 000 SECONDARY CLUTCH ACTUATING 6 096 PRESSURE M10 X 10 TH D 6 350 METRIC PORT CONFORMS e TO ISO 6149 250 4 22 4 7 3 8 16UNC THREAD L88 7 6 L 301 DEEP 1003 _ SUCTIHN SCREEN 3 95 CLEARANCE TEMPERATURE SUCTION PICK UP PORT SCREEN 1 4 18 NPTF DRYSEALD 136 4 5 37 228 6 9 00 COMPANION FLANGE BORES 95 2 3 75 WITH 22 2 7 8 SQUARE KEY 114 3 4 50 WITH 25 4 1 00
153. 278245 DITCH PLATE SEE CHART SEAT 1017584 SPACER 2885 SCREW SEE CHART A BODY 1018094 BALL MA1034A BALL MA1034D 2 BALL M1990H NOTE BALL M1990Y 5 INSTALL USING MA908 LOCTITE 242 SCREW MUST FLUSH WITH SLIGHTLY BELOW BOTTOM FACE OF VALVE 34 28 PORT PORT HYDRAULIC DIAGRAM A7 119Y HYDRAULIC DIAGRAM 47197 METRIC O wam SIMILAR TO SCREW 1042 4 ATMOSPHERIC PRESSURE ANIT SERVICEABLE SEPARATELY ATMOSPHERIC PRESSURE INTERMEDIATE PRESSURE CLUTCH PRESSURE 1 HESE PARTS ARE BE PACKAGED SEPARATELY AND SHIPPED WITH UNIT A Gi 2 P P 28678 7 24 98 NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT UNLESS OTHERWISE SPECIFIED 1 PROPRIETARY INFORMATION AND IS MACHINED DIMENSIONS 12 97 MAIN PRESSURE PICKUP PDRT 2861 y 6 98 m i pm INCORPORATED 3095 1 4 18 NP T F DRYSEAL 28585 6 3 98 6 29751 12 16 99 EET TREAT FIRST USE 52 1 00 53403 USA purum When Seam o 1017178 x Y14 175 0 284574 3 98 H 2 28937 11 13 98 TO NULLIFY OR LIMIT SIGNIS _ SERIES 276445 7 97 G 28762 5 98 ASS Y GUONTREL REV ZDNE CH DATE REV zone CH DATE WITHOUT
154. 3 MGN 650 MGN 800 MGN 1000 MGN 1400 MGN 1600 PUMP ALL MODELS VALVE ALL MODELS September 4 2001 TDW P2003A Table of Contents Marine Transmission Service and Installation Manual Models MG 5202SC MG 5202DC MG 5203SC MG 5204SC Section 1 Introduction lisi o meer 1 1 12 Safety and General Precautions La SIR 141 A TEE 14 B inparant Sal NAI cn E PERRA E e oo C PO 1 1 18 Preventative 1 2 1 2 NS 1 3 00 ete ee ene eer eas cena rape mae 1 3 Section 2 Description G KT L u TT 2 1 2 2 2 1 ons tS u u u u u R 2 2 A isis Kuu unas EM 2 2 B Primary and Secondary Pinion and Shaft Bearings 2 2 C Mee 2 2 D 2 2 Sub 2 2 P Fl Y gt e eee 2 2 B 2 2 H Input in CET 2 2 l Hear 2 3 Trelling ve Por a aeu 2 3 K 2 3 L ranlin Pump u n a aqa buie ert rrr tee s aqa 2 3 Twin Disc Service Manual MG 5202S
155. 3 10 SI uorsuauiip 161 Y suoisueauiip JO 5195 uauM SECTION 13 Trans Section View MG5202SC MG5203SC MG5204SC 13 6 1 2102 ejqixejj INN yeys pue yeys Ajquiasse yeys yeys Buiusnq yeys 1 49A09 Hu eys 9115802 do peau xau do jeuseM do Jeysey yey Duidnoo ejqixerj INN Buisnou SVS ejqixoj peau xeu Guisnou peau xeu ejqixey p ullds uoisuedxe Buura ejqixojp peau xeu ajqixey yey iSUSEAA uonduoseg yeys
156. 3 7 2 48 1 85 3 3 4 2 031 73 0 3 0 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 1 NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE 15 NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT C s SZ PLACES eeo L88 Ge PRIMARY CLUTCH ACTUATING PRESSURE M10 x 10 THREAD METRIC PORT CONFORMS TO ISO 6149 0 HOUSING OUTLINE 5 16 180 TAP THRU EN 2 HOLES SUITABLE FUR CONTROL MOUNTING LUBE P S I 6 LL x 15 THREAD ENGAGES CLUTCH EN eS SHAFT CALLED AUXILIARY LUBE SUPPLY 2 PRIMARY C INLET SEE HYDRAULIC DIAGRAM DISTANCE REQUIRED REMOVE DIL GAGE GAGE IS FLEXIBLE AND CAN BE BENT IF NECESSARY DIL FILLER HOLE 535 6 21 09 0 ou n v Y ed 5 lt 4 IN D QI x T gt LI Oe aJ gt ND JD u D CJ 9 V 915 ER CLUTCH DS SHAFT Na Ms Duc N I nado 1 NA 5 GREASE e FITTING lt al I DRIVING THRU PRIMARY CLUTCH b L Ir CO UU SE D 0 SF 24 5 1961 9 THRU 8 HOLES EQUALLY SPACED DRIVING THRU SECONDARY CLUTCH OUTPUT SHAFT t OIL DR
157. 30 1 X XX s X XXX 25 1 00 RACINE VI 53403 USA ALL ANGULAR TOLERANCES 1 DRN GEOMETRIC TOLERANCING 1 1 6 C J PER ANSI Y14 5M 1982 CHK 5204 10162504 APPD MARINE TRANSMISSION pas seer or 5 rev AD PINIUN ASS Y 1015213 Se Vel RATIO PINIUN ASS Y 1015215 6 251 RATIO 201 PINION ASS Y 1015217 PALO oN PUNTEN AS S Ta Maela 5 041 RATIO 257 PIMAN AS Te 4 591 RATIO e7T PINION SS TUIS 4031 RATIU SOT Ca C2 C2 C2 MN SS 12 x NS COUPLING 4002337 BEARING 170 PIN Co PLUG MI945BW SEE NOTE 4 Zzz zzzzzz HUB 1002067 2 SHAFT ASS Y 1015231 X do 1019230 BALL MA1034B 2222 59 LA LIAS TEI HS Z ZZ 7 RING B1048X 222 N 0 Of SEAL 4016127 LETS uU CAPSCREW 996 4 gt N WASHER MA1039B 4 BEARING M2795 2 S CAPSCREW 996 12 INN SCREW MA9964 lt 8 N 5 lt s WASHER MA1039B 8 SE JE RING 1001387 SS WITH S A E 0 ONLY axes N gt HOUSING 1015018 CS 02 SHAFT 1000798 SHIELD 1001421 BEARING 1014858 HOUSING ASS Y 1015236 5 TUBE 1002699 AS a gt CAPACITY 3141 LESS HOSES
158. 4 3 General Maintenance A 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 B System Oil Level The oil level should be checked daily or every 10 hours Check oil level before starting the engine to confirm that the transmission has oil in it With the engine running at low idle and the transmission in Neutral check the oil again The oil level should be near the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval With a new transmission change the oil and filter element within the first 50 hours of opera tion Change oil and filter element after each 1000 hours thereafter or more often if condi tions warrant SECTION 4 Specifications and Maintenance Specifications and Maintenance For a rebuilt transmission check the filter element after eight hours of operation If the filter is clean install a new filter element and then change the oil and filter element after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the filter is clean and then change t
159. 5 GLE 11 26 Special Tools Output Flange Press Fixture T 21397 11 27 P 49 5 119 39348 031319345 3SI BN3HID 5537 1019101 L4AVHS ALON Y B SW 1 934 31V ld vid 2 L uen ca Z 4 77 Z L L 2 i N MS 19101 1 AdLNO N NA M 90 46612 313 092 11 27 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 11 28 Lifting Bracket for Clutch Removal Boat 1 DRILL 9 16 DIA 0 DIA 0 75 MAKE ROM 1 1 2 ANGLE IRON Use a Mle 1 75 x 30 mm bolt to attach to shoft 4 Use o 1 9 13 NC x 6 bolt to support shoft 11 28 SECTION 11 Special Tools 5 E Ors mo 2 PLCS IN DET 1A 97 8 THRU DETS 1B amp 1 1 1 2 SQ TUBING 5 8 stk A q EN cc 15 3 8 SSS 11 SYMBOL CHARACTERISTIC SYMBOL MODIFIER FLATNESS MAX MATER PARALLELISM CONDITION L RFS REGARDLESS OF FEATURE 517 2 CONCENTRICITY SMOL
160. 5 WITH 31 8 1 1 4 SQUARE KEY 139 7 5 50 e WITH 31 8 1 1 4 x 22 2 7 8 KEY amp 1251 X150IN FT TAPER 2 OPTIONAL TEMPERATURE INDICATING SWITCH CUSTOMER INSTALL IN 3 4 X 3 4 X 3 41 PIPE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSION PUMP THE HEAT EXCHANGER INLET REFER HYDRAULIC DIAGRAM NLITE ALL POINTS AVAILABLE FUR TESTING ARE CODED V b MARINE C a TRANSMISSION 22200 10000 0 FLYWHEEL 000 005 gt 006 004 gt 460 187 711 2 679 45 647 70 571 50 498 3 157 35 0 484 PEU 6 0 8 00 26 750 25 500 22 500 21 375 19 62 1 38 gt 24 gt 1 355 1471 222 4 530 20 511 17 466 72 438 15 409 4 25 4 25 7 1e UF BF 12 0 lt 21 75 gt 20 875 gt lt 20 125 gt lt 18 375 gt lt 17 250 gt lt 16 12 gt lt 1 00 gt 1 012 48732 Ces 32 9 131 3 48 1 100 5 4 01 HOLE AT THIS LOCATION OMITTED SAE 0 HSG ENGAGES CLUTCH ON SHAFT t CALLED SECONDARY CONTROL LEVER 6 35 1 4 DRILL TROLLING SECONDARY CLUTCH 228 600 9 000 REF S N 203 2 8 00 211 91 8 343 BASIC 245 1 L9 65 332 6 u3 09 374 7 14 75 42 92 GEAR IDIM FROM PORT SETS ISFACE PINION giae 92 8
161. 500 1 19 69 x 228 6 9 00 P 5 pes 259 _ 2451 965 266 7 10 50 FLANGE p Bones _ REF LUBE 51 PORT 95 2 3 75 WITH 22 2 7 8 SQUARE KEY 5478 2157 114 3 4 50 WITH 25 4 1 0071 SQUARE KEY OIL DRAIN PLUGS METRIC d 120 6 4 75 e WITH 31 8 1 1 4 SQUARE KEY 14 00 M33 THREAD u E 139 7 5 50 e WITH 31 8 1 1 4 x 222 7 8 OT KEY amp 1251 1 501 gt TAPER 374 7 14 75 t PROJECTION GEAR SETS S FAGE S PINION 2481 853 34 990180 INCH DIMENSIONS AND SIMILAR TO POUNDS SHOWN IN BRACKETS 1 NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED PROPRIETARY INFORMATION AND IS DIMENSIONS ARE mm BE USED IN ANY MANNER kg Nem MACHINED DIMENSIONS DETRIMENTAL TO THE INTERESTS OF X X OPTIONAL TEMPERATURE INDICATING SWITCH CUSTOMER INSTALL IN A 3 4 X 3 4 X 3 41 PIPE TEE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSION PUMP TO THE HEAT EXCHANGER INLET AU d TRANSMISSION 0008 0200 F 3 x K m v FLYWHEEL lt 000 005 gt lt 006 604 gt 1 460 181 711 2 679 45 647 70 571 50 542 92 498 3 15 7 350 155 6 0 lt 28 00 gt lt 26 750 gt lt 25 500 gt lt 22 500 gt lt 21 375 gt lt 19 62 gt C625 lt 1 38 gt eg lt 242
162. 7134 B1337F 1018163 1018688 27077 27077 A2703T 1725 lt 250 gt 1017129 1 7 x B2451B M2089F 2089 5112 4 A l n a EE li o M8 X 125 6 1017172 ooo Eo 2098 no wer nuzzeu VIEW SCREW 10525 4 e d TORQUE 54 2 N m ji 40 0 lbf ft 1017172x NOTE INSTALL USING MA908 LOCTITE 242 THREAD DOG POINT INTO DETENT GROOVE UNTIL SNUG BACK OFF 1 2 TURN COVER 1017324 SETSCREW M2038W PISTON SEE CHART 4 SPRING ASSY SEE CHART PLATE SEE CHART SHIM SEE CHART GASKET 10171368 BALL M1990G APPLY Mass AREAD SEALANT WITH TEFLON gt THREADS BALL M1990E BALL M1990M COVER 1017128 777 Z NZ LL PML 22242 Nie A lt x Wey gt as NY gt SS Z lt 227 sa DE MA Z d SS 4 ZZ NN ENS 2 22 it Wi GASKET 1017334 22 SECTION B m H SECTIDN seem D D GASKET 1017130 TRANSMISSION GASKET BALL M1990H SPRING 1801 PISTUN B1399H SETSCREW 2870 0 RING A2916DK uS DLATE Q RING 2916 SPRING A2702T PIN 1927 SEE CHART WASHER
163. 7255 XA 7352 5 620 DIA KNURI 5252 6 3 BN Suis 5 058 068 DTA 03 X M AG UR BEARING 43 7278 MATERIAL BEARING SEAT DRIVER 10 02 97 T 18050 96 WIN DISC INCORPRATED Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 3 11 Bearing Driver 18050 116 11 4 SIA 3NIOVM ONI 2510 A8 3190 9159531 NDISN3WIQ 311 dS 911 050811 3114 ava NDISN3WIQ TYWI93C GML C 30 I 13385 a NDISN3AIG ASAIAd ONIS 38 2 12345 3SIA33HI Y TENA NT SH3NNUO Tv 2 7 66 2 01 230 EET c6c WX DN 3215 2901 NBILdINOS3G Josey laa 91 06081 x Wid 6 1 1 11 0508 DN 7001 sarg x 51 I x mis 29806SVN m SAS Lad dyl 140 111840 1 1 1 pe OST e 5 d J i l 1 2s ee H bae Dy 09 OE A dAl 90
164. 7314F STEEL BALL H B1867 MUN O 22 1014902 2 SIS ERE Ug m UN IN AS 19278 102745 Me042aT y 1014851 NI MX td ff 1014883 MDUNT LUBE INSTRUCTIUN PLATE SEE 8 ISS N 2 Y Less WITH WORDS MARINE TRANSMISSION x 1 gt NN E LUBRICANT TOWARDS BREATHER SSS 1014885 2 zh lt ale e gt gt lt E 1201 gt M1990C q STS STEEL BALL e SSS i re SS S NN 77 E IN Z S 2 WORDS MARINE TRANSMISSION S H P NN S TOWARDS BREATHER 1014850 N Z ZINN N a zen T ey P 55 N i STEEL BALL X E S 2 1014896 1014895 1761 RATIO 33 T 1014851 1014850 ES NE M1990C E STEEL BALL A MEHE AS lt s XE N I P f 1 1014871 1 SET SPRING LENGTH TO 1 19 IN FICTER IY S STEEL BALL LX x x x 2703 1014870 SEE NOTE b 1 HOUSING M1990H
165. 76 2 VALUES CONTROL VALVE 22 2 88 P DIL FILLER HOLE 3 00 R 6 4 25 310 9 18 24 63 5 2 50 FACE USED FOR CONTROL MOUNTING BRACKET THIS LOCATION 2 PLACES am S A E 0 HOUSING 5 Z wo ee DUTLINE eir THIS SIDE EAS E r 5 16 18UNC 2B THRU CLUTCH ACTUATING H 16 7 21 321 DRILL THRU 2 WOLES ENGAGES CLUTCH ON 2 aces SUITABLE FOR PRESSURE 1 2 20UNF TH D OUTLINE OF OPTIONAL FOR 5 8 11UNC STANDARD SHAFT t CALLED CONTROL MOUNTING PER SAE J514 O RING CONNECTION S AE 1 TO SAE 0 EYE BIL TS WITH NUTS THESE HOLES SECONDARY BRACKETS HOUSING ADAPTER MAY BE USED FOR LIFTING MARINE TRANSMISSIUN DNLY Er 6 FLYWHEEL OUTLINE ENGAGES CLUTCH DN 2 4 LOUNF 1 IH D MUST CONFORM TD SAE 1 CONTROL LEVER SHAFT CALLED PER SAE 2514 O RING CONNECTION SAE J620 HOUSING zi 6 35 11 41 PRIMARY DISTANCE REQUIRED REMOVE GAGE amp ACCESS TE CAT 0 TROLLING E GAGE IS FLEXIBLE AND 2 4 2 Sia VALVE MOUNTING BOLTS OIL IN FROM HEAT EXCHANGER E LEVER LEE WASHERS R30N 1 11 1 2 THD lt DRYSEALD e 61 MIN UNDER REMOVE ALUMINUM THREAD JD 7 SCREW HEADS 7 PROTECTOR BEFORE e OIL FILLER HOLE ND NE DPERATING UNIT 9 m I Bun Q N In db DIL DUT HEAT EXCHANGER A 2 1 11 1 2 NPTF1 CDRYSEAL A N REM
166. 8 M2000H Me0e7C HEX NUT PORT FOR end CLUTCH dar B2451B lt B2465B SEE CHART 75 DIA HOLE MUST BE LOCATED IN THIS AREA IN MATING PART FOR TORQUE CONVERTER DR BEARING LUBE NOT TO EXCEED 80 P S I L I C L I x 4 lt 1 INN SES A 31 MIN HOLE MUST LOCATED IN THIS AREA IN MATING PART FOR CLUTCH DRAIN RATE OF RISE MATERIAL section 3 28958 1 21 29 NOTICE THIS PRINT CONTAINS section 1 11 THESE TO Be PACKAGED dea UMANE SEPARATELY AND SHIPPED WITH UNIT 2 20 97 Nor TH BE USED IN ANY MANNER A7361B VALVE BODY AS XA7361B VALVE BUDY AS 2 20 97 DETRIMENTAL THE INTERESTS USED FOR FACE PURTED USED FOR HOSE INLET NOT SERVICEABLE SEPARATELY A ATMOSPHERIC PRESSURE TWIN DISC INCORPORATED VALVE INLET THRU PORT X W REMOVE BEFORE OPERATING UNIT ATMOSPHERIC PRESSURE Y 26182 8 21 95 i _ RACINE WI 53403 USA XA7361B CHNSISTS A7361B ALUMINUM THREAD PROTECTOR LP INTERMEDIATE PRESSURE X 24804 12 7 94 THIS NOTICE IS NUT INTENDED VALVE BODY AND 945 CLUTCH PRESSURE 5 16 94 Th THE US GOVERNMENT CORE PLUG E D OR OTHERS BY CONTRACT vare ome cH par FUNCTIONS DETENT 22 P INSTR PLATE S 66 R
167. 98 x BP45iB 1 2 ese 5 Q 40958 1017133 1017134 B1337F 1016688 2 pwe7serme voc XA2707Z 7072 AS703T 1725 250 1017129 7 x esrb MALOSEA 2 MG 52022C 154 END SHURT 1018084 41088 1017569 1018688 e XMP7S9FL 12 VDC xA2707AD A2707AD A2703AB 2000 290 10171298 Mai038Ewe7 20 68 24518 50 0 6 fiis STRAP M29428 T e ireoe4z aroas 117154 e Kwe7ssrMe4 vhc xae707ap AP707aD 7 2000 lt 296 1017129 einsateer x 222 INSTALL USING MA908 LOCTITE 101808444 11017583 1017569 1017613 1018688 2 XMe7S9rL ie VDC XAe7072 427072 2703 2000 290 1017129 10 8 7 x 20 66 24518 0 1062 2 MA1062J wc SeoR PE TENT BACK DFF 1 2 TURN 018084 40967 1017383 1017179 YES 3 XMe7S9FM24 2655 385 10171294 x 2451 MG 6449 RV 357543 aui osese ND 2 jezseri ie vac ez as 2415 GS 10171698 10 WaT x hososaae 415 osese xwez5
168. 996F 9 N PLUG 1040 lt FITTING 92 FILTER ASS Y XB3614 FIGTER B2614 LABEL MA950 EH RING Si r E COVER 2502 A Z A 3 gt 2 PLATE 2127 34 8 STRAINER 2130 SIMILAR NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED TVR duy DISE PROPRIETARY INFORMATION AND IS Be EAR Ieee D NDT T USED IN ANY MANNER IN CD gt m NACRINED DINENSTONS R PORATED DETRIMENTAL TO THE INTERESTS OF RE 152 Scie X XX 0 13 TWIN DISC INCORPORATED ASSY ALL ANGULAR TOLERANCES ANG DRN KS TM RACINE WI 53403 USA GEOMETRIC TOLERANCING PEN kosm THIS NOTICE IS NOT INTENDED PER ANST TIASM 1988 ERN 1 2 v TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT NAME MG5202 pc dnos GRANTED THE US GOVERMENT APPD 5 OR OTHERS BY CONTRACT MARINE TRANSMISSION TBC SHEET 2 of 79 krv T 222522 554 75 HE INLET amp FILTER DRAIN PLUG 5 551 42 557 91 IN FRUM HEAT EXCHANGER 264 8 SEE SHEET 4 FOR TH D SIZE E FOR LIFTING DRILL THRU 240 86 MARINE TRANSMISSION HOLES EQUALLY SPACED i 2 BOLTS ONE EACH SIDE FILTER DRAIN PLUG USE 88 PRUPERTY CLASS QUALITY CAPSCREWS pore sem 209 11 EQUALIZE LUAD UN SEE SHEET 4 FOR SIZE PER ISU 898 1 AND TORQU
169. 9FM24 senes 2415 10171298 aroaren x eoe pensis 5 e teescm se 2220 ARE NOT POLARITY SENSITIVE N 101808446 41163 1017134 1018688 2 75 1 VDC xAa2707AD A2707AD 270 2000 lt 290 1017129 x MG Se0SDC Tn 47 1017179 e Fwe755FM24 vod 7072 27072 7 725 1017129 x 45 wasione 27 HYDRAULIC LOCK ONLY T a eeu p p 6 6557 00 pas USE AS REQUIRED PIN A2711AC 2 SPOOL 1017432 2 4 NOTE HYDRAULIC LOCK ONLY _ Z HYDRAULIC LOCK ONLY LEVER MAY BE LHCATED ANYWHERE ITS SHAFT PERMITS FREE PLUG MA1038E 2 PISTON SEE CHART 9 MOVEMENT WITHIN THE 50 2 ROTATION amp 11 4mm AXIAL MOTION WASHER 1017522 REQUIRED FOR CONTROL THESE SOLENOID CONNECTIONS H3 ARE NOT POLARITY SENSITIVE SOLENOID ASS Y SEE CHART GASKET B1334C a TORQUE TO 33 9 PARTS FOR UNITS WITHOUT NEUTRAL SOLENOID AND COVER ASSY 1017336 SPRING A2705AH 2 BALL M1990G 29 0 2 HYDRAULIC LOCK OPTIONAL CO
170. AIN PLUG M33 X 2 THREAD 8 00 266 7 10 50 V THIRD ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIDNS X 0 75 INCH DIMENSIONS AND POUNDS SHOWN IN BRACKETS L 1 MATERIAL WEIGHT wr kg Nm 5 FIRST USE XXX ASSY ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING MODEL PER ANSI 14 5 1982 SURFACE TREATMENT NAME MG5203 SC transmiss TRANSMISSION 9 14 95 SCALE 201 DRN 1016249 TUIN p SC INC R AT E D RACINE WI 53403 USA OPTIONAL TROLLING VALVE INSTALLATION AND OPERATING NOTES 1 REFER TO VALVE ASSEMBLY DRAWING ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TO THE PROPELLER MAXIMUM ENGINE SPEED WHILE TROLLING 1100 RPM 60 OF FULL LUAD ENGINE SPEED WHICHEVER IS SMALLER 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUUCTION BY MOVING TROLLING CONTROL LEVER OF LOCKED DETENTED POSITION TO MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION TRAVEL BY MOVING CONTROL VALVE LEVER TO THE PRIMARY CLUTCH DR SECONDARY CLUTCH POSITION MOVE TROLLING CONTROL LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED CLOSE TH DETENTED NO TROLL
171. AL MODE ELECTRIC MANUAL VALVE FOR MG 509 THRU MG 61242 PRESS LUBE gt P REFERENCE VALVE ASSEMBLY ND 1018440 SS RUE TUS ERR DIAGRAM HYDRAULIC WITH TROLLING VALVE gt a e Ep Section NEUTRAL START Section SWITCH MAX TROLLING PRESSURE SUMP RATE OF RISE FUNCTIONS DETENT 70 75 __ TROLLING 90 RANGE MIN TROLLING PRESSURE CLUTCH ENGAGED Trolling LLL K 7 l I sss DA n A 272 Gss NS p s 7 NI NS lt 2 OT Gr ENGAGED MANUAL CONTROL SWAT RE FUR MESEI EAE SINE uo VALVE AND a gm F Sw 224 eer cH gt 5 section NEUTRAL START section ES SWITCH Sump 4 CLUTCH B ENGAGED 7 2 2 BE 2 CLUTCH ENGAGED _ e PES Ts MANUAL CUNTROL VALVE FUR MG 509 THRU MG 6124e2e r T u p n NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT wre UNLESS OTHERWISE SPECIFIED IN DISE ai 7 Eee Wu A TO USED IN ANY MANNER 9 X 10 75
172. AND SHEET 2 28477 8 17 98 D 25631 12 7 94 5 FIRST USE 9 50 100 RACINE V satoa usa LIVE P T O XBoet3 CAUXILIARY PUMP DRIVE NOT SERVICEABLE SEPARATELY SUCTION SCREEN Le 27632 8397 E4 25260 6 2 94 RACINE WI 53403 USA GEDMETRIC TDLERANCING HYDRAULIC CLUTCHED P T O D E MODEL PER ANSI Y14 5M 1982 CHK FLEXIBLE COUPLING INPUTS SEE SHEET 66 26826 2 15 96 24983 5 16 94 NOTICE 15 INTENDED NAME REMOVE BEFORE OPERATING 2 PLACES ALUMINUM PLUGS m TO NULLIFY OR LIMIT RIGHTS SURFACE TREATMENT MARINE G 25997 4 6 95 ce 25221 4 12 94 GRANTED THE US GOVERNMENT MG5202 SC APPD en ev en s em UR DTHERS BY CONTRACT TRANSMISSION E 8 HEAT EXCHANGER REQUIREMENTS OPTIONAL TROLLING VALVE INSTALLATION AND OPERATING NOTES D REFER TO VALVE ASSEMBLY DRAWING FOR ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE TROLLING RANGE 238 5 9 391 I MUST INCLUDE DEVICE LOCK TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION DURING MSS Ge GAG SIDED SERRATIDN MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TO THE PROPELLER aera ele TROLLING PRESSURE gt RESSURE CONTROL VALVE 2 MAXIMUM ENGINE SPEED WHILE TROLLING 1100 RPM OR 60 DF FULL LOAD ENGINE SPEED WHICHEV
173. ASTIC DATA REFER TO B3904 4F CUUPLING A 1016215 ELEMENT nan COUPLING MA1041E HEX CAPSCREW 16 MA947D HEX NUT 16 1016520 HUB SPLINED COUPLING 1016217 ELEMENT SAE J620 COUPLING FOR TRANSMISSIDN CDUUPLING ASSEMBLY ENGINE IN STALL COUPLING AND HUB TO ENGINE FLYWHEEL ADVANCE MARINE TRANSMISSION INTO POSITION WITH ENGINE FLYWHEEL HOUSING MOUNTING FLANGE LINE UP INPUT SHAFT EXTERNAL SPLINE WITH INTERNAL SPLINE IN COUPLING HUB AND MOVE ENGINE AND MARINE TRANSMISSION TOGETHER MAINTAINING ENGINE FLYWHEEL HOUSING AND MARINE TRANSMISSION FLYWHEEL HOUSING MOUNTING FACES IN PARALLEL RELATIONSHIP ENGAGE FLYWHEEL HOUSING PILOTS AND INSTALL ALL MOUNTING CAPSCREWS USING 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 GRADE 5 QUALITY CAPSCREWS PER SAE 24091 TORQUED 574 SERVICE MANUAL VALUES 1008557 ESE COUPLING UPLING COUPLING 2900 FLYWHEEL SIZE NO 1514 4400 RIN EDA IUU A A A 4 SVK NS DYNAMIC TORSIONAL STIFFNESS kN m rad NOMINAL TORQUE kN m 2 2 NN S COUPLING WR WITHOUT OUTER PARTS INNER PARTS WEIGHT SEE SHEETS 1 3 AND 4 FOR PART NUMBERS AND DIMENSIONS 6 FOR COUPLINGS C AND 0 SAE 1 HOUSING COUPLING WEIGHT 2 kg WITH HUB WITH zi RING 2152 0 17 WITHOUT 017 phe THIRD ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED
174. AXIMUM TROLLING POSITION SELECT TROLLING DIRECTION TRAVEL BY MOVING CONTROL VALVE LEVER TO FORWARD OR REVERSE MOVE TROLLING CONTROL LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED CLOSE TO DETENTED NO TROLL POSITION THE TROLLING CLUTCH MAY ENGAGE FULLY CONTROL VALVE 18 62 N AT THE 560 R LOCATION OF THE 6 35 HOLE IS REQUIRED TO OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE FULL PRIMARY CLUTCH FULL SECONDARY CLUTCH AND NEUTRAL LEVER POSITIONS THE DETENT SPRING AND PIN MAY BE OMITTED WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY NEUTRAL AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS FORCE AT THE LEVER THE VALVE THEN REDUCES 13 31N THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 55 8 LINEAR TRAVEL FROM NEUTRAL AT THE 6 35 HOLE LOCATION ROTATIONAL STOPS THE STATED VALVE TRAVEL LIMITS HAVE A MAXIMUM CAPACITY 445 AT THE 6 35 2 HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES 50 CAPACITY OF THE VALVE ROTATIONAL STOPS IS NOT EXCEEDED EXCEEDING THE CAPACITY THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS CONTROL amp SECONDARY CLUTCH ACTUATING PRESSURE M18 X 15 THREAD SPEED TS eT PORT M16 X 1 5 THREAD PS METRIC PORT CONFORMS M18 X 15 THREAD TO ISO 6149 METRIC PORT CONFORMS T
175. Bracket an Engine Flywheel Housing Fap Shim here Ls 1_ 1 Bedrail T and Engine __ __ TIT TT fg 10 Set the indicator gauge at zero 0 Lift the marine gear with a hoist or other suitable means and place the unit in position against the engine flywheel housing Secure the flange of the marine gear main housing to the engine flywheel housing Use a feeler gauge to measure the space between each mounting bracket and engine bedrail Add shims between the brackets and bedrails to equal the feeler gauge readings Carefully release the lifting force on the marine gear The indicator gauge must remain steady at the zero mark Torque bed bolts to proper rating If the reading moves from zero lift the marine gear and insert additional shims Continue this procedure until the marine gear is completely at rest on the bedrails and the gauge maintains a steady zero reading After obtaining the correct zero reading the mounting brackets can be secured to the engine bedrails How Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 10 5 SECTION 10 10 8 Fig 10 8 Checking parallel alignment of the coupling 0 002 Feeler Gage Male Female 1 Straight Edge fg 10 As the engine and marine transmission come into their aligned position it will be possible to match the output flange and propeller coupling
