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Twin Disc MG-5170DC, Service Manual

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Twin Disc MG-5170DC Service Manual Download Page 6

TWIN DISC, INCORPORATED

FLAT RATE HOUR ALLOWANCE

(Hourly Labor Rate Must be Acceptable to Twin Disc, Incorporated.)

COMMERCIAL MARINE TRANSMISSIONS - ALL RATIOS:

MODEL SERIES

R&R

UNIT REBUILD

 

CLUTCH

 

REPAIR

(BOTH PACKS)

MG 502, MG 5010, MG5011, MG5005A
MG5015A

10.0

8.0

 -

MG 506, MG5061, MG 5050, MG5055A

10.0

11.0

 -

MG 507, MG 5081, MG5085, MG5090,

10.0

12.0

-

 MG 5091

10.0

12.0

 4.0

MG5112,MG5113

10.0

17.0

-

MG 509, MG 5111, MG5114

10.0

17.0

4.0

MG5114A, MG5114RV

10.0

17.0

-

MG 514C, MG514M, MG5141, 
MG514CHP

10.0

25.0

6.0

MG516, MG5161, MG5170DC

10.0

28.0

8.0

MG 518-1

10.0

32.0

10.0

MG520-1, MG 5202, MG5203, MG5204

10.0

32.0

10.0

MG5205

MG 530, MG530M, MG5301

12.0

32.0

16.0

MG 540

20.0

62.0

20.0

MG5600

20.0

62.0

20.0

MG6000

10.0

32.0

10.0

MGN80, MGN232, MGN233, MGN272,
MGN273, MGN332, MGN334, MGN335,
MGN432, MGN433, MGN472, MGN493

10.0

32.0

10.0

MGN650, MGN800,MGN1000,MGN1400,
MGN1600

20.0

62.0

40.0

PUMP  - ALL MODELS

1.0           

            

-

VALVE  - ALL MODELS: 

1.0 

           .5

September 4, 2001                                                     

                                         TDWP2003A

Summary of Contents for MG-5170DC

Page 1: ...nual Marine Marine Marine Marine Marine T T T T Tr r r r ransmission ansmission ansmission ansmission ansmission Document Number 1020667 TWIN DISC TWIN DISC TWIN DISC TWIN DISC TWIN DISC INCORPORA INCORPORA INCORPORA INCORPORA INCORPORATED TED TED TED TED Components MG 5170DC ...

Page 2: ... 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 ...

Page 3: ...Document Number 1020667 July 2002 Marine Transmission Service Manual ...

Page 4: ......

Page 5: ...y repair 2 The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared f...

Page 6: ...12 MG5113 10 0 17 0 MG 509 MG 5111 MG5114 10 0 17 0 4 0 MG5114A MG5114RV 10 0 17 0 MG 514C MG514M MG5141 MG514CHP 10 0 25 0 6 0 MG516 MG5161 MG5170DC 10 0 28 0 8 0 MG 518 1 10 0 32 0 10 0 MG520 1 MG 5202 MG5203 MG5204 10 0 32 0 10 0 MG5205 MG 530 MG530M MG5301 12 0 32 0 16 0 MG 540 20 0 62 0 20 0 MG5600 20 0 62 0 20 0 MG6000 10 0 32 0 10 0 MGN80 MGN232 MGN233 MGN272 MGN273 MGN332 MGN334 MGN335 MGN...

Page 7: ...anty 16 Description and Specifications 17 General 17 Power Ratings 18 Construction Features 19 Lubrication Features 20 Specifications 23 Optional Equipment 25 Torque Values for Fasteners 30 Operation 33 General 33 Hydraulic System with Manual Control Valve 34 Hydraulic System with Optional Electric Control Valve 42 Trolling Valve Optional 52 Power Take off Optional 55 Trailing Pump Optional 56 Pow...

Page 8: ...lf electric section 102 1017555 Trolling Valve Optional Equipment 104 Cleaning and Inspection 109 Cleaning 109 Inspection 111 Assembly 115 Prior to Assembly 116 Preliminary Assembly 117 Installation of Output Shaft and Gear 119 Installation of Output Shaft Rear Bearing 121 Output Shaft Tapered Roller Bearing Adjustment 122 Assembly and Installation of Primary and Secondary Shafts 126 Installation ...

Page 9: ...r T 18050 321 190 Bearing Driver T 18050 323 191 Bearing Driver T 18050 327 192 Bearing Driver T 18050 335 193 Bearing Driver T 18050 585 194 Bearing Driver T 18050 611 195 Oil Injection Tool T 18614 5 196 Spring Retainer Hold Down T 19998 197 Output Gear Shaft Puller for Assembly T 20023 Sheet 1 198 Details for Puller T 20023 Sheet 2 199 Details for Puller T 20023 Sheet 3 200 Sleeve for Runout Ch...

Page 10: ...sheet 2 of 4 Marine transmission 232 1017463 sheet 3 of 4 Marine transmission 233 1017463 sheet 4 of 4 Marine transmission 234 1017463A sheet 1 of 4 Marine transmission 235 1017463A sheet 2 of 4 Marine transmission 236 1017463A sheet 3 of 4 Marine transmission 237 1017463A sheet 4 of 4 Marine transmission 238 A7119V Hydraulic diagram 239 XA7371 Mechanical Control Valve 1017463 assemblies 240 10204...

Page 11: ...Operation and maintenance personnel responsible for this equipment should be familiar with this publication and have it at their disposal A thorough understanding and application of the material in this manual will result in consistent performance from the unit and help reduce downtime Safety and General Precautions General All personnel servicing this equipment should employ safe operating practi...

Page 12: ... transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a shaft brake or other shaft locking device must be used To prevent accidental starting of the engine when performing routine transmission maintenance disconnect the battery cables from the battery and remove ignition key from the switch Most Twin Disc products have provision...

Page 13: ...peller shaft is being driven by the flow of water across the propeller which in turn rotates the components in the marine transmission During backdriving conditions the transmission does not receive proper lubrication Conditions where backdriving may occur q Vessel is being towed q One or more engines on a multiple transmission vessel are shut down while under way q Sailboat under sail with auxili...

Page 14: ...r or service dealer Contact Twin Disc for the distributor or service dealer near you Note Do not order parts from the part numbers on the cross sectional drawings These numbers may be referenced for part identification however they should be verified on the bill of material BOM before an order is placed BOM numbers are stamped on the unit nameplate Twin Disc having stipulated the bill of material ...

Page 15: ...act any Twin Disc distributor or service dealer This can be done on the Twin Disc corporate web site found at http www twindisc com Provide your model number serial number and bill of material number to obtain information on your unit If necessary contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA by e mail at service twindisc com ...

Page 16: ...which this manual was written has a limited warranty For details of the warranty refer to the warranty statement at the front of this manual For details of the warranty contact any Twin Disc Authorized Distributor service dealer or the Warranty Administration Department Twin Disc Inc Racine Wisconsin U S A ...

Page 17: ... standard mechanical valve Assembly 1017463A uses the 1020412 series control valve as the standard mechanical valve Service information is provided for both variations within this manual and the assembly drawing number is identified on the bill of material BOM Nameplate The nameplate identifies the model bill of material BOM and the serial number of the unit These numbers are necessary to identify...

Page 18: ... rotation engine counterclockwise flywheel rotation when viewing rear of engine This series of marine transmissions cannot be driven by a left hand rotation engine Contact an authorized Twin Disc distributor for more information Transmission clutches are hydraulically applied using main oil pressure All bearings clutches and gears are lubricated and cooled with low pressure oil Always reference th...

Page 19: ...complete the housing enclosure Bearings The primary and secondary clutch shafts and pinions are supported and located by a combination of straight and tapered roller bearings Bearing clearances for each clutch shaft and pinion assembly are set by use of a single shim pack at the rear tapered roller bearing on each shaft Tapered roller bearings also support the output shaft and have bearing clearan...

Page 20: ...ngs are gravity and splash lubricated Suction Strainer The marine transmission has a serviceable suction strainer located below the oil pump The strainer is between the sump and the oil pump in the hydraulic circuit The strainer can be replaced if necessary Filter Assembly A spin on oil filter is located between the heat exchanger outlet and the selector valve in the hydraulic circuit The replacem...

Page 21: ...system to move critical frequencies out of the operating speed range q Accommodate a certain amount of misalignment q Absorb shock and reduce noise q Minimize gear rattle Several couplings are available from Twin Disc and are selected based on the customer supplied engine information Final coupling selection must be confirmed by the packager based on the torque rpm ratings and the results of the s...

