Twin Disc - Marine Transmission Owner`s Manual
Contents
1. FIG 15 Oil Drain Plug Oil Filler Oil Filter a Oil Level Gauge Lube fitting Suction Strainer ee Soi Drain Plug Appendix Oil Filler Oil Filter OUO 595959959 S A LY F N 09090808 Oil Level Gauge Sucti uction Lube fittin Strainer obo 06 Lo i Oil Drain Plug FIG 17 Oil Filler Ng me Oil Level Al 02080 a 3 JL Gauge O i UE Suction Strainer Lube fitting Oil Drain Plug FIG 18 6 13 SECTION 6 Oil Filler Suction Strainer Oil Drain Plug FIG 19 Oil Filer __ Oil Level Gauge Oil Filter Suction Strainer Oil Drain Plug FIG 20 6 14 Appendix Oil Level Gauge Oil Filler Oil Filter u VL Lo SIL Suction di C Lube Fitting ex 7 TER FE Oil Drain Plug FIG 21 Oil Filter Oil Filler bs u Oil Level m PSA e O2. D Inthe case of an inoperable engine or pump failure where pressure lubrication of the transmission is not possible plug the dipstick tube and completely fill the transmission with oil Prior to backdriving or towing drain the oil down to full oil level Repeat this process every eight hours 3 7 A Operation Emergency Operation Mechanical Stop on Failed Torsional Coupling Many torsional couplings used with Twin Disc transmissions have mechanical stops to allow power to be transmitted to the transmission in the event of a coupling failure Continued operation at high power levels could result in costly damage to the transmission internal components In the event of a torsional coupling failure return to a safe harbor immediately to initiate repair or replacement of the failed coupling Limit operation to 50 of maximum engine speed or a maximum of 1000 rpm to avoid additional costly internal damage to transmission components Come Home Screws 1 Description Certain marine transmissions are equipped with come home screws that permit mechanical lock up of a clutch in the event hydraulic pressure is lost Come home screws are intended to be used on malfunctioning single transmission vessels On vessels with multiple transmis sions if one transmission malfunctions propel the vessel with the remaining good transmission as described in the instructions for windmilling backdriving Section 3 6 In the event o
3. Operation 6 To return to no troll operation a Movetrolling valve control lever to detented no troll position b Resume normal no troll operations NOTE Moving the trolling valve control lever to the no troll position while engine speed is at the high limit for trolling operations will cause an abrupt change in propeller and vessel speed Reducing engine speed to idle before selecting no troll will result in a smoother transition to no troll operation Assure that the trolling valve cable control system is adjusted properly The trolling valve control lever on the transmission must be in the detented no troll position when the control at the operator s station is moved into the no troll position Failure to do so could result in inadequate response to power and or direction changes endangering personnel and equipment 3 6 Windmilling Backdriving and Towing Backdriving occurs when an engine is shut down and the propel ler shaft is being driven by the flow of water across the propeller This is sometimes referred to as windmilling The propeller shaft is rotating components in the marine transmission Locking the propel ler shaft in place will prevent backdriving Situations where backdriving may occur e Vessel being towed for any reason e Multiple transmission vessel with one or more engines shut down while under way e Sailboat under way with auxiliary eng
4. ture information on lubrication plate 3 3 SECTION 3 NOTE Sustained operation of the marine transmission with oil temperature outside of normal operating range is not recommended 4 Shifting Limits The following chart contains the recommended engine rpm for all shifts NEUTRAL into FORWARD or REVERSE and FORWARD or REVERSE through NEUTRAL into the opposite direction for all Twin Disc marine transmission models Model Maximum Engine Speed for Shifting MG 340 MG 360 MG 5005A All shifts 900 rpm maximum MG 5012SC MG 5015A MG 5020SC MG 5055A MG 540 MG5600 Series All shifts 750 rpm maximum MG 6000 Series except MG 6650 50 ofengine rated operating speed MG 6690 and MG 6848 All other models All shifts 1000 rpm maximum 34 NOTE The recommended engine rpms pertain to normal operation only In an emergency the owner operator is expected to employ whatever procedures are necessary to prevent loss of life and reduce damage to property 3 5 Operation with Optional Trolling Valve A General Trolling valves are available as optional equipment for most Twin Disc marine transmissions The trolling valve allows reducing and controlling propeller speed below that normally attained by operat ing the engine at low idle Examples of operations requiring such slow speeds are trolling or movement through no wake restricted areas Most trolling valve can be used with the selector v
5. 4 1 General Maintenance nerne nenn 4 1 A Oil Level Check 4 1 B EubtiCatlOll into e eee ante 4 1 C Filter and Oil Change Interval 4 1 D Oil Capacity iioii res 4 3 E Heat Exchanger Check 4 3 F SUCHON StraiNe eae aio eed e kae dd en 4 3 G Flexible Input Coupling esses 4 3 H Bearing Inspection and Replacement 4 4 l Overhaul Interval sse 4 4 4 2 Storage Maintenance Procedures 4 4 A Short Term Storage Less than One Year 4 4 B Long Term Storage More than One Year 4 5 C Heat Exchanger Storage sss 4 6 Section 5 Troubleshooting 5 1 Troubleshooting Tables sss 5 1 Standard Transmission Charts sss 5 2 MGX Series LED CAFE eie ae 5 8 MGX Transmission Charts 5 9 Section 6 Appendix 6 1 Accessories and Optional Equipment 6 1 6 2 Marine Transmission Illustrations esses 6 3 Speed Pick Up Location sss 6 3 6 3 Commercial Transmission Warranty 6 19 64 Pleasure Craft Transmission Warranty 6 20 Introduction Section 1 Introduction 1 1 General Information This publication provides general operating information for Twin Disc Marin
6. 8 Rebuilt 8 hrs hrs then hrs then 1000 hrs 1000 hrs Maintenance Record MODEL NUMBER SERIAL NUMBERS DATE PLACED IN SERVICE DATE HRS AT OVERHAUL Check Oil Grease Oil Change Oil Clean Check Heat Check Level Seals and Filter Suction Exchanger Input if appl Strainer Coupling Daily Every 100 New 50 hrs New 50 hrs Every 30 First 100 hours then every then every 90 days hrs then 1000 hrs 1000 hrs every 2000 Rebuilt 8 Rebuilt 8 hrs hrs then hrs then 1000 hrs 1000 hrs vi Table of Contents Marine Transmission Owners Manual Section 1 Introduction 1 1 General Information anale 1 1 1 2 Safety and General Precautions i 1 1 A Gehetal tr een 1 1 B Important Safety Notice 1 1 1 3 Preventative Maintenance 1 2 1 4 Ordering Parts and Obtaining Service ee 1 2 A Ordenng T 1 3 B Source of Service Information 1 3 C Warranty Information sescca n 1 3 Section 2 Description and Specifications 21 Description isses an un EIAS E aaa 2 1 2 2 Construction Features n eee aa 2 2 A Oil Pump Drive nn 2 2 B Lubrication Features 2 2 C SUC
7. 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 B Source of Service Information For the latest service information on Twin Disc products contact any Twin Disc distributor or service dealer Product service manuals are available which provide more specific and detailed overhaul and installation instructions Provide your model number serial number and bill of material number to obtain information on your unit C Warranty Information The Commercial Twin Disc marine transmission warranty can be found in the Appendix Section 6 3 of this manual The Pleasure Craft Twin Disc marine transmission warranty can be found in the Appendix Section 6 4 of this manual This warranty may be supplemented by additional published warranty terms dependent upon the product involved Supplementary warranty terms are available upon request For details on administering the warranty contact any Twin Disc distributor service dealer or the Warranty Administration Department Twin Disc Incorporated Racine Wisconsin U S A SECTION 1 Description and Specifications Section 2 Description and Specifications 2 1 l Description While most Twin Disc marine transmissions are forward reverse reduction units some units provide speed increas ing capability All may be used with standard right hand r