176. C MG 5202DC MG 5203SC 5204 Table of Contents Section 3 Operation 3 1 E s MN ern 3 1 de 3 1 3 3 Control de a ete orae __ 3 2 A rct E ES 3 2 B Manga Conta value 3 2 C Manual Valyg 3 4 D Mamai Value SEGUI LI 3 6 3 4 Ric NS Uu l n o 3 8 eto 3 8 Electric Control Valve Assembly Neutral eese nnns 3 9 C Electric Control Valve Assembly Primary or Secondary 3 9 D ee mE 3 11 E 3 14 25 Topa yave 3 15 10175559 HANGS u l 3 15 3 6 DBE lt etr PM 3 16 3 7 Clutehed 3 16 3 8 3 16 3 9 wc Wd o RERUM 3 17 A Kul e c UE 3 17 B Philip RTT 3 18 C 3 19 Section 4 Specifications and Maintenance 4 1 Sa Cn gt 4 1 A ober A 4 1 elei L R An D o ULL 4 1 Minimum Oil Pressure When Cruising 4 1 D Maximan uku
177. CEABLE SEPARATELY C3 RACINE WI 53403 USA ende GEOMETRIC TDLERANCING FLEXIBLE CLUPLING INPUTSSSEE SHEET 3 1 428657 7 21 98 cure DEDE WA EMEN PER ANSI 14 5 1982 NAME K BUM NL 1096 METRIC TO NPTF ADAPTER KIT REMOVE BEFORE OPERATING 2 PLACES THREAD PROTECTORS Y jeeese a es ss 1 S El saran sev ze SURFACE TREATMENT 28544 5 4 98 GRANTED TH THE US GOVERNMENT MARINE i CH ND DATE OR OTHERS BY CONTRACT CSS TRANSMISSION DAS SHEET 4 REV _ OPTIONAL TROLLING VALVE INSTALLATION AND OPERATING NOTES 1 REFER TO VALVE ASSEMBLY DRAWING ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TO THE PROPELLER MAXIMUM ENGINE SPEED WHILE TROLLING 1100 RPM 60 OF FULL LUAD ENGINE SPEED WHICHEVER IS SMALLER 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUUCTION BY MOVING TROLLING CONTROL LEVER OF LOCKED DETENTED POSITION TO MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION TRAVEL BY MOVING CONTROL VALVE LEVER TO THE PRIMARY CLUTCH DR SECONDARY CLUTCH POSITION MOVE TROLLING CONTROL LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED CLOSE TH DETENTED NO TROLL POSITION THE TROLLING CLU
178. CH AND NEUTRAL LEVER POSITIONS THE DETENT SPRING 7 SHAFT q AND PIN OMITTED WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY NEUTRAL cu 4 ae AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS 00 Nit FORCE AT THE LEVER HOLE OPERATE THE VALVE THEN REDUCES 13 1 00 gt THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 35 8 LINEAR TRAVEL FREM NEUTRAL AT THE 6 35 DIA HOLE LOCATION ROTATIONAL STOPS THE QU b STATED VALVE TRAVEL LIMITS HAVE MAXIMUM CAPACITY 445 N AT THE es REF amp 6 35 DIA LUCATION VALVE ACTUATORS WITH CAPABILITY EXCEEDING Z SECONDARY CLUTCH MES THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES SU CAPACITY OF THE VALVE ACTUATING PRESSURE MIO X 10 THREAD ROTATIONAL STOPS IS NOT EXCEEDED EXCEEDING THE CAPACITY METRIC PORT CONFORMS ISO 6149 THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS OF CONTROL MIO X lo TAREAD SECONDARY AUXILIARY LUBE SUPPLY CLUTCH INLET SEE HYDRAULIC 2 Tene C SPEED PICK UP PORT 4 5 M16 X 1 5 THREAD UBE BIST CENTER GREASE FITTING METRIC PORT CONFORMS MIB X 15 THREAD 0 150 6149 METRIC PORT CONFORMS DUTPUT iu 150 6149 SHAFT q DIL OUT TO FROM HEAT EXCHANGER 220 M33 X THREAD METRIC PORT CONFORMS N A X ISU 6149 REMOVE THREAD E BEFORE OPERATING UNIT pum E
179. CREWS PER 150 898 1 DRAIN PLUG USE ALL 162 HOLES FOR MOUNTING UNIT 0 USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE 574 SERVICE MANUAL VALUES 53941 281 23 6 REF LUBE P SI 586 9 23 1 608 3 283 95 S A E J620d MARINE 634 3 84 97 TRANSMISSIUN 9 scum E F J K L FLYWHEEL ND 006 005 008 004 18 711 2 679 45 647 70 571 50 542 92 495 3 15 7 318 19 7315 28 00 gt 26 750 gt lt 25 500 gt lt 22 500 gt lt 21 375 gt lt 19 503 62 gt 1 25 gt lt 2 882 1 14 552 4 530 20 511 17 466 725 438 15 409 4 25 4 224 22 4 21 75 20 875 lt 20 125 418 3752 17 2507 16 12 lt 1 002 688 5732 1688 2 LJ lt 22 238 5 9 39 MIN TROLLING PRESSURE NO Sa DE TENT TROLLING RANGE RESSURE T TROLLING P 90 111 0 4 371 THE TRDLLING LEVER ND DETEN HEAT EXCHANGER HE REQUIREMENTS REFER TO B3649K FOR HEAT EXCHANGER DATA SAE 172 36 STRAIGHT SIDED SERRATION CONTROL VALVE 444 133N 10 30 LBS J AT THE 56 0 Ce ec0JR LOCATION THE 6 35 1 41 DIA HOLE 2 2 RATE DF RISE 5 X 5535 635 1 41 CONTROL IS REQUIRED OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE 2 72 PUNGA TENS DRILL THRU PENER FULL
180. DVE ALUMINUM THREAD sid Ne H p DPERATING UNIT NS s 2 iD fg 1 LUBE h 7 00505 172 14 NPTF TH D UE d 5 5 9 0 DRYSEAL gt lt A pc V Gp m AUXILIARY LUBE SUPPLY BI Xo x u INLET HYDRAULIC ES D i DIAGRAM IN mM ND 7 0 QN LJ ln D QUII e Y i x lt Xx X ex M DE eu 3 JD QN D EN N 21 3 u 0 CENTER pF GRAVITY _ u 6 CLEARANCE e 2 DIL PUMP 27 4 S ae 4 D LUBE PRIMARY 374 16UNF T TED c 7 PER SAE J514 D RING s LLM NS LAE CONNECTION Se pu ur LLL S667 Sesi x D R Z FILTER DRAIN DAE Tee 9 t9 68 y 611224 CUSTOMER TH FINISH BORE 5 u C Z 5 SEE NOTED 2 LUBE 51 M O Q O AUXILIARY LUBE lt SUPPLY INLET E GREASE 3 4 16 UNC FITTING O RING PORT SECONDARY CLUTCH QJ s S 0605080601 0 D DRIVING THRU E PRIMARY CLUTCH lt 0 DI L ON e MI 1 LO cO Q a 2 J ol S OQ r y 104 ps A Ao 010 E
181. E THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED SECURE FLEXIBLE COUPLING ROUSING FEANGE HOLES USING STANDARD METHOD BEFORE SHIPMENT LNT Ta RACINE WI 53403 USA THIS NOTICE IS INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT HEAT TREAT FIRST USE ASSY MELLRE ec THIRD ANGLE PROJECTION SIMILAR TO MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED MACHINED DIMENSIDNS LBS LBS IN X X 0 030 0 010 0 005 ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING PER ANSI 14 5 1982 MoS MARINE TRANSMISSION A DATE 8 1 95 SCALE 1mm RN CHK DAS Tu Uil DISS INCORPORATED RACINE WI 53403 USA pos OC 250 101625045 ser 4 oF 5 ASSEMBLY 10162504 ASSEMBLY 1016250 WAS a c os NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT MATERIAL WEIGHT LBS HEAT TREAT FIRST USE ASSY MODEL SURFACE TREATMENT NAME B THIRD ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED DATE A mac INED THEN I TAUN use LBS IN X X 0 0
182. E TU TS TO LIFT S574 SERVICE MANUAL VALUES rec qas MARINE TRANSMISSION si UNL Y M8 1 25 THRU 2 HOLES SUITABLE FOR EH T CONTROL MOUNTING HOUSING ADAPTER CONFORM TO H USE HARDENED S AE J620 FLAT STEEL WASHERS o DRILL TARU ND 355 R30N 61 MIN UNDER SCREW HEADS SAE 1 HOUSING ENGAGES CLUTCH ON SHAFT q CALLED PRIMARY M16 x 1 5 METRIC THREAD CONFORMS TO 150 6149 REFER TO CHART FOR REQUIRED PICK UP DEPTH 59 NEUTRAL N PLUG 29 09 UP PORT gd N L 22 524 09 REF LUBE PST PORT lt 5 Z AUXILIARY LUBE s lt ENGAGES OI UTO ON SAFI d CALLED REVERSE UH BUT LI REAL EXGEANEIS SEE SHEET FUR SIZE 21 3 CLEARANCE REMOVE OIL PUMP N TOCS CLEARANCE TO REMOVE SUCTION SCREEN CENTER OF GRAVITY L4 e CO OR FLYWHEEL OUTLINE cis MUST CONFORM E NO ON S AE J620 NN QJ QJ 0 460 m E AG 1359 70 DRILL THRU HOLES EQUALLY SPACED USE 88 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE 574 OR SERVICE MANUAL VALUES STUCK SZE CUSTOMER TO FINISH BURE SEE NEUTE END X eo THREAD SLS tS HOLES EACH
183. ECTION 1 Introduction SECTION 2 2 1 Section 2 Description 2 1 General 1 The MG 5200 series transmission can be operated through either the primary shaft or secondary shaft at its full rated horsepower 2 The model MG 5202SC marine transmission is manufactured in both English and metric dimensions Check the bill of material BOM for applicable drawings and parts listings 3 Transmission clutches are hydraulically applied using main oil pressure All bearings clutches and gears are lubricated and cooled with low pressure oil 2 2 Direction of Drive Input power to the transmission is through a torsional coupling mounted on the engine flywheel The coupling is splined to the forward end of the primary shaft causing the primary shaft to rotate in engine direction Power is transmitted to the secondary shaft through transfer gear teeth on the outer diameter O D of the primary clutch housing These teeth are in mesh with gear teeth on the O D of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and second ary 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 shaft direction and causing the output shaft to rotate in anti engine direction Application of the secondar
184. EF LUBE PRESSURE PORT lt 547 8 esu 374 7 FLANGE 595 2 95 2 WITH 22 2 SQUARE KEY 114 3 WITH 25 4 SQUARE KEY 120 6 WITH 318 SQUARE KEY 139 7 WITH 318 X 22 2 M IRIC KEY 8 1251 TAPER THIRD ANGLE OPTIONAL TEMPERATURE INDICATING SWITCH E PREVEC TIEN CUSTOMER TO INSTALL IN 3 4 X 3 4 X 3 41 PIPE TEE TRANSFER GEAR IDIM FROM PORT IN THE HYDRAULIC LINE LEADING FROM THE MARINE GEAR SETS IS FACE PINION OLD SUTRA 3 481 100 5 MATERIAL WEIGHT wR UNLESS OTHERWISE SPECIFIED PROPRIETARY INFORMATION AND TS rim USED IN ANY MANNER DETRIMENTAL THE INTERESTS TRANSMISSION PUMP TO THE HEAT EXCHANGER INLET REFER TO HYDRAULIC DIAGRAM 2924 2 481 ae HEAT TREAT FIRST USE XX TWIN DISC INCORPORATED nu RACINE WI 53403 USA MODEL Saupe M aE THIS NOTICE IS INTENDED E MARINE 1 APPD OR OTHERS BY CONTRACT 5204 TRANSMISSION REV AD A NOTE ALL POINTS AVAILABLE FUR TESTING ARE CODED e 1334 516 O 16 x 15 METRIC THREAD CONFORMS ISO 6149 REFER CHART REQUIRED PICK UP DEPTH 763719501 9 674 2 631 0 547 8 MANUAL LIVERRIDE 245 3 POSITION 543 9 ELECTRIC CONTROL Es 231 3 POSITION 525 6 EYEBOLT t OTHER
185. ENGINE INSTALL CDUPLING AND ENGINE FLYWHEEL ADVANCE MARINE TRANSMISSION INTO POSITION WITH ENGINE FLYWHEEL HOUSING MOUNTING FLANGE LINE UP INPUT SHAFT EXTERNAL SPLINE WITH INTERNAL SPLINE IN COUPLING HUB AND MUVE ENGINE AND MARINE TRANSMISSION TOGETHER MAINTAINING ENGINE FLYWHEEL HOUSING AND MARINE TRANSMISSION FLYWHEEL HOUSING MOUNTING FACES IN PARALLEL RELATIONSHIP ENGAGE FLYWHEEL HDUSING PILUTS AND INSTALL ALL MUUNTING CAPSCREWS USING 8 8 PROPERTY CLASS QUALITY ISH 898 1 LGRADE 5 QUALITY CAPSCREWS PER SAE J429 TURQUED TU 55 4 SERVICE MANUAL VALUES NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 15 NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERMENT OR OTHERS BY CONTRACT MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm 2 MACHINED DIMENSIONS 1052 Nim X 0 75 XX 10 25 HEAT TREAT m joo F E EN 20 0 4 0 20400 K N b 22122 WASHER 1504 196 0 9 223 0 1 59 98 9 RING B1048L N HUB 1019735 SHAFT 5 1015231B 16 0 6 IHRU HOLES EQUALLY SPACED USE 10 9 PROPERIY CLASS QUALITY CAPSCREWS PER 150 898 1 AND TORQUE 55 4 OR SERVICE MANUAL VALUFS HUB THIRD ANGLE EM DATE
186. ENSIONS X X 0 030 NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS LBS 0 010 0 005 ALL ANGULAR TOLERANCES 1 HEAT TREAT FIRST USE ASSY GEOMETRIC TOLERANCING MODEL PER ANSI Y14 5M 1982 SURFACE TREATMENT NAME B TWIN DISC INCORPORATED RACINE WI 53403 USA SEE CHART THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT 2 2 M2089F M2089AA SF Gr NE CUNTAINED IN VALVE SPECIFICATION MG518 9 3 80 Me089F 2089 1 089 3 MGS16 e meoso 2 PFE e 217 87 2 5 2 MG521 8 0527 10 14 83 2 MG512 ONLY REB JS BCA gt 22 CLUTCH PRESSURE IN NEUTRAL WILL BE BETWEEN 30 AND 90 P S L WHEN MEOSICD PLUG IS DEPENDING SPRING ASS Y USED THRU VALVE AND SPECIFIED 47 gt 7X ES li INTERMEDIATE PRESSURE SEE CHART 14008 32 4 14 lof AT THE 2 208 LOCATION OF THE 1 4 DIA HOLE IS REQUIRED DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 1 41 LINEAR TRAVEL FROM NEUTRAL AT THE 1 4 DIA 703 LOCATION WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT 55 SIT m pem E 199014
187. ENT NAME 29350 6 24 99 ALL 28208 GRANTED THE U S GDVERNMENT WAIVE TROLLING mv zw cw me 204 cH mer DR OTHERS BY CONTRACT BE sheet 1 nr 1 mev ENEMIES WIRING DIAGRAM DITCH uvp SOLENOID VALVE SPRINGS CLUTCH SHIMS MOUNTING SCREWS VALVE BOM DITCH TRANSMISSION SOLENOID ORIFICE NC 5 PISTUN RAULIC VOLTAGE CONSISTS OF kPa PSD w E ns uma ASS mure part lary S CUNNECTHR PORT SOLENOID 1018084 40750 1017133 1017134 B1337F 1018688 YES 3 2759 24 7072 427077 A2703T 725 250 1017129 1038 7 x 20 6 B2451B 1052 2 1052 52020 10180844 40751 1017383 1017179 NU XMe759FM24 VDC A2707BD 2704 0 2415 lt 350 1017129 MA1038E we7 x Be451B 00 MG 6619 00 RV D PLUG M2051K 2 1018084 40752 1017133 1017134 B1337F 1017179 no 759 24 VIC A2707AD 1585 1017129 2051 0536 51 089 2 2089 2 NEUTRAL SOLENOID E 10018084C 40753 1017133 1017134 B1337F 1017179 759 24 VDC XA2707BZ A2707Bw A2703BA 1380 2002 1017129 M20SIL Go 10535 51 M2089Y
188. ER IS SMALLER ANGULAR LOCATION MAY _ we EE bikes 444 133 110 30 LBS AT THE 56 0 Le cOJR LOCATION OF THE 6 35 1 4 DIA 6 35 11 41 CONTR IS REQUIRED TO OVERCOME DETENT EFFORT THE DETENT FEATURE IS PROVIDED IN THE 3 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUUCTION BY MOVING TROLLING CONTROL LEVER ADJUSTED 50 THAT THE 90 FUNCTIONS DETENT 2 DRILL THRU FULL PRIMARY CLUTCH FULL SECONDARY CLUTCH AND NEUTRAL LEVER POSITIONS THE DETENT SPRING OUT OF LOCKED DETENTED POSITION TO MAXIMUM TROLLING POSITION SELECT TROLLING DIRECTION OF TRAVEL LEVER ROTATION REQUIRED Tay 9 AND PIN BE OMITTED WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY NEUTRAL BY MOVING CONTROL VALVE LEVER TO THE PRIMARY CLUTCH OR SECONDARY CLUTCH POSITION MOVE TROLLING CONTROL n D AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED 560 RANGE IN WHICH THE a FORCE AT THE LEVER HOLE TO OPERATE THE VALVE THEN REDUCES TH 13 31N 3 7 LBSJ CLOSE TO DETENTED NO TROLL POSITION THE TRULLING CLUTCH MAY ENGAGE FULLY LEVER MAY BE LOCATED 00 THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 35 8 1 41 LINEAR TRAVEL ead PE FROM NEUTRAL AT THE 6 35 1 4 DIA HOLE LOCATION ROTATIONAL STOPS AT THE D Dy STATED VALVE TRAVEL LIMITS HAVE MAXIMUM CAPACITY 445N
189. ESSURE 1 GAUGE 1052 9 ale lt CU ojig Ll e lt THESE STANDARDS APPLY 5074 FASTENER TORQUE REQUIREMENTS S692 BEARING SHIMMING 5765 TAPERED JOINT ASSEMBLY 6 1014861 1 90444 4 SIDE AWAY FROM BEARING ue _ 2915 2 Mece20aD 4 lt Qu ON lt gt B6232 203190B 2706 19900 MA960E MA1039A i 2 5 I L M NIN lt lt mum 1001380 Bees AP669AU 1016877 806107B 206106 B3616A Me693E A a lt gt lt MAS90AR 1016271 1016268 j 1016274 2 1014884 SEE NOTE 6 MDUNT LUBE INSTRUCTIDN PLATE WW 1014895 8 2 INSTRUCTIDN PLATE WORDS MARINE TRANSMISSION SIN 22 TOWARDS BREATHER gt E EE TUE NS D 2 F F 1 1015109 HOUSING MA977 1 e MA1038C Ru lt 2 30 2 LT L L SEE 21
190. EXCEED 552 kPo IN MATING PART CLUTCH DRAIN u 1 DATUM Hom 2 22 E N N SECTION D D SECTION E SECTION N ee 4 GASKET ORIFICE PLATE GASKET W 1 W V 3 0 MIN HOLE MUST BE 2821 LOCATED IN THIS AREA IN MATING gt F 1 q PART FUR VALVE DRAIN GENERAL NOTES ME RIC See eee Geb 1 0 10 DRILL THRU SECTION J Y REMOVE BEFORE OPERATING UNIT PORT FOR 127 4 HOLES THREAD THIRD ANGLE Pues ccc VALVE BODY AS ist CLUTCH FOR MOUNTING BOLTS PROJECTION USED FUR HOSE INLET 0 41 008 SERVICEABLE SEPARATEL Y SIMILAR TD VALVE INLET HERE THRU PORT X 0 41 X 7372 XA 122 255 CUNSISTS 1001138 11 1 DRILL 0 THESES PARTS ARE PACKAGED gt HOLES 69 60 OIL INLET 1001138 SEPARATELY AND SHIPPED WITH UNIT SERIES VALVE BODY AND 19454 VALVE BODY ONLY CORE PLUG 78 87 THIS PRINT CONTAINS MATERIAL WEIGHT wR UNLESS OTHERWISE SPECIFIED DATE 102 1 PROPRIETARY INFORMATION AND IS all s TUN MISE E d BE USED IN ANY MANNER ped EBEN X 0 75 SCALE INCORPORATED A ATMOSPHERIC PRESSURE 104 14 s E4 28958 1 21 99 DETRIMENTAL TO THE INTERESTS OF 0 25 RACINE 53403 USA ATMOSPHERIC PRESSURE 28958 FIRST USE
191. Fixture T 21397 Lifting Bracket for Clutch Removal in Boat No P N Output Gear Lifting Fixture T 19987 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 1 11 Twin Disc recommends the following products for use in the assembly and removal of tapered shafts using the oil injection method THAP 300 Air Driven Pump Set This set consists of the air driven pump with accessories such as an adapter block pres sure gauge high pressure pipe or pressure hose with quick connection couplings and connection nipples The set includes one of each air driven pump THAP 300 adapter block 226402 pressure gauge 1077589 and high pressure pipe 2m 6 5 ft 2279574 Mounting Fluid LHMF 300 and Dismounting Fluid LHDF 900 SKF LHMF 300 and LHDF 900 are recommended when using SKF hydraulic equipment like hydraulic pumps HMV nuts oil injection equipment etc The fluids contain anticorrosives and are non aggressive to seal material like nitrile rubber Buna N Perbunan chrome leather PTFE etc SKF LHMF 300 and LHDF 900 are available in 5 liter 5 3 qt cans Designation LHMF 300 5 and LHDF 900 6 Order through your local authorized SKF distributor 11 2 SECTION 11 Special Tools Special Tools 11 3 Driver T 18050 96 STAMP T 18050 96 PT amp X A
192. HEAT TREAT FIRST USE i See uar 5064 39 80 51117 46676 43815 4094 85 4 257 6 3 1 761 671 12 6 TWIN DISC INCORPORATED 21 75 20 8752 20 1257 18 375 17 25016 12 lt 1 002 lt 1 01 gt 44732 53 C85 SUD EINE Lost 509 0 2 3 1 331 51 6 2 0 1 174 43 0 1 7 RACINE WI 53403 USA MODEL PER ANSI Y14 5M 1982 CHK RUTES de race semen GRANTED THE U S GOVERNMENT DTHERS TRANSMISSION NOTE ALL POINTS AVAILABLE FOR TESTING ARE CODED d L 615 27 Leu 1 1 2 11 1 2 NPTF THREAD 507 3 19 97 WATER 014 47 18 4441 417 5 116 441 3 02 1 1 2 11 1 2 NPTF THREAD 123 83 4 8 751 430 6 116 95 Y 389 7 15 34 1605 26 36 WATER IN 47 041 L18 51 poss p DIIS NOTICE THIS PRINT CONTA 333 8 113 141 123 83 4 875 10161053 INS BE USED IN ANY MANNER DETRIMENTAL THE INTERESTS TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OT HERS BY WATER 1 dE 1 2 NPTF THREAD T RE N zd lt lt lt ANS F lt Od
193. I uoisueuiip puooes y pue SUN 1 uoisuauiip 15 uaAID suoisueuilp JO 5495 uauM SECTION 13 MG5202DC ission Rear Vi Transm 13 5a Joujeoug 9158012 ureip edid peau xeu peau peau xeu lt pue peau xau pjojiueuJ peau xau uonduosoeg 6 6 Aio Jd c0cS9IN plojiueuu edid pepeeJu qn 5150 jquesse eqn Ajquiasse o l n sneg 5 5 eqni SAUP MAIS eqni Seld AD SECTION 13 Illustrations 13 10 Illustrations EX dex viet N Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 13 11 mon uols 2025 1 uo pasn jou jeu sued sejoueg Syun 104 SI puooes pue usilBu
194. IN PILOT 4 CONTRUL 7 HOUSE 1 8 27 ind EXTERNAL TROLLING FEATURE OPTIONAL SN 1 8 27 NPTF Gn EXTERN 69 DETENT CONNECT GAGE INTO BIL LINE BETWEEN AND CONTROL VALVE 6 4 9 THRU CERES SURE REMOVE 4 PLASTIC PLUGS CONTROL VALVE TROLLING VALVE NO DETENT ACCESS TEH cb VALVE MDUNTING BULTS 0 90 OIL IN FROM HEAT EXCHANGER M33 X 2 THREAD 2 METRIC PORT CONFORMS E TH 150 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT MIN TROLLING x 2 PRESSURE THE TROLLING LEVER ANGULAR LOCATION _ 25 6 DETENT ADJUSTED 50 THAT 90 E LEVER ROTATION REQUIRED FUR CONTROL FALLS ANYWHERE WITHIN THE 3607 RANGE IN WHICH THE LEVER MAY BE LOCATED 386 33 2 TROLLING VALVE INSTALLATION AND NOTES 12 REFER TO VALVE ASSEMBLY DRAWING FUR ADDITIONAL INSTALLATION NOTES CONTROL HEAD FOR TRULLING VALVE MUST INCLUDE A DEVICE TO LUCK TROLLING VALVE CONTROL LEVER IN DETENTED NO TROLL POSITION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TO THE PROPELLER ga MAXIMUM ENGINE SPEED WHILE TROLLING 1100 SEM OR 60 OF FULL LOAD ENGINE SPEED WHICHEVER IS SMALLER TO ISO 6149 247 60 FILTER 3 2 WITH CONTROL VALVE LEVER IN NEUTRAL SELECT TROLLING FUNCTION BY MOVING TROLLING CONTROL LEVER BUT LOCKED DETENTED POSITION TO M
195. ING 10504 x1 ra BALL M1990U NY A O RING A2916DD SSH RING A29168 E f NS Y PIN PM 3036 M C A f INSERT SPRING A2701BN OVER ROLLPIN 4 Xx j PM 3036 M UNTIL FIRST SPRING COIL YNY REMAINS LOCATED AGAINST STEM FACE ND 18 55 SN SPRING A2701BM 1 SPRING A2701BN SECTION D 40 00 H G BOM NO 40588 M8 X 1 25 19 1 DEEP 9 00 70 00 5 I 1017553 88 0 PLATE GREASE APPLICATION PROCEEDURE THIRD ANGLE G BEFORE INSTALLING VALVE STEM INTO BODY APPLY GENERAL PURPOSE GREASE PER SIMILAR TU 1 6 USE EXISTING PLATE FROM CONTROL VALVE THE VALVE STEM FROM THE O RING GROOVE PX 8671 TO NECKED DOWN DIAMETER AT LEVER END 29117 2 4 99 NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED 3 4 PROPRIETARY INFORMATION AND IS 7 30 97 eO ua MISE 29015 12 17 98 TH USED IN ANY MANNER Nn X 10 75 INCORPORATED 0 25 1 0 1 0 RACINE WI 53403 USA DETRIMENTAL TO THE INTERESTS OF s TWIN DISC INCORPORATED ass TORRE ae x VARIOUS SERE 1017555 LL 5 Q 5 THIS NOTICE IS NOT INTENDED D TO NULLIFY OR LIMIT RIGHTS SURFACE TREATM
196. IONAL STIFFNESS kN m rad DYNAMIC TORSIONAL e STIFFNESS COUPLING WR 2 OUTER PARTS NO 460 2800 PER CHART 0477 9415 C SAE 1 HOUSING 2 FLYWHEEL OUTLINE AL MUST CONFORM TO EN SAE J620 No 3551141 V 1616385 T 1 TA lt Z 1 7 s CHUP GING SES 2 f x Z 2 AN __ Nes NN COUPLING pe J Eu A N Ny 1016386 1 y Y 1 M 22 2 FLYWHEEL DUTLINE MUST CONFORM SAE J620 No 460 18 SALE 0 HOUSING DYNAMIC TORSIONAL TORQUE STIFFNESS STAGE X xTkn KN m kN m rad lof lof in rodl 0 25 2 5 T 2210 22000 0 50 1 0 10 44251 28000 Le 1 025 D 11050 602000 2 50 1 amp 2 050 22100 1044000 3 30 163 0 T 29200 1442500 3 75 198 0 0 75 4 10 234 0 1 amp 2 0 82 5 00 44250 T 348 0 DYNAMIC WR2 TORSIONAL kg m ll in2 3 RATED TORQUE lbf in SAE J620 COUPLING WEIGHT kg lb COUPLING STIFFNESS PRIMARY SECONDARY 355 CF DS 59 5 00 4 10 3 30 0 61 0 16 24 4 2800 44250 363001 292001 20817 5471 53 8 460 CF DS 59 5 00 440 3 30 0 61 0 24 375 s Five 44250 363001 292001 20811 8207 60 6 FLYWHEEL d COUPLING PLEASURE INTERMEDIATE CUNTINUDUS SIZE ie e
197. ISSION SHIPMENT SECURE FLEXIBLE COUPLING HOUSING SALE FLANGE HOLES USING STANDARD METHOD BEFORE SHIPMENT UNIT NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND 15 NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF 0 005 ALL ANGULAR TOLERANCES 1 TWIN DISC INCORPORATED RACINE WI 53403 USA GEOMETRIC TOLERANCING PE 8 THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT DETAIL MECHANICAL VALVE LE J 7 AN AS gt EMEL Y ENT NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT MATERIAL WEIGHT LBS HEAT TREAT FIRST USE ASSY B SIMILAR WR UNLESS OTHERWISE SPECIFIED MACHINED DIMENSIONS X X 0 030 0 010 X XXX 0 005 ALL ANGULAR TOLERANCES 1 GEOMETRIC TOLERANCING PER ANSI Y14 5M 1982 Moje CS MARINE TRANSMISSION THIRD ANGLE PROJECTION Preces TUN DISE i vi end m 9 1016103 10161034 p 101610 3B _DAS AD A 4 amp ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 55704 NOTES 1 THRU 8 ARE IN 570 54