Page 22: ...t exchanger is designed to maintain the oil in the hydraulic system of the marine transmission at the proper temperature by passing raw or fresh water through the heat exchanger The heat exchanger should be installed in a location convenient to both coolant and marine transmission oil Figure 2 Heat Exchanger Requirements ...

Page 23: ...p temperature 93 C 200 F Oil type and viscosity See data plate below Oil capacity 28 liters 7 5 gal plus hoses and heat exchanger Oil Pump 53 4 liters per minute 14 1GPM at 1800 RPM Approximate Dry weight 849 kg 1870 lbs Oil pressure See Table 1 for oil pressure specifications Minimum oil pressure when cruising is 1620 kPa 235 psi Figure 3 Oil Specification Plate ...

Page 24: ... 0 140 340 20 50 1800 Secondary 1725 1862 250 270 0 0 1696 246 140 340 20 50 Oil pressure Limits 1725 kPa 250 psi rating 235psi minimum pressure when cruising 1018084 1017172 1020412 series control valve Input Speed Shift Position Main Pressure at Valve Inlet Primary Clutch Min Secondary Clutch Min Lube kPa psi kPa psi kPa psi kPa psi 600 Neutral 255 310 37 45 0 0 0 0 28 83 4 12 600 Primary 1586 1...

Page 25: ...J744 No 38 4 A hydraulically clutchable PTO is available in sizes SAE J744 No 32 4 and SAE J744 No 38 4 Mounting Brackets Steel fabricated mounting brackets for rigid mounting are available They are part number 1016428AD Torsional Input Coupling Several models of torsional input couplings are available including Vulkan VKE4911S in both 14 and 18 flywheel sizes as well as Centa CF R in both 14 and ...

Page 26: ... to secure it to the marine transmission s output flange Trolling Valve Several trolling valve kits are available for use with this transmission The XA7371 control valve uses the XA7373Q trolling valve which is mechanically actuated The 1020412 control valve uses K1331 which is mechanically actuated The 1018084 and 1017172 control valves use BOM 40588 which is mechanically actuated or BOM 41063 wh...

Page 27: ... Gear Advance Minimum Maximum 1 96mm 077 in 2 97mm 117 in Transmission Output Gear Advance Minimum Maximum 3 35mm 132 in 4 42mm 174 in Table 3 Bearing End Play Transmission Primary and Secondary Shaft Tapered Roller Bearing Endplay Minimum Maximum 0 05 mm 002 in 0 15 mm 006 in Transmission Output Shaft Bearing Endplay Minimum Maximum 0 05 mm 002 in 0 15 mm 006 in ...

Page 28: ...28 Twin Disc Incorporated Description and Specifications Marine Transmission Service Manual 1020667 Figure 4 MG 5170 Marine Transmission Installation Specifications ...

Page 29: ...29 Twin Disc Incorporated Description and Specifications Marine Transmission Service Manual 1020667 Figure 5 Control Valve Installation Specifications ...

Page 30: ...1375 1625 1865 2203 Thread Diameter SAE Grade 5 SAE Grade 8 lb ft Nm lb ft Nm 1 4 6 8 8 11 10 12 14 16 5 16 13 17 18 23 20 24 27 32 3 8 25 29 34 39 35 41 48 55 7 16 37 43 51 58 55 65 75 88 1 2 60 70 81 95 83 97 113 131 9 16 82 98 111 132 120 140 163 190 5 8 120 140 163 190 165 195 224 264 3 4 205 245 278 332 295 345 400 467 7 8 330 390 448 528 470 550 638 745 1 495 585 671 793 715 835 970 1132 1 1...

Page 31: ...perty Class 10 9 Property Class 12 9 lb ft Nm lb ft Nm lb ft Nm M6 6 5 7 5 9 10 9 10 12 14 10 12 14 16 M8 16 18 21 25 23 26 31 35 25 29 34 40 M10 32 36 43 49 44 51 60 68 51 59 70 80 M12 55 63 74 86 77 88 104 120 89 103 121 139 M16 132 151 179 205 189 217 256 294 219 253 298 342 M20 257 295 348 400 364 418 493 567 429 493 581 669 M24 445 511 603 693 626 720 848 976 737 848 1000 1150 M30 714 820 987...

Page 32: ...11 16 34 25 M16X1 5 24 18 7 8 54 40 M18X1 5 34 25 1 1 16 75 55 M22X1 5 54 40 1 3 16 88 65 M27X2 0 75 55 1 1 4 88 65 M33X2 0 88 65 1 5 16 108 80 M42X2 0 108 80 1 3 8 108 80 M48X2 0 108 80 Nominal Thread Diameter Nm or 5 lb ft or 5 Nominal Thread Diameter Nm or 5 lb ft or 5 5 16 5 3 5 1 5 8 108 80 3 8 11 5 8 5 1 7 8 108 80 7 16 16 12 2 1 2 108 80 1 2 20 15 M10X1 0 12 9 9 16 24 18 M12X1 5 16 12 5 8 2...

Page 33: ...imary neutral and secondary positions When these positions are selected the control valve directs high pressure oil through internal passages to operate the clutches The pressure rate control piston within the control valve assembly provides a rapid smooth oil pressure increase in the hydraulic system during clutch engagement ...

Page 34: ...Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the clutch pistons is open to sump the clutches are disengaged Oil is distributed through the lubrication system The area between the pressure regulating piston and the rate of rise piston is connected to sump at all times to prevent any leakage oil from affecting the pressure regulation When the control v...

Page 35: ...35 Twin Disc Incorporated Operation Marine Transmission Service Manual 1020667 Figure 6 A7119V Hydraulic Schematic ...

Page 36: ... 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 ma...

Page 37: ...37 Twin Disc Incorporated Operation Marine Transmission Service Manual 1020667 Figure 7 Manual Control Valve Neutral Sectional View Figure 8 Manual Control Valve Neutral Cutaway View ...

Page 38: ...nst the springs until the piston is stopped by a shoulder in the valve body This causes the pressure in chamber B to rise to clutch engaging pressure When in primary passage E remains at atmospheric pressure because slot F remains open to sump When a shift is made from primary to neutral the valve stem is rotated to the position illustrated by Figures 7 and 8 Under these conditions passage D is co...

Page 39: ...39 Twin Disc Incorporated Operation Marine Transmission Service Manual 1020667 Figure 9 Control Valve Primary Sectional View Figure 10 Control Valve Primary Cutaway View ...

Page 40: ...t springs until the piston is stopped by a shoulder in the valve body The causes the pressure in chamber B to rise to clutch engaging pressure When in secondary passage D remains at atmospheric pressure because slot F remains open to sump When a shift is made from secondary to neutral the valve stem is rotated to the position illustrated by Figures 7 and 8 Under these conditions passage E is conne...

Page 41: ...41 Twin Disc Incorporated Operation Marine Transmission Service Manual 1020667 Figure 11 Control Valve Secondary Sectional View Figure 12 Control Valve Secondary Cutaway View ...

Page 42: ... to become lubrication oil Lubrication oil flows through the heat exchanger to the lubrication oil circuit in the transmission to lubricate and cool the clutches and bearings There is a lubrication oil pressure relief valve to limit maximum lubrication oil pressure to approximately 690 kPa 100 psi In Neutral the inlet port of both clutches is connected to the atmosphere Since the area behind the c...

Page 43: ... Shuttle Ball The electric control valve can be used in a manual override mode in the event of an electrical power failure When the control valve is energized or shifted to engage either clutch the valve directs main pressure to engage the selected clutch pack Oil is also directed to move the rate of rise piston compressing the pressure regulator springs This progressively increases the clutch eng...

Page 44: ...ump 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 regul...

Page 45: ...e of rise piston and resulting pressure rate of rise is controlled by the orifice size regulator spring stiffness and the final main pressure after completion of the rate of rise cycle Neutral main pressure controls the start time of the rate of rise cycle When the rate of rise piston is against the stop pressure regulating springs are compressed the most the main oil pressure reaches approximatel...

Page 46: ...trolled by a solenoid operated pilot valve control clutch engagement When a solenoid is energized it opens the pilot valve and allows main pressure oil to flow to the end of the spool The pressure acting on the end of the spool overcomes the return spring at the opposite end causing the spool to stroke over and connect the clutch passage with main pressure passage Figure 16 Pilot Spool Passages ...