8. ing the cause of problems that could be encountered and the corrective actions for those difficulties The transmission is one part of a complete propulsion system Problems before the transmission in the engine or after the transmission in the output shaft or propeller can cause problems to develop in the transmission It is important that the entire propulsion system be considered when transmission problems are encountered Note that there are three separate charts on the following pages o Troubleshooting charts for Standard MG Marine Transmissions o LED Troubleshooting chart for MGX Series of Marine Transmissions o Troubleshooting charts for MGX Series of Marine Transmissions Note Troubleshooting assistance as well as maintenance repair and parts service is available from your Twin Disc distributor or service dealer 5 1 SECTION 5 1 5 2 Symptom Low main oil Pressure Standard MG Chart 1 Partially clogged oil strainer Stuck pressure regulation piston in selector valve Worn or broken piston rings on clutch shaft s Damaged or worn oil pump assembly Incorrect linkage adjustment to control valve assembly Clogged or plugged orifice in orifice plate Shimming required between inner and outer springs and rate of rise piston Engine idle speed too low Remove and clean oil strainer Disassemble the selector valve and clean the piston Remove the collecto
9. 1016313 Marine Transmission Owner s Manual ADMINSTRATIVE OFFICES RACINE WISCONSIN NOTICE Twin Disc Incorporated makes no warranty or guaranty of any kind expressed implied or otherwise with regard to the information contained within this manual Twin Disc Incorporated has developed this manual through research and testing of the information contained therein Twin Disc Incorporated assumes no responsibility for any errors that may appear in this manual and shall not be liable under any circumstances for incidental consequential or punitive damages in connection with or arising out of the use of this manual The information contained within this manual is subject to change without notice 1016313 Marine Transmission Owner s Manual Revision 4 May 2004 Parent Company Twin Disc Incorporated 1328 Racine Street Racine Wisconsin 53403 U S A Phone 1 262 554 2488 Fax 1 262 554 2764 Web site www twindisc com Twin Disc Incorporated Latin America Office 11700 NW 101 Rd Suite 19 Medley Florida 33178 U S A Phone 1 305 887 9050 Fax 1 305 887 9090 Email eberhardt Erwin twindisc com Twin Disc International S A Chauss e de Namur 54 B 1400 Nivelles Belgium Phone 32 67 887 211 Fax 32 67 887 333 Twin Disc Technodrive s r l Via S Cristoforo 131 1 40010 S Matteo Decima BO Italy Phone 39 051 6819711 Fax 39 051 6824234 or 6825814 Twin Disc Far E
10. Overhaul marine transmission Remove marine transmission Replace a wom or damaged coupling Select proper torsional coupling Overhaul marine transmission Check alignment of engine and transmission output flange to propeller shaft Correct as necessary Repair propeller Repair engine MGX Series Chart 3 Troubleshooting Symptom Cause Remedy 6 No neutral 6 1 Clutch plates warped 6 1 Remove clutch plates Overhaul unit 6 2 Disengaged clutch has 6 2 Replace Proportional apply pressure Valve Service transmission oil filter 7 Harsh engagement or no 7 1 Faulty Proportional Val ve 7 1 Replace Proportional engagement Valve 7 2 Faulty Temperature 7 2 Replace Temperature Sensor if equipped Sensor 7 3 Profile Generator defective 7 3 Replace Profile or out of adjustment Generator Adjust if proper equipment is available 8 Low lube oil pressure 8 1 Pump flow output too low 8 1 Replace pump 8 1 Pump suction strainer 8 2 Remove clean inspect plugged and install the suction Screen 8 3 Air leak on suction side of 8 3 Inspect and correct cause pump of suction leaks 8 4 Lube relief valve 8 4 Remove and clean or malfunction replace parts as necessary 8 5 Broken piston rings 8 5 Replace damaged piston rings 9 Oil spilling out of 9 1 Oil level too high 9 1 Adjust oil level breather 9 2 Wrong type of oil 9 2 Draw and refill with recommended oil 10 Low
11. Rate Schedule re quired to remove disassemble inspect repair reassemble reinstall and test the Twin Disc Incorporated product only Authorized reasonable travel and living expenses will be considered for payment Under no circumstances including a failure of the exclusive remedy shall Twin Disc Incorporated be liable for economic loss consequential incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation pre paid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair 2 The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engi neered and in accordance with the practices methods and instructions approved or provided by Twin Disc Incorpora
12. the shafts Output shaft bearings are gravity and or splash lubri cated Some transmissions use pressurized oil spray to lubricate gears and bearings C Suction Screen All units have a suction strainer located between the sump and oil pump in the hydraulic circuit Its purpose is to prevent debris from entering the inlet side of the pump The suction strainer must be cleaned as a part of every oil change Consult the illustrations found in Section 6 2 for the suction strainer location on your unit D Filter Assembly Many units have an oil filter installed in the system Some units incorporate a spin on filter Other units use a cartridge type filter plumbed into the hydraulic circuit between the pump outlet and the transmission inlet port Replace oil filter as part of every oil change Consult the illustrations found in Section 6 2 for the filter location on your unit 2 3 Specifications All Twin Disc marine transmissions are equipped with an identifica tion plate See sample identification plate at the front of this manual In addition to information identifying the unit i e model number BOM number ratio serial number and customer number Description and Specifications the identification plate provides information on oil capacity minimum cruise oil pressure and oil check oil change intervals for your particular transmission All operators of this equipment are respon sible to read and apply the information provided on
13. 2 Type 2 Electric Selector Manual Override Lever Electric Control Position 1 Push in lever 2 Rotate clockwise to lock Manual Override Position 1 Rotate counterclockwise to neutral position 2 Pull out lever 2 Port A lever position we OT Neutral Port B lever position Operation Fig 3 Type 3 GP Valve Manual Direction Control Valve N Locking Pin 3 17 SECTION 3 2 Type 1 Selector Installation of Override Plug Consult Fig 1 for items referenced in the following steps Once the override plug is installed the transmission cannot be shifted to neutral or into the opposite gear Shut down the engine and place the vessel under tow before entering any congested area or dock area Failure to do so will endanger the safety ofthe crew and vessel as well as other people and vessels in the area a b c d Locate and remove the stored manual override plug from the selector valve body for use in step c NOTE The location of the stored override plug varies on different models Determine which clutch should be engaged primary or secondary clutch and remove the appropriate solenoid Install the override plug in place ofthe removed solenoid A CAUTION The selected clutch is engaged whenever the engine is running If the vessel is going in the wrong direction stop the engine and remove the override plug Reinstall the removed solenoid