198. ITH 31 8 1 1 4 X 22 2 7 8 KEY amp 125 1 XLOUIN ZF TAPER OPTIONAL TEMPERATURE INDICATING SWITCH CUSTOMER TO INSTALL IN 3 4 X 3 4 X 3 4 PIPE TEE IN THE HYDRAULIC LINE LEADING FRDM THE MARINE TRANSMISSION PUMP TO THE HEAT EXCHANGER INLET REFER TO HYDRAULIC DIAGRAM NOTE ALL POINTS AVAILABLE FOR TESTING ARE CODED I L 76 2 R 3 00 LE AT THIS LOCATION OMITTED 0 HSG ENGAGES CLUTCH CONTROL LEVER EYEBOLT q 150 8 5 94 144 8 5 70 OIL FILLER HOLE V 139 7 5 50 111 3 4 38 109 7 4 38 V V NEUTRAL 50 8 2 00 22 2 83 63 5 2 50 x 2 PLACES S A E 0 HOUSING OUTLINE PRIMARY CLUTCH ACTUATING PRESSURE 10 X 10 THREAD 3 16 18UNC 2B THRU HOLES SUITABLE FOR CONTROL MOUNTING BRACKETS LUBE P S I 6 ENGAGES CLUTCH UN M18 X 15 THREAD SHAFT CALLED PRIMARY DISTANCE REQUIRED TO REMOVE DIL GAGE GAGE IS FLEXIBLE AND TROLLING CAN BE BENT IF LEVER NECESSARY L N DIL FILLER HOLE i 19 a 9 5 a CAUT e u e 9 S V N CJ 7 V Q M F i ut PRIMARY CLUTCH q i x d 5 u 19 eS lt lt GREASE FITTING
199. ITH NUTS THESE HOLES MAY BE USED FOR LIFTING MARINE T Bis TRANSMISSION ONLY OIL IN FROM HEAT EXCHANGER M33 X 20 THREAD METRIC PORT CONFORMS TO ISO 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT DIL OUT TO HEAT EXCHANGER M33 X 2 THREAD METRIC PORT CONFORMS TO ISO 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT tout 82 5 3 25 50 37698 Det oot 21 3 84 CLEARANCE DIL PUMP LUBE P S I M18 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 AUXILIARY LUBE SUPPLY 1 INLET SEE HYDRAULIC DIAGRAM BASIC 2 119 48 4 704 O E 70 E 62 gt s 152 349 5 998 152 400 6 0001 190 5 7 50 4 228 6 9 00 aye ec 57221251 STUCK SIZE CUSTOMER FINISH BORE SEE 279273 10 995 279 400 11 000 SECONDARY CLUTCH ACTUATING 6 096 PRESSURE M10 X 10 TH D 6 350 METRIC PORT CONFORMS e TO ISO 6149 250 4 22 4 7 3 8 16UNC THREAD L88 7 6 L 301 DEEP 1003 _ SUCTIHN SCREEN 3 95 CLEARANCE TEMPERATURE SUCTION PICK UP PORT SCREEN 1 4 18 NPTF DRYSEALD 136 4 5 37 228 6 9 00 COMPANION FLANGE BORES 95 2 3 75 WITH 22 2 7 8 SQUARE KEY 114 3 4 50 WITH 25 4 1 00 SQUARE KEY 120 6 4 7
200. Installation Installation 2 With the indicator mounted as in the above paragraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing See Figure 10 2 Fig 10 2 Checking flywheel housing bore eccentricity Engine T Engine Thousandths Indicator 7 t Flywheel Crankshaft Engine Flywheel Housing 19 10 Rotate the engine flywheel and note the bore eccentricity of the engine flywheel housing bore The bore eccentricity must not exceed 0 41 mm 0 016 in Bolt a thousandths dial indicator to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the face of the flywheel See Figure 10 3 Fig 10 8 Checking flywheel face runout Engine Flywheel 1 Ir lt Engine Crankshaft Engine Housing Engine oy 5 Flywheel Thousandths Indicator fg 10 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC 5204 10 3 SECTION 10 Rotate the flywheel The variation 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 Thrust on the flywheel should be in one direction at all times to obtain a correct reading 4 With the indicator mounted as in the paragraph above adjust the i
201. LE SEPARATELY PARTS ARE PACKAGED SEPARATELY AND SHIPPED WITH UNIT D RING 2916 PLUG 1017389 SESS N ERN y AAA SPOOL 1017433 2 HYDRAULIC DIAGRAM 119 SHEET 3 DF 3 THIRD ANGLE PROJECTION MILAR TO ps 2917 224 99 5 29067 1 25 99 246 29015 12 17 98 5 29694 11 22 99 LB 28921 u e e H 29878 5 13 99 28844 10 28 98 E3 29232 4 15 99 REV 20 CH DATE REV ZUNE CH DATE NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT FIRST USE ASSY MODEL MG S202DC SURFACE TREATMENT NAME UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS X 0 75 XX 0 25 XXX 0 13 ALL ANGULAR 1 GEOMETRIC TOLERANCING PER ANSI 14 5 1982 CONTROL WITH TROLLING VALVE 1015207 DATE SCALE 0 DRN louse INC R POR ATE D RACINE WI 53403 USA 1018440 SERIES APPD SHEET 1 1 REV K 1 00 CHK DIMENSION TO SAE 0 HOUSING MOUNTING FACE SAE J744 No 127 2 127 4 FLANGE AND NOTE SAE J744 No 38 4 PUMP DRIVE ADAPTER SHOWN ABOVE
202. LES PLUG _ j 3 7 6 13 96 e eere 8 21 95 v 2 49 3 1516 9441 ame we ze cw wo pam D Te sss SECTION B VALVE VALVE mv 12 PT SCREVS ORIFICE VALVE SPRINGS mo SHIMS DATE ASSEMBLY BODY PLATE X SPRING CONSISTS BF Y PART loty Q De AND NUMBER c cy QTY PART NO SIZE ASS Y OUTER INNER NOM 656 ulii QTY 2o GG XA7371E 7 61 813970 EER 4270740 160 82334 1 5 Me051L Qe XA7371K 7 61 813370 13970 EEN 250 YES 82334 9 XA73714 A73618 559 355 3 53 CENTER 1 052 Me70eD V A2707BD 704 7 xa7a7iN 85 97 338 324518 roaroa 707 230 vts xA737iP misero 338 2418 hoeroa 7 230 vts xA73710 8597 388 sarun 27 200 G XA7371S 837 xarra ae707Ax 70480 230 YES XA737iT 2597
203. LES MAY BE USED LIFTING MARINE TRANSMISSION ONLY SHAFT q CALLED SECONDARY 6 4 L25 6 35 1 4 DRILL THRU IL IN FROM HEAT EXCHANGER M33 X 2 0 THREAD REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT O 3863 ns an IL TO HEAT EXCHANGER M33 X 2 THREAD REMOVE THREAD PROTECT BEFORE OPERATING UNIT R X 50 3 1 98 LUBE P S I REF M10 X 1 THREAD AUXILIARY LUBE SUPPLY INLET SEE HYDRAULIC DIAGRAM 19 8 L 78 4 82 5 3 2 eus 84 CLEARANCE REMOVE OIL PUMP LUBE P S I M18 X 15 THREAD 57 2 2 25 t STOCK SIZE CUSTOMER TO FINISH BORE CSEE E G x OOo C OUTPUT _ _ 2 5 D nad 2 72 27 Ov SiS e cucu 46 H mE aw ES he AS U QU 4 LLLI SECONDARY CLUTCH ACTUATING 6 096 PRESSURE M10 X 10 TH D dd 6 350 E240 Lie 90 _ 224 n 3 8 16UNC THREAD L88 7 6 1301 DEEP 100 3 SUCTION SCREEN 3 95 CLEARANCE TO REMOVE SUCTION SCREEN 136 4 5 37 228 6 9 00 FLANGE BDRES 95 2 3 75 t WITH 22 2 7 8 SQUARE KEY 114 3 4 50 t WITH 25 4 1 00 SQUARE KEY 120 6 4 75 t WITH 31 8 1 1 4 SQUARE KEY E 139 7 5 50 t W
204. LLATION DRAWING AND n n c CONNECTION LINES INSTALL LUBE LINE TU E DIRECT LUBE FLOW INTO TRANSMISSION HYDRAULIC 1 INSTALLATION CIRCUIT EIE ccm EU Iu gu MES uS CI eei ier ENG DIS DRAWING SHOWN FILTER PORTION ENCLOSED WITHIN 20 PSI THESE LINES IS REQ D im ll in OPTIONAL HYD P T D ONLY o X 7371M p AUN MN _ FILTER E Buen d TEMP HOSE CE j a K s 25 MICRON FULL FLOW N S x FILTER xS ET si REAR S d esses B EN J ELECTRIC MUTHUR Ee 2 Ans 6 L Sce x CLUTCH CUSTOMER SUPPLIED HEAT EXCHANGER INSTALLATION OF OPTIONAL 3 4 DIA MIN COOLING NN AND CONNECTION LINES REFER TO TEMPERATURE INDICATING 6 0 LD HOSE TIUN DRAWING SWITCH USING PIPE WITH E STRAINER C PRESSURE REDUCER BUSHING REDUCER BUSHING TT INSTALLATION OF OPTIONAL gt MA1040B DRAIN PLUG LUCATIUN x es x 20 THREAD 2 d re s PER MARINE TRANSMISSION DE INSTALLATIUN AND ASSEMBLY 0 CONTROL DRAWING B m MG5202 HYDRAULIC DIAGRAM 222 HYDRAULIC DIAGRAM GRA
205. LY 713 2 88 08 670 1 26 38 586 9 23 11 582 9 22 95 579 6 22 82 570 4 22 46 564 6 22 231 546 0 21 50 J DRILL THRU HOLES EQUALLY SPACED 4595 0809 USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER 3997 19807 ISO 898 1 AND TORQUE 5574 SERVICE MANUAL _ EYFBOLT 6 VALUES 330 2 13 00 OTHER SIDE E 6 4 L 25 310 9 18 24 OIL FILLER HOLE 1 E EYEBOLT B 228 5 9 0015 sie H 12 77 50 OUTLINE OF OPTIONAL SAE 1 TO SAE 0 HOUSING ADAPTER FLYWHEEL OUTLINE MUST CONFORM gt J620q 14 S A E 1 HOUSING L REMOVE 4 PLASTIC PLUGS TO OBTAIN ACCESS 45 VALVE MOUNTING BOLTS et NER SOC 2 lt gt z 525506 22 R N N NS N 05252 757 xX PL LAS ZI 8 CENTER GRAVITY 2 2 Yj 2217 REF LUBE P S I PORT AUXILIARY LUBE D SUPPLY INLET 247 7 9 75 Z X FLYWHEEL OUTLINE HOUSING MUST CONFORM TO SAE J620d ND 18 177 8 7 00 101 6 4 00 101 6 4 00 101 6 4 00 Fe H H G DRILL THRU HOLES EQUALLY SPACED Meo X 25 32 0 1261 DEEP 15 07 20 894 USE 8 8 PROPERTY CLASS QUALITY 16 HOLES 8 EACH SIDE CLEARANCE TO REMOVE CAPS
206. MG 5202DC MG 5203SC MG 5204SC 3 11 SECTION 3 pressure from the energized solenoid operated pilot valve also acts the return spring side of the opposite spoolto ensure the opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the previous section 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 pressur ized oil from the pressurized clutch passage to flow inside the spool Oil pressure inside the spool forces the dowel pin against the O ring plug Neutral solenoid Spring U 3 gt m HYDRAULIC LOCK UNITS Mvc 010a 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 pressur ized oil pressure will keep the spool in that position This keeps the transmission in gear as long as the engine is running The hydraulic lock is disabled when either the engine is stopped or the neutral sole noid is energized When the neutral solenoid is energized it sends pressurized oil to the dowel pins at the return spring end of each spo
207. MG 5202SC except drawing numbers 1014841 and 1015389 MG5203SC MG5204SC MG5202DC require the use of an SKF THAP 300 Oil Injection Kit see Section 11 Special Tools or similar device to remove the output shaft NOTE The illustrations used in this manual are for the MG5202SC transmission MG5203SC MG5204SC and MG5202DC transmissions are similar Remove drain plug and drain the oil from transmission Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 61 6 6 2 Remove External Components a Remove filter drain plug and drain filter Remove filter fig 6 1 Fig 6 1 b Remove control valve and gasket c Remove torsional coupling from spline on primary shaft if not previously re moved d Remove front housing from main housing e Remove top cover and gasket f Remove oil pump 0 Remove hex head capscrew securing clamp plate for suction strainer cover Remove clamp plate suction strainer cover with O ring and suction strainer Fig 6 2 6 2 SECTION 6 Disassembly Disassembly 6 3 Remove Output Flange 1 Turn transmission and lay on wood blocking with output side up Be sure that transmission is supported securely and that primary shaft is clear of floor 2 Remove hex head capscrews securing output flange to output shaft Remove retaining washer shims and O ring seal If your output shaft is splined follow this instruction Use hydraulic jack to
208. N JD 4 gt 24 31594 ILIM Y TAVISNI 0 JATA 25 SLV SECTION 11 Special Tools 11 12 Special Tools Seal Sleeve T 21347 11 13 get T 44 S 1919935 3215 2U01S G S WAS 4219101 3NIOVS ONI 55811 NIAL 3196 WIC 66 81 6 VI SYM y IZ0cS9h 133HS W d DN N Lco JNITIVISNI 193 L Ag 66 9 NDI 81425 30 038 130 18 ONITIVISNI 7935 Orly 13318 7001 6662 1962 005 2025 50 87 a 00 19711915 1935 431593 6SS 2 19S 2 NI 02 OL 51973 91 1 9 TWN ILLdU 9 415 l eStol 313 avo 404 11 13 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 Seal Driver 21347 1 11 14 C Le SIA 3NIOVS l 13365 ONITIVISNI IS 21025 Ag 6 61 7 184 00 ONT 2510 NIM 3190 NDILdINOS3G 3DNVH3 404 3WVN 3215 SOLS 14142530 LVW 79341130 SZ AJAI ON VISNI 1935 173 DAGOI ZvEIG 4219101 8 7435 1626101 aL 3114 WI 50
209. N SIS EM SENI B 7 3 TRANSMISSIUN GASKET GASKET 1012894 Li GASKET 1017130 A P A VA SER CHART 2 SNAP RING A2915V PORT n BALL M1990H MN E UM 4 SCREW 1042 4 SPRING A2702T DITCH PLATE SEE CHART SPRING 1801 BALL M1990E SETSCREW 2870 0 RING A2916DK VALVE BODY ASSY 1018095 FY U RING A2916AT A BODY 1018094 gt 5 gt S SPRING 2705 WASHER A2782AS S e m y 95 1017524 Sec WW 2 AmA BALL M1990Y 5 SN NY NNN RNN SNS SPOOL 1017433 2 MAIN PRESSURE PICKUP PORT PORT 1 4 18 DRYSEAL TH D INSTALL USING 908 lt LOCTITE 242 gt TOP OF SCREW MUST SCREW 10424 4 FLUSH WITH SURFACE HYDRAULIC DIAGRAM A7119W SHEET 1 SWITCH MA866A 2 APPLY 895 THREAD SEALANT WITH TEFLON 8 TO THREADS TORQUE 300 lbf ft NUT M2027C SABES SCREW M2000H ERO O S ATMOSPHERIC PRESSURE SERVICEABLE SEPARATELY WAR Ta A ATMOSPHERIC PRESSURE L L i LP INTERMEDIATE PRESSURE THESE PARTS ARE TU BE PACKAGED LEVER B2103 CLUTCH PRESSURE SEPARATELY AND SHIPPED WITH Pent d ACES BENI Sasa
210. NDISC COM
211. NDITION SOLENOID A CARRIER 1017335 SHLENHID BALL 1990 WIRING DIAGRAM OPTIONAL MATING WIRING HARNESS 1017404 SCREEN 221336 CONNECTOR SERIES SPECIFY LENGTH PORT SOLENOID A PIN A2711R 2 WITH OR WITHOUT HYDRAULIC LOCK SPRING ASSY dies NS SEE CHART SS qas S B1399H BALL M1990Y M8 X 125 6H TH D e H ULES BALL M1990M IE Z H NS Ses INS SS N ANN B PORT SOLENOID VALVE BODY ASS Y 1017444 D A BODY 1017443 Z Jm MANUAL DVERRIDE N POSITION ELECTRIC 247 t SQ CONTROL N N SSNS 7 BALL MA1034A 10 OR 11 THESE SOLENOID CONNECTIONS LEVER IAN gt PDSITIDN PERT SNESONNN NS 4 Oy BALL M1990Y 6 ARE NOT POLARITY SENSITIVE SSSN y TERY Z PRAY S PLATE SEE CHART AMD li SEAL MA778 N 4 SHIM CHART N CUVER 1017128 217 3 it 1 VALVE GASKET 1017136B IN INCH 26 6 NOB SUN Z ALLL LLG NSN ans VS 2 d 2 EE hy Z E 84 1 CONNECTOR SHROUD 1001434 c 2 595 2 N I He 7 lt 4 2 EN NS gt WN DITCH GASKET RT 64 9 THE Z A E NU
212. NOTES 1 THRU 8 ARE IN 570 TRESE STANDARDS APPLY 574 FASTENER TORQUE REQUIREMENTS S692 BEARING SHIMMING 5765 TAPERED JOINT ASSEMBLY HOUSING 929 BALL 1034 CAPSCREW MA960E WASHER 1 GASKET 9 SHART ISS ty 018233 SHAFT 1015232 BALL MA1034B RING M1904AQ 4 PUMP 1001349 SEE NITE 6 SHIM 1014883 SHIM 1014884 AS REQ D SHIM 1014885 SEE NOTE 6 PLUG MA1038D 4 RING M1904DA GEAR 10 01118 RING SPRING ASS Y 322 SPRING 701 SPRING INPUT SPEED 2500 RPM CONSULT SALES DEPT APPLICATION ENGINEERS FOR OTHER LIMITING CONDITIONS 03BD SHEET CROSS SECTIONS DF 5 AND PART NUMBERS SHEET CROSS SECTIONS 2 DF 5 AND PART NUMBERS SHEET INSTALLATION 3 5 DRAWING SHEET INSTALLATION 4 DF 5 DRAWING SHEET FLEXIBLE 5 DF 5 COUPLING INPUTS MASS ELASTIC B3504AF SES HEAT EXCHANGER B3649K REQUIREMENTS HYDRAULIC 119 DIAGRAM SIMILAR WR UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE mm MACHINED DIMENSIONS 0 75 X X 0 25 0 13 DR ALL ANGULAR TOLERANCES GEOMETRIC TOLERANCING PER ANSI 14 5 1982 CDG MARINE TRANSMISSION N CDR 5 1 RACINE WI 53403 USA TWIN DISC KS TM 101520 JS DAS APPD SHEET 1 nr 7
213. NTROL VALVE REQUIRES 4 14 lbf AT THE 28 20R LOCATION THE 1 4 DIA HOLE TO OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 1 41 LINEAR TRAVEL FROM NEUTRAL AT THE 1 4 DIA HOLE LOCATION WHEN SUITABLE REMOTE CONTROLS ARE USED THE DETENT SPRINGS AND BALL MAY BE OMITTED THEN THE FORCE WILL BECOME 3 7 LBS THE DETENT FEATURE IS PROVIDED IN THE FULL 15 CLUTCH ENGAGED FULL end CLUTCH ENGAGED AND NEUTRAL LEVER POSITIONS TORQUE MOUNTING BOLTS TO 30 36 LB FT AS RECEIVED S374 OR 25 29 LB FT LUBRICATED PER 5574 AFTER TORQUING MOUNTING BOLTS INSTALL M2026Q PLUGS IN MOUNTING BOLT 5 TROLLING VALVE REQUIRES 20 35 LBS AT THE 181R LOCATION OF THE 1 4 DIA 4 HOLE TO OVERCOME DETENT EFFORT REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 2 56 LINEAR TRAVEL FROM DETENT AT THE 1 4 DIA HOLE LOCATION THE DETENT FEATURE IS PROVIDED IN THE RATE OR RISE POSITION ONLY CONTROL HEAD FOR TROLLING VALVE MUST INCLUDE A DEVICE TO LOCK TROLLING VALVE CONTROL LEVER IN THE DETENTED NO TROLL POSITION DURING MANEUVERING DOCKING AND OTHER OPERATING CONDITIONS THAT REQUIRE FULL POWER TO THE PROPELLER INSTALL EACH O RING FROM ITS RESPECTIVE SIDE TROLLING VALVE COVER DO NOT PASS D RINGS THROUGH CENTRAL CAM SLOT COVER INSTALL O RINGS AFTER CAM AND CAM SHAFT ARE PLACED INTO COVER BUT PRIOR TO INSTALLING CAM ROLL PIN THIS SETSCREW IS USED TO INSURE THAT THE TROLLING CAM DOES NOT
214. NY MANNER Nn MACHINED DIMENSIONS SCALE INCORPORATED l1lmm RACINE WI 53403 USA OPTIONAL EXTRA SUPPLIED ASSEMBLY 10162504 WHEN SD SPECIFIED 10168564 1064 HELI CHIL CU OMER NATES DIL CAPACITY 265 L 7 GALS LESS HOSES AND HEAT EXCHANGER 1 770 1 EE se T ES 55 EN se T ES MA960J M2081D 1016275 3 48 1 RATIO 1016272 2 92 1 RATIO 1016269 2 48 1 RATIO 1016113 2 031 RATIO 1016602 1761 RATIO 1016119 153 1 RATIO 1018493 133 1 RATIO 1016104 1174 RATIO 1016109 1 Maseia 6 Me68 1 m SE lt gt lt L lt Ix 00 00 TIS O O I Li TI I lt gt MAS8SHD CONE MASS90EZ b gt THIS UNIT CAN USED WITH LEFT HAND ENGINE Qu CO CO SF c OPTIONAL EQUIPMENT COMPANION FLANGE ASSEMBLY 1015378 m LIVE P T O 624 AUXILIARY PUMP DRIVE HYDRAULIC CLUTCHED P T O X47554 SHAFT DRIVE AND 7554 PUMP DRIVE TRAILING PUMP 1016473 FLEXIBLE COUPLING INPUTS SEE SHEET 3 K BOM 1096 METRIC NPTF ADAPTER KIT MANUAL TROLLING VALVE KIT 1017555 ELECTRIC TROLLING VALVE KIT 1017554 mu gt gt gt 8 1298 DETRIMENTAL THE INTERESTS 2 ELECTRIC CONTROL VALVE 12 VDC 1018084AG TWIN DISC INCORPORATED
215. O ISO 6149 OIL OUT TO FROM HEAT EXCHANGER M33 X THREAD METRIC CONFORMS TO ISO 6149 REMOVE THREAD BEFORE OPERATING UNIT AUXILIARY LUBE SUPPLY INLET SEE HYDRAULIC DIAGRAM TEMRERATURE PIE CD PURT 1 4 18 NPTF DRYSEAL 3 8 16 UNC THREAD Te SUL SCREEN TRANSFER GEAR DIM X FROM PORT GEAR ES S FACE PINION O D 112 3 442 108 3 4 267 104 4 4 117 FETE 90 1 3 557 824 3 247 OPTIONAL TEMPERATURE INDICATING SWITCH FILTER DRAIN PLUG MIO X LO THREAD METRIG CHNEBHRMS CUSTOMER INSTALL IN 3 4 X 3 4 X 3 4 Gnd PIPE TEE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSIUN PUMP TH THE HEAT EXCHANGER INLET REFER HYDRAULIC DIAGRAM NOTE ALL POINTS AVAILABLE FOR TESTING ARE CODED lt Z lb d den The ddd 382 53 x SPEED PICK UP PORT 8952 M16 X 1 5 THREAD METRIC PORT CONFORMS TO ISO 6149 330 20 382 53 T 290 89 267 44 234 95 237 74 FILTER 235 20 210973 S A E 0 HOUSING we SIA lt 346 71 272325 406 4 CENTER OF akes 56 INE HOLE AT THIS LOCATION a mM d OMITTED LUN SAE 0 HSG SECONDARY CLUTCH SHAFT ea ecd NOTICE THIS PRINT CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE USED IN
216. ONAL SIOP INCLUDED SEE SHEET 1 MAXIMUM TRANSMISSION R P M THE INNER PARTS INCLUDES HUB AND 1 4 NTC A FOR TRANSMISSION SHIPMENT TH HOUSING SAE FLANGE HOLES USING STANDARD METHOD SECURE FLEXIBLE COUPLING BEFURE SHIPMENT UNIT OPTIONAL INERTIA 5 RING COMPONENTS WR MA1041K HEX CAPSCREW 16 053 kg m J THRU d HOLES EQUALLY SPACED 6 4 USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE T TO S574 OR SERVICE MANUAL VALUES SAE 0 L HOUSING COUPLING C 1019699 COUPLING FLYWHEEL OUTLINE MUST CONFORM S A E 4620 NO ka ML 920 026 0000050 4 25 S 5 SS 25020 55 xx OOO 55255 2 DYNAMIC TORSIONAL SIIFENESS kN m rad 2 52 054 52 XS 52 5 SSS N B1048X SNAP RING 1 FLYWHEEL OUTLINE MW MUST CONFORM Tum 0 THRU HOLES FQUALLY SPACED USE 8 8 PROPERTY CLASS A QUALITY CAPSCREWS PER 0009900000000 COUPLING p 50 898 1 AND TORQUE 000009900 99 wer gt 55 4 OR SERVICE MANUAL VALUES AAS 555 x 525 A N lt N 1019698 COUPLING H IL 107 35 0 A SAE 1 1 38 HOUSING TRANSMISSIDN CDUPLING ASSEMBLY
217. OTHERWISE SPECIFIED DATE nou DIMENSIONS ARE nn X 0 75 SCALE INCORPORATED PRIS f WI 53403 USA ALL ANGULAR TOLERANCES 1 ASSY MODEL SEE CHART X6 540 as SERIES VEE oS A GEOMETRIC TOLERANCING PE R ANSI 14 5 1982 CHK BRN D B 16 CLUTCH ENGAGED FOR 3 POSITION va VALVE ORIFICE VALVE SPRINGS SOCKET HD SCREWS INSTR D FWD NEU REV USE BODY GASKET PLATE CLUTCH PLATE FIRST M8 1 25 TAP THRU CORD ASSEMBLY C uM AX SPRING CONSISTS DF E AND 2 HOLES NUMBER c c QTY PART SIZE ASS Y MIDDLE INNER SY QTY USE Ke 7600 1001138 Bi397c i28 _____ 27078 27 A2702BC 1725 5 2 10524 29 2 WHEN 20678 TH D PROTECTOR 0209 81397 183 A2707BV 2704 A27028W 1585 1 5 2 1 WITH IS SPECIFIED GASKET 1001136 T3975 195 iiit A27079x A270280 1725 2 waiosan 2 pesca 50 DIESES E PS EE JE SIT 3E jx IEEE 15 12 HEN LEVER NEUTRAL FOR 3 Q POSITION FWD NEU REV gt USE DISENGAGED FOR 2 POSITION CENGAGED amp DISENGAGED USE
218. OUNT INSTRUCTION PLATE WITH lt lt lt SS SSS WORDS MARINE TRANSMISSION 1016324 p 227 A LE E 2 NI 5 SE 1761 RATIO 33 P md E P BREEN zu N 5 KAN 1016318 1014890 1171 RATIO SET SPRING LENGTH TO 30 2 7 cs Z 1001218 REPLACEMENT PINIONS DO REQUIRE x m SPACERS 1014854 AND 1015108 1383 FILTER BY PASS x x HOUSING UICE SEE OTE 1 1018468 x x REMOVE NUT 77 5 75 Tem 77 1 BEFORE INSTALLATION 1001116 1003738 FLYWHEEL ses HS YN 1520205 Vrim Ir Me7oer Ji BY f d 52500505 2 550 546 X N pee SS 2 KG g o 2 OS Z SSE 1015358 o 22200177 4 SZ MA1034B P Sl o
219. OUT NEUTRAL SOLENOID AND HYDRAULIC LOCK OPTIONAL CONDITION 1 UN T 522 xs III mmn us i 36 7774 vie T 5 Lu 2 SETSCREW DOG POINT SPRING 2 UNITS WITH HYD LOCK 3 SPOOL UNITS WITH HYD LOCK PISTON 2 76 SPRING PRESS REGULATING PISTON 1 2 BATE office L O sam 0 00 1 1 C 12 GASKET tf 0002 13 GASKET 14 BALL 1002 15 SPRING 1 NEUTRALPRESS REGULATING 16 O RING _ _ _ _ __ ___ 49 WASHER RNG snap SEA 1 23 COVRR at O OO 24 GASKET 25 O oOo dado OO ff E _28 CONNECTOR SHROUD 1 UNITS WITH HYD LOCK 29 CLIP CONNECTOR 1 30 4 31 SCREW 4 SOCKTHEAD 32 BALL 1 1 SPRING 4 00 34 SETSCREW 35 36 38 PING SCREN 4 VAVEBODY tf 42 _43 PLUG ASSEMBLY 1 SOME MODELS GASKET 45 1 46 screw 4 SOOKETHEAD ___ 47 SCREW 1 SOCKET HEAD LEVER 1 49 CONNECTOR SHROUD UNITS WITHOUT HYD LOCK TE UNITS WITHOUT HYD LOCK
220. PHICAL JIC SYMBOLS C STRAINER PICTORIAL Lu NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT wre UNLESS OTHERWISE SPECIFIED D SUMP PROPRIETARY INFORMATION AND IS MACHINED DIMENSIONS 4 14 93 Vo UN DUSE USED IN ANY MANNER EBS CBS IN 202030 SCALE INCORPORATED DETRIMENTAL TO THE INTERESTS OF 0 010 TWIN DISC INCURPDRATED ALL ANGULAR TOLERANCES 1 29222 3 29 99 RACINE WI 53403 USA M DET GEOMETRIC TOLERANCING A 7 1 9 Q CHK JS B 3 29090 1 25 99 THIS NOTICE IS NOT INTENDED a S UOS NULLIFY LIMIT RIGHTS SURFACE TREATMENT NANE Collo 7 1 93 GRANTED TO THE U S GOVERNMENT DIAGRAM HYDRAULIC APPD UR OTHERS BY CONTRACT TBC REV B A SHOWN WITH CLUTCH Clutch ENGAGED Clutch Solenoid Solenoid ASCO SHOWN WITH CLUTCH A ENGAGED Neutral Clutch Clutch Neutral B Solenoid Solenoid Solenoid Solenoid Solenoid ASCO ASCO ae WITH HYDRAULIC LOCK WITH HYDRAULIC LOCK MANUAL OVERRIDE MODE SHOWN IN NEUTRAL MANUAL OVERRIDE NEUTRAL START SWITCH MANUAL OVERRIDE NEUTRAL START SWITCH EP 29 Eo Z CLL 27777 ima 7772 Section dep Section B B Section C C ee mur E CONTROL MODE ELECTRIC CONTROL MODE SWITCH Section Sectio