Page 47: ...verride stem These connecting slots are aligned with passages in the valve body when the valve is in the electric mode Figure 17 Flow Path in Override Spool Main pressure from the energized solenoid operated pilot valve also acts on a pin on the return spring side of the opposite spool to ensure the opposite spool is connecting its clutch to sump The clutch engagement cycle is outlined in the prev...

Page 48: ...on occur while the clutch is engaged The hydraulic lock is accomplished by allowing pressurized oil from the pressurized clutch passage to flow inside the spool Oil pressure inside the spool forces the dowel pin against the O ring plug Figure 18 Hydraulic Lock Units The resulting reaction is a force on the spool that overcomes the spool s return spring force Should the solenoid become de energized...

Page 49: ...solenoid is energized it sends pressurized oil to the dowel pins at the return spring end of each spool Since the dowel pin used at the return spring side of the spool is larger in diameter than the dowel pin inside the spool the hydraulic force acting on the larger pin forces the spool to connect the clutch passage to sump with assistance from the return spring Figure 19 Neutral Solenoid Engaged ...

Page 50: ... manual override position shifting is controlled by rotating the lever on the manual override stem In the Neutral position both clutches are vented to sump by two pockets in the stem Figure 20 Stem Pocket or Passage Main pressure oil can flow through the hole in the end of the stem to a narrow slot between the two pockets This slot does not connect to any other passages when the stem is in the Neu...

Page 51: ...51 Twin Disc Incorporated Operation Marine Transmission Service Manual 1020667 Figure 21 Hydraulic Schematic electric control valve ...

Page 52: ...ce Manual 1020667 Trolling Valve Optional The trolling valve is used to reduce and control propeller speed below that normally attained by operating the engine at low idle Actuating the trolling function reduces clutch apply pressure to reduce the propeller speed ...

Page 53: ...e 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 opened orifice closed Figure 22 Mechanical Trolling Valve Rotating the trolling valve lever into the trolling mode opens the variable orifice allowing some of the oil to escape from the rate of rise chamber to sump This reduces the oil pressu...

Page 54: ...e causes the rate of rise piston to remain against its stop in the valve body bore and main oil pressure is not reduced The trolling valve is actuated by sending a controlled amount of current through the valve s coil As the current is increased the orifice progressively opens allowing oil pressure from the rate of rise chamber to escape to sump Since oil is always flowing into the rate of rise ch...

Page 55: ...lic clutched PTO also allows accessories to be driven using engine horsepower Since the PTO is attached to the primary shaft of the transmission the accessories can be driven any time the engine is running The PTO is engaged by the PTO control valve which is very similar to the valve used to control the transmission clutches The hydraulic clutched PTO operates with an engaged clutch pressure great...

Page 56: ...red to windmilling occurs when the engine is shut down and the transmission output shaft is being driven by water flow across the propeller The remote trailing pump option is driven by an electric motor This trailing pump pulls oil through its suction strainer and discharges it through a filter to a check valve The oil then flows through an oil to air heat exchanger and into the transmission s lub...

Page 57: ... constant mesh with gear teeth on the of the secondary clutch housing causing the secondary shaft to rotate in anti engine direction The primary and secondary pinions on their respective shafts are in constant mesh with the output gear which is connected to the output shaft through a keyless tapered joint Application of the primary clutch locks the primary pinion to the primary shaft causing the p...

Page 58: ...rated Operation Marine Transmission Service Manual 1020667 Neutral When in neutral the primary and secondary shafts transfer gears and clutch friction plates rotate at engine speed Figure 23 MG 5170DC Power Flow in Neutral ...

Page 59: ...mary 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 Figure 24 M...

Page 60: ...es together The secondary input pinion will then rotate at engine speed and anti engine direction because the steel clutch plates are spline connected through the clutch hub assembly to the input pinion Because the secondary input pinion is in mesh with the output gear the output gear and shaft will rotate in engine direction The primary input pinion will be backdriven anti engine direction when t...

Page 61: ... filter q Removing cleaning and installing the suction strainer q Removing and installing the control valve q Removing and installing the manifold or top cover bearing carrier and lube tube q Removing and installing the primary and secondary shaft assemblies Note See special tools section for lifting bracket to aid in shaft removal or installation q Changing primary and secondary clutch plates Not...

Page 62: ...ar the low oil level mark Transmission oil temperature should be in the normal operating range prior to finalizing the oil level between the low and full marks on the oil level gauge Oil and Filter Change Interval With a new transmission change the oil and filter element within the first 50 hours of operation Change oil and filter element after each 1000 hours thereafter or more often if condition...

Page 63: ...er weight and type oil See Description and Specifications for oil recommendations 3 Start the engine and let it idle with transmission in neutral until oil is circulated throughout the hydraulic system Add oil if necessary to bring the oil level up to the low mark with the engine at low idle 4 With the oil at operating temperature transmission in neutral and the engine running at low idle check th...

Page 64: ...ffect the life of the coupling element When inspecting the flexible coupling look for evidence or conditions identified in the following steps q Cracks in the surface of the rubber May be caused by torsional vibrations excessive misalignment or exposure to contaminants heat petroleum products chemicals ozone ultraviolet radiation etc excessive system torques q Separation of rubber from flex plate ...

Page 65: ...tenance Marine Transmission Service Manual 1020667 Inspect the hub looking for the following q Damaged or worn splines q Cracked parts q Oil seal surface for wear or damage Replace any defective parts including defective fasteners that are found ...

Page 66: ... 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 Overhaul Interval A complete overhaul and thorough inspection of the unit should be made at the scheduled engine overhaul Refer to Cleaning and Inspection for more detailed inspection instructions Periodic Visual Inspection q Ch...

Page 67: ...problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete power package Problems in the input power system or the output power delivery components can cause problems to develop in the transmission It is therefore important that the entire power package be considered when problems are encountered Tables begin on the next page ...

Page 68: ...detent 1 6 Clogged or plugged orifice in orifice plate of control valve assembly 1 6 Remove orifice plate cover Clean parts 1 7 Shimming required between regulator springs and rate of rise piston 1 7 Shim as required 1 8 Engine idle speed too low 1 8 Raise engine speed 2 No oil pressure or erratic low pressure at control valve tap 2 1 Oil pump suction strainer plugged 2 1 Remove and clean strainer...

Page 69: ... of engine and transmission output flange to propeller shaft Correct as necessary 5 6 Damaged propeller 5 6 Repair propeller 5 7 Misfiring engine 5 7 Repair engine Symptom Cause Remedy 3 High main oil pressure 3 1 Regulating valve stuck 3 1 Remove and clean regulating valve 3 2 Improperly shimmed 3 2 Shim as required 3 3 Lube relief valve malfunction 3 3 Inspect repair or replace parts as necessar...

Page 70: ...lace damaged piston rings 9 Oil spilling out of breather 9 1 Oil level too high 9 1 Adjust oil level 9 2 Wrong type of oil 9 2 Draw and refill with recommended oil Symptom Cause Remedy 6 No neutral 6 1 Clutch plates warped 6 1 Remove clutch plates Overhaul unit 6 2 Control valve incorrectly indexed 6 2 Check and adjust control linkage 6 3 Solenoid malfunction units equipped with electric selector ...

Page 71: ...nsmission Service Manual 1020667 Disassembly The following procedure is for complete disassembly of the unit Prior to this procedure the transmission should be removed from the boat Qualified personnel should do the work in a fully equipped facility ...

Page 72: ...e you don t forget the quantity size etc Drain the oil from the transmission sump by removing the hex drain plug from the bottom of the oil pan Drain the oil from the filter housing as well by removing the pipe plug located below the oil hose coming back from the heat exchanger The physical size and weight of many of the parts for this transmission assembly are such that adequate lifting devices a...

Page 73: ... shaft if not previously removed 2 Remove front housing from main housing 3 Support the unit on an assembly stand or blocks with the output side facing up Use caution to prevent damaging the primary shaft splines 4 Remove the oil filter element Figure 26 Removing Filter Element 5 Remove filter bypass valve components from manifold Figure 27 Removing Filter Bypass Valve Components ...

Page 74: ... 1020667 6 Remove the control valve and gasket Set it aside for later disassembly 7 Remove breather and oil filler screen from top cover plate Figure 28 Removing Breather and Screen 8 Remove top cover plate and gasket 9 Remove oil pump and gasket Figure 29 Removing Oil Pump ...