14. 2V MG5113 MG509 MG514C MG X 5114SC MG5114DC MG X 5114A MG514CHP MG514M MG X 5135 MG X 5145 MG516 MG X 5114IV MG X 5114RV MG5141 MG518 MG520 MG5161 MG5170DC MG521 MG527 MG530 MG530M MG5202SC MG5202DC MG5203 MG5204 MG5222DC MG5225DC MG5205DC MG540 MG5010 MG5010A MG5301DC MG5600 MG5600DR MG5010V MG5011 MG5011A MG6449A MG6449R V MG6557A MG6557RV MG50111V MG5050 MG5050A MG6557SC MG6557DC MG6600DC MG5061 MG5061A MG5061V MG6619A MG6619RV MG6619SC MG5062V MG5075 MG5075A MG6650 MG6984SC MG6984A MG5081 MG5081A MG5082 MG5082A MG5085 MG5085A MG6984RV MG61242SC MG61242A MG5090A MG5091 MG61242RV OM 22A Appendix Suction Strainer FIG 1 Oil Drain Plug Alternate Oil Level 34 Oil Filler Gauge Location IS Oil Level Suction Strainer SECTION 6 Alternate Oil Filler and Oil Filler Oil Level Gauge A and H Oil Level PUT SHar vel TAE Oil Drain Plug FIG 3 Strainer om 12 Come Home Screw Oil Filler Access Plugs Alternate Oil Level oa leon Gauge Location Oil Level Gauges ap OZ Lube Fitting Oil Drain Plug Appendix Alternate Oil Level Gauge Location Suction IN Strainer a n EI IN d Oil Level t i 3 SR Fitting Oil Drain Plug om 14 Alternate Oil Level Gauge Location MG 5161 only Come H
15. ALS WITH WATER PUMP GREASE TO PREVENT BILGE WATER EVERY 1000 SERVICE HOURS OR 6 MONTHS WHICHEVER COMES FIRST OR DAILY CHECK OIL LEVEL WITH ENGINE RUNNING AND AND REFILL HOUSING e CLEAN UIL REMOVE AND REPLACE FILTER ELEMENT WHERE APPLICABLE CLEAI EN BEEN VE RUD ORES NH SHS WAN CAI LUBRICANT PLATE SHIPPED WITH UN BILL OF MATERIAL No MUST BE GIVEN WHEN ORDERING PARTS S PORATED A DRAIN MADE IN U S A Ol 204098C Lubrication Plate Fill in the blanks below with the information from your unit s lubrication data plate Keep this information at hand and refer to it when servicing your transmission e e 2 MARINE TRANSMISSION LUBRICANT e See the Lubrication Plate on your Marine Transmission for Oil Specs STARFUP STEADYOPERATION VISCOSITY Go meas a Oil temperature listed is temperature of oil to the heat exchanger NOTE Some MG6000 series transmissions built before 2002 do not utilize a lubrication data plate See Section 2 4 for oil recommenda tions Maintenance Record MODEL NUMBER SERIAL NUMBERS DATE PLACED IN SERVICE DATE HRS AT OVERHAUL Check Oil Grease Oil Change Oil Clean Check Heat Check Level Seals and Filter Suction Exchanger Input if appl Strainer Coupling Daily Every 100 New 50 hrs New 50 hrs Every 30 First 100 hours then every then every 90 days hrs then 1000 hrs 1000 hrs every 2000 Rebuilt
16. Clutch Apply 10 1 Low Main Pressure 10 1 See Paragraph 1 Pressure 10 2 Defective Proportional 10 2 Replace Proportional Valve Valve 10 3 Low voltage to Profile 10 3 Verify that green voltage Generator supply light and red clutch energized lights are bright 5 11 SECTION 5 5 12 6 1 Appendix Section 6 Appendix Accessories and Optional Equipment A number of options and accessories are available for use with Twin Disc marine transmissions Contact your Twin Disc distributor for specific information on items to fit your unit and procedures for installation The following items are available for all units l Oil Temperature Gauges Used to monitor transmission sump oil temperature Scales calibrated in Centigrade and Fahrenheit ranges Oil Pressure Gauges Used to monitor main clutch apply oil pressure Scale calibrated in kilopascal and pound force per square inch ranges The use of oil pressure gauges is recommended for all installations Output Shaft Companion Flanges Used to connect transmission output flange with vessel propeller shaft Hub to Fit Flexible Input Couplings Provides the connection between the engine driven input coupling and the transmission input shaft Trolling Valves Used to reduce propeller speed below what can be obtained by operating the engine at low idle e g trolling operations operating in no wake areas etc Heat Exchangers Used to contro
17. One Year Transmission installed in a boat where the engine cannot be run Boat out of water 1 Use standard recommended oil for the following proce dures Once each year remove dipstick and plug dipstick tube Completely fill the transmission with oil Rotate the output shaft at least five revolutions Partially drain oil reinstall dipstick and then drain oil down to full mark on the dipstick Seal breather dipstick tube and all other openings with waterproof tape Grease exposed members that are subject to corrosion Every three months rotate output shaft four or five revolutions 4 5 SECTION 4 4 6 5 Tag transmission to show date it was placed in storage and current status relating to storage procedure 6 To remove from storage and place in regular service a Remove waterproof tape from breather dipstick tube and all openings b Drain oil and remove oil filter c Install new oil filter and fill transmission with new recommended oil to full mark on dipstick d Replace zinc rods in heat exchanger C Heat Exchanger Storage When storing a heat exchanger oil and water ports must be kept sealed Heat exchangers stored during cold weather must have the water chamber drained to prevent freezing Take precautions to prevent damage from freezing and corrosion Troubleshooting Section 5 Troubleshooting 5 1 Troubleshooting Tables The following charts are intended as a guide for determin
18. TION SCHEEN ur en rr ree Celi vv eda 2 2 D Filter Assembly escl iii 2 2 23 Specifications 2 2 24 QOllRecommendatiOls anses 2 3 A Oil VISCOS 2 3 B Oil Pressure and Temperature 24 C Heat Exchanger annen 2 5 Section 3 Operation 3 4 Selector Valve ssir a a 3 1 A General Description 3 1 B LER 3 2 32 Prestart up Checks oreet ee 3 2 33 Stamp use XE a a a e raden I Ut AU E 3 3 3 4 Normal Operation RH 3 3 3 5 Operation with Optional Trolling Valve 3 4 A General ur REE NES SE SS SEERE NES BESES SES elas 3 4 B Operating EiMiS un ee 3 5 C Normal Operation Trolling Mode 3 6 3 6 Windmilling Backdriving and TOWING nennen 3 7 3 7 Emergency Operation u a anne 3 9 A Mechanical Stop on Failed Torsional Coupling 3 9 B Come Home Screws ii 3 9 1 DESPON ete 3 9 2 Table Transmissions with Come Home Screws 3 10 3 Using Come Home Screws 3 11 C Electric Selector Manual Override 3 15 1 Determine Your Electric Selector Type 3 15 2 Type 1 Selector Installation of Override Plug us 3 18 3 Type 2 Selector Manual Override Lever 3 19 4 Type 3 Selector Manual Direction Control Valve 3 20 viii Section 4 Maintenance
19. al A CAUTION Engagement of a clutch using the Manual Direc tion Control Valve should only be done with the engine at idle speed 3 20 Maintenance Section 4 Maintenance 4 1 General Maintenance NOTE A chart is provided in the front of the manual to record the dates hours that maintenance procedures are performed A Oil Level Check Check oil level daily or every 10 hours of engine operation Check with engine running at low idle and with marine trans mission in neutral Transmission oil temperature should be in normal operating range prior to checking oil level See Section 3 3 Start Up B Lubrication If your unit is equipped with a lubrication fitting grease the oil seals at the output end of the transmission output shaft with water pump grease through the lubrication fitting See illustra tions in Section 6 2 for location of the lubrication fitting Apply grease every 100 hours or when boat is docked No other lubrication is required NOTE Preferred grease is one with lithium soap NLGI consistency 2 for component temperatures above 20 C 68 F C Filter and Oil Change Interval With a new transmission change the oil and filter element within first 50 hours of operation Change oil and filter element after each 1000 hours of operation or six months whichever comes first The oil may need to be changed more frequently if conditions warrant 4 1 SECTION 4 For a rebuilt transmission check th