221. PLUG PICK UP PORT 2 3 a Ere PLUG SPEED x 252 05 PORT x 524 09 G EN E p 2 P RT AUXILIARY LUBE CDM Li das NEIN ENGAGES CLUTCH ON SHAFT CALLED REVERSE OIL UUT TU HEAT EXCHANGER SEE SHEET 4 FUR TH D SIZE O io 208 CLEARANCE REMOVE OIL PUMP CN 100 8 CLEARANCE TO REMOVE SUCTION SCREEN CENTER OF GRAVITY A D O gt i E S I 4 gt en LO l gt N x p OUTLINE OF OPTIONAL Y SAE 1 TO SAE 0 HOUSING ADAPTER MeO Xx uec Sle DEEP 18 HHEES 2 EACH i SIDE USE ALL 18 HOLES FUR MOUNTING UNIT USE 8 8 PROPERTY CLASS QUALITY CAPSCREWS PER ISO 898 1 AND TORQUE 52 4 SERVICE MANUAL VALUES 220520 Sod NE TS DRAIN e SOA 554 91 B DIL IN FROM HEAT EXCHANGER SEE SHEET 4 FOR THD SIZE 240 86 FYEBOLT FOR LIFTING MARINE TRANSMISSION BOL PSS ONE EACH SIDES FILTER DRAIN PLUG 209 11 FQUALIZE LOAD BOTH SEE SHEET 4 RES HB SIZE EYEROLTS TD DET MARINE TRANSMISSION ONL Y M8 X 1 25 TAP THRU 2 HOLES SUITABLE FOR Z CONTROL MOUNTING TEF BRACKETS ZA HLIUSING LAIZ 6 4 THRU ENGAGES CLUTCH ON SHAFT CALLED PRIMARY 145259 HUB END 540 CLEARANCE REMDVE DRAIN PLUG 168 8 200 1
222. POSITION THE TROLLING CLUTCH MAY ENGAGE FULL Y 674 2 26 54 631 0 24 84 547 87 21 57 16 1 5 METRIC THREAD CONFORMS ISO 6149 REFER CHART REQUIRED PICK UP DEPTH 543 9 540 6 21 28 531 3 20 95 517 5 20 371 J DRILL THRU 506 9 19 96 HOLES EQUALLY SPACED BREATHER 4 _ USE 8 8 PROPERTY CLASS 443 5 17 46 QUALITY PER ISD 898 1 GRADE 5 QUALITY CLASS 420 4 16 60 PER SAE J429 CAPSCREWS 354 6 13 96 EYEBOLT t 291 1 11 4 Hyper spe 2718 10 70 DIL FILLER HOLE 240 3 9 46 SPEED PICK UP PORT AND TORQUE 5574 UR SERVICE MANUAL VALUES LT kh dM 6 4 25 EYEBOLT 185 4 7 46 THIS SIDE 12 7 L50 OUTLINE OPTIONAL 1 SAE 0 FLYWHEEL OUTLINE HOUSING ADAPTER MUST CONFORM TO gt J620 355 1141 gt 1 HOUSING REMOVE 42 PLASTIC PLUGS TO OBTAIN ACCESS 4 VALVE MOUNTING ss LLL AG x 75 0 e 95 od 20 77 FILTER DRAIN 525 6 20 69 2 LUBE P S I PORT AUXILIARY LUBE SUPPLY INLET CENTER GRAVITY 9 75 FLYWHEEL OUTLINE MUST USE 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 AND TORQUE TO PER ISO 898 1 GRADE 5 QUALITY CLASS 552 74 UR SERVICE MANUAL VALUES PER SAE J429 CAPSCREWS AND TORQUE 5574 SERVICE MANUAL VALUES
223. PRIMARY CLUTCH FULL SECONDARY CLUTCH AND NEUTRAL LEVER POSITIONS lt THE DETENT SPRING TROLLING LEVER AND PIN MAY BE OMITTED WHEN REMOTE CONTROL SYSTEMS PROVIDE THE PRIMARY NEUTRAL 22 77 S c 6 AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS 22 B FORCE AT THE LEVER HOLE TO OPERATE THE VALVE THEN REDUCES 13 31N 3 7 1881 301 00 THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 435 8 1 41 LINEAR TRAVEL 2 FROM NEUTRAL THE 6 35 1 41 DIA HOLE LOCATION ROTATIONAL STOPS AT THE ox Y STATED VALVE TRAVEL LIMITS HAVE MAXIMUM CAPACITY DF 445N 100 1881 AT THE ori d WIE 6 35 1 4 DIA HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING io THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES SO CAPACITY DF THE VALVE SUE ROTATIONAL STOPS IS EXCEEDED EXCEEDING THE CAPACITY THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS CONTROL VS ds E TROLLING FEATURE OPTIONAL 3432 13 51 lt 247 9 9 7 OLI q DIL DRAIN amp DIL IN FROM HEAT EXCHANGER 7 247971926 177 8 L7 00g DIL PRESSURE GAGE LINE HERE X 13 THREAD AT VALVE MOUNT GAGE IN PILOT HOUSE 1 8 27 NPTF EXTERNAL TH D CDRYSEAL AT GAGE CONNECT GAGE INTO LINE BETWEEN AND CONTROL VALVE FACE USED FOR CONTROL MOUNTING BRACKET HO le 21321 DRILL THRU HBLES FOR 5 8 STANDARD EYEBDLTS WITH NUTS THESE HO
224. S 514 amp ONT 2514 A8 3454 114142530 35NVH2 909 0S081 1 00269 C 13365 x Segui Y 203 ONTNY 7103 1291995 Zrv 66 0 1 2500 1715 20015 NULLdTNOS 3d X AGATA 1 l ZZZZZZZZ F pt o e 7j JANNA 0062 334 22222222222 909 0G081 3114 ava A SSV dNUJ 03 11 7 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC SIM 3NIvH ONT 2514 NOLL 182530 NOISN3WIG ND 209 050811 313 QVO NOISNAWIG 791230 445 0085958 DAL TVNDIL3V83J NU 010 NDISN3HIC 30914 33NHl NU 100 3199 ONISV38 031410345 3SI M3HlU SSSINN 5 9 13238 TANG 21925 779 66 0 1129 90 Jy 371 72015 14142530 935 134 IN 1001 dWvIS 3d A avi 335 BAT I I Bearing Driver T 18050 607 SECTION11 11 8 806S VN 126 Teg 1 8 85 006 v 809 05081 1 dV06GSVN 788 7871 8 GZ8 209 05081 1 dno I J V 38 1001 SYSNAOO dasvHS 11 Vad 24 INN 0622 1 222 SECTION 11 S
225. S i o IN i N N es FITTING M1275 SEAL MA440 2 SHIM 1015260 SHIM 1015261 HAS REQ D SEE NOTE 7 PISTUN SHIM 1015262 PLATE 206106 622 PLATE 206107 20 WASHER 3421 PLATE B6231 lt 2 RING A2669AU 2 SS in m FLANGE ASS Y 1002312 7 Z FLANGE 1002276 6 CAPSCREW MA1046A 12 S EXTRA SUPPLIED WAEN Si CAPSCREV MA996A 4 RING 9160 FLANGE 1001042 BEARING MA437 CAPSCREW MA996A 8 RING A2916HH CARRIER SHIM SHIM Bee4eA FAS REQ D SEE NOTE 6 SIL THIS INFORMATION BE ADDED WHEN IT BECOMES AVAILABLE 2763 3 13 97 BE ust IN ANY MANNER tes P pez 4 96 00 THE INTERESTS OF 8 27243 8 23 96 s T 28033 1 27 98 27516 B 80 96 15 1 S e 27901 7 15 97 kesa L ee 26997 4 30 96 ID RIGATS zone cn par sern pev zone pave DR OTHERS BY CONTRACT GEAR RATIOS 6 0 6 5 6 9 031 9 594 5 04 1 6 PPR MATERIAL WEIGHT 931 HEAT TREAT FIRST USE ASSY MODEL SURFACE TREATMENT NAME ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 5 0
226. SHTND REV ZONE ND DATE R OTHERS BY CONTRACT MARINE RANSMISSI DAS SHEET 1 7 0 MOUNT LUBE INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION LUBRICANT AWAY FROM BREATHER PLATE 415 SCREW M42eeB 8 GASKE Tz BISISE Ge SCREW WASHER 249 BALL M1990H MOUNT INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION TOWARDS BREATHER PLATE oe GAUGE B3631X LINK 2007 6 BREATHER 1251 SPRING A2703P CHAIN 1072 GAUGE B1 03D CLIP 17634 PLUG MA1038E EYEBULT 1047 MeatOSee XT A CLUSURE 542 SPRING 2707 SPRING 2 04 0 SPRING N PLUG 9 SPRING 201341QP BALL MI99UE BEARING 08 K N gt X 7540 BODY 1001138 CONTROL VALVE ASSEMBLY PLATE B1397D Q9 PLUG MA1038A J N D N LEVER 2040878 SEAL 778 M SEER DERA NT PIN M1927B 24 Z x SSO 7 SHIM B2334 48 NE TAG MA656C NVI LT RODEO Z SCREW 960 4 U gt A TUBE ASS Y XB2301N 1009 6 2226 0 2702 lt 2 TUBE B2301L PIS TUN BI4 005 ADAPTER B2300 O DENA THENTE GASKET B1337F
227. SIB O _______ 1017134 37 1017179 e 759 24 vnc Ses 630 17129 pemsereer x 0 108440 1017133A 1017134 1017179 e peezssriie ses cesp in7zie9 x 20 61 854518 be eeto o ev ec IMA1062B 2 10626 2 MG 5600 USE AS REQUIRED SCREW MA1052P 4 TORQUE 54 2 N n 40 0 lbf f CLIP CONNECTOR 1017388 CONNECTOR SHROUD 1001825 INSTALLATION NOTE MIN TROLLING PRESSURE M8 X 1 25 6 19 1 DEEP 2 HOLES VIEW ASA _____ 1017179 e pwe7ssrMea vnc 1017363 1 voe pn caso 11696 x BEAST 197583 1017569 1017613 1018688 no e xme7s9FM 24 27072 827072 e000 250 1017129 pwwossteer x O U 1017383 147479 pee7ssrMea 2550 370 10171298 x 5 6557 10184407 41164 1017134 1018688 no 2 759 4 vpc xa27o7ap A2707AD 2703 2000 290 gt 1017129 MA1038E e7
228. SIDE USE ALL 18 HOLES MOUNTING UNIT USE 88 PRUPERTY CLASS QUALITY CAPSCREWS PER SH TORQUE 52 4 SERVICE MANUAL VALUES CUMPANIDN FLANGE MAX BORES 96 8 t WITH 22 2 SQUARE KEY EL 117 3 t WITH 25 4 SQUARE KEY 139 7 t WITH 31 8 SQUARE KEY 139 7 t WITH 31 8 X 22 2 RECT KEY amp 125 1 TAPER 168 1 t WITH 38 1 X 25 4 RECT KEY amp 125 1 TAPER 199 7 159 168 8 m n REMDVE DRAIN PLUG 500 1 amp 029 59 PRIMARY amp SECONDARY PRESSURE HOLES 24 02 PRIMARY amp SECHNDARY LUBE 2 6 00200 E 030 99 SIMILAR TU 670 75 S A E J620 i MARINE A C D E 3 H J K NOTICE THIS PRINT CONTAINS MATERIAL WEIGHT WR UNLESS OTHERWISE SPECIFIED DATE LJ TRANSMISSION 0 000 0 000 PROPRIETARY INFORMATION AND IS CAD 50 Vo du 215 FLYWHEEL 0127 0 102 k n MACHINED DIMENSIDNS s 0 12 USED IN ANY MANNER 9 X 10 75 INCORPORATED B NOT DETRIMENTAL THE INTERESTS XX 0 25 RACINE WI 53403 USA HEAT TREAT FIRST USE XXX 013 SEIT TWIN DISC INCORPORATED ASSY ALL ANGULAR TOLERANCES ANG RACINE WI 53403 USA GEOMETRIC TOLERANCING 12 OF 6 4 MODEL PER ANSI Y14 5M 1982 CHK sse s9020 3015 ese BE 18 lt _ ru banana 1015207 GRANTED TO THE U S GOVERMENT APPD MARINE
229. SURFACE 4 90 M204eN OF COVER INSTALL O RINGS AFTER CAM AND CAM SHAFT ARE M1927B C h PLACED INTO COVER BUT PRIOR TO INSTALLING CAM ROLL PIN XB1399G MAX TROLLING A B1334A B1399G B3 PRESSURE 82 THIS SETSCREW IS USED TO INSURE THAT THE TROLLING CAM DOES SEE CHART SECTIDN DETENT NOT TRAVEL BEYOND DETENTED POSITION TO INSTALL ROTATE TROLLING LEVER FROM THE TROLLING RANGE INTO DETENTED POSITION B2103 RATE DF RISE THEN WHILE APPLYING SLIGHT REVERSE PRESSURE AGAINST THE DETENT ye C lt lt A M2000H SEE CHART FUNCTIONS DETENT m ADVANCE SETSCREW AGAINST CAM BACK IT HUT A QUARTER TURN THEN 6 4 2 LOCK IN PLACE WITH LOCKSCREW JINN E 4 M2027C INSTR PLATE SEE CHART SN 4 HEX NUT SEE CHART B1398E E ADJUSTS CONTROL 92 THIS SETSCREW IS USED ADJUST THE MINIMUM TROLLING PRESSURE 3 C CONS QB 78 B2385 B1400B 2451 5 AND REFER TO TEST SPECIFICATION FOR ADJUSTMENT PROCEDURE THIS NS QN NS APOIGDD FIELD N TROLLING PRESSURE ADJUSTMENT SHOULD ONLY BE MADE AFTER THE DETENT PLUNGER AND INSTALLATIUN DETENT DVERTRAVEL SETSCREV HAVE BEEN INSTALLED PER 8 B2452A INSTRUCTIONS 83 3 5 y 572 2465 46 7 46 PORT FOR l OR 2nd CLUTCH HOS Gm A 19 0 HOLE MUST BE LOCATED IN m THIS AREA IN MATING PART FOR TORQUE CONVERTER OR BEARING A 7 9 MIN HOLE MUST BE LOCATED IN THIS AREA LUBE
230. SYSTEMS PROVIDE THE PRIMARY NEUTRAL BY MOVING CONTROL VALVE LEVER TO THE PRIMARY CLUTCH OR SECONDARY CLUTCH POSITION MOVE TROLLING CONTROL CONTROL FALLS ANYWHERE WITHIN AND SECONDARY DETENTS THAT CORRESPOND EXACTLY WITH VALVE DETENT POSITIONS LEVER FROM MINIMUM TROLLING POSITION TO SELECT DESIRED TROLLING SPEED WHEN TROLLING LEVER IS ADVANCED THE 260 RANGE IN WHICH THE FORCE AT THE LEVER HOLE TO OPERATE THE VALVE THEN REDUCES TO 13 31N 3 7 LBSJ CLOSE TO DETENTED NO TROLL POSITION THE TROLLING CLUTCH MAY ENGAGE FULLY LEVER MAY BE LUCATED THE REMOTE CONTROL VALVE ACTUATOR MUST PROVIDE 35 8 1 41 LINEAR TRAVEL FROM NEUTRAL AT THE 6 35 1 41 DIA HOLE LOCATION ROTATIONAL STOPS AT THE STATED VALVE TRAVEL LIMITS HAVE A MAXIMUM CAPACITY 445 100 LBS J AT THE 6 35 1 41 DIA HOLE LOCATION VALVE ACTUATORS WITH FORCE CAPABILITY EXCEEDING THIS LIMIT MUST HAVE SEPARATE STOPPING DEVICES 50 CAPACITY OF THE VALVE 674 2 26 54 631 0 24 84 FILLER HOLE ROTATIONAL STOPS IS EXCEEDED EXCEEDING THE CAPACITY M 547 8 21 57 THE VALVE ROTATIONAL STOPS CAN CAUSE LOSS OF CONTROL TROLLING CONTROL 543 9 21 41 VALVE ee VALVE MiG x 1 5 METRIC THREAD TROLLING FEATURE OPTIONAL lt 3493 03751 1016103B REQUIRED PICK UP DEPTH E Sone 2098 343 2
231. Seat gear on shaft taper with 445 to 890 100 155 to 200 16 of force 4 Use a depth micrometer and measure distance from rear end of shaft to machined face of transfer gear at small diameter of tapered bore Record this distance as dimension B 5 Calculate expected advance Expected advance Calculated advance must be 2 56 mm to 3 38 mm 0 101 in to 0 133 in If calculated advance is not within the range recheck all measurements and calculations for Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 13 SECTION 9 errors If no errors are found contact the Product Service Department at Twin Disc Incorporated for information C Set secondary transfer gear on fixture T18050 609 with large diameter of tapered bore up Move fixture and transfer gear to a press with at least 445 kN 50 tons capacity D Install secondary shaft front end up into tapered bore of transfer gear Seat shaft in tapered bore of gear by applying 445 N to 890 N 100 165 to 200 lbs downward force on shaft E Center fixture gear and shaft under ram of press and apply approxi mately 276 kN to 409 kN 31 tons to 46 tons of force on front end of secondary shaft Release pressure and turn fixture shaft and gear 180 Reapply pressure to complete advance Fig 9 14 F Using a depth micrometer measure distance from rear end of shaft to face of transfer gear Record as dimension C Transfer
232. Shatt Bearing LLL a rp Re RAPI de 9 9 9 5 Output Shaft Tapered Roller Bearing 9 10 9 6 Installation of Top Cover Assembly Oil 9 13 9 7 Assembly and installation of Primary and Secondary Shaft 933 9 8 400 9 21 99 Assembly and Installation of Mamo 9 23 9 10 Primary and Secondary Shaft Bearing Adjustment 9 23 Installation of Manifold Exterior Components LLL A i 9 25 smt pete 9 25 9 43 Installation of Transmission Exterior Components 4 000 00 9 29 Section 10 Installation 10 1 10 2 Engine Runout Checks Table of Contents Table of Contents Also reterence SAE J 1033 and J617 iiiaae 10 2 sean u UU 10 5 M 10 5 B mec 10 6 10 4 Engine and Marne IransmissionAlignment LLULLU IIS 10 7 Section 11 Special Tools ioo END rm 11 1 Section 12 Torque Charts 121 Metric Coarse Thread Capscrews Bolts and Nuts 12 2 121 Metric Coarse Thread Capscrews Bolts and Nuts
233. TCH MAY ENGAGE FULL Y 674 2 26 54 631 0 24 84 547 87 21 57 16 1 5 METRIC THREAD CONFORMS ISO 6149 REFER CHART REQUIRED PICK UP DEPTH 543 9 540 6 21 28 531 3 20 95 517 5 20 371 J DRILL THRU 506 9 19 96 HOLES EQUALLY SPACED BREATHER 4 _ USE 8 8 PROPERTY CLASS 443 5 17 46 QUALITY PER ISD 898 1 GRADE 5 QUALITY CLASS 420 4 16 60 PER SAE J429 CAPSCREWS 354 6 13 96 EYEBOLT t 291 1 11 4 Hyper spe 2718 10 70 DIL FILLER HOLE 240 3 9 46 SPEED PICK UP PORT AND TORQUE 5574 UR SERVICE MANUAL VALUES LT kh dM 6 4 25 EYEBOLT 185 4 7 46 THIS SIDE 12 7 L50 OUTLINE OPTIONAL 1 SAE 0 FLYWHEEL OUTLINE HOUSING ADAPTER MUST CONFORM TO gt J620 355 1141 gt 1 HOUSING REMOVE 42 PLASTIC PLUGS TO OBTAIN ACCESS 4 VALVE MOUNTING ss LLL AG x 75 0 e 95 od 20 77 FILTER DRAIN 525 6 20 69 2 LUBE P S I PORT AUXILIARY LUBE SUPPLY INLET CENTER GRAVITY 9 75 FLYWHEEL OUTLINE MUST USE 8 8 PROPERTY CLASS QUALITY PER ISO 898 1 AND TORQUE TO PER ISO 898 1 GRADE 5 QUALITY CLASS 552 74 UR SERVICE MANUAL VALUES PER SAE J429 CAPSCREWS AND TORQUE 5574 SERVICE MANUAL VALUES DRAIN PLUG 525 6
234. TERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE 15 NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT ASSEMBLY INSTRUCTIONS ASSEMBLE AND TEST PER 5570 NOTES 1 THRU 7 ARE IN 5570 OIL PRESSURE GAGE THESE STANDARDS APPLY 55 4 FASTENER TORQUE REQUIREMENTS S692 BEARING SHIMMING 5765 TAPERED JOINT ASSEMBLY MOUNT LUBE INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION LUBRICANT TOWARDS BREATHER MOUNT INSTRUCTION PLATE WITH WORDS MARINE TRANSMISSION TOWARDS BREATHER M422B 204098 ASSEMBLY 1016103 836310 ASSEMBLY 10161034 ASSEMBLY 1016103 AND ASSEMBLY 10161034 SHEET CROSS SECTIONS AND PART NUMBERS N 1 5 SHEET ASSEMBLY 1016103 C 1 SHEET INSTALLATIUN DRAWING ASSEMBLY SHEET 1016103 amp 1016103B 3 5 INSTALLATION DRAWING SHEET FLEXIBLE MA1040B 5 SHEET B ee 2 25 EN MASS ELASTIC B3504AE SuSE HEAT EXCHANGER B3649K REQUIREMENTS HYDRAULIC 711928 DIAGRAM THIRD ANGLE UNLESS DTHERVISE SPECIFIED DATE DIMENSIONS ARE 3 9 95 Wo dud DISS SCALE INCORPORATED 1mm RACINE WI 53403 USA DRN H INPUT SPEED 2500 R P M CONSULT SALES DEPT APPLICATION ENGINEERS FOR OTHER LIMITING CONDITIONS MATERIAL WEIGHT FIRST USE 008 ASSY MODEL NAME MARI 1
235. TRAVEL BEYOND DETENTED POSITION TO INSTALL ROTATE TROLLING LEVER FROM THE TROLLING RANGE INTO DETENT POSITION THEN WHILE APPLYING SLIGHT REVERSE PRESSURE AGAINST THE DETENT ADVANCE SETSCREW AGAINST CAM BACK IT 1 4 TURN THEN LOCK IN PLACE WITH LUCKSCREW THIS SETSCREW IS USED TO ADJUST THE MINIMUM TROLLING PRESSURE REFER TO TEST SPECIFICATION FOR ADJUSTMENT PROCEDURE THIS ADJUSTMENT SHOULD ONLY MADE AFTER THE DETENT PLUNGER AND DETENT OVERTRAVEL SETSCREW HAVE BEEN INSTALLED PER NOTE 8 3 57 ied p 9 1 M ba ES PD PRESSURE GAUGE LINE LOCATION 3 Es Ed WHEN M8051CD 5 A2916DK SPECIFIED A9870K KS X q ppm __ 1 n Mw HM 2 sss SP AE zm do NEU C Vy as gt n 154 r C 7 j o AARG RNA RS NTRS S S EAS SSS pre 20 22 5 2 INKS 813996 1 m867 p H Ha 5S SS SESS SINS 4 3 CMISe7EBD m E r u ss ST SSS S N unica RC IE AS H IN A St SIRES SEED SES 314008 ae E SHOWING CURRENT PRODUCTION PISTON a ae p 2721 21600 OPARE T E TROLLING PRESSURE Be45e4 18 MA77
236. TROLLING VALVE GRANTED TO THE US GOVERNMENT BOTTOM VIEW OR OTHERS BY CONTRACT APPD sern ra 1 ur 1 REV JS SURFACE TREATMENT STEM 1017901 SEAL 5591 ADAPTER 1017530 INSTALLATION NOTE 0 6 0 9N 5 5 8 3 Ib AT THE 46 0 1 81 LOCATION THE 6 4 1 4 DIA IS REQUIRED TO OVERCOME DETENT REMOTE CONTROL ACTUATOR MUST PROVIDE 65 0 mm 2 56 TOTAL LINEAR TRAVEL AT THE 6 4 1 4 DIA HOLE LOCATION CAPSCREW MA1042B 2 Ad 2 SEISCREW MA1037D 4 SCREW IN UNTIL POINT N THE 90 LEVER ROTATION REQUIRED GaN BOTTOMS THEN LOOSEN PN P te EX LEVER MAY BE CLAMPED PROVIDED BALL 5 NO TROLL K CLEARANCE EXISTS FOR FULL 90 4 POSITION OF TRAVEL PISTON 10491 MESE INSTALL USING MA908 NUI VALVE BODY 1017529 sues LOCTITE 242 AT DETENT INSTRUCTION TAG 2385 INSTRUCTION PLATE B2464 NS MIN TROLLING 90 PRESSURE MAX TROLLING PRESSURE SECTION CAPSCREW M2000H 3 70 75 TROLLING NUT M2027C LEVER B2103 MIN IROLLING PRESSURE lt 7 QT T NO TROLLING sa WAH SETSCREW M2041AB RATE OF RISE DETENT ADJUST SETSCREW SO THAT THE TORQUE REQUIRED ON STEM TO OVERCOME DETENT IS 1 1 1 7 10 15 Ibf in p ees T E SHINS gt SPR
237. UT TO HEAT EXCHANGER O M33 X THREAD METRIC PORT CONFORMS TO ISO 6149 REMOVE THREAD PROTECTOR BEFORE OPERATING UNIT e UN Bi IT HDD I I O LUBE PRESSURE MIS X 15 THREAD METRIC PORT CONFORMS 150 6149 AUXILIARY LUBE SUPPLY INLET SEE HYDRAULIC El DIAGRAM H 57 2 6 STOCK BORE SIZE CUSTOMER TO FINISH BORE NOTED pae a IH B lt I k ss E OUTPUT SHAFT t Sy Vu 2 i 00 QN aJ 1 ly f H Y E NN eris 3 di D 7 SECONDARY CLUTCH ACTUATING PRESSURE M10 X 10 TH D B 6223504187 METRIC PORT CONFORMS 1 0 6149 B 3 8 16UNC THREAD 7 6 L 301 DEEP SUCTION SCREEN TEMPERATURE PICK UP PORT 228 6 COMPANION FLANGE MAX BORES 93 2 WITH SQUARE KEY 114 3 WITH 254 SQUARE KEY 120 6 WITH 318 SQUARE KEY 139 7 WITH 318 X 22 2 RECT KEY amp 1251 TAPER GEAR SETS S FACE PINION D D OPTIONAL TEMPERATURE INDICATING SWITCH CUSTOMER TO INSTALL IN A 3 4 X 3 4 X 3 41 PIPE TEE IN THE HYDRAULIC LINE LEADING FROM THE MARINE TRANSMISSION PUMP TO THE HEAT EXCHANGER INLET REFER TO HYDRAULIC DIAGRAM NOTE ALL POINTS AVAILABLE FOR TESTING ARE CODED 1 4 18 NPTF DRYSEAL
238. _ WS SG LLL ASSEMBLY 10161038 4 2 ASSEMBLY 1016103B 2 y meu cem s s DNA N Z NU E S Z HW ALE LAT Zu a 1014883 4 777 GWA 1014885 Ft Ng BS lt lt lt Z 2 S lt lt lt 1016191 1 228 4 SS Z Ges 2 7 Z 2272 22 a m Z D 1945 1015018 Q b ASSEMBLY 1016103 1016105 ASSEMBLY 1016103A 1016105 ASSEMBLY 1016103B 1016105 COSS ETMEAS NETE S 960 0810 OIL CAPACITY BOO L 7 GALS LESS HOSES AND HEAT EXCHANGER THIS UNIT CAN NOT BE USED WITH LEFT HAND ENGINE OPTIONAL EQUIPMENT MOUNTED HEAT EXCHANGER 1018342 ELECTRIC VALVE W MECHANICAL BACKUP 10180840 COMPANION FLANGE ASSEMBLY 1013378 CONTROL TROLLING VALVE XA7600B LIVE P T O XB6243A AUXILIARY PUMP DRIVE HYDRAULIC CLUTCHED P T O XA7554 SHAFT DRIVE AND XA7534A PUMP DRIVE TRAILING PUMP 1016473 FLEXIBLE COUPLING INPUTS SEE SHEET 3 K BUM 1096 METRIC TO NPTF ADAPTER KIT 1014858
239. a BALL MA1034B MANIFOLD T0086 734 EW C16 gt lt I RING M19041 as oa E MA947D HEX NUT 16 AJ ING BIO48BC EO SW Sie N AJ LS 1016520 HUB SPLINED Im VER 1015518
240. and inverted fittings per standards 512 514 516 Lb ft Equivalent Lb in 1 3 HI Low o esee Lowe w m ere 0 ww mem wmm m wma 04 400 2 _____ Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 12 7 SECTION 12 12 5 1506149 Port Fittings Torque Values for ISO 6149 O Ring Port Fittings Recom sposa 70 52 100 74 81 60 Aluminum vie Body 12 8 SECTION 12 Torque Charts 13 0 Illustrations Section 13 Illustrations List of Illustrations This section contains the following illustrations 13 1 13 2 13 3 13 4 13 5 13 5a 13 6 13 6a 13 7 13 8 13 9 Clutch Group Selector Valve Suction Strainer Filter Transmission Rear View MG5202SC MG5203SC MG5204SC Transmission Rear View MG5202DC Transmission Section View MG5202SC MG5203SC MG5204SC Transmission Section View MG5202DC Control Valve Group Control Valve Group Trolling Valve Group Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 13 1 SECTION 13 Clutch Group 13 1 pdwuano 2025 uo p sn jou ey sued s lousd SHUN 10 SI uoisueuirp u pue usi Du3 SI uoisuauilp 151 94 suoisu uuip JO 5495 OM uauM Buueeq wees yeys 5
241. 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 90 180 and 270 degrees Move the feeler blade around the flange again in each successive position If the alignment is correct the feeler gauge will fit snugly with the same tension all around the flange coupling If the alignment varies during rotation then additional alignment is necessary or the marine transmission and shaft couplings should be checked for improper face runout See Figures 10 9 and 10 10 Runout must not exceed 0 10 mm 0 004 in Face runout on the matine transmission output flange can usually be corrected by repositioning the flange on its spline or taper Shaft coupling runout could be due to inaccuracy of taper fit key interference or bent flanges SECTION 10 Installation SECTION 10 10 6 ever before the mounting brackets are secured to the engine bedrails the propeller shaft should be checked for alignment NOTE The transmission output flange and companion flange bolts must be torqued to specifications found in Section 12 B 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
242. ating information for Twin Disc MG 5202DC MG 5202SC MG 5203SC and MG 5204SC transmissions Specific engineering details and perfor mance characteristics can be obtained from the Product Service Department of Twin Disc Incorporated Racine Wisconsin U S A Operation and maintenance personnel responsible for this equipment should be famil iar with this publication and have it at their disposal thorough understanding and application of the material in this manual will result in consistent performance from the unit and help reduce downtime 1 2 Safety and General Precautions 1 2 General All personnel servicing this unit should employ safe operating practices Twin Disc Incor porated will not be responsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unaccepted maintenance working practices 1 2 B Important Safety Notice Because of the possible danger to person s or property from accidents that may result from the use of machinery proper installation maintenance and operation procedures must be followed Twin Disc Incorporated 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