Page 75: ... Twin Disc Incorporated Disassembly Marine Transmission Service Manual 1020667 10 Remove suction strainer cover hex head O ring plug Remove spring and suction strainer Figure 30 Removing Suction Strainer ...

Page 76: ...gure 31 Removing Primary Shaft Cover left and O ring right 2 Remove manifold attaching screws Install two of the removed screws into the pusher screw holes near the dowel pins Tighten the screws alternately and evenly to push the manifold off of the bearing carrier and dowel pins Remove the manifold and gasket Figure 32 Using Pusher Screws To Remove Manifold ...

Page 77: ... the bearing spacers and shims from the bearing bores of the bearing carrier Mark the shims and spacers for location identification Figure 33 Removing Spacers and Shims 4 Remove the lubrication tube from the bearing carrier Figure 34 Lube Tube in Bearing Carrier left and Removing Tube right ...

Page 78: ...evenly to push the bearing carrier off of the housing and dowel pins Remove the bearing carrier and prevent the bearing cups from falling out of the bores Figure 35 Using Pusher Screw To Remove Bearing Carrier 6 Remove the bearing cups from the bearing carrier Mark the bearing cups for location identification 7 Remove the lubrication oil pressure relief valve from the bearing carrier Figure 36 Lub...

Page 79: ... diameter and should remain in the housing On some ratios the diameter of the output gear will allow the bearing to come out with the shaft and it could easily fall off causing damage Set the shaft aside for further disassembly Figure 37 Removing Primary Clutch Shaft Assembly 2 Lift and push aside the suction tube to allow the secondary shaft assembly to pass by Lift out secondary shaft assembly A...

Page 80: ...tput gear as primary and secondary shafts were removed Note Tapered roller bearing cups of front bearings on the primary and secondary shafts are an interference fit in the housing Removal of these bearing cups should not be attempted unless replacement of the bearing is necessary 4 Remove the oil pump suction tube and O ring Figure 39 Removing Suction Tube ...

Page 81: ...Remove Output Flange and Oil Pan 1 Remove the output flange retaining capscrews Remove the retaining washer shims and O ring Figure 40 Removing Washer and Shims left and O ring right 2 Use hydraulic ram to pull the output flange from the output shaft Figure 41 Removing Output Flange ...

Page 82: ...isassembly Marine Transmission Service Manual 1020667 3 Remove the oil gauge tube assembly Figure 42 Removing Oil Gauge Tube Assembly 4 Remove the oil pan attaching screws Remove the oil pan and gasket Figure 43 Removing Oil Pan ...

Page 83: ...83 Twin Disc Incorporated Disassembly Marine Transmission Service Manual 1020667 5 Remove the gear pan from the oil pan Figure 44 Removing Gear Pan ...

Page 84: ... Output Shaft and Gear 1 Remove output shaft seal carrier attaching screws Use two of the removed screws as pusher screws to separate seal carrier from housing Figure 45 Removing Seal Carrier 2 Remove the seal carrier shim pack and O ring Figure 46 Removing Shim Pack left and O ring right ...

Page 85: ...nstall the six hexhead capscrews and torque to 60 Nm 45 ft lb The gap between the seal carrier and the housing should be approximately 4 5mm 0 17 in Figure 47 Washers Installed 4 Remove the four setscrews from the two threaded holes in the output gear hub Figure 48 Output Gear Setscrews 5 Fill one hole in the output gear with oil until it flows out of the other hole Be sure all air bubbles are rem...

Page 86: ...614 5 Note If the gear does not come loose rewrap the threads on the screw with teflon tape refill the cavity with oil and try again Figure 49 Removing Output Gear from Output Shaft 9 When the output gear comes loose remove T 18614 5 from the output gear Remove the output seal carrier 10 Install two eyebolts into the output shaft and hoist out the shaft Press the rear bearing cone off of the outpu...

Page 87: ...rference 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 electric welder This will shrink the cup and facilitate removal Bearings removed in this manner must be replaced 14 Remove input oil seal Remove input oil seal protector plug if replacement is necessary ...

Page 88: ...ove 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 Use a 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 rac...

Page 89: ...on is a tight fit and will likely be destroyed during removal Remove the straight roller bearing with the use of a puller behind the roller ends Figure 50 Removing Round Retaining Ring From Input End Of Shaft 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 we...

Page 90: ...e 7 Remove clutch plates 8 steel 9 friction maintaining the respective order for inspection purposes 8 Remove clutch apply piston A Place clutch in a press input side up Use special tool T 19998 to compress clutch release springs and expose round retaining ring Figure 51 Removing Retaining Ring From Spring Retainer B Remove retaining ring Slowly release pressure on press and remove shaft from pres...

Page 91: ...ing must be replaced and the mating part remains serviceable Use the following procedure to separate the housing transfer gear from the primary or secondary shaft 9 To remove clutch housing place shaft and clutch housing on a press front end of shaft down Place a sleeve over input front end of shaft with an I D only slightly larger than the O D of the shaft taper large end 95 25mm 3 75 in Rest one...

Page 92: ...l is under pressure from the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Remove the orifice plate cover orifice plate and check ball Figure 53 Removing Orifice Plate and Check Ball 2 Remove the check ball spring and shim s from the valve body Figure 54 Removing Check Ball Spring ...

Page 93: ...move the rate of rise piston and remove the pressure regulator adjustment shims from the rate of rise piston Figure 55 Removing Shims from Rate of Rise Piston 4 Remove the pressure regulating springs and pressure regulator piston Figure 56 Removing Regulator Springs and Regulator Piston ...

Page 94: ...lug Detent Spring and Ball 6 Mark the lever and the stem to indicate the position the lever was installed on the stem Loosen the screw clamping the lever to the stem and remove the lever It may be necessary to 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 Figure 58 Removing Lever ...

Page 95: ...ng Stem and Cover Together 8 Mark the stop collar and the stem to indicate the position the collar was installed on the stem While supporting the collar drive the roll pin out of the collar with a drift punch and remove the collar Figure 60 Removing Roll Pin and Stop Collar 9 Slide the stem out of the cover 10 Remove the oil seal from the cover ...

Page 96: ...sion Service Manual 1020667 11 Remove the O ring from the stem Figure 61 Removing O ring from Stem 12 Remove the thrust bearing and races from the stem Figure 62 Removing Thrust Bearing and Races from Stem 13 Remove the remaining plugs from the valve body ...

Page 97: ...the spring Care must be taken when removing the cover and orifice plate to prevent loss of steel ball 1 Loosen and remove four of M8 x 25 socket head capscrews and remove orifice plate cover and gasket Figure 63 Removing Orifice Plate Cover Gasket 2 Remove orifice plate 3 Remove steel ball and neutral pressure regulating spring 4 Remove orifice plate gasket ...

Page 98: ...ings 7 Remove pressure regulating piston with an external retaining ring pliers Figure 65 Removing Regulating Piston with Pliers 8 Remove external retaining ring from the lever end of the stem 9 Loosen the clamping nut and remove the control lever from the stem 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 setscre...

Page 99: ... valve body 13 Remove the O ring and oil seal from the cover assembly Figure 66 Removing O ring from Cover 14 Remove the two electrical switches from the sides of the valve body and the two steel balls from each of the switch bores in the valve body some models 15 Remove the detent setscrew spring and steel ball from the valve body Figure 67 Removing Detent Setscrew and Spring ...

Page 100: ...Remove the dog point setscrew Note that the setscrew is retained with MA908 threadlocker Figure 68 Removing Dogpoint Setscrew 17 Remove the stem from the valve body partially 18 Remove the thrust washer from the stem Figure 69 Removing Thrustwasher 19 Remove the stem from the valve body ...

Page 101: ...0 Remove the roll pin retains the shuttle ball seat with a needle nose pliers Figure 70 Removing Roll Pin Retaining Shuttle Seat 21 Thread a M8x1 25 screw one of the cover screws works well into the seat and remove it from the valve body 22 Remove the shuttle ball from the valve body ...

Page 102: ...etters that are on the Weatherpak connector Open the end of the Weatherpak connector to allow removal of the pins and wires 3 Remove the pins for the wires of all but one solenoid from the Weatherpak connector using the extraction tool Tool is Packard Electric P N 12014012 Figure 71 Removing Wires using Extraction Tool 4 Mark the two solenoids for location identification and remove them 5 Remove t...