20. alve in either the forward or reverse positions Actuating the trolling valve reduces clutch apply pressure which reduces propeller speed Operation B Operating Limits The following chart lists the maximum engine speeds for marine transmissions to operate in the trolling mode Continuous trolling is permitted if engine speed does not exceed prescribed limits NOTE Additional cooling is not required when in the trolling mode but trolling valve performance can be affected by operating oil tempera ture In some cases a thermostatic bypass valve is recommended to maintain operating oil temperature at desired level Marine Transmission Maximum Engine Speed with Transmission in the Trolling Mode 1200 RPM Engine Speed MG 5015A MG 5055A MG502 Series Up to 42 of full load RPM but not below 500 RPM or above 1100 RPM engine speed MG5010 Series MG509 1100 RPM or 40 of full load RPM MG5011 Series MG5090A whichever is smaller MG506 Series MG5091 MG507 Series MG5111 Series MG5075 Series MG5112V MG5081 MG5113 MG5050 Series MG514C 1100 RPM or 60 of full load RPM MG5061 Series MG5141 sc Whichever is smaller MG5062V MG516 MG5082 MG5170DC MG5085 MG518 MG X 5114 Series MG520 MG X 5135 MG5200 series MG X 5145 MG5301 MG540 1000 RPM or 50 of full load RPM whichever is smaller MG5600 Series MG 6650 MG 6848 35 SECTION 3 3 6 C Normal Operation Trolling Mode The following is the normal pro
21. ansmissions The illustrations are grouped into similar model designs and show the general locations of the e Oil Filler e Oil Filter if applicable e Suction Strainer e Oil Level Gauge e Lube grease Fitting if available e Oil Drain Plug e Come Home Screws if applicable To find the illustration that matches your model look up the model number on the following chart then go to the referenced figure number Speed Sensor Location Marine Transmission models that require engine and output speed signals will have speed sensors included that are not shown on the following figures The output speed sensor is generally located on the rear of the unit and to the right of the output flange as viewed from the rear Integral V units generally have the output speed sensor located on the top of the housing The engine speed sensor is generally located on the top of the transmission housing or clockwise from the top as viewed from the rear of the transmission Consult the Service Manual for the exact location SECTION 6 NOTE The illustrations identified by figure number are accurate for the general location of features however they may not be an exact depiction of all designs If more specific information is needed on your marine transmission s features please refer to your service manual Illustration Reference Chart Model Figure Model Figure MG502 1 MG506 MG506A MG5111 MG5111A MG506 DC MG507 MG507A MG511
22. ast LTD 40 Lok Yang Way Jurong Singapore 628643 Phone 65 6267 0800 Fax 65 6264 2080 Subsidiaries Twin Disc Pacific PTY LTD Brisbane Main Office 40 Telford Street Virginia Queensland 4014 Australia Phone 61 7 3265 1200 Fax 61 7 3865 1371 Twin Disc Pacific PTY LTD Perth Western Australia Branch 130a Radium Street Welshpool WA 6106 Australia Phone 61 8 9451 9366 Fax 61 8 9451 9318 Twin Disc Inc Representative Office Room 21G Ai He Mansion 629 Ling Ling Road Shanghai China 200 030 Phone 86 21 6427 3212 or 14 Fax 86 21 6427 5192 Twin Disc s r l European Propulsion Group Via dei Calzolai 92 1 55040 Capezzano Pianore LU Italy Phone 39 0584 969696 Fax 39 0584 969692 Identification Plate Transcribe the following information from your unit s nameplate to the illustration below for ease of reference e Model Number e BOM Number e Ratio e Serial Number e Customer Number if applicable e Oil Capacity e Minimum Oil Pressure at rated engine speed Keep this information at hand and refer to the model number serial number and BOM number when requesting any parts or service Or NO DIL CAPACITY RATIO O SERIAL NO N GAL MARINE TRANSMISSION Seli u MIN DIL PRESSURE AT ini RPM SI LUBRICATION MARINE TRANSMISSION IN NEUTRAL E HOURS WHERE A GREASE FITTING IS PROVIDED LUBRICATE DUTEUT SHAFT SE
23. cedure for engaging and operating a marine transmission when trolling mode is to be used 1 Shift transmission selector to NEUTRAL 2 Reduce engine rpm to low idle 3 Move trolling valve control lever out of detented no troll position to maximum troll slowest vessel speed position 4 Move transmission selector lever to desired direction of travel 5 Adjust trolling valve lever setting and if necessary engine rpm up to specified limit to attain desired vessel speed Do not exceed specified maximum engine speed while operat ing in the troll mode To do so will result in excessive clutch heat buildup and possible clutch failure The trolling valve must be in the detented no troll position when docking the vessel or when operating in congested areas Failure to do so could result in sluggish response to power changes or shift reversals with loss of necessary control of vessel speed or direction of travel NOTE Do not attempt to use a marine transmission equipped with a trolling valve as a power dividing device The capability to run the engine at a constant rpm to power accessories pump generators compressors etc while maintaining independent control of output shaft speed can be adequately accomplished by Omega type drives only e g MG530M MG514M Attempts to use a trolling valve equipped transmission for such a purpose at engine speeds above the limits specified will result in clutch failures
24. crew access plug holes in the manifold ateach clutch location Use a flashlight to look into come home screw access plug holes For most transmissions with come home screws slowly bar engine over to align come home screws in clutch housing with access plug holes in manifold Models MG514C and MG530 require barring over the output propeller shaft rather than the engine NOTE Procedure used to bar engine over to align come home screws with access plug holes in the manifold will vary depending upon engine involved auxiliary equipment installed etc Whatever the situation it is necessary to rotate the transmission clutch housings and to stop rotation when alignment is achieved Bumping the starter may be possible and may achieve necessary alignment Where possible using a bar or other device attached to the front of the engine crankshaft after releasing engine compression is the most effective method for achieving desired alignment e g h Operation Use tool specified for your transmission and alter nately tighten turn clockwise the accessible come home screws until screws are tightened as far as they will go Assure the accessible come home screws are tightened evenly Failure to do so may cause the clutch apply piston to cock and bind in the clutch cylinder preventing compression of the clutch plates and lock up of the clutch Unlock transmission output shaft NOTE Steps g through j belo
25. e This valve cannot be disassembled 2 6 Oil pump defective 2 7 Replace oil pump 2 7 Leaking heat exchanger 2 7 Replace heat exchanger has caused oil to be lost over board SECTION 5 MGX Series Chart 2 3 4 5 5 10 Symptom High main oil pressure High temperature Excessive Noise 3 2 4 3 4 5 4 6 5 2 5 3 5 5 5 6 5 7 Cause Pilot Relief Valve out of adjustment Main Regulating Valve orifice missing Improper oil level Faulty heat exchanger Clutches slipping Bearing failure Air leak on suction side of pump Control valve malfunction Bearing failure Worn or damaged input coupling Excessive torsional vibration Worn or damaged gears Improper alignment Damaged propeller Misfiring engine 3 2 4 1 4 3 4 4 4 5 4 6 5 1 5 2 5 3 5 4 5 5 5 6 5 7 Remedy Adjust the Pilot Relief Valve Replace if necessary Replace Main Regulating Valve Cartridge Check and fill or drain with proper oil to the correct level Inspect repair or replace heat exchanger Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch If pressure is low replace Proportional Valve and service transmission oil filter Overhaul marine transmission Inspect and correct cause of suction leak Inspect repair or replace control valve