243. ator and mark a starting position on the gear face Rotate the output shaft observing the dial indicator for indication that thte output gear is cocked on the output shaft Dial indicator vasriations in excess of 0 06 mm 0 003 in as the shaft is turned indicate the gear is cocked on the 9 6 SECTION 9 Assembly 7 9 4 Assembly Use portable press 1340 kN 150 ton capacity and fixture T20023 to seat hub using 1340 N 300 Ibf load Fig 9 9 Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating surfaces Advance gear to shaft shoulder stop with the portable press Release injection oil pressure between the mating surfaces and wait five min utes before lowering the press force and removing the assembly tool Check actual advance See fig 9 6 Installation of Rear Output Shaft Bearing Install heated rear output shaft tapered roller bearing Install with small O D of bearing to the rear Press drive bearing to shaft shoulder using special tool T18050 606 for shallow case and T18050 96 for deep case units After bearing cools press drive bearing down again to assure that bearing is against shaft shoulder For deep case models install chilled cup into output seal carrier using tool 118050 116 For shallow case models push cup to seat against cone installed above Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC
244. ator and mark the spot where the reading was taken E Using a hoist exert 2225 N to 4000 N 500 Ibs to 900 Ibs of lifting force onto the shaft Rotate the shaft several revolutions with lifting force applied Stop rotation with dial indicator finger on mark previously made continuing to hold lifting force Read shaft endplay on dial indicator It should be 0 05 mm to 0 15 mm 0 002 in to 0 006 in F Release upward force Apply downward force and rotate the shaft sev eral revolutions Stop rotation with dial indicator finger on mark Dial indicator should again read zero If total endplay is out of tolerance add or remove shms as necessary to achieve a measured endplay of 0 05 mm to 0 15 mm 0 002 in to 0 006 in Model MG5202DC A Install seal carrier without seals or O ring Secure seal carrier with capscrews using very little torque on capscrews Use a taper gauge or feeler gauge to measure gap between rear housing face and flange of output seal carrier Build a trial shim pack of thickness equal to gap plus 0 50 mm 0 020 in Install the shim pack B To lift output shaft install eyebolts and strap to rear of output shaft Apply 1340 N to 4000 300 105 to 900 165 of downward force on rear end of output shaft Seat front bearing by rotating shaft several revolutions with weight ap plied C Install dial indicator onto the housing with finger resting on rear of output shaft or on lifting fixtures Minimum of 2224 500
245. ature C Torsional Coupling Do not obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling The ambient temperature of the air around the coupling should be between 69C 22 F and 800C 1760F Assure baffles are installed properly so hot air is ported out of the housing Visually inspect the element after the first 100 hours of operation and every 2000 hours thereafter or every six months whichever comes first Torsional vibration misalignment degradation by contaminants oil heat ultraviolet radiation and excessive system torque Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 4 7 SECTION 4 4 8 can cause cracks other signs of distress to appear surface of the rubber The above described items affect the life of the coupling element When inspecting the flexible coupling follow the steps 1 Look for A Cracks in the surface of the rubber May be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum prod ucts 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 A 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
246. ax min max min min min min min max min max 1800 Primary 1725 1862 250 270 97 234 Neutral 276 690 40 100 214 372 Secondary 1725 1862 250 270 97 234 600 Primary 1586 1793 230 260 Neutral 138 517 20 75 Secondary 1586 1793 230 260 5202 02 4 2 SECTION 4 Specifications and Maintenance Specifications and Maintenance Cil Pressure Limits 2000 kPa 290 psi units 275 psi minimum pressure when cruising Input RPM amp X Zsc Shift Position Valve Inlet Primary Secondary Collector Collector psi Kpa psi Kpa psi kPa psi min max min min min min max 1800 Primary 1960 2140 285 310 100 380 Neutral 689 1034 100 150 280 450 Secondary 1960 2140 285 810 100 380 600 Primary 1860 2000 270 290 Neutral 255 310 37 45 Secondary 1860 2000 270 290 If the marine transmission is equipped with a hydraulic clutched PTO oil pressure should be at these values at the PTO inlet PTO Clutch PTO Clutch Input Eaa 2 E HE de Zi Transmission RPM 724 1862 250 270 Primary 1800 0 1758 1896 255 275 Secondary 600 1655 1793 240 260 Neutral 1800 1689 1827 245 265 T 5202 05 Note Transmission control valve is the right valve and the PTO valve is the left valve when viewed from the rear of the transmission For units with a hydraulic clutched PTO installed cooling lube pressure may be less than the charted values by the followin
247. chined Surfaces 7 2 B naa 7 2 ITU O ee ea 7 3 D Ege adc CIGBUDE T A 7 3 UT 7 3 F T 7 3 PARE iuo cda 7 3 H ______ _ ____ 73 elu ce m 7 3 vii Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC 5204 Table of Contents viii Section 8 Subassemblies 8 1 TT DT 8 1 8 1 8 2 ES u eT 8 2 8 2 1017390 0r 1018084 ESC WIG Control Valves iius 8 3 A Disassembly of lower valve body half manual section 8 3 B Disassembly of upper valve body half electric section 8 6 C Cleaning A IPSS CIMT aces 8 8 D Assembly of upper valve body half 8 8 E Assembly ot lower valve pody half uii oe a ent eia 8 8 8 3 puru hls e 8 12 A Bir DP eee EE EET 8 12 B 8 14 Section 9 Assembly 9 1 A E 9 2 9 2 9 2 93 9 3 9 4 Installation Rear Output
248. ctor to allow removal of the pins and wires 8 6 SECTION 8 Subassemblies Subassemblies 3 Remove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool Tool is Packard Electric P N 12014012 758 Mark the two solenoids for location identification and remove them Remove the third Neutral solenoid units with hydraulic lock or plug units without hydraulic lock 6 Remove the filter screen from the valve body Remove the two O ring plugs from the bores in the end of the valve body 8 Remove the two spools from the valve body Remove one dowel pin and spring from each of the spools hydraulic lock units only 10 Remove the spool return spring and dowel pin from the bottom of each of the spool bores in the valve bogy Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 7 SECTION 8 Cleaning and Inspection See Section 7 D Assembly of upper valve body half 1 Install one dowel pin large diameter into each of the two bores of the valve 2 Install one spring into each the two bores of the valve body 792 Install one spool into each of the two bores of the valve body 4 Onunits 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 specification see Torque Chart 6 Apply
249. d E Suction Strainer The unit has a suction strainer located below the oil pump The strainer is between the sump and oil pump in the hydraulic circuit F Filter Assembly A spin on filter is located between the heat exchanger inlet and the selector valve in the hydraulic circuit G Gears All gears are helical carburized hardened and ground for smooth quiet operation All gears are in constant mesh The primary and secondary transfer gears and the output gear are mounted on keyless tapers H Flexible Input Coupling The purpose of the torsional coupling is to transmit power from the engine to the marine transmission through a rubber or silicone element that will a Dampen torsional vibrations b Change the natural frequencies of a system to move critical frequencies out of the operating speed range Accommodate a certain amount of misalignment d Absorb shock and reduce noise e Minimize gear rattle Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 2 2 SECTION 2 Heat Exchanger The heat exchanger is designed to maintain the oil in the hydraulic system the ma rine transmission at the proper temperature by passing coolant from the engine through the heat exchanger The heat exchanger should be installed in a location convenient to both engine coolant and marine transmission oil J Trolling Valve Optional The trolling valve is used to reduce and control propeller speed belo
250. d should remove easily Remove internal snap ring at front of clutch housing and remove clutch backing plate Remove clutch plates 10 steel 11 friction Remove clutch apply piston a Place clutch in a press input side up Use special tool T19998 to compress clutch release springs and expose round retaining ring Fig 6 16 b Remove retaining ring Slowly release pressure press and remove shaft from press Remove specialtool 19998 and spring retainer Re move clutch release springs form pockets in face of piston Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 6 13 SECTION 6 6 14 NOTE Do not separate clutch housing transfer gear from the secondary shaft unless the shaft or the clutch housing must be replaced and the mating part remains service able Use the following procedure to separate the housing transfer gear from the primary c Apply compressed air to hydraulic pressure port to force piston from piston bore Remove clutch apply piston u GE i Te h Bin Tar CT araca acu d Remove piston ring from ring groove in shaft seals I D of clutch piston and piston ring from ring groove in O D of clutch piston or secondary shaft 9 To remove clutch housing place shaft and clutch housing on a press front end of shaft down Place a sleeve over input front end of shaft with an only slightly larger t
251. e snap ring groove of shaft Keep force on springs and install retaining ring into exposed groove of shaft Fig 9 17 D Slowly release force on springs assuring that spring retainer counterbore covers snap ring and prevents retaining ring from coming out of the groove Remove tool T19998 9 16 SECTION 9 Assembly Assembly 6 Use driver T18050 152 and hydraulic press to press rear tapered roller bearing cone onto secondary shaft Install bearing with large O D toward transfer gear and press to seat against transfer gear Fig 9 18 7 Install external retaining ring Assemble tapered edge side away from bearing Beginning with a friction plate alternately install 11 friction plates and 10 steel plates into clutch drum and against clutch apply piston fig 9 18 9 Install the shim plate some models Check Bill of Material to determine if shim plates are to be used Shim plates were used with the 1014866 and 1014867 transfer gears which have a 104 9 mm to 105 2mm 4 130 in to 4 140 in distance from the bottom of the gear where the clutch piston fits to the top edge of the retaining ring groove Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 17 SECTION 9 10 Install clutch backplate and internal retaining ring 11 Install tapered roller bearing cone onto secondary shaft Install with large diam eter of bearing seating against shoulder of shaft inside the transfer gear open
252. eal carrier C Pack area between the seals with water pump grease 1 2 gt Fig 9 13 9 12 SECTION 9 Assembly 9 6 9 7 Assembly D Install grease fitting if not previously installed Install established shim pack Install assembled output seal carrier onto housing Install attaching screws and torque to specification see Torque Chart Installation of Top Cover Asembly and Oil Gauge Turn transmission over and block securely to rest in upright position Install top cover gasket Install the attaching screws and torque to specification see Torque Chart Install breather filler cap Install oil gauge tube assembly and oil level gauge Verify that the oil gauge tube assembly did not enter the output gear pan opening Assembly and Installation of Primary and Secondary Shaft Assembly of transfer gear to secondary shaft A Clean taper on secondary shaft and tapered bore in transfer gear using OSHA approved cleaner Wipe dry with clean paper towels Do not touch cleaned tapers B Determine if secondary shaft and transfer gear can be advanced prop erly 1 Hold secondary shaft in a vertical position standing on its front end 2 Use a depth micrometer and measure distance from the rear end of the shaft to the shaft shoulder at small end of taper Record this distance as dimension A 3 Install secondary transfer gear on secondary shaft taper small diam eter of tapered bore up
253. ed 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 crocus cloth replace the part D Bushings and Sleeves Inspect bushings for size and out of roundness Inspect for scores burrs sharp edges and evidence of overheating Remove scores with crocus cloth If the bushing is out of round deeply scored or excessively worn replace it E Thrust Washers and Spacers Inspect thrust washers for distortion scores burrs and wear Rework or replace any defec tive thrust washers or spacers F Gears 1 Inspect gears for scuffed nicked burred or broken teeth If you cannot remove the defect with a soft stone replace the gear 2 Inspect gear teeth for wear that may have destroyed the original tooth shape If you find this condition replace the gear 3 Inspect thrust faces of gears for scores scratches and burrs If you cannot remove these defects with a soft stone replace the gear G Splined Parts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found H Springs Inspect springs for broken or distorted coils Replace the spring if either of these defects is found Clutch Plates Inspect clutch plates
254. es to be driven using engine horsepower Since the PTO is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The PTO is engaged by rotating the lever of the PTO control valve The hydraulic clutched PTO operates with an engaged clutch pressure greater than that of the transmission s primary and secondary clutches For this reason the PTO control valve pressure increasing valve is in the transmission s hydraulic circuit before the control valve s inlet and pressure regulator Pressurized oil from the filter is di rected to the PTO control valve with the overage oil flowing to the transmission s con trol valve 3 8 Trailing Pump Optional The trailing pump supplies oil flow to the transmission lubrication circuit when the output shaft is rotating This lubrication oil is required when the transmission is in a backdriving condition Backdriving sometimes referred to windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller When the engine is running and the output shaft is rotating oil flow from the trailing pump supplements the oil flow supplied to the lubrication circuit by the main oil pump The trailing pump is driven by an electric motor and oil flow from the trailing pump flows through a check valve into the oil inlet of the heat exchanger and into the trans mission lubrication circuit 3
255. essure oil through internal passages to oper ate the clutches 3 2 Hydraulic System The oil pump draws oil through the strainer from the oil sump and discharges it through the filter to the combination control and pressure regulating valve The oil enters the pressure regulating area of the valve where main pressure is regulated by cascading excess oil into the heat exchanger to the lubrication oil circuit Lubrication oil is distributed through fixed controlled orifices to lubricate and cool the clutches and bearings There is a lubrication oil relief valve to limit the maximum lubrication oil pressure to approximately 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 When the control valve is shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston com pressing 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 disen gaged clutch is connected to vented to sump atmospheric pressure The clutch return springs move the disengaged clutch s clutch piston to the disengaged position preventing clutch drag
256. ft front bearing bore Be sure shield is properly centered 6 Install chilled front output tapered roller bearing cup into housing bore Use driver T18050 611 to press drive cup to bottom of its bore NOTE Care must be taken to ensure that the shield remains centered 7 Placea 250 mm 9 85 in dia x 13 mm 1 2 in thick steel plate over the bear ing cup Place a suitably sized puller inside the housing to push on the steel plate The puller yoke must span the opening of the transmission housing Tighten puller rod to standard torque limit for thread size of puller rod or 275 N m 200 ft Ib whichever is less Maintain this torque until bearing cup and housing temperatures equalize approx 10 minutes Fig 9 2 Fig 9 3 8 Remove puller and steel plate Measure and record the distance from the machined surface of the housing to the top of the bearing cup dimension D Dimension must equal dimension minus dimension B minus dimen sion C within 0 025 mm 0 001 in 9 3 Installation of Output Shaft and Gear Model MG5202SC assemblies 1014841 and 1015389 only 1 Turn housing over so that the input side is up 2 Clean tapered surface of output shaft and tapered bore of output gear Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 93 SECTION 9 Wipe surface with clean paper towel Do not touch c
257. fting force on the shaft Rotate the shaft several revolutions in each direction stopping with the dial indicator probe resting on the mark 6 Dial indicator reading is secondary shaft endplay Endplay should be between 0 05 mm to 0 15 mm 0 002 in to 0 006 in Add or remove shims as neces sary to achieve correct endplay Use dial indicator and above procedure to confirm that desired endplay has been attained 9 24 SECTION 9 Assembly Assembly 7 Check endplay for primary shaft Repeat steps 1 through 6 above to adjust for primary shaft 9 11 Installation of Manifold Exterior Components 1 Install pump suction strainer into bore in manifold 2 Install O ring into groove in suction screen cover Apply assembly grease to the O ring 3 Install suction screen cover and secure with clamp plate and screw Torque attaching screw to specification see Torque Chart 4 Install O ring into groove in face of manifold at primary shaft location Install cover onto manifold at primary shaft bore Install attaching screws and torque to specification see Torque Chart Fig 9 29 Fig 9 30 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 25 SECTION 9 9 12 Install oil pump gasket and oil pump mounting location at end of secondary shaft Mesh drive tang on pump shaft with drive slot in secondary shaft Install attaching screws and torque to specification see Torque Chart Insta
258. g amount 34kPa 5 5 less in primary neutral or secondary at 1800 rpm 14 kPa 2psi less in primary neutral or secondary at 600 rpm but not less than 10 kPa 1 5psi For units with a trolling valve with trolling lever at its minimum trolling pressure posi tion mechanical trolling valve or maximum electrical current into trolling valve electrical trolling valve test pressures 2 and G or X must be at the values of the following chart for both input speed and shift specified Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 4 3 SECTION 4 4 4 TROLLING OIL PRESSURE LIMITS Zic Zsc Input RPM amp Primary Collector Secondary Collector Shift Position kPa psi kPa psi min max min max min max min max min max min max 600 RPM Primary 124 165 18 24 0 0 14 55 2 8 Neutral 0 0 0 0 34 83 5 12 Secondary 0 0 124 165 18 24 14 55 2 8 T 5202 04 For mechanical trolling valves the clutch oil pressure with the lever at the maximum trolling pressure position just before the detent and rate of rise event must be at least 138 kPa 20psi more than the values at the minimum trolling pressure position H Viscosity NOTE Steady operation below 669C 1509F or above 939C 2009F is not recommended Oil Recommendation Based on Oil Temperature at Heat Exchanger Inlet During Start up Steady Operating Conditions Recommended Oil Viscosity Below 66 150 F This o
259. gaged A shuttle ball connected to both clutch pressure ports permits pressurizing this passage with oil from the engaged clutch without allowing oil to flow to the disengaged clutch Mvc 001 3 8 SECTION 3 Operation SECTION 3 forces the rate of rise piston to stroke over to its stop the valve body compressing the pressure regulating springs even further yet Em eS Mvc 003a 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 com pressed the most the main oil pressure reaches approximately 250 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 it is to be regulated at the ball unseats from the orifice plate allowing main oil pressure to return to the neutral pressure level rapidly and again be regulated by the ball and spring regulator The ball returns
260. gear face should be 9 14 SECTION 9 Assembly Assembly within 0 05 mm 002 in of the shaft shoulder at the small diameter end of the taper NOTE Actual advance C B must be 2 56 mm to 3 38 mm 0 101 in to 0 133 in NOTE If transfer gear has not been advanced as specified above contact the Product Service Department at Twin Disc Incorporated for information Install piston seal ring into groove in secondary shaft Apply a coat of assembly grease or oil to seal ring Install piston ring in groove in O D of clutch apply piston Apply a coat of assem bly grease or oil to seal ring Install clutch apply piston into piston bore in transfer gear ix Fig 9 15 Installation of clutch return springs A Install 16 clutch return spring assemblies into pockets in face of clutch apply piston Each assembly consists of one inner and one outer spring B Install spring retainer over springs with groove toward springs Working through holes in retainer use a small punch or probe to assure that all springs Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 15 SECTION 9 are in pockets in face of piston and that springs are aligned correctly stand straight up Fig 9 16 C Install external retaining ring over shaft to rest against spring retainer Move shaft assembly to press and install tool T19998 Exert force on tool 119998 to compress springs and expos
261. grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance of gear on shaft and adversely effect torque carrying capacity of the as sembled joint 3 4 Coat the tapered surface with thin oil such as SKF mounting fluid Install oil shield bearing and output gear Use a board for shallow case models or special tool T19987 for deep case to position gear into correct location Install the output shaft into the output gear in the transmission housing Seat shaft onto the taper of the gear using only the weight of the shaft Use gauge blocks and a feeler gauge to measure between the output gear and shaft shoulder This is the potential advance The advance for shallow case models must be 6 86mm to 8 38 mm 0 270 in to 0 330 in Deep case models must be 9 52 mm to 11 05 mm 0 375 in to 0 435 in See figure 9 6 NOTE Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be neces sary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance Connect the oil injector to the output shaft SECTION 9 Assembly SECTION 9 6 Using a board slide the output gear small diameter end of tapered bore up into housing so that the bore of the gear aligns with the bore in the housing for the output
262. gt AND CONNECTION LINES REFER TEMPERATURE INDICATING 60 LD HOSE iudi INSTALLA TINN DRAWING SWITCH USING PIPE TEE WITH E STRAINER ReneR mse ____________ REDUCER BUSHING fe inj q ERMERERS MAIO40B DRAIN PLUG LOCATION TEMP L WITCH USING PIPE TEE WITH M33 X 2 THREAD pio er REDUCER BUSHING PER MARINE TRANSMISSION SS Se INSTALLATION AND ASSEMBLY E ER CONTROL 3 4 X 3 4 X 3 4 in DRAWING d cl THIRD ANGLE P N XA7540B OIL PUMP SIMILAR TD 22 CE d NE SIG END CC QE MEE DIM LE LN MMC ONU PICTORIAL HYDRAULIC DIAGRAM M E S C e TRUE E em GRAPHICAL JLC SYMBOLS STRAINER NOTICE THIS PRINT CONTAINS MATERIAL ae aa e es 7 93 TOD DISE 1 29090 1585 59 ca na mv F D SUMP PROPRIETARY INFORMATION AND IS NOT TO BE USED IN ANY MANNER DETRIMENTAL TO THE INTERESTS OF TWIN DISC INCORPORATED RACINE WI 53403 USA THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U S GOVERNMENT OR OTHERS BY CONTRACT PRIMARY SECUNDARY MACHINED DIMENSIDNS X 0 75 FIRST 081015207 MG AA d MODEL PER ANSI Y14 5M 1982 SURFACE TREATMENT NAME DIAGRAM HYDRAULIC B
263. han the O D of the shaft taper large end 95 25mm 3 75 in Rest one end of sleeve on a heavy wood block while the other end supports the inner face of the clutch housing Apply press force to rear end of shaft to separate shaft from clutch housing Restrain parts to prevent damage as thetapered joint separates SECTION 6 Disassembly Cleaning and Inspection Section 7 Cleaning and Inspection 7 1 Cleaning NOTE Replace all oil seals gaskets O rings piston rings seal rings snap rings etc as a part of any maintenance or overhaul procedure Replace shims that are damaged or destroyed in disassembly 1 Clean parts using EPA OSHA approved solvents or by steam cleaning Parts must be dried and oiled immediately 2 Examine all parts carefully for grit dirt and abrasives and reclean them if necessary 3 Clean all oil passages by working a piece of wire back and forth through the pas sages and then flushing them with cleaning solvent 4 Use clean solvent to flush oil pumps valves etc Flush all hoses tubing coolers etc particularly if the unit is being disassembled because of an internal failure 6 De burr the housing and bearing carrier with a stone or file in the vicinity of all pusher screw locations A 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 harde
264. he next two pages Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 12 1 SECTION 12 1 of 2 Torque Values for Metric Coarse Thread Capscrews Bolts and Nuts Dry as received See note below Property Class 8 8 Property Class 10 9 Property Class 12 9 Torque 6 8 Torque in N m Ib ft Torque in lb ft Min Nominal Min Nominal Max Min Nominal Max oe nm m m n nm om 329 243 435 321 500 369 501 369 614 4 706 521 800 590 856 631 1445 809 597 ve emm 1060 782 1140 841 1220 900 1256 926 1350 996 4066 1450 1552 2046 2200 2354 2511 2700 2889 1069 1144 1509 1623 1736 1852 1991 2131 Use these torque values for all capscrews bolts and nuts coated only with the manufacturer s rust preventative oil and use for all parts wiped or washed nearly free of oil Do not use for plated parts 131 240 117 257 189 318 235 106 159 117 169 125 207 1 260 122 SECTION 12 Torque Charts Torque Charts 2 of 2 Torque Values for Metric Coarse Thread Capscrews Bolts and Nuts Lubricated See notes below Property Class 8 8 Property Class 10 9 Property Class 12 9 Torque bt Torque in lb ft Torque in Nm lb ft Min Nominal Min Nominal Min Nominal 8 8 6 5 EXC 7 5 12 8 9 13 9 6 14 10
265. he oil and filter after 1000 hours of service or more often if conditions warrant Draining Drain the transmission by removing the O ring plug at the rear side at the bottom Oil Suction Strainer Remove and clean the pump suction strainer at every oil change or sooner if necessary See Section 13 4 for suction strainer location Type Oil Recommended See Section 4 1 Specifications amp Maintenance Filling 1 Remove the filler breather in the top cover of the transmission 2 Fill the transmission s sump with 26 5 liters 7 0 U S gal for shallow case models or 31 4 liters 8 3 U S gallons for deep case models of the proper weight and type oil See preceding specifications for oil recommendations 3 Startthe engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle 4 With the oil at operating temperature transmission in neutral and the engine run ning at low idle check the oil level with the oil gauge Add or remove oil if neces sary to bring the oil level to FULL mark on the oil gauge 5 Allow the oil temperature to cool to normal cold oil conditions perhaps overnight Check the oil level while cold at low idle engine speed while in neutral Make note of the oil level in the cold conditions for future reference as it corresponds to the correct oil level at operating temper
266. heck actual advance by confirming that flange has been pulled onto shaft until flange shoulder is within 0 00 mm to 0 05 mm 0 000 in to 0 002 in of shaft end Attach dial indicator to housing with probe resting on face of output flange Locate indicator probe as close to O D of flange as possible Check flange face runout by rotating flange Total indicated runout must not exceed 0 10 mm 0 004 in Attach dial indicator to housing with probe resting on O D of output flange pilot Check pilot runout by rotating output flange Total indicated runout must not exceed 0 10 mm 0 004 in NOTE Should total dial indicator runout exceed 0 10 mm 0 004 in proceed as follows A With a felt tip pen draw a line across the end of the output shaft and face of output shaft counterbore to mark original installed position of the output flange versus the output shaft B Remove output flange as described in Section 6 and reinstall 90 from original position Recheck runout of flange face and flange pilot using proce dures in steps 12 and 13 above If runout is within specification do nothing more C If runout continues to exceed tolerance repeat procedure in B above at positions 180 and 270 from originally installed output flange position Stop at whatever position output flange runout is no more than 0 10 mm 0 004 in SECTION 9 Assembly Assembly D If output flange runout cannot be reduced to acceptable tolerances contact
267. ide of housing to premit transmis sion housing to be turned over Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 67 SECTION 6 11 12 Turn housing so that the input side is up Remove external retaining ring from output shaft Move housing to 200 ton press Install sleeve over output shaft end to butt against rear side of output gear Sleeve dimensions are 33mm 5 25 in 1 0 x 356 mm 14 in long with a wall thickness of 13mm 1 2 in to 19 mm 3 4 Remove internal blocking that was holding gear and shaft in position Place heavy wood block 51 mm 2 in to 76 mm 3 in thick under sleeve and output shaft Locate transmission housing sleeve and block directly under press so cup plug hole is under ram Lower housing far enough so that sleeve raises gear and shaft assembly until front bearing cone on output shaft is aligned with the bearing cup in housing Fig 6 9 Block or hold housingso that press orce can be exerted squarely against front end of output shaft see fig 6 9 Apply 1334 kN 150 tons to 1557 kN 175 tons of force to press shaft out of output gear and to press front output bearing cone off output shaft SECTION 6 Disassembly Disassembly 14 Lift housing off of press and raise high enough so that sleeve and output shaft can be removed 15 Remove output gear and front output bearing cone through top cover opening in housing 16 Tapered roller bearing cups for fr
268. ined face Rotate input shaft and note total indicator runout The runout must not exceed 0 42 mm 0 016 in for both a SAE 0 and SAE 1 housing Fig 9 34 Attach a dial indicator to the input shaft spline using fixture T21302 1 with the probe on the O D of the front housing pilot Rotate input shaft and note total indicator runout The runout must not exceed 0 30 mm 0 012 in for both a SAE 0 and SAE 1 housing NOTE Should total indicator runout exceed stated limits contact the Product Service Department of Twin Disc Incorporated for information and recommendations 9 30 9 Installation Section 10 Installation 10 1 Prior to Installation CAUTION Most Twin Disc products mount directly onto the flywheel of the engine Flywheel to driven nent 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 compo nent is installed After installation of the driven component crankshaft endplay must be measured again at the second measurement must be the same as the first A difference in these two endplay measurements is an indication of interference Consequently the driven component must 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 com ponent
269. ing inside hous ing to hold output shaft and gear against front tapered roller bearing Lay hous ing on blocking or assembly stand with input side up Apply anaerobic sealant Twin Disc part number M2828 around O D of cup plug and install in housing bore at front end of output shaft Install with cup side up flush with front face of housing Fig 9 8 Turn housing over so that output side is up If using blocking block securely and high enough to permit installation of gear pan capscrews and washers Remove blocking holding gear and shaft against front output bearing from inside hous ing Install gear pan assembly with caged nuts toward the front Pan must be rolled in around output gear to proper position Install attaching screws with a seal Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 7 SECTION 9 washer under each screw s head Torque the screws to specification see Torque Chart Model MG5202SC except assemblies 1014841 and 1015389 MG5202DC MG5203SC and MG5204SC Turn housing over so that the input side is up Install the input oil seal using tool T 18050 699 Clean tapered surface of output shaft and tapered bore of output gear Use OSHA approved cleaning solvent to remove all traces of dirt grease oil etc Wipe surface with clean paper towel Do not touch cleaned surfaces A CAUTION Tapered surface of shaft and matching tapered bore of gear must be completely free of
270. interference regardless of the cause of interference This engine crankshaft endplay check is considered mandatory The transmission housing flange and pilot the engine flywheel and the flywheel housing must be checked for trueness Make certain the engine flywheel and the flywheel housing are clean prior to making the tests 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 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 10 1 SECTION 10 10 2 Engine Runout Checks Also reference SAE J 1033 and J 617 1 Boltathousanaths increment dial indicator to the engine flywheel so that the indica tor is perpendicular to the face of the engine flywheel housing and the indicator stem is riding on the face of the flange See Figure 10 1 Fig 10 1 Checking flywheel housing flange for deviations Thousandths Indicator Engine Iz Flywheel Engine Crankshaft Engine Flywheel Housing fg 10 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 0 41 mm 0 016 in 10 2 SECTION 10
271. is blocked when either clutch is engaged This full pressure causes the rate of rise piston to remain against its stop in the valve body bore and main oil pressure is not reduced Detent position Trolling mode orifice closed orifice opened 1017555 1 Rotating the trolling valve lever into the trolling mode opens the variable orifice allowing some of the oil to escape from the rate of rise chamber to sump This reduces the oil pressure in the rate of rise chamber Since oil is always flowing into the rate of rise cham ber through the orifice in the orifice plate the pressure in the rate of rise chamber is con trolled by how much oil is allowed to exit through the trolling valve s variable orifice The Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 15 SECTION 3 trolling valve lever position determines pressure in the rate of rise chamber which determines main oil pressure Main oil pressure is always the same as the oil pressure in the engaged clutch with this type of trolling valve 3 6 Live PTO Optional The live PTO drives accessories using engine horsepower Since the live PTO connects the accessory to the primary shaft of the transmission via a direct coupling the accessory is driven when the engine is running 3 7 Hydraulic Clutched PTO Optional The hydraulic clutched P TO also allows accessori
272. isc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 6 11 SECTION 6 2 If rear bearing must be removed remove bearing retaining ring from rear end of shaft Remove the bearing as follows NOTE Do not remove rear bearing unless bearing must be replaced Bearing is an interference fit with shaft and will be destroyed during removal a With a hammer and chisel cut cage off bearing to remove bearing cage and rollers b Usea split type bearing puller cheese cutter to grip flange at small end of tapered inner race c With a hydraulic jack pull on bearing inner race while pushing on rear end of shaft to remove bearing inner race from shaft Set shaft upright with input end up 4 Remove and disassemble pinion s a Remove round retaining ring from input end of shaft and remove pinion from shaft b Remove internal retaining ring from input end of pinion and remove straight roller bearing 6 12 SECTION 6 Disassembly Disassembly c Remove tapered roller bearing outer race from bore at rear of pinion if bearing requires replacement This bearing race is an interference fit in the pinion bore To remove use an electric welder to weld a light bead around the 1 0 of the bearing race This will shrink the bearing cup to facilitate removal Bearings removed with this method must be replaced Remove tapered roller bearing inner race from shaft Bearing supports rear of pinion This bearing is a slip fit an
273. iston is stopped by a shoulder in the valve body This causes the pressure in chamber B to rise to clutch engaging pressure When in primary passage E remains at atmospheric pressure because slot F remains open to sump When a shift is made from primary to neutral the valve stem is rotated to the position illustrated by Figures 3 1 and 3 2 Under these conditions passage D is connected to sump by slot F Passage J also is connected to sump by port H in the valve stem Because passage D is connected to slot F oil drains rapidly from the primary clutch to sump Because passage is now at atmospheric pressure the oil pressure in chamber L unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The primary clutch is now disengaged and main system pressure reduced to neutral pressure PRIMARY a Control x Valve Body Clutch Control Valve Stem Atmospheric Pressure Engaging Pressure 03 pix Fig 3 3 Control Valve Primary Sectional View SECTION 3 Operation Operation A Oil Entry Passage B Oil Pressure Chamber High Pressure C Oil Pressure Overflow Port Regulator Piston D Oil Engaging Passage E Oil Engaging Passage Rate of F Oil Interconnection Slot 4 Rise Piston G Oil Directional Port Y H Oil Connec
274. leaned surfaces CAUTION Tapered surface of shaft and matching tapered bore of gear must be completely free of grease oil dirt or solvent residue Failure to properly clean mating parts could prevent proper advance of gear on shaft and adversely effect torque carrying capacity of the as sembled joint Preassembly procedure to determine advance during assembly of output shaft and gear A Stand output shaft upright withh front end up splined end down Mea sure distance from front end of shaft to to shoulder at large end of taper Record this distance as dimension C See fig 9 4 B Measure width of output gear at tapered hub Record this distance as dimension B See fig 9 5 Fig 9 5 Fig 9 4 C Seat output gear on taper of output shaft Apply 890 N to 1340 N 200 lbs to 300 Ibs of thrust on gear to seat gear on shaft taper Measure distance from front end of shaft to face of gear hub Record this distance as dimension SECTION 9 Assembly Assembly D Calculated expected advance C A B Calculated advance should be 3 04 mm to 3 86 mm 0 120 in to 0 152 in See fig 9 6 OUTPUT SHAFT OUTPUT GEAR Fr Fig 9 6 NOTE Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be neces sary to change parts Con
275. lies 9 Installthe spring and check ball orifice plate gasket Install the orifice plate with the chamfered side of the hole check ball seat toward the check ball Install the cover gasket cover and attaching screws Torque the screws to specification see Torque Chart 8 2 1017390 or 1018084 Electric Control Valve Remove valve from transmission and separate the valve body halves Remove the gasket from the valve body half A Disassembly of lower valve body half manual section CAUTION Steel ball is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Remove orifice plate cover and gasket 2 Remove orifice plate 3 Remove steel ball and neutral pressure regulating spring 4 Removeorifice plate gasket Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 5 Remove rate of rise piston See J 1 4 6 Remove pressure regulating springs 7 Remove pressure regulating piston with an external retaining ring pliers 8 Remove external retaining ring from the lever of the stem some models 9 Remove control lever from stem at the other end of the valve body 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 dam aged 10 Remove the external retaining ring from
276. ll oil filter Installation of Output Flange If your output shaft is splined follow these instructions 1 2 9 26 Heat output flange in 300 F 150 C maximum oven for a half hour to an hour Install heated output flange Assure that flange seats solidly against rear tapered roller bearing on output shaft With a depth micrometer measure distance from rear face of output flange to end of output shaft Record this distance as dimension A Measure distance from rear face of output flange to inner shoulder of flange against which retainer washer is installed Record this distance as dimension B Determine gap between retainer washer and end of shaft by subtracting dimension B from dimension A Fig 9 31 Use shims to develop a shim pack to reduce gap between retainer washer and end of shaft to 0 076 mm to 0 152 mm 0 003 in to 0 006 in Install O ring to seal output shaft splines and output flange Install shim pack developed in step 3 and retainer washer Install retainer SECTION 9 Assembly Assembly washer attaching screws and torque to specification see Torque Chart 6 Attach dial indicator to housing with probe resting on face of output flange Locate indicator probe as close to O D of flange as possible Check flange face runout by rotating flange Total indicated runout must not exceed 0 10 mm 0 004 in 7 Attach dial indicator to housing with probe resting on O D of output flange pilot
277. me as for the secondary shaft Repeat above procedure in steps 1 through 18 Install forward tapered roller bearing cones for primary and secondary pinions SECTION 9 Assembly Assembly onto cups previously installed in bearing bores in front of transmission housing Fig 9 23 16 Install primary and secondary shaft assemblies into the transmission housing Fig 9 24 9 8 Installation of Bearing Carrier 1 Install bearing carrier gasket over dowels onto rear face of housing Install with silicone beaded side up 2 Assemble lube relief valve spring and lube relief valve steel ball into lube relief valve housing Attach assembled lube relief valve to inner face of bearing carrier Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 21 SECTION 9 with the screws and washers Torque the screws to specification see Torque Chart 3 Install two alignment studs into face of transmission housing Install bearing carrier over studs and onto dowels in housing face Use a soft hammer near the dowels to seat carrier against gasket and over dowels Fig 9 25 4 Install lube tube through hole in bearing carrier and into machined pocket in front inner face of housing Rotate tube so elongated key of tube fits into corresponding key in bearing carrier Properly installed lube tube will be flush with rear face of bearing carrier TY Fig 9 26 9 22 SECTION 9