Page 103: ...moving Filter Screen 7 Remove the two socket head O ring plugs from the bores in the end of the valve body 8 Remove the two spools from the valve body 9 Remove one dowel pin and spring from each of the spools hydraulic lock units only 10 Remove the spool return spring and dowel pin from the bottom of each of the spool bores in the valve body ...

Page 104: ... Care must be taken when removing the trolling valve and orifice plate to prevent loss of steel ball 2 Remove the trolling valve from control valve 3 Remove the gaskets orifice plate and steel ball from control valve 4 Remove the screw and nut clamping the lever to the stem 5 Remove the lever from the stem It may be necessary to splay the lever to be able to remove it DO NOT apply any impact force...

Page 105: ...ransmission Service Manual 1020667 6 Remove the detent setscrew spring and detent ball Figure 74 Removing Detent Setscrew left and Detent Spring and Ball right 7 Remove the dog point setscrew from the valve body Figure 75 Removing Dog point Setscrew ...

Page 106: ...one piece Push the stem out of the adapter such that the spring end of the stem exits the adapter first Note that the inner spring will come out with the stem Figure 76 Removing Stem and Adapter from Valve Body left and Removing Stem from Adapter right 9 Remove the O ring from the groove in the end of the stem Figure 77 Removing O ring From Stem ...

Page 107: ... the bore of the valve body some models Note the washer may have been removed with the stem 12 Remove the outer spring and piston from the bore of the valve body Note that there may be washer s in the bore of the piston some models Figure 78 Removing Spring and Piston from Valve Body 13 Remove the O ring from the groove and the oil seal from the end of the adapter Figure 79 Removing O ring From Ad...

Page 108: ...108 Twin Disc Incorporated Disassembly Marine Transmission Service Manual 1020667 ...

Page 109: ...by steam cleaning Parts must be dried and oiled immediately to prevent corrosion q Examine all parts carefully for grit dirt and abrasives and reclean them if necessary q Clean all oil passages by working a piece of wire back and forth through the passages and then flushing them with cleaning solvent q Use clean solvent to flush oil pumps valves etc q Flush all hoses tubing coolers etc particularl...

Page 110: ...t in bearings are often responsible for bearing failure consequently it is important to keep bearings clean Do not remove grease from new bearings Keep the wrapper on new bearings until they are installed Do not expose clean bearings if they are not to be assembled at once Wrap them with a clean lint free cloth or paper to keep out dust Previously Sealed Joints q For previously sealed joints scrap...

Page 111: ...tches nicks and foreign matter If you cannot remove the defect with crocus cloth or a soft stone replace the part q Inspect ground tapers for burrs or nicks If you cannot remove the defect with a soft stone replace the part q Inspect ground tapers for scratches galling or scoring damage If any of these the defects replace the part q Inspect threaded openings for damaged threads Chase damaged threa...

Page 112: ...scratched cracked pitted or chipped races If you find one of these defects replace the bearing q Inspect bearing bores and shafts for grooved burred or galled conditions that would indicate the bearing has been turning in its housing or on its shaft If you cannot repair the damage with a crocus cloth replace the part Bushings and Sleeves Inspect bushings for size and out of roundness Inspect for s...

Page 113: ... defects with a soft stone replace the gear Splined Parts Inspect splined parts for stripped twisted chipped or burred splines Remove burrs with a soft stone Replace the part if other defects are found Springs Inspect springs for broken or distorted coils Replace the spring if either of these defects is found Flexible Hoses Inspect all flexible hoses for cracks and sponginess Replace damaged hoses...

Page 114: ...114 Twin Disc Incorporated Cleaning and Inspection Marine Transmission Service Manual 1020667 ...

Page 115: ...1020667 Assembly Unless otherwise specified all torque values listed are for capscrews that have been lubricated on the threads and contact surfaces The following discussion contains frequent reference to the transmissions parts and components Refer to Engineering Drawings ...

Page 116: ...tify and place the following bearing components in an oven at 120 C 250 F for 30 minutes output shaft rear tapered roller bearing cone and the rear bearing cones for both clutch shafts Submerge all new friction clutch plates in transmission oil for a minimum of one hour prior to installation Identify and place the following bearing components in a deep freeze 51 C 60 F for at least two hours prior...

Page 117: ...a soft hammer Figure 80 Seal Protector Installation 3 Install the chilled cups for the primary and secondary front tapered roller bearings into their respective bores in the front inner face of the housing Use driver T 18050 585 to press drive cups to the bottom of the bore It is important to maintain downward force as temperatures equalize to ensure that cup is at bottom of bore Figure 81 Front P...

Page 118: ...apered roller bearing cup into housing bore Use driver T 18050 611 to press drive cup to bottom of its bore Note Care must be taken to ensure that the shield remains centered 7 Use T 18050 772 to ensure the bearing cup is properly seated Tighten puller rod to standard torque limit for thread size of puller rod or 275 Nm 200 ft lb whichever is less Maintain this torque until bearing cup and housing...

Page 119: ...lure to properly clean mating parts could prevent proper advance measurement of gear on shaft and adversely effect torque carrying capacity of the assembled joint 2 Install front output bearing cone and output gear Use special tool T 19987 to position gear into correct location Install the output shaft into the output gear and bearing cone in the transmission housing Seat shaft onto the taper of t...

Page 120: ...assistance 4 Install T 20023 onto the output shaft and gear Figure 84 Output Gear Advancing Tools Installed 5 Advance gear to shaft shoulder stop with the portable press 6 Remove T 20023 from the output shaft and gear 7 Confirm that the output gear has been advanced completely such that there is no gap between the shaft shoulder and the gear hub 8 Install the two setscrews into each hole in the ou...

Page 121: ...Install with small O D of bearing to the rear Press drive bearing to shaft shoulder using special tool T 18050 323 After bearing cools press drive bearing down again to assure that bearing is against shaft shoulder 2 Install chilled bearing cup into output seal carrier After bearing warms press drive bearing cup down to assure that bearing cup is bottomed in bore of seal carrier ...

Page 122: ...cator onto the housing with finger resting on rear of output shaft or on lifting fixtures Zero the dial indicator and mark the spot where the reading was taken D Using a hoist exert 2225 N to 4000 N 500 lbs to 900 lbs of lifting force onto the shaft Minimum of 2224 N 500 lbs lifting force is required to overcome weight of gear and shaft and still exert a minimum of 1334 N 300 lbs lifting force on ...

Page 123: ...anaerobic sealant and install oil seals into output seal carrier using driverT 18050 321 Remove excess sealant that is wiped off as seals are pressed into position A Install forward seal with spring loaded lip toward the inside of the transmission Install flush with inner face of seal carrier B Install rear seal with spring loaded lip of seal toward rear of the transmission Install flush with oute...

Page 124: ...s with water pump grease Figure 86 Packing Cavity Between Output Seals With Grease D Install grease fitting if not previously installed 5 Install established shim pack aligning screw holes of shims with threaded screw holes of transmission housing Figure 87 Installing Shim Pack left with Holes Aligned right ...

Page 125: ...Disc Incorporated Assembly Marine Transmission Service Manual 1020667 6 Install assembled output seal carrier onto housing Install attaching screws and torque to 122 Nm 90 ft lb Figure 88 Installing Seal Carrier ...

Page 126: ...ered bore up Seat gear on shaft taper with 445 N to 890 N 100 lbs to 200 lbs of force d Use a depth micrometer and measure distance from rear end of shaft to machined face of transfer gear at small diameter of tapered bore Record this distance as dimension B e Calculate expected advance Expected advance A B Calculated advance must be 1 96 mm to 2 97 mm 0 077 in to 0 117 in If calculated advance is...

Page 127: ... complete advance Figure 89 Pressing Clutch Shaft Into Transfer Gear F Using a depth micrometer measure distance from rear end of shaft to face of transfer gear Record as dimension C Transfer gear face should be within 0 05 mm 002 in of the shaft shoulder at the small diameter end of the taper Note Actual advance C B must be 1 96 mm to 2 97 mm 0 077 in to 0 117 in If transfer gear has not been adv...

Page 128: ... ring into groove in secondary shaft Apply a coat of assembly grease or oil to seal ring 3 Install piston ring in groove in O D of clutch apply piston Apply a coat of assembly grease or oil to seal ring 4 Install clutch apply piston into piston bore in transfer gear Figure 90 Installing Clutch Piston ...