26. e Transmissions Specific product details and performance characteristics can be obtained by contacting your nearest Twin Disc Authorized Distributor or Service Dealer This manual is current at the time of printing When required changes are made to reflect advancing technology and im provements in state of the art 1 2 Safety and General Precautions A General All personnel servicing this equipment should employ safe operating practices Twin Disc Incorporated will not be re sponsible for personal injury resulting from careless use of hand tools lifting equipment power tools or unaccepted maintenance working practices 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 1 1 SECTION 1 specified in safety codes should be provided These devices are neither provided by nor are they the responsibility of Twin Disc Incorporated Selecting NEUTRAL disengages transmission clutches but does not prevent propeller shaft rotation If you require positive neutral propeller shaft locked a shaft brake or other shaft l
27. e suction screen and filter element after eight hours of operation Look for lint or other material that may collect from rags or towels used in the parts cleaning process Look for chips or shavings particularly if the transmission has had a problem that caused debris in the system For units with spin on filters this will require cutting the filter element apart to access the element core If the filter is clean install a new filter element and then change the oil and filter element after 1000 hours of service If the filter is dirty change the element and operate for another eight hours Check the filter again Continue this cycle until the filter is clean and then change the oil and filter after 1000 hours of service or more often if conditions warrant NOTE Situations involving debris in the hydraulic system will require that heat exchangers and all connecting lines and hoses be thoroughly cleaned Ifthe heat exchanger cannot be disassembled or if it cannot be assured that all debris is removed the heat exchanger should be replaced Draining Drain the transmission by removing the oil drain plug from the rear bottom of the transmission See illustrations in Section 6 2 or service literature for your transmission for location of transmission and filter drain plugs NOTE Dispose of used oil and oil filters in accordance with federal state or local laws Exercise precautions to prevent environmental contamination during any transmis
28. eaned with a wire brush F Suction Strainer Remove and clean the suction strainer at every oil change or sooner if necessary See illustrations in Section 6 2 for location G Flexible Input Coupling Do not obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling Life of the coupling may be reduced if the ambient temperature of the air around the coupling is outside the operating range Operating air tempera tures above 6 C 22 F and below 82 C 180 F should be maintained If possible visually inspect the coupling after the first 100 hours of operation and every 2000 hours thereafter or every six months 4 3 SECTION 4 whichever comes first Torsional vibration misalignment degrada tion by contaminants oil heat ultraviolet radiation and excessive system torque can cause cracks or other signs of distress to appear on the surface of the rubber The above described items affect the life of the coupling element If coupling access is restricted inspection may be possible only at engine overhaul or whenever the transmission is separated from the engine On such units frequently check the flywheel housing vents Coupling deterioration from a variety of causes may be indicated by an accumulation of residue at the vents Should this be evident inspect to determine the cause H Bearing Inspection and Replacement At the engine overhaul interval or more frequently inspect all
29. es Operation NOTE Should you need to replace a plate assure that all pertinent information is transcribed to the new plate Failure to do so could result in the loss of important information necessary to obtain parts and service Start up Assure that transmission control is in NEUTRAL s soon as engine starts check transmission oil pressure oil pressure gauges are recommended for all installations Pressure should register within 15 seconds If no pressure is indicated stop engine and determine cause Check oil level as follows A Fill transmission to low mark on dipstick Run engine at idle until oil temperature reaches operating range B Continue running at idle and check oil level with oil level gauge dipstick Level should be at full mark on gauge Add or remove oil as necessary to bring level to full mark on gauge C Allow oil to cool perhaps overnight Check the oil level while cold at low idle engine speed while in neutral Make note of this adjusted cold oil full level for future reference DO NOT OVERFILL Normal Operation For maximum service life make all shifts from NEUTRAL into either FORWARD or REVERSE with engine running at low idle When a shift range is selected assure that the control lever is in the fully detented position for the range selected Monitor transmission oil pressure and temperature See oil pressure information on identification plate and oil tempera
30. eutral with both voltage and current trollsignals present or power isapplied to Solenoid A and B switch inputs at the same time Both red lights flashing Not applicable Either or both speed signals alternately missing MGX Series Chart 1 Troubleshooting Symptom Cause Remedy 1 Low main oil pressure 1 1 Partially cloggedoil strainer 1 1 Remove and clean oil strainer 1 2 Contamination on Pilot 1 2 Disassemble the Pilot Relief Valve seat Relief Valve and clean Servicethetransmission oil filter 1 3 Contamination in Main 1 3 Clean or replace the Main Valve Cartridge Valve Cartridge and service the transmission oil filter 1 4 Broken piston rings on 1 4 Remove the collector and clutch shaft s inspect piston rings 1 5 Damaged or worn oil pump 1 5 Replace damaged or worn assembly oil pump assembly pump is not serviceable 1 6 Engine idle speed too low 1 6 Raise engine speed 2 No oil pressure or erratic 2 1 Oil pump suction strainer 2 1 Removeandclean strainer low pressure at control plugged valve 2 2 Oil level low 2 2 Checkoil level and correct 2 3 Air leak on suction side of 2 3 Correct cause of air leak pump 2 4 Pump drive on reverse 2 4 Disassemble and repair as clutch shaft broken required 2 5 Pilot Relief Valve or Main 2 6 Remove disassemble Regulating Valve stuck in clean and repair the Pilot open position Relief Valve Remove clean or replace the Main Regulating valv