278. mp assembly Damaged wiring to control valve Clogged or plugged orifice in orifice plate of control valve assembly Shimming required between regulator springs and rate of rise piston Engine idle speed too low Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive on reverse clutch shaft broken Regulating valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost overboard SECTION 5 Troubleshooting Remove and clean oil strainer Disassemble valve and clean piston amp spools Remove the collector and inspect piston rings Replace broken piston rings Replace damaged or worn oil pump assembly pump is not serviceable Replace damaged or worn wiring 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 t 5205 06 Troubleshooting High main oil pressure High temperature Excessive noise 3 1 Regulating valve stuck Improperly shimmed Lube relief valve malfunction Improper oil level high or low Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control
279. n Sump Pye LEVER LOCKED CLUTCH ENGAGED ELECTRIC i B OPERATION H A illl wi ROR Orifice T ROR Orifice j j i rz a KSSS a LIT Id EA D LN 2 SU H Ai EZ 3 PET HI Ez aN EK mu 4 k elle EN NS D SS SEN CLUTCH ENGAGED Si SS 4 LZ 7 7 da m MANUAL ELECTRIC MANUAL VALVE FUR MG 9509 THRU MG 61242 apply 444 444 INTERMEDIATE REFERENCE VALVE ASSEMBLY 10180840 PRESS LUBE is ise aH MAIN PRESS TT TL T sie A 119W SUMP 9314 2799 _ ae al DIAGRAM HYDRAULIC ame wo me ee sa CWITHQUT TROLLING VALVE CO _ METRIC ELECTRIC 1 Electric Manual valve for MG 509 thru 61242 pw REFERENCE VALVE ASSEMBLY 1018084 SHOWN WITH CLUTCH Clutch A ENGAGED Clutch Solenoid Solenoid Solenoid ASCO SHOWN WITH CLUTCH A ENGAGED Neutral Clutch Neutral A Solenoid Solenoid Solenoid Solenoid ASCO Solenoid WITH HYDRAULIC LOCK WITH HYDRAULIC LOCK
280. ncurred by this procedure Twin Disc Incorporated having stipulated the bill of material number of the unit s name plate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old emanating from any of the above stated changes will not be accepted for credit Furthermore any equipment that has been subjected to such changes will not be covered by a Twin Disc Warranty 1 5 Source of Service Information This manual is current at the time of printing When required changes are made to reflect advancing technology and improvements in state of the art Individual product service bulletins are issued to provide the field with immediate notice of new service information These service bulletins are distributed to all Twin Disc distributors throughout the United States and in many foreign countries For the latest service information on Twin Disc products contact any Twin Disc distributor 1 6 Warranty Twin Disc marine transmissions have a warranty which can be found at the front of this manual For details of the warranty contact any Twin Disc distributor service dealer or the Warranty Administration Department Twin Disc Incorporated Racine Wisconsin U S A Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 1 3 SECTION 1 THIS PAGE INTENTIONALLY LEFT 14 S
281. ndicator tip so that it will ride on the driving ring pilot bore of the engine flywheel See Figure 10 4 Fig 10 4 Checking flywheel pilot ring bore eccentricity Engine Flywheel Housing Thousandths Indicator Engine Y Crankshaft Flywheel fg 10 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 10 4 SECTION 10 Installation Installation 10 3 Installation A Alignment Proper alignment of an engine and marine transmission is critical both during the initial installation and at frequent intervals during the life of the boat It is rather common for a boat to change its form with various loads and with age Engine and shaft alignment can also change on a boat due to varying loads and the boat s age The following steps may be taken to secure proper marine transmission alignment When reinstalling a marine gear after a repair or when installing a new marine gear to an engine already mounted in the bedrails the flywheel housing should be checked for deflec tion using the following procedure Install the mounting brackets on the side mounting pads of the marine gear Install the driving ring on the engine flywheel Bolt an indicator to the engine block and set the indica tor stem on the engine flywheel housing Fig 10 6 Checking for housing deflection Indicator Indicator Stem Y Marine Gear Support
282. nected to sump by port H in the valve stem Because passage E is connected to slot F oil drains rapidly from the secondary clutch to sump Because passage J is now at atmospheric pres sure the oil pressure in chamber L unseats the steel ball against the compression spring permitting a rapid oil drain from chamber L to sump and allowing the pressure rate control piston to move back against the orifice plate The secondary clutch is now disengaged and main system pressure reduced to neutral pressure SECONDARY Control Valve Body To Secondary Clutch Control Valve Atmospheric Pressure Engaging Pressure 05 pix Fig 3 5 Control Valve Secondary Sectional View SECTION 3 Operation SECTION 3 3 4 Manual Control Valve Primary When a shift to the primary position is desired the control valve lever is moved The shift causes the control valve stem to rotate and assume the position indicated in Figures 3 3 and 3 4 The pressurized oil in chamber B is directed through ports G and K to passages D and J Passage D is aligned with a passage directing main pressure oil to the primary clutch Pressurized oil from port K travels through passage J and enters chamber L through an orifice in the orifice plate The orifice in this plate meters the oil for a steady smooth pressure rise in chamber L As chamber L fills with oil the pressure rate control piston moves against the springs until the p
283. ned grease CAUTION Never dry bearings with compressed air Do not spin unlubricated bearings bearings with SAE 10 engine oil immediately after cleaning Oil bearings before inspection B Preventing Dirt from Entering into Bearings Dirt and grit in bearings are often responsible for bearing failure consequently it is impor tant 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 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 7 1 SECTION 7 7 2 1 7 2 Previously Sealed Joints For previously sealed joints remove all 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 Inspection Housings Cast Parts and Machined Surfaces Replace cast parts or housings that are cracked Inspect bores for wear grooves scratches and dirt Remove burrs and scratches with crocus cloth or soft stone Replace deeply grooved or scratched parts Do not remove excess material by sanding This will cause loss of press of bearings or races
284. ntrol valve not seating properly Blown gasket on either side of orifice plate Pump flow output too low Pump suction strainer plugged Lube relief valve malfunction Broken piston ring Oil level too high Wrong type o oil 54 SECTION 5 Troubleshooting Remove clutch plate Overhaul unit Disassemble valve and clean spools Replace defective solenoid Inspect repair or replace hydraulic lock spool Disassemble control valve Clean parts Replace parts if necessary Remove orifice plate cover Clean parts Replace parts if necessary Replace gasket Replace pump Remove clean inspect and install the suction Screen Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Draw and refill with recommended oil t 5205 08 Disassembly Section 6 Disassembly 6 1 Prepare Transmission for Disassembly Note The following procedure is for complete disassembly of the unit Prior to this procedure the transmission should be removed from the boat The work should be done in a fully equipped facility by qualified personnel During service of this unit all O rings gaskets and seals must be replaced It is good practice to keep the old O rings gaskets and seals with the appropriate components being disassembled for future reference during the assembly process to make sure you don t forget the quantity size etc NOTE The
285. ol 3 12 SECTION 3 Operation Operation Since the dowel pin used at the return spring side of the spool is larger in diameter than the dowel pin inside the spool the hydraulic force acting on the larger pin forces the spool to connect the clutch passage to sump with assistance from the return spring Dowel pin Return spring Mvc 012a Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 13 SECTION 3 3 14 E 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 pres sure 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 Mvc 013a Main pressure oil can flow through the hole in the end of the stem to a narrow slot between the two pockets This slot does not connect to any
286. onnects with slot F This area between pistons and around springs is vented to the sump of the transmission This area is at atmospheric pressure at all times permitting the return to sump of any leakage oil past the pistons NEUTRAL Control Valve Body Forward Clutch To Sump Clutch Y i Control Valve Stem Es Atmospheric Pressure Engaging Pressure 0 1 Fig 3 1 Manual Control Valve Neutral Sectional View 3 2 SECTION 3 Operation Operation A Oil Entry Passage High Pressure B Oil Pressure Chamber A Regulator Piston C Oil Pressure Overflow Port D Oil Engaging Passage k M E Oil Engaging Passage m F Oil Interconnection Slot G Oil Directional Port H Oil Connection Port J Oil Pressure Passage K Oil Directional Port L Oil Pressure Chamber Control Valve Lever J Piston Springs Control Valve Stem Control Valve Body Atmospheric Pressure Es Engaging Pressure Fig 3 2 Manual Control Valve Neutral Cutaway View Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 3 Operation A Oil Entry Passage High Pressure B Oil Pressure Chamber Regulator Piston C Oil Pressure Overflow Port D Rate of D Oil Engaging Passage Rise Piston E Oil Engaging Passage F Oil Interconnection Slot G Oil Directional Port H Oil Connection Port J Oil Pressure Passage K Oil
287. ont bearings on primary pinion secondary pinion and output shaft are an interference fit in their respective bearing bores Remove these bearing cups only if replacement is required To remove these bearing cups weld a light bead around the 1 0 of the bearing cup with an elec tric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced If your unit is a MG5202SC assembly 1016103 a MG5202DC a MG5203SC or a MG5204SC follow these instructions 1 Remove four gear pan attaching screws and sealing washers Remove gear pan from transmission housing 2 Lay transmission on blocks with the output side up Leave at least 50mm 2 inches clearance between housing and floor 3 Remove output shaft seal carrier TUS Fig 6 10 Remove O ring and oil seals from seal carrier 4 Remove shims from output bearing bore of housing Shims on a MG5202DC are located between the output seal carrier and the housing 5 Useahoist to lift output shaft and gear assembly until gear contacts housing Place blocks under gear to support it in a position where a bearing puller can be used to remove the tapered roller bearing cone from the output shaft see fig 6 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 6 9 SECTION 6 12 Remove the bearing from above the bearing cone Remove the bear ing cone from the output shaft by pulling on the cone and pushing on
288. other passages when the stem is in the Neutral position When lever and stem are rotated to 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 SECTION 3 Operation Operation 3 5 Trolling Valve Optional The trolling valve is used to reduce and control propeller speed below that normally at tained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure to reduce the propeller speed A 1017555 Trolling Valve manual This trolling valve is a variable orifice that controls the pressure in the rate of rise cham ber The pressure in the rate of rise chamber determines the rate of rise piston posi tion which ultimately controls the main and clutch pressures for the transmission When the trolling valve lever is in the detent non trolling position the orifice in the trolling valve is closed Oil cannot exit from the rate of rise chamber through the trolling valve s orifice and the rate of rise chamber is fully pressurized the ball and spring regulator
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290. pecial Tools 11 8 Special Tools Driver T 18050 609 11 9 SI 3NIOV8M 435 00280MW 2514 3190 0119149 5 davHS 119 I 10 33HS 403 TT 3NVN 1925 66 70 9291 3215 73015 114142530 834 130 SJAISG 5 WI STIVA H 1 77 1 dN 979 00 G Y 1 609 0S0811 3114 avo DAL NDISN3WIQ 3997 031410395 3SI B3HID SS37ND 3ONVN37D SH3NHUO TIV 3E UN LYVe UN TOOL dWvis 11 9 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC 11 Bearing Driver T 18050 610 612 11 10 NULLdIN2S3Q C 3 v amp 130 9 2 1 v TEENE 1987 ASSY B3AIMO ONINV3E yoy A8 96 9390 0114142530 VN 3130 T sa S 3NID3 39356 8 3598 31180 SW vat S a V 2 45 3SIAS83HID SSIINN ALON 162 II 73 066 VW FEE 981 6 6 4 29 066 857 dno 3 WIG wid 3 Wid amp Wid n p i So E
291. perating condition is not recommended 2 35 F Minimum 66 93 150 185 F SAE 40 10 C 50 F Minimum 80 93 175 200 F SAE 50 Above 93 200 This operating condition is not recommended 5205 04 Minimum Clutch Thickness Minimum recommended clutch friction plate thickness is 2 90mm 0 114 inch Minimum recommended clutch steel plate thickness is 2 29mm 0 090 inch SECTION 4 Specifications and Maintenance Specifications and Maintenance J Heat Exchanger Requirements PERMISSIBLE OIL TEMPERATURE INTO HEAT EXCHANGER Ratio Oil Viscosity Max Min All SAE 40 85 1859 F 65 1509F All SAE 50 93 C 2009 80 C 1759F MIN HEAT TRANSFER CAPACITY KW BTU MIN PER ENGINE Apply appropriate service factor Continuous Duty 026 1 484 for fresh and raw water P C amp Int Duty 022 1 272 Approx Oil Flow to H E 3 82 L Min 1 01 gpm per 100 Engine rpm Peak Oil Pressure at H E Proof Test H E at 1 5 X kPa psi 2840 kPa 412 psi Max Oil Pressure Drop Across with 66mm sec 300 SUS at Rated Engine rpm 207 kPa 30 psi Water Flow to H E Use 1 5 to 3 0 Times Oil L Min gpm H E Water Pressure Rating Min 1 5 X H E Inlet Water kPa psi DATA H E PURCHASER MUST ALSO TELL VENDOR State if raw open channel amp sea or fresh closed keel cooler water will cool H E State max water temp into H E Typical Raw water 29 C 85 F
292. perty For mechanical controls Movement of the operator s selector lever to forward neutral or reverse must position the transmission selector valve in the forward neutral or reverse detent position Power operated 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 of the selector valve stem Selecting neutral must place the selector valve in the neutral detent position Improper installation of power engaging devices could cause failure of the selec tor valve rotational stop permitting improper positioning of the selector valve and resulting in control malfunction See specific marine transmission installation drawings for detail and dimensional information needed for proper installation of power engaging devices SECTION 10 Installation 11 0 11 2 11 3 11 4 11 5 11 6 11 7 11 8 11 9 11 10 11 11 11 12 11 13 11 14 11 15 11 16 11 17 11 18 11 19 11 20 11 21 11 22 11 23 11 24 11 25 11 26 11 27 11 28 11 29 Special Tools Section 11 Special Tools List of Special Tools SKF Air Driven Pump Set THAP 300 Bearing Driver T 18050 96 Bearing Cup Driver T 18050 116 Seal Drive e au N a
293. products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Renewal Parts and Service Parts Kits may be obtained from any authorized Twin Disc distributor or service dealer They can be found under POWER TRANSMISSION EQUIP MENT in the Yellow Pages of most metropolitan telephone directories or contact Twin Disc for the nearest distributor 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 Follow these instructions to order parts 1 Specify the model bill of material and serial number of the unit involved These numbers are stamped on the unit s nameplate 2 State exactly each item required using the part number from the BOM 3 Specify the quantity of each part required SECTION 1 Introduction Introduction 4 Furnish the complete shipping destination and postal address All parts ship ments made from the factory will be F O B factory location U S A 5 State specifically whether the parts are to be shipped by freight express etc If shipping instructions are not specified on the order the equipment will be shipped the best way considering time and expense Twin Disc Incorporated will not be responsible for any charges i
294. pull output flange from output shaft Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 6 If your output shaft is tapered follow these instructions 3b Connect oil injector to output flange hub 3c Install two eyebolts with nuts into the holes of the output flange Install one eye bolt into each of the side mounting pads of the transmission housing 3d Install a safety strap through the eyebolts in the output flange and attach the strap s ends to the eyebolts in the housing The parts separate with EXTREME force potentially causing great physical harm Use EXTRA CAUTION and proper safety procedures Inject oil with a viscosity of 900 mm S 900 cSt at room temperature dismount ing fluid into the output flange hub until it separates from the output shaft taper 6 4 Remove and Disassemble Manifold and Bearing Carrier 1 Remove capscrews securing manifold and bearing carrier to housing 2 Use two of the removed screws as pusher screws to separate manifold from bearing carrier and dowel pins Remove manifold and gasket Remove the manifold bushings and O rings used on some models check unit Bill of Mate rial for usage 3 Remove bearing retainers and shims from bearing bores in bearing carrier for primary and secondary shafts 4 Removeinternal retaining ring and filter bypass valve 5 Remove lubrication tube from bearing carrier 6 X Use two of the removed screws as p
295. r part without the prior written consent of Twin Disc Incorporated The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorporated The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal and otherwise identical with components of the original equipment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated As consideration for this warranty the original customer and subsequent purchaser agree to indemnify and hold Twin Disc Incorporated harmless from and against all and any loss liability damages or expenses for injury to persons or property including without limitation the original customer s and subsequent purchaser s employees and property due to their acts or omissions or the acts or omissions of their agents and employees in the installation transportation maintenance use and operation of said equipment Only a Twin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or
296. r to Assembly 1 Place all tapered roller bearing cones in a 120 C 250 F oven for a minimum of one hour prior to installation 2 Submerge all new friction clutch plates in transmission oil for a minimum of one hour prior to installation 3 Place the cups for the front pinion bearings on the primary and secondary pin ions and the cups for the front and rear tapered roller bearings on the output shaft in a deep freeze 51 C 60 F for at least two hours prior to assembly NOTE In the discussion that follows the input side of the transmission is the front and the output side is the rear Left and right sides are deter mined by facing the output side of the transmission 9 2 Assembly 1 Lay the transmission on blocking with rear side up 2 Install dust plug into input shaft front bearing area using a soft hammer 3 Install chilled cups for front tapered roller bearings on primary and secondary pinions into bores in front inner face of housing Use driver T18050 610 to press drive cups to bottom of bore 9 2 SECTION 9 Assembly Assembly 4 Measure and record the distance from the machined surface of the housing to the bottom of the bearing cup bore where the oil shield contacts dimension A Measure and record the thickness of the oil distribution shield at the outer edge dimension B Measure and record the width of the bearing cup dimension 5 Install oil distribution shield into output sha
297. shaft Transport housing and gear to the press Use care when transporting housing with output gear inside Keep housing level so gear does not slide out Failure to do so could cause damage to parts and or injury to personnel Fig 9 7 7 Lifthousing and output gear keeping them level over output shaft previously installed in fixture in press Lower housing and gear over output shaft so that shaft enters bores of housing and gear Lower housing approximately half way 8 Place tapered roller bearing small OD end up on front end of output shaft Keep housing level and lower until housing is resting on bearing 9 Center shaft housing under press keeping housing level Use tool T 18196 6 through bore in housing at front end of output shaft to push bearing onto shaft Lower housing as pressure is applied to bearing After bearing is fully seated against gear continue applying pressure to approximately 890 kN 100 tons Release pressure on bearing and turn gear and shaft 180 Reapply pressure up to 810 kN to 1210 kN 91 tons to 136 tons to complete advance of gear onto output shaft Release pressure and use taper gauge or feeler gauge to assure that gear has been advanced to within 0 05 mm 0 002 in of shaft shoulder NOTE If gear has not been advanced to within 0 05 mm 0 002 in of shaft shoulder proceed as follows A Install a dial indicator with probe contacting a machined surface of the output gear face Zero the indic