Page 129: ... 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 are in pockets in face of piston and that springs are aligned correctly stand straight up Figure 91 Return Springs and Spring Retainer Ready for Installation ...

Page 130: ...l T 19998 Press down tool T 19998 to compress springs and expose retaining ring groove of shaft Keep force on springs and install retaining ring into exposed groove of shaft Figure 92 Installing Spring Retainer Retaining Ring D Slowly release force on springs assuring that spring retainer counterbore covers retaining ring and prevents retaining ring from coming out of the groove Remove tool T 1999...

Page 131: ...Manual 1020667 6 Use driver T 18050 327 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 Figure 93 Installing Clutch Shaft Rear Bearing Cone ...

Page 132: ...s and 8 steel plates into clutch housing transfer gear against clutch apply piston 9 Install clutch backplate and internal retaining ring Figure 94 Installing Clutch Backplate 11 Install tapered roller bearing cone onto secondary shaft Install with large diameter of bearing seating against shoulder of shaft inside the transfer gear opening Note This bearing is a slip fit and will not require speci...

Page 133: ...ly of pinion A Use special tool T 18050 11 to install chilled tapered roller bearing cup into rear of pinion for secondary shaft Bearing cup is installed with small I D of taper toward the front and seated against shoulder of bore in clutch hub Figure 95 Installing Pinion Rear Bearing Cup ...

Page 134: ...ith T 18050 25 C Install internal retaining ring into groove in pinion bore Figure 96 Installing Internal Retaining Ring Into Pinion D Align plates in clutch pack and install pinion on secondary shaft so that external teeth on clutch hub mesh with internal teeth of steel plates in clutch pack Assure that clutch hub is in mesh with all clutch plates ...

Page 135: ...ring to retain pinion on shaft Figure 97 Installing External Retaining Ring Onto Clutch Shaft 13 Install two piston rings into grooves at rear end of shaft 14 Assemble primary shaft Assembly procedure for primary shaft is exactly the same as for the secondary shaft Repeat above procedure in steps 1 through 13 ...

Page 136: ...he secondary shaft assembly to pass by Figure 98 Installing Suction Tube left with Flange Positioned right 16 Install clutch shaft assemblies into transmission housing Use caution to prevent damaging the shafts gears and bearings Figure 99 Installing Clutch Shaft Assembly 17 Move the oil suction tube into the installed position so its flange is seated within the housing counterbore ...

Page 137: ...ief valve spring and lube relief valve steel ball into lube relief valve housing Attach assembled lube relief valve to inner face of bearing carrier with the screws and washers Torque the screws to 20 Nm 15 ft lb 4 Install two alignment studs into face of transmission housing Install bearing carrier over studs and onto dowels in housing face Use a soft hammer near the dowels to seat carrier agains...

Page 138: ...rrier Tap cups down gently with soft hammer or brass drift to seat against bearing cones on shafts 7 Install manifold gasket over alignment studs and against bearing carrier 8 Push tapered roller bearing cups with shim retainers firmly against roller bearing cones on rear of primary and secondary shafts Use a depth micrometer to measure from manifold gasket face to shim retainers Measured distance...

Page 139: ...d sealant to the 1 4 NPTF plug and install it into the manifold below the oil filter torquing it to 34 Nm 25 ft lb Apply pipe thread sealant to the 3 4 NPTF plug and install it into the manifold above the oil filter torquing it to 73 Nm 54 ft lb 2 Assemble and install filter bypass valve components Torque the screws to 20 Nm 15 ft lb Figure 102 Installing Filter Bypass Valve Components 3 Apply a c...

Page 140: ... Secondary Shaft Bearing Adjustment 3 Install an eyebolt into the end of the shaft and exert 890 N 200 lbs downward force while rotating the shaft several revolutions in each direction Stop so that the dial indicator probe is resting on the mark 4 Zero the dial indicator 5 Remove downward pressure and exert 1334 N to 1557 N 300 lbs to 350 lbs lifting force on the shaft Rotate the shaft several rev...

Page 141: ...ted Assembly Marine Transmission Service Manual 1020667 7 Check endplay for primary shaft Repeat steps 1 through 6 on the previous page to adjust endplay for primary shaft Figure 104 Checking Primary Shaft Bearing Adjustment ...

Page 142: ...r into Manifold 2 Install new O ring onto suction strainer O ring plug Apply assembly grease or oil to the O ring and install the plug torquing it to 108 Nm 80 ft lb 3 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 112 Nm 83 ft lb Figure 106 Installing Primary Shaft Cover O ring left ...

Page 143: ...sion Service Manual 1020667 4 Install oil pump gasket and oil pump at mounting location at end of secondary shaft Mesh drive tang on pump shaft with drive slot in secondary shaft Install attaching screws and torque to 37 Nm 27 ft lb 5 Install oil filter ...

Page 144: ...ver Oil Gauge and Oil Pan 1 Install top cover assembly with its gasket Install attaching screws and torque to 37 Nm 27 ft lb 2 Install strainer and breather filler cap Figure 107 Installing Strainer and Breather 3 Install oil gauge tube assembly and oil level gauge Figure 108 Installing Oil Gauge Tube ...

Page 145: ...lling Gear Pan 5 Install two alignment studs into the transmission housing to help guide and align the oil pan Install a new gasket over the alignment studs Install the oil pan aligning the oil gauge and suction tube with the appropriate holes in the gear pan flange Install the attaching screws and torque to 88 Nm 65 ft lb Figure 110 Suction Tube Engaged into Gear Pan Flange ...

Page 146: ...sure 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 Figure 111 Measuring Output Flange Gap U...

Page 147: ...stall O ring to seal output shaft splines and output flange Figure 112 Installing Output Flange O ring 5 Install shim pack developed in step 3 and retainer washer Install the hexhead capscrews and torque to 434 Nm 320 ft lb Figure 113 Installing Output Flange Shims and Retainer Washer ...

Page 148: ... 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 noth...

Page 149: ...Control Valve 1 Install the thrust race thrust bearing and remaining thrust race onto the stem Figure 114 Installing Thrust Bearing and Races 2 Install a new oil seal and O ring into the valve cover 3 Apply assembly grease or oil to the shaft of the valve stem the oil seal and the O ring Install the stem into the valve cover ...

Page 150: ...e at disassembly Drive the roll pin into the collar and stem while supporting the stem to prevent damage to the parts Figure 115 Installing Stop Collar left and Roll Pin right 4 Place the cover gasket over the stem assembly against the cover Install the assembly into the valve body and torque the attaching screws to 33 Nm 24 ft lb Figure 116 Installing Stem Assembly into Valve Body ...

Page 151: ...ug Torque the plug to 37 Nm 27 ft lb Figure 117 Installing Detent Ball Spring and O ring Plug 6 Install the valve lever aligning the marks made at disassembly Torque the screw to 15 Nm 11 ft lb 7 Install the pressure regulator piston and springs into the valve body Figure 118 Installing Regulator Piston left and Springs right ...

Page 152: ...ure regulator adjustment shims into the rate of rise piston Figure 119 Pressure Regulator Adjustment Shims 9 Install the rate of rise piston with shims into the valve body 10 Install the check ball spring shim s and spring into the valve body Figure 120 Installing Check Ball Spring Shim s and Spring ...

Page 153: ... Check Ball and Orifice Plate 12 Install the remaining gasket and orifice plate cover onto the valve body Install the attaching screws and tighten them alternating and evenly to 33 Nm 24 ft lb 13 Install valve onto the transmission and torque the attaching screws to 20 Nm 27 ft lb 14 Install the remaining O ring plugs Torque the M12 plugs to 16 Nm 12 ft lb and the M27 O ring plug to 75 Nm 55 ft lb...

Page 154: ...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 75 Nm 55 lb ft 6 Apply lubricant such as Dow Corning 200 30 000cSt fluid to the O rings of the solenoids and plug plug used on units without hydraulic lock Install solenoids and plug if equipped into the valve body and torque them to 34 Nm 25 lb ft 7 Insert the wi...

Page 155: ...at with the holes in the valve body One of the valve s M8x1 25 cover screws threaded into the seat can be used to adjust the seat location in the valve body 4 Install the roll pin to retain the shuttle ball seat Drive the roll pin in until it is flush with the gasket surface of the valve body Figure 123 Installing Shuttle Ball Seat Roll Pin 5 Install the stem into the valve body aligning the slot ...