31. f hydraulic pump failure using the come home screws to mechanically lock up a clutch will cause the transmission to operate without pressure lubrication which may cause further damage to the transmission Avoid using come home screws unless there is no other means available to bring the vessel into port 3 9 SECTION 3 Situations that may require the use of come home screws are e Loss of hydraulic pump drive or failure of hydraulic pump e Loss of oil e Cracked clutch apply piston e Broken worn or blown seal rings on clutch shaft s or clutch apply piston 2 Table Transmissions with Come Home Screws The following table shows the marine transmissions that cur rently incorporate come home screws in their design the number of screws and the tool needed to engage them Number of Come Home Screws Tool Needed MG509 Common screw driver MG514C 3 16 internal hex wrench MG514CHP 3 16 internal hex wrench MG514M 3 16 internal hex wrench MG516 3 16 internal hex wrench MG5161 3 16 internal hex wrench MG5202 3 16 internal hex wrench or 5 mm internal hex wrench MG521 1 2 12 point socket MG527 1 2 12 point socket MG530 5 16 internal hex wrench MG530M 5 16 internal hex wrench MG540 5 16 internal hex wrench Tbl 002 Not all units in these model designations contain come home screws a b c Operation Using Come Home Screws Shut down engine Remove ignition key or take w
32. hatever action necessary to prevent accidental engagement of engine starter Failure to do so could result in injury to personnel or damage to equipment Lock transmission output shaft to prevent shaft rotation When using come home screws the following factors must be considered NEVER engage both clutches at one time To do so will lock up the transmission and will prevent engine start or operation Identify and always engage the clutch used for forward ahead propulsion Failure to correctly identify the clutch to be engaged will cause loss of time and may place the vessel and crew in jeopardy Locate come home screw access plugs in manifold at rear of transmission See Section 6 2 for locations Remove the two access plugs for the clutch to be engaged Mostsingle transmission vessels equipped with standard right hand rotation engines engage the clutch on the transmission primary shaft for forward ahead propulsion Propeller shaft turns in anti engine direction for forward Most units equipped with come home screws have four screws in each clutch housing that are accessed through two come home screw access plug holes in 3 11 SECTION 3 3 12 d the manifold for each clutch Two screws can be tightened at a time Then the clutch housing must be turned to provide access to the remaining two screws Some MG509 transmissions are equipped with two come home screws in each clutch housing with two come home s
33. id valves must NOT permit actuation of both forward and reverse sole noids at the same time B Safety Whenever maintenance is performed on the marine transmission or control valve always assure that the transmission control are free and are adjusted properly Be certain that the transmission range selected at the operator s station places the control valve in the fully detented position for the selection made 3 2 Prestart up Checks Prior to starting the engine check the transmission as follows 1 Check that there is oil in the transmission NOTE This check will determine that there is oil in the transmission but will not determine if oil level is correct Oil level check must be performed with engine operating at low idle with transmission in neutral and oil temperature in operating range 2 Check transmission for leaks cracks and obvious damage 3 Check mountings for tightness or damage such as cracks Tighten loose mountings and replace damaged parts 4 Inspect heat exchanger oil and coolant lines and hoses for leaky connections kinks cracks and other damage Re place damaged lines and or hoses 5 Check pressure and temperature gauges where applicable 6 Inspect driveline and input and output shaft oil seals for signs of leakage Replace parts as required 7 Inspect unit identification plate and lubrication plate for looseness and corrosion Tighten mounting screws that are loose and replace corroded plat
34. il Level Gauge Gauge A alternate location Suction Lube Fitting Strainer Oil Drain Plug FIG 22 6 15 SECTION 6 Oil Filler Oil Level Gauge Suction Strainer FIG 23 Oil Drain Plug Oil Filler Suction Strainer Oil Drain Plug FIG 24 6 16 Appendix Oil Level Gauge Oil Filler ee Suction i Strai an Oil Drain Plug FIG 25 Oil Level Gauge Oil Filler gt O m oo BC o o SA OO ANO M Ove SOO 5 O Q e o i ON o O TE O O Suction Strainer zd Oil Drain Plug FIG 26 6 17 SECTION 6 6 18 Oil Filler Suction Strainer FIG 27 Oil Level Gauge Oil Drain Plug Suction Strainer FIG 28 Oil Filler Oil Level Gauge Oil Drain Plug Appendix 6 3 TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY COMMERCIAL MARINE TRANSMISSION A Twin Disc Incorporated warrants all assembled products and parts ex cept component produc
35. ine shut down e Vessel tied up or docked in heavy current 3 7 SECTION 3 3 8 Most current Twin Disc production marine transmissions with the exceptions that follow can be backdriven in the situations listed Vessel speed under all towing or backdriving conditions must not exceed the normal propulsion speed of the vessel Do not exceed normal vessel speed during backdriving Oil sump temperature must not exceed 100 C Damage will occur to internal components If oil temperature increases to 100 C reduce temperature either by reducing backdriving speed or supplying additional cooling with water flow or by idling the engine The following backdriving towing options are applicable to all transmissions except MG5170 series MG5200 series MG5300 series MG5600 series and all MG6000 series without the optional trailing pump For these transmissions instructions in only B and C below are applicable You need to employ only one of the following methods A Start the engine and operate the marine transmission in neutral at normal fluid pressures for five minutes doing this once every eight hours Maintain the backdriven marine transmissions oil level at the full mark on the dipstick Lock the propeller shaft to prevent rotation Add a trailing pump to the lube circuit See the hydraulic system prints for more details on auxiliary pump specifica tions for the applicable transmission or contact your Twin Disc distributor
36. ion of the transmission without sufficient lubrication will cause bearing and or gear failure placing the safety of vessel and crew in jeopardy Start engine and operate at no more than 1 3 throttle Transmission cannot be shifted to neutral or reverse with a mechanically locked up clutch Engine must be shut down and vessel placed under tow before entering any congested area or dock area Failure to do so will endanger safety of vessel and crew as well as others in the area C Operation Electric Selector Manual Override 1 Determine Your Electric Selector Type If an electrical power interruption occurs the electric selector can be overridden as follows a Stop the engine b Based on Figures 1 2 and 3 determine the type of electric selector valve used on the transmission c Gotothe following instructions e Type 1 manual override plug under Section AIC e Type 2 manual override lever under Section 3 7 C 3 e Type 3 manual direction control valve under Section 3 7 C 4 3 15 SECTION 3 Fig 1 Type 1 Electric Selector Manual Override Plug i Cartridge Screw Torque 34 Nm 25 Lbs Ft Manual override plug 9 3 used in place of appropriate solenoid Secondary Clutch Solenoid Primary Clutch Solenoid N 6 E Stored S O OV manual override o Do NN O plug Check C 000 y your Rer O model for exact d T location Oo OQ clfc ot L S e O O Q om 24 Fig