298. shed to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of shipment by Twin Disc Incorporated to original customer but not to exceed twelve 12 months of service whichever occurs first This isthe or intended to be given by Twin Disc Incorporated The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering The exclusive rem Incorporated be either the repair or replacement of any T win Disc Incorporated part or Disc Incorporated to be defective and the labor to rm that work and to remove and reinstall or equivalent credit In this context labor is defined asthe flat rate labor hours established Twin Disc Incor i Incorporated be liable for economic loss incidental punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident The warranty is void if any modifications are made to any product o
299. ssembly 1 Remove the trolling valve attaching screws 1017555 2 Steel ball is under pressure from the spring Care must be taken when removing the trolling valve and orifice plate to prevent loss of steel ball 2 Remove the trolling valve from control valve 3 Remove the gaskets orifice plate and steel ball from control valve 4 Removethe screw and nut clamping the lever to the stem 5 Remove the lever from the stem It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 6 Remove the detent setscrew spring and detent ball 1017555 4 8 12 SECTION 8 Subassemblies 8 11 Remove the washer from the bore of the housing some models Note the washer may have been removed with the stem and adapter assembly 12 Remove the outer spring and piston from the bore of the housing Note that there may be washer s in the bore of the piston some models 0203 03 13 Remove the O ring from the groove and the oil seal from the end of the adapter 1017555 10 CLEANING AND INSPECTION See Section 7 B Assembly 1 Press anew seal into the counterbore in the end of the adapter Install new O ring into the groove of the adapter 8 14 SECTION 8 Subassemblies Subassemblies 7 Removethe dog point setscrew from the valve body 101755560000 8 Remove the stem
300. t Capscrews Bolts and Nuts Torque N m for Coarse and Fine Threads As Received Nominal SAE Grade 5 SAE Grade 8 Thread Lem 25 8 19 28 5 21 36 6 27 100 7 141 104 163 120 Note Use these torque values for all capscrews bolts and nuts coated only with the manufacturer s rust preventative oil and use for all parts wiped or washed nearly free of oil Do not use for plated parts 124 SECTION 12 Torque Charts Torque Charts 2 of 2 Torque Values for U S Standard Unit Capscrews Bolts and Nuts Torque N m Ibf ft for Coarse and Fine Threads Lubricated Nominal SAE Grade 5 Thread Diameter 3 8 so 95 37 54 40 58 85 70 113 83 111 82 122 90 133 98 163 58 163 120 176 130 190 140 224 278 205 305 225 332 245 529 793 585 emm 1491 1100 1607 1185 1 1 4 1152 850 1254 925 1356 1000 1864 1375 Note Use these torque values for all capscrews bolts and nuts whose threads and washer face are lubricated Also for screws or nuts whose washer face is assembled against a hardened washer or smooth finished part Rc 40 or above and 40AA max Also use for plated screws except zinc plated Lubricating the threads and screws or nut face with SAE 20 or 30 oil is recommended for best results for all Grade 8 screws 11 8 23 39 lt I jaz 2 T e
301. t setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn Install the steel detent ball into the valve body Install the detent spring over the detent ball Apply 908 threadlocker to the threads of the hollow setscrew and install into the threaded hole A stepped Allen wrench or one wrapped with tape will ease the installation of the hollow setscrew Tighten the setscrew until it is flush with the gasket surface of the valve body Check the stem rotation and detent action Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 9 8 8 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 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 705 Torque the cover capscrews to specification see torque chart Install washer over stem against oil seal Install spring s over stem against washer Install washer over stem against spring if equipped Install external retaining ring onto stem if equipped Install lever onto the stem It may be necessary to splay the lever to be able to
302. tact the Product Service Department at Twin Disc Incorporated for assistance NOTE Assembly of the output shaft and gear in a MG5202 SC transmission will require a press with at least 1557 kN 175 ton capacity A fixture to hold the output shaft in a rigid position perpendicular to to press bed during the assembly process must also be available The fixture specified in the instruc tions following fits a 1779kN 200 ton Enerpac press Shops possessing different equipment must design a similar fixture that will fit the equipment available Install press fixture T 18196 6 on bed of hydraulic press see note above Place output shaft in fixture with splined end down Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 95 Assembly output shaft B If gear is square on the shaft as confirmed by the dial indicator readings above apply additional press force up to 1557 kN to 1779 kN 175 tons to 200 tons to fully advance the output gear to the shaft shoulder Recheck to assure that the gear has been advanced to within 0 05 mm 0 002 in of shaft shoulder C If output gear cannot be advanced to shaft shoulder or if gear is cocked on output shaft contact the Product Service Department at Twin Disc Incorpo rated for further information Install retaining ring in groove at front end of output shaft some models Install with shamfer away from bearing Remove housing shaft and gear from press Use wood block
303. tandard 0 05 mm 0 002 in During the process of securing final alignment it may be necessary to shift the engine many times When it becomes apparent that the alignment is reasonably close mark and drill the holes for the lag studs Then with final alignment secured make up the necessary steel or hardwood shims and fasten the engine and transmission in place Then recheck the alignment and if satisfactory bolt the coupling together There are many types of flexible couplings in the market today that solve a variety of prob lems not just for noise and vibration In some cases the alignment of these couplings requires accuracy equal to that of rigid couplings Some couplings are made to allow a permanent angular misalignment while others allow engines to be flexibly mounted and take out the momentary misalignment Always use the alignment procedures recom mended by the coupling manufacturer A CAUTION Be sure the transmission is filled with oil before starting See Section 4 for proper oil and filling procedure Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 10 9 SECTION 10 10 10 Transmission controls must be checked for proper function and alignment after any transmission service is performed The selector valve must be 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 pro
304. the Product Service Department at Twin Disc Incorporated for informa tion recommendations 9 13 Installation of Transmission External Components 1 Assemble selector valve See Section 8 Subassemblies 2 Install selector valve gasket and ditch plate some models Torque capscrews to specification see Torque Chart unless torque is specified on selector valve Fig 9 33 Turn transmission over supporting it by the output side input side up 4 Coat input seal bore of housing and outside diameter of input seal with a thin film of M2828 anaerobic sealant do not apply excessive sealant as seal and or bearings may be damaged Verify that there is no M2828 sealant on primary shaft Apply a film of oil or assembly grease to the seal surface of the primary shaft most models Install input shaft oil seal into housing using appropriate driver protector driver T18050 696 T 18050 722 or T 21347 T 21347 1 tool usage depends on model Press oil seal into bore with the spring loaded lip of seal toward the inside of the housing Press seal into bore until outer face is flush with adjacent face of housing 5 Install front housing onto transmission housing Install attaching screws and torque to specification see Torque Chart Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 29 SECTION 9 Attach dial indicator to the input shaft spline using fixture T21302 1 with the probe on the front housing mach
305. the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when the unit is in the secondary position Secondary Clutch Engaged Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 19 SECTION 3 THIS PAGE INTENTIONALLY LEFT SECTION 3 Operation Specifications and Maintenance Section 4 Specifications and Maintenance 4 1 Specifications Frequent reference to this data and application of the information will result in better ser vice from the transmission A Oil Capacity 26 5 liters 7 0 U S gal for shallow case models 31 4 liters 8 3 U S gal for deep case models plus hoses and heat exchanger The transmission should be warmed to operating temperature when oil is checked B Oil Pump Capacity 88 Ipm 23 2 gpm at 2 300 rpm C Minimum Oil Pressure When Cruising Check transmission identification plate D Maximum Input Speed Maximum input speed is dependent on the input coupling Refer to transmission s installa tion drawing E Dry Weight WEIGHT MODEL NUMBER MG 5202SC DRAWING NUMBERS 1014841 578 kg 1 292 Ibs 1015389 580 kg 1 275 16 MG 5202SC DRAWING NUMBER 1016103 1016103A 10161035 931 kg 2 052 16 MG 5202DC DRAWING NUMBER 1015207 1032 kg 2 275 lbs MG 5202DC DRAWING NUMBER 10152074 4
306. the stem some models 11 Remove the washer if equipped and spring s from the stem 12 Remove the second washer from the stem 13 Remove the cover assembly from the valve body 8 4 SECTION 8 Subassemblies Subassemblies 14 Remove the O ring and oil seal from the cover assembly 15 Remove the two electrical switches from the sides of the valve body and the steel balls from each of the switch bores in the valve body some models 16 Remove the detent setscrew spring and steel ball from the valve body 718 17 Remove the dog point setscrew Note that the setscrew is retained with 908 threadlocker 716 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 5 8 18 Remove the stem from the valve body partially 19 Remove the thrust washer from the stem 723 20 Remove the stem from the valve body 21 Remove the roll pin retains the shuttle ball seat with a needle nose pliers e 732 22 Thread a M8x1 25 screw one the cover screws works well into the seat and remove it from the valve body 23 Remove the shuttle ball from the valve body B 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 conne
307. tion Port J Oil Pressure Passage K Oil Directional Port L Oil Pressure Chamber Control Valve Lever Valve Stem Control Valve L Atmospheric Pressure Engaging Pressure Fig 3 6 Control Valve Secondary Cutaway View Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 7 SECTION 3 3 4 Electric Control Valve Assembly A General Oil is pumped from the sump of the transmission and forced 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 lubrica tion 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 in the transmission to limit maximum lubrication oil pressure to approximately 100 psi The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation The pressure in the rate of rise chamber is controlled by a ball that is spring loaded against the orifice plate The passage behind the ball and spring is connected to the atmosphere in Neutral and to main pressure when either clutch is en
308. tness or damage such as cracks Tighten loose mountings and replace damaged parts 2 Check pressure and temperature gauge where applicable Inspect the oil lines and heat exchanger for leaky connections cracks or other damage Replace damaged lines 4 Periodically inspect the drive line and the input and output shaft oil seals for leak age Replace parts as required Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 4 9 SECTION 4 4 10 THIS PAGE INTENTIONALLY LEFT BLANK SECTION 4 Specifications and Maintenance Troubleshooting Section 5 Troubleshooting 5 1 Troubleshooting Chart The following chart is intended as a guide for determining the cause of problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be consid ered when problems are encountered Tables begin on the next page Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC 5204 5 1 SECTION 5 5 2 Low main oil pressure No oil pressure or erratic low pressure at control valve tap Partially clogged oil strainer Stuck pressure regulator piston or shuttle spool Broken piston rings on clutch shaft s Damaged or worn oil pu
309. to properly clean mating parts could prevent proper advance of flange on shaft and adversely effect torque carrying capacity of the as sembled joint 3 Coat the tapered surface with thin oil such as SKF mounting fluid 4 Place the output flange onto the output flange Seat flange onto the taper of the shaft using 1340 300 165 force Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 27 SECTION 9 9 28 Use gauge blocks and a feeler gauge to measure between the output shaft end and flange shoulder This is the potential advance The advance for the output flange 6 32mm to 8 13 mm 0 249 in to 0 320 in NOTE Should the calculated advance fall outside the range given above check to assure that all measurements and calculations are correct If no errors are found and the expected advance is out of tolerance it will be neces sary to change parts Contact the Product Service Department at Twin Disc Incorporated for assistance Connect the oil injector to the output flange Install tool T21397 onto output shaft to pull output flange onto output shaft Inject oil with a viscosity of 300 mm S 300cSt at room temperature mounting fluid into the shaft until it leaks out of both ends of the mating surfaces Tighten the screws to advance flange shoulder to shaft end while injecting oil Release injection oil pressure between the mating surfaces and wait five min utes before removing tool T21397 C
310. tor MATING WIRING HARNESS 1017404 BALL 1990 SCREEN 221336 T M8 X 1 25 6 lt gt x 7 PORT SOLENOID MANUAL DVERRIDE 364 WEEN NNN VES PORT SOLENOID POSITION 55 5 NUT M2027C ELECTRIC 247 SS 3t STEM 1017901 PORT A CONTROL SNS SN HA SEAL 5591 THESE SOLENOID CONNECTIONS PASITION POSITION T LN FANAN HN ANNI SN H ADAPTER 1017530 ARE PDLARITY SENSITIVE ZZ ENS Ail SEAL 778 2 BALL 19900 Y ai SS EAA E QY SPRING 10504 6 ZZ 7 5 542 SETSCREW 2041 TO a 022040 366 Dis P ELI 1 CALA 4 S VV 2 RING A29 _ Eme PIN PM 3036 M q ANN WAS 1 CONNECTOR SHROUD 1001434 Mase N NEN SPRING A2701BM OK d pe NE WAKES 222 1222 a SPRING A2701BN S NS 275 PT 5 SSS SS y KA O VAL D RING MA379CP ey ee OO POPUL IOS VALVE BODY 1017529 SNES SNAP RIN EE POSITION ap SCREW SPRING 2705 T OPERATING LIMITATIONS SWITCH MA866A APPLY MA895 THREAD SEALANT WITH TEFLON 9 TO THREADS TORQUE 300 Ibf f t 40 7 N m USE ENGINE IDLE RPM FOR MIN VESSEL SPEED Tum Wi ES usa 0915 1042 45 D RING 2916
311. usher screws again to separate bearing carrier from housing Remove bearing carrier and gasket 7 Remove tapered roller bearing cups from bearing carrier for rear bearings for primary and secondary shafts 8 Remove lube relief valve housing relief valve spring and steel ball 64 SECTION 6 Disassembly 6 5 Remove Primary and Secondary Shafts 1 Lift out primary and secondary shafts d QM T Fig 6 5 Disassembly NOTE Tapered roller bearing cups of front bearings on the primary and secondary shafts are an interference fit in the housing Removal of these bearing cups should not be attempted unless replacement of the bearing is necessary 2 Remove front pinion tapered roller bearing cones and spacer shallow case units only that were pulled off by output gear as primary and secondary shafts were removed NOTE Spacer used on 3 48 1 ratio transmissions only will be pulled off with tapered roller bearing cones 3 Remove gauge and oil gauge tube assembly 4 Position transmission upright Support securely Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC SECTION 6 6 6 Remove Output Shaft and Gear If your unit is a MG5202SC assembly 1014841 or 1015389 follow these instruc tions 1 Remove four gear pan attaching screws and sealing washers Remove gear pan from transmission housing 2 Lay transmission on blocks with the output side up Leave at least 5
312. vl 651 851 SEL ZEL LEL 051 621 821 Zet 921 Gel ect Lol 021 81 uonduoseq Jd c0cs9IN SECTION 13 Illustrations 13 14 Illustrations REN f XN N 9 ED NE e AN 2 SO P S A MS Ca 2 S o N 4 2 NU N N QN two s G AN N N wey Ve Nx MS 597 Za 220 ume gt 8 AB 8 Twin Disc Service Manual MG 5202SC MG5202DC MG5203SC MG5204SC gt JCN Nm N 13 15 SECTION 13 THIS PAGE INTENTIONALLY LEFT 13 16 SECTION 13 Illustrations 13 07 CONTROL VALVE GROUP g ii A 3 4 gt LJ Ec NEUTRAL SOLENOID 5 SECTION B WINN D gt EC A KD A Lal ANOS 9 E 222220 atta Z Ze PARTS FOR UNITS WITH
313. w that normally attained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure allowing the clutch plates to slip to reduce the propeller speed K PTO Optional The PTO is used to power accessories using horsepower from the engine The PTO accepts a SAE 4 pump Two types of PTO s are available a live PTO and a hydraulic clutched PTO Live PTO The live PTO rotates in the same direction as the engine at engine speed all of the time This PTO is a direct connection to the primary shaft of the marine transmission Hydraulic Clutched PTO The hydraulic clutched PTO is connected to the primary shaft of the transmission When oil pressure is applied to the clutch the PTO rotates in the same direction as the engine and at engine speed When the clutch does not have oil pressure appled to it the PTO does not transmit power L Trailing Pump Optional The trailing pump supplies oil to the lubrication circuit of the transmission for windmilling backdriving situations This remote mounted pump with oil to air heat exchanger is electrically powered 2 3 SECTION 2 Description Description THIS PAGE INTENTIONALLY LEFT BLANK Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 2 4 Operation Section 3 Operation 3 1 General The control valve obtains primary neutral and secondary positions When these positions are selected the control valve directs high pr
314. y Pressurized oil is directed to one of the transmission s clutches to engage it The pressur ized oil in the clutch port of the engaged clutch acts on the shuttle ball sealing off the pas sage 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 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 3 9 Operation D 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 Mvc 006a Main pressure oil flows from the spools above to the clutch passages of the transmis sion 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 Mvc 006b Twin Disc Service Manual MG 5202SC
315. y clutch locks the secondary pinion to the second ary shaft causing the pinion to turn in shaft direction and causing the output shaft to rotate in engine direction 2 3 Construction Features A Housings The MG 5200 series transmission has a one piece main housing Front housing sizes in SAE No 0 and SAE No 1 sizes are available A top cover bearing carrier rear mani fold sealed with gaskets completes the housing enclosure SECTION 2 Description Description B Primary and Secondary Pinion and Shaft Bearings The primary and secondary clutch shafts and pinions are supported and located by a combination of straight and tapered roller bearings Bearing clearances for each clutch shaft and pinion are set by use of a single shim pack at the rear tapered roller bearing on each shaft Tapered roller bearings also support the output shaft and have bearing clearance adjusted by use of shims C Oil Pump Drive The oil pump is tang driven by the secondary clutch shaft D Lubrication Features The MG 5200 series transmission has a lubrication tube located inside the main hous ing The tube extends from the front to the rear of the inside of the housing The lubri cation tube has drilled holes in the tube that spray oil on the transfer gears and the primary and secondary pinions Bearings and clutches on the primary and secondary shafts are lubricated through drillings in the shafts Output shaft bearings are gravity and splash lubricate
316. y impact force to the lever as the stem or dog point setscrew might get damaged Rotate the lever if necessary on the stem to the position shown on the valve installation drawing see Section 14 10 Install the screw and nut to clamp the lever to the stem Tighten the screw and nut to specification see Torque Chart SECTION 8 Subassemblies Subassemblies 14 Installthe neutral pressure regulating spring into the bore of the control valve if removed 15 Installthe steelballontothe neutral pressure regulating spring 1017555 14 16 Install the orifice plate gasket orifice plate trolling valve gasket and trolling valve onto the control valve Install the attaching screws and torque them to specification see Torque Chart 1017555 3 1017555 17 Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 8 17 8 8 18 THIS PAGE INTENTIONALLY LEFT SECTION 8 Subassemblies Assembly Section 9 Assembly NOTE The MG 5205SC except assemblies 1014841 and 1015389 MG5202DC MG5203SC and MG5204SC require the use of an SKF THAP 300 Oil Injection Kit see Section 11 Special Tools or similar device to assemble the output shaft NOTE The illustrations used in this manual are of the MG5202SC transmission Mg5202DC MG5203SC and MG5204SC transmissions are similar Twin Disc Service Manual MG 5202SC MG 5202DC MG 5203SC MG 5204SC 9 1 SECTION 9 9 1 Prio

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