Page 156: ... 7 Install the steel detent ball into the valve body 8 Install the detent spring over the detent ball 9 Apply MA908 threadlocker to the threads of the hollow setscrew and install into the threaded hole Astepped Allen wrench or one wrapped with tape will ease the installation of the hollow setscrew Tighten the setscrew until it is flush with the gasket surface of the valve body Check the stem rotat...

Page 157: ... and Cover Must be Aligned 15 Install cover capscrews and torque to 23 Nm 17 lb ft 16 Install washer over stem and against oil seal 17 Install spring over stem against washer 18 Install lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew may be damaged Torque the lever s attaching screw to ...

Page 158: ...ate of rise piston Install the rate of rise piston over the springs and into valve body 24 Install neutral pressure regulating spring into the pocket of valve body Figure 127 Neutral Pressure Regulating Spring Location 25 Install the orifice protection screen into the valve body Figure 128 Installing Screen 26 Install orifice plate gasket onto valve body 27 Install orifice plate and steel ball aga...

Page 159: ... capscrews and torque to 23 Nm 17 lb ft 29 Install gasket over lower valve body half 30 Set upper valve body half over lower valve body half Insert the valve attaching screws through valve body halves to keep parts in alignment until installation onto the transmission When installing the valve onto the transmission torque the screws to 54 Nm 40 lb ft ...

Page 160: ...ting motion The spring is to be installed onto the roll pin such that the first coil contacts the end of the stem 5 Apply assembly grease to the stem from the O ring to the reduced diameter end Install the stem into the adapter with the reduced diameter end entering the adapter first Adjust the position of the stem if necessary to bring the helical slot into alignment with the dog point setscrew h...

Page 161: ... Trolling Valve Body 9 Apply MA908 threadlocker to the threads of the dog point setscrew and install Tighten the dog point setscrew until snug then back off 1 2 turn The end of the setscrew should protrude approximately 3mm 0 12 in from the valve body when the dog point of the setscrew is fully engaged in the helical slot Figure 131 Installing Dog point Setscrew 10 Check the action of the stem in ...

Page 162: ...setscrew if necessary to achieve the proper torque to rotate the lever out of the detent position 13 Install the lever onto the stem It may be necessary to splay the lever to be able to install it DO NOT apply any impact force to the lever as the stem or dog point setscrew might get damaged 14 Rotate the lever if necessary on the stem to the position shown on the valve installation drawing see Eng...

Page 163: ... regulating spring Figure 133 Installing Neutral Pressure Regulating Spring and Ball 17 Install the orifice plate gasket orifice plate trolling valve gasket and trollingvalveontothecontrolvalve Installtheattachingscrewsandtorque them to 23 Nm 17ft lb Figure 134 Installing Orifice Plate left and Trolling Valve Onto Valve Body right ...

Page 164: ...p 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 Install input shaft oil seal into housing using seal protector T 21347 and drive...

Page 165: ...ch a dial indicator to the input shaft spline using fixture T 21302 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 ofTwin Disc Incorporated for information and recomme...

Page 166: ...166 Twin Disc Incorporated Assembly Marine Transmission Service Manual 1020667 ...

Page 167: ...dication of interference Consequently the driven component should be removed and the source of interference found and corrected Twin Disc will not be responsible for system damage caused by engine to Twin Disc component interference regardless of the cause of interference This engine crankshaft endplay check is considered mandatory The transmission housing flange and pilot the engine flywheel and ...

Page 168: ...l so that the indicator is perpendicular to the face of the engine flywheel housing and the indicator stem is riding on the face of the flange Figure 137 Checking Flywheel Housing Flange for Deviations 2 Rotate the engine flywheel always keeping a thrust in the same direction and note the face deviation of the engine flywheel housing flange The face deviation must not exceed the figures given in T...

Page 169: ...er Face Deviations and Bore Eccentricity mm in 00 0 48 0 019 0 0 41 0 016 1 2 0 36 0 014 1 0 30 0 012 2 0 28 0 011 3 0 25 0 010 4 0 23 0 009 5 0 20 0 008 6 0 18 0 007 3 With the indicator mounted as in the previous paragraph adjust the indicator stem so that it will ride on the bore of the engine flywheel housing Figure 138 Checking Flywheel Housing Bore Eccentricity ...

Page 170: ...lerances 5 Bolt a thousandths dial indicator or gauge to the engine flywheel housing so that the indicator is perpendicular to the engine flywheel and the indicator tip is riding on the inner face of the flywheel Rotate the flywheel The variation of the face runout of the surface to which the driving ring is bolted should not exceed 0 013 mm 0 0005 in per inch of diameter Figure 139 Checking the F...

Page 171: ... it will ride on the driving ring pilot bore of the engine flywheel Rotate the flywheel The driving ring pilot bore eccentricity of the engine flywheel should not exceed 0 13 mm 0 005 in maximum total indicator reading Thrust on the flywheel should be in one direction at all times to obtain a correct reading Figure 140 Checking the Flywheel Pilot Ring Bore Eccentricity ...

Page 172: ...at 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 bed rails the flywheel housing should be checked for deflection using the following procedure Install the mounting brackets on the side mounting pads of the ...

Page 173: ...rving the indicator The indicator gauge must remain steady at the zero mark Torque the bed bolts to the proper rating If the reading moves from zero lift the marine gear and insert additional shims Continue this procedure until the marine gear is completely at rest on the bed rails and the gauge maintains a steady zero reading After obtaining the correct zero reading indicating no distortion of th...

Page 174: ...142 Transmission Mounting Configurations When mounting the engine and transmission in the boat all of the mounting pads on both the engine and the transmission must be used Failure to do so may result in damage to the transmission It is important to align the engine and transmission only when the boat is afloat and NOT in dry dock During this alignment period it is also advisable to fill the fuel ...

Page 175: ...acking off on the jacking screws to obtain the desired adjustment Steel plates must be inserted under the jacking screws so that the bolts will not damage the engine bed Lifting can also be accomplished by the use of chain hoists or properly placed jacks Adjustable shims also are available and can simplify the alignment process particularly for future realignment It may also be necessary to move t...

Page 176: ...ill fit snugly with the same tension all around the flange coupling in all four positions if the alignment is correct If the alignment varies during rotation additional alignment is necessary or the marine transmission and shaft couplings should be checked for proper face runout Runout must not exceed 0 10 mm 0 004 in Excessive face runout on the marine transmission output flange can usually be co...

Page 177: ...important to apply common sense alignment techniques to minimize the potential damage to any of the components During the process of securing final alignment it may be necessary to shift the engine many times When the final alignment is accomplished mark and drill the holes for the lag studs or locating dowel pins Then with final alignment secured make up the necessary poured steel or hardwood shi...

Page 178: ...nt In some cases the proper alignment of these couplings requires an accuracy equal to that of rigid couplings Always use the alignment procedures recommended by the coupling manufacturer Torsional Input Couplings Installation For Models Provided by Twin Disc Be sure the internal retaining ring is properly installed inside the torsional input coupling hub See Engineering Drawings section of this m...

Page 179: ...nd eliminated before you proceed Check the axial length dimension G1 in sketch 1 between the gearbox mounting flange and coupling flange do this in several places and take the average result Measure engine flywheel flywheel housing mounting dimension Dimension G2 in sketch 1 G1 should be less than or equal to G2 G1 G2 The CENTAFLEX CF R has a generous 2 mm to compensate for this difference SKETCH ...

Page 180: ...ion by engaging both halves of the coupling again ensu ring the arrows cast into both flange and hub are aligned see sketch 2 SKETCH 2 ENSURE CORRECT ASSEMBLY ALIGNMENT WITH THE ARROWS Bolt the gearbox mounting flange to the engine flywheel housing using the gearbox manufac turers engine manufacturers instruction MANDATORY Caution Before you start the engine Check there is axial play in each direc...

Page 181: ...m the last support bearing to the gearbox is excessive or a flexible stuffing box is used the shaft must be centered prior to engine and gearbox to propeller shaft alignment Transmission Controls Transmission controls must be checked for proper function and alignment after any transmission selector valve is properly indexed in relation to the operator s control lever Failure to do so could cause c...

Page 182: ...182 Twin Disc Incorporated Installation Marine Transmission Service Manual 1020667 Figure 146 Mechanical Control Valve Installation Specifications ...

Page 183: ...183 Twin Disc Incorporated Installation Marine Transmission Service Manual 1020667 Figure 147 Optional Electric Control Valve Installation Specifications ...