37. l and maintain hydrau lic system oil temperature at the proper level Thermostatic bypass valves are available for use where needed Contact 6 1 SECTION 6 6 2 your Twin Disc distributor for specific cooling information and recommendations to fit Your transmission installation The following options accessories are available for use where needed Contact your Twin Disc distributor for specific cooling information on items compatible with your transmission installation 1 Front Mount Power Take Offs Used to drive a variety of items pumps compressors generators etc Equipped with spring loaded clutches housing one or two driving plates Available in a variety of SAE housing sizes and plate diameters Top Mounted Clutch Controlled Power Take Offs Lever actuated or hydraulically applied clutch models are available Live Power Take Offs Provides live power to accesso ries at all times engine is operating Electric Solenoid Valves Used to select FORWARD NEUTRAL or REVERSE Available in 12 and 24 volt DC power configurations Must be mated with a control system for selection of desired range Flexible Input Coupling Used to reduce gear rattle caused by input vibrations Trailing Pump Used to supply oil pressure for lubrication during windmilling or backdriving situations Appendix 6 2 Marine Transmission Illustrations The following illustrations are representative samples of Twin Disc Marine Tr
38. lipping Check clutch apply oil pressure If pressure is normal remove disassemble and repair slipping clutch lf oil pressure is abnormal determine cause and repair as listed under previous troubleshooting sections 4 5 Bearing failure Overhaul marine transmission 4 6 Air leak on suction Inspect and correct side of pump cause of suction leak Tbl 003 Troubleshooting Standard MG Chart 4 5 Excessive noise Bearing failure Overhaul marine transmission Worn or damaged Remove marine input coupling transmission Replace worn or damaged coupling Gear rattle from Raise low idle torsional vibrations setting Worn or damaged Overhaul marine gears transmission Improper Check alignment alignment of engine and transmission and transmission output flange to propeller shaft Correct as necessary Damaged propeller Repair propeller Misfiring engine Repair engine Tbl 003 SECTION 5 Standard MG Chart 5 Symptom 6 No neutral Neutral selected but boat continues to move 7 Harsh engagement Clutch plates warped Control valve incorrectly indexed Worn seal rings Broken or faulty clutch linkage Regulating piston or rate of rise piston stuck Orifice plate ball in control valve not seating properly Engine speed too high Overhaul unit and replace clutch plates Check and adjust control linkage Check clutch apply pressure Re
39. living expenses will be considered for payment in all model except MG340 and MG360 Under no circumstances including a failure of the exclusive remedy shall Twin Disc Incorporated be liable for economic loss consequential incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 1 Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc Incorporated within sixty 60 days after completion of the in warranty repair 2 The warranty is void if in the opinion of Twin Disc Incorporated the failure of the part or product resulted from abuse neglect improper maintenance or accident 6 21 SECTION 6 3 The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc Incorporated 4 The warranty is void unless the product or part is properly transported stored and cared for from the date of shipment to the date placed in service 5 The warranty is void unless the product or part is properly installed and main tained 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 6 The warranty is void unless all required replacement parts or products are of Twin Disc origin or eq
40. notify the operator in the event that the oil pressure falls below the minimum pressure when cruising specifi cation If you detect abnormal oil pressure 1 Verify that the pressure reading is accurate Gauges can fail or malfunction 2 If gauge is malfunctioning determine that actual operating pressure is within allowable range before resulting opera tion 3 If pressure reading is accurate and pressure is outside of the allowable range shut down the engine and correct the problem See troubleshooting procedures in Section 5 of this manual NOTE If problem cannot be corrected and engine must be shut down see instructions for windmilling backdriving and towing in Section 3 6 of this manual If unit must be kept in operation to prevent injury to person nel or damage to equipment operate at lowest power possible until unit can be safely shut down Description and Specifications C Heat Exchanger The heat exchanger is required to maintain the oil temperature in the hydraulic system within the recommended operating range Proper oil temperature is maintained by passing coolant through the heat exchanger Some models such as the MG5300 series and MG6000 series transmissions may have an integral heat exchanger On models with aremote mounted heat exchanger the heat exchanger should be installed in a location convenient to coolant and marine transmission oil See your unit s lubrication plate for operating oil tem
41. ocking device must be used To prevent accidental starting of the engine when performing routine transmission maintenance disconnect battery cables and remove ignition key from the switch 1 3 Preventative Maintenance Frequent reference to the information provided in this manual regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation Schedules are pro vided for recommended maintenance of the equipment in Section 4 ofthis manual as well as a chart in the Appendix Section 6 1 4 Ordering Parts and Obtaining Service All replacement parts or products including hoses and fittings must be of Twin Disc origin or equal and otherwise identical with components of the original equipment Use of any other parts or products will void the warranty and may result in malfunction or accident causing injury to personnel and or serious damage to the equipment Introduction A Ordering Renewal parts service parts kits optional equipment and product service assistance may be obtained from any autho rized Twin Disc distributor or service dealer Contact Twin Disc for the distributor or service dealer near you Twin Disc having stipulated the bill of material number on the unit s nameplate absolves itself of any responsibility resulting from any external internal or installation changes made in the field without the express written approval of Twin Disc All returned parts new or old
42. ome Screw Access Plugs i not available on all models T Come Home Screw 4 Access Plugs if applicable Lube Fitting if applicable Suction Strainer Oil Drain Plug om 15 6 7 SECTION 6 Oil Filler Oil Filter Oil Level Gauge Lube fitting i er TON ejf Strainer FIG 7 Cil Drain Plug Oil Filler Come Home Screw Access Level Gauge Come Homel Screw Access Plugs AT Strainer Lube Fitting t lt lt Oil Drain Plug Appendix Come Home Oil Filler Screw Access Oil Drain Plug om 18 Oil Level Gauge alternate locations Oil Filler Come Home Screw Access Plugs Suction Strainers Lube Fitting Oil Drain Plug SECTION 6 Oil Filler alternate locations y Fitting if applicable i Oil Drain Plug Suction Strainer amp Lube Fitting 6 10 Appendix Oil Level Oil Filler in hose Fitting Oil Level Gauge Oil Filler Oil Filter N Lube fitting ey Suction E65 gt Strainer ME FIG 14 Oil Drain Plug 6 11 SECTION 6 6 12 Oil Filler Oil Filter Suction Strainer Gauge Lube fitting
43. otation engines and certain models may be modified to accommodate nonstandard left hand rotation engines Contact your Twin Disc distributor if you anticipate using nonstandard engines NOTE Engine direction of rotation is determined by facing the front of the engine opposite engine flywheel From this viewpoint clockwise crankshaft rotation is defined as right hand rotation All current Twin Disc marine transmissions can be operated through either primary or secondary clutch at full rated horsepower for forward ahead propulsion using standard engines Contact your Twin Disc distributor for the rated horsepower if you anticipate using nonstandard engines NOTE The primary clutch has the shortest power path through the transmission The secondary shaft is driven in opposite rotation by the primary shaft Transmission clutches are hydraulically applied using regulated oil pressure All bearings clutches and gears are lubricated and cooled with oil 2 1 SECTION 2 2 2 2 2 Construction Features A Oil Pump Drive For most transmissions the secondary clutch shaft drives the oil pump One exception is the MG540 having two pumps one driven by the primary shaft and one driven by the secondary shaft B Lubrication Features The transmission case serves as the reservoir sump for all oil used in the transmission Bearings and clutches on the primary and secondary shafts are lubricated and cooled through passageways in