Page 184: ...places the transmission selector valve in the detent position for forward or reverse as selected without exerting pressure on the rotational stop on the selector valve stem Selecting neutral must place the selector valve in the neutral detent position Improper installation of power engaging devices could cause failure of the selector valve stop permitting improper positioning of the selector valve...

Page 185: ...Driver q T 18050 25 Driver q T 18050 183 Bearing Driver q T 18050 321 Seal Driver q T 18050 323 Bearing Seat Driver q T 18050 327 Bearing Driver q T 18050 335 Driver q T 18050 585 Bearing Driver q T 18050 611 Bearing Driver q T 18614 5 Oil Injection Tool q T 19998 Spring Retainer Hold Down q T 20023 Output Gear and Shaft Puller Sheet 1 q T 20023 Output Gear and Shaft Puller Sheet 2 q T 20023 Outpu...

Page 186: ...186 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 q Lifting Bracket for Clutch Removal in Boat q T 18050 772 Bearing Driver q T 19987 Output Gear Lifting Fixture ...

Page 187: ...187 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Bearing Driver T 18050 11 ...

Page 188: ...188 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Driver T 18050 25 ...

Page 189: ...189 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Bearing Driver T 18050 183 ...

Page 190: ...190 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Seal Driver T 18050 321 ...

Page 191: ...191 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Bearing Driver T 18050 323 ...

Page 192: ...192 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Bearing Driver T 18050 327 ...

Page 193: ...193 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Bearing Driver T 18050 335 ...

Page 194: ...194 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Bearing Driver T 18050 585 ...

Page 195: ...195 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Bearing Driver T 18050 611 ...

Page 196: ...196 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Oil Injection Tool T 18614 5 ...

Page 197: ...197 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Spring Retainer Hold Down T 19998 ...

Page 198: ...198 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Output Gear Shaft Puller for Assembly T 20023 Sheet 1 ...

Page 199: ...199 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Details for Puller T 20023 Sheet 2 ...

Page 200: ...200 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Details for Puller T 20023 Sheet 3 ...

Page 201: ...201 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Sleeve for Runout Check T 21302 1 ...

Page 202: ...202 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Oil Seal Protector T 21347 ...

Page 203: ...203 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Oil Seal Driver T 21347 1 ...

Page 204: ...204 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Lifting Bracket for Clutch Removal in Boat ...

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Page 206: ...206 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Notes ...

Page 207: ......

Page 208: ...208 Twin Disc Incorporated Special Tools Marine Transmission Service Manual 1020667 Notes ...

Page 209: ...low Note Any part numbers listed in the following illustrations are for reference only Please refer to your bill of material for part numbers specific to your model q Clutch Group q Suction Strainer q Oil Filter q Transmission Rear View q Transmission Section View q Torsional Input Coupling q Manual Control Valve q Trolling Valve for Manual Control Valve q Electric Control Valve optional equipment...

Page 210: ...210 Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1020667 Clutch Group 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 ...

Page 211: ...ch 11 2 Ring internal retaining clutch backplate 12 2 Retainer spring primary and secondary shaft 13 2 Ring external retaining primary and secondary shaft spring retainer 14 32 Spring assembly compression clutch release 15 2 Ring piston clutch piston inner 16 2 Piston clutch 17 2 Ring piston clutch piston outer 18 1 Gear transfer secondary shaft LH helix 19 2 Bearing tapered roller primary and sec...

Page 212: ...Transmission Service Manual 1020667 Suction Strainer 32 33 34 35 36 37 Item Qty Description 32 1 Strainer suction 33 1 Spring compression 34 1 O ring suction tube 35 1 Tube assembly suction 36 1 O ring suction strainer plug 37 1 Plug suction strainer ...

Page 213: ... Tube lubrication 39 1 Filter oil 40 1 Gasket filter bypass valve 41 3 Screw hex head cap filter bypass valve 42 1 Cover filter bypass valve 43 1 Spring compression filter bypass valve 44 1 Poppet filter bypass 45 1 Ball steel lube relief valve 46 2 Washer flat 47 2 Screw hex head cap 48 1 Housing lube relief valve 49 1 Spring compression lube relief valve ...

Page 214: ...214 Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1020667 Transmission Rear View 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 66 65 67 68 69 70 71 72 73 74 75 76 77 78 ...

Page 215: ...et head cap 12pt on some models 58 1 Valve assembly 59 1 Plate identification 60 1 Plug pipe oil filter drain 61 1 Screw socket head cap 12pt on some models 62 1 Screw socket head cap 12pt on some models 63 2 Plug ass y O ring 64 1 Plug pipe 65 1 Screw drive instruction plate 66 1 Plate lubrication instruction 67 1 Breather 68 2 Eyebolt 69 1 S link 70 1 Chain 71 1 Washer 72 1 Clip 73 2 Plate 74 2 ...

Page 216: ...Illustrations Marine Transmission Service Manual 1020667 Transmission Section View 79 80 81 82 83 84 85 86 87 88 89 90 92 93 94 95 98 99 100 101 91 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 96 97 ...

Page 217: ...op cover plate 97 1 Plate top cover 98 1 O ring breather 99 1 Strainer oil filler 100 2 Ring piston primary shaft 101 1 O ring primary shaft end cover plate 102 1 Plate primary shaft end cover 103 1 Ring external retaining primary and secondary shaft rear bearing 104 1 Gear transfer primary shaft RH helix 105 1 O ring output seal carrier 106 1 Fitting grease 107 4 Screw hex head cap output flange ...

Page 218: ... Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1020667 Torsional Input Coupling 121 122 123 124 125 130 126 127 128 129 130 131 132 133 134 135 SERVICE REFERENCE REFERENCE SERVICE ...

Page 219: ...ub splined coupling close coupled units 125 1 Ring internal retaining 126 1 Coupling assembly SAE 0 127 1 Coupling assembly SAE 1 128 1 Ring internal retaining 129 1 Coupling assembly SAE 0 130 8 Element to service item 127 or 129 131 1 Hub splined coupling free standing units 132 1 Ring internal retaining 133 1 Washer retaining 134 1 Shaft assembly primary free standing units 135 3 Screw hex head...

Page 220: ...porated Illustrations Marine Transmission Service Manual 1020667 Manual Control Valve 141 140 139 138 137 136 169 168 167 166 165 164 163 162 161 160 159 158 156 157 155 154 153 151 150 149 147 148 146 145 144 143 142 152 ...

Page 221: ...g 152 3 Screw short 12pt head or socket head depending on model 1 Screw long 12pt head or socket head depending on model 153 1 Spring outer pressure regulating 154 4 Closure plastic valve to manifold screw holes 155 1 Shim neutral pressure adjustment 156 1 Spring inner pressure regulating 157 1 Body valve 158 1 Spring check ball 159 1 Ball steel check 160 2 Gasket orifice plate and orifice plate c...

Page 222: ... Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1020667 Trolling Valve for Manual Control Valve 170 171 172 173 174 175 176 177 178 179 181 180 182 183 184 185 186 187 188 189 190 ...

Page 223: ... Screw hex head 177 1 Seal oil 178 1 Cover valve 179 1 Gasket valve cover 180 1 Spring detent 181 2 O ring 182 2 Plug O ring 183 1 Plug optional oil inlet 184 2 Plug 185 1 Piston pressure regulating 186 3 Screw short 12pt head or socket head depending on model 187 1 Spring outer pressure regulating 188 4 Closure plastic valve to manifold screw holes 189 1 Shim neutral pressure adjustment 190 1 Spr...

Page 224: ...224 Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1020667 Notes ...

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Page 228: ...228 Twin Disc Incorporated Illustrations Marine Transmission Service Manual 1020667 Notes ...

Page 229: ... 1017463 sheet 2 of 4 Marine transmission q 1017463 sheet 3 of 4 Marine transmission q 1017463 sheet 4 of 4 Marine transmission q 1017463A sheet 1 of 4 Marine transmission q 1017463A sheet 2 of 4 Marine transmission q 1017463A sheet 3 of 4 Marine transmission q 1017463A sheet 4 of 4 Marine transmission q A7119V Hydraulic diagram q XA7371 Mechanical Control Valve 1017463 assemblies q 1020412 Mechan...

Page 230: ...230 Twin Disc Incorporated Engineering Drawings Marine Transmission Service Manual 1020667 ...

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Page 250: ... 1020667 07 02 TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM ...

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