44. pera ture ranges and the recommended viscosity for each 2 5 SECTION 2 2 6 Operation Section 3 Operation 3 1 Selector Valve A General Description A selector valve controls application of forward or reverse clutches in Twin Disc marine transmissions In most transmissions a lever actuated mechanical valve with detented positions for FORWARD NEUTRAL and REVERSE is used An electric solenoid operated valve is available as an option for certain transmissions and is standard equipment on other transmissions The mechanical and solenoid operated valves both perform two functions selecting FORWARD NEUTRAL and REVERSE and controlling main clutch apply pressure Omega units the MG530M and MG514M use a mechanical selector valve actuated by a sprocket wheel to select FORWARD NEUTRAL and REVERSE and to control pressure applied to the selected clutch Most transmissions incorporate a rate of rise system that causes clutches to engage at a lower pressure then progressively increases pressure to lock up the clutch This results in smooth clutch engage ment and minimizes shift shock Control Systems that fail to place a mechanical selector valve in detented positions will damage or cause failure of the clutch packs Manually holding the shift selector out of the detented position will also damage or cause failure of the clutch packs 3 1 SECTION 3 3 2 Control systems for units equipped with electric soleno
45. place seal rings as necessary Repair control linkage Disassemble control valve Clean parts Replace parts if necessary Remove orifice plate cover Clean parts Replace parts if necessary Reduce engine speed Tbl 003 Standard MG Chart 6 Symptom 8 Low lube oil pressure 9 Oil escaping from breather Pump GPM output too low Pump suction strainer plugged Air leak on suction side of pump Lube regulator valve stuck Broken piston rings Oil level too high Wrong type of oil Troubleshooting Replace pump Remove clean inspect and install the suction screen Inspect and correct cause of suction leak Remove and clean or replace parts as necessary Replace damaged piston rings Adjust oil level Drain and refill with recommended oil Tbl 003 5 7 SECTION 5 MGX Series LED Chart Light Status Profile Generator E troll Module Non trolling Green light on Supply Voltage gt 9 0 Volts Supply Voltage gt 9 0 Volts Illuminated only when Clutch A or B is selected Not illuminated in Neutral Red lighton Valve coil commanded on Valve coil commanded on O ne red light flashing Open circuit in an energized Open circuit in an energized valve coil circuit valve coil circuit or Valve coil leads shorted together or Low coil current Both red lights flashing Not applicable After entering troll from simultaneously n
46. r and inspect piston rings Replace damaged piston rings Replace damaged or worn oil pump assembly Pump is not serviceable Adjust linkage so that control valve stem is indexed properly by detent Remove orifice plate cover Clean parts Shim as required Raise engine speed Tbl 003 Standard MG Chart 2 Symptom 2 No main oil pressure or erratic low pressure at control valve tap 3 High main oil pressure Oil pump suction strainer plugged Oil level low Air leak on suction side of pump Pump drive broken Regulating valve stuck in open position Oil pump defective Leaking heat exchanger has caused oil to be lost overboard Regulating valve stuck Wrong oil type Troubleshooting Remove and clean strainer Check oil level and correct Correct cause of air leak Disassemble and repair as required Remove disas semble clean and repair the regulating valve Replace oil pump Replace heat exchanger Remove and clean regulating valve Use recommended oil Tbl 003 SECTION 5 Standard MG Chart 3 4 High temperature Improper oil level Check and fill or drain high or low with proper oil to the correct level Faulty heat exchanger Inspect repair or if used replace heat exchanger Blockage in heat Replace defective exchanger line pre line venting free flow of oil or water through heat exchanger Clutches s
47. r materials F 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 6 20 Appendix 6 4 TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY MARINE PLEASURE CRAFT A Twin Disc Incorporated warrants all assembled products and parts except com ponent products or parts on which written warranties issued by the respective manufactur ers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of thirty six 36 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twenty four 24 months of service whichever occurs first This is the only warranty made by Twin Disc Incorporated and is in lieu of any and all other warranties express or implied including the warranties of merchantabil ity or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc Incorporated This warranty applies only to private non commercial non revenue earning marine pleasure craft applications deliv ered by Twin Disc Incorporated to the original customer on or after May 1 1995 The o
48. riginal customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering Twin Disc Incor porated is not responsible for any specific application installation of performance standard Any analysis program by Twin Disc Incorporated based upon customer supplied information is done solely as an accommodation to the customer and is not to be interpreted or con strued as an approval for specific application or a guarantee of performance Twin Disc Incorporated cannot be held liable or responsible for incorrect information supplied or deviations from specifications provided by customer B The exclusive remedy provided by Twin Disc Incorporated whether arising out of warranty within the applicable warranty period as specified or otherwise including tort liability shall at the sole option of Twin Disc Incor porated be either the repair or replacement of any Twin Disc Incorporated part or product found by Twin Disc Incorporated to be defective For all models except MG340 and MG360 this include the labor to perform that work and to remove and reinstall or equivalent credit In this context labor is defined as the flat rate labor hours established by Twin Disc Incorporated in the published Twin Disc Flat Rate Schedule required to remove disassemble inspect repair reassemble reinstall and test the Twin Disc Incorporated prod uct only Authorized reasonable travel and
49. sion servicing procedure Filling 1 Remove the breather or the oil fill closure from the top of transmission case 2 Pour new oil through breather or closure opening Fill with recommended clean oil taking necessary precau tions to prevent entry of dirt or debris See lubrication plate on transmission and information transcribed to the front of this manual for additional oil information Maintenance D Oil Capacity See lubrication plate Capacity given will be internal quantity required to fill transmission to proper level but may NOT include quantity to fill external hoses and heat exchanger Check oil level per Section 3 3 Start Up E 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 30 to 90 days depending on coolant conditions pH factor salinity etc If over one half of the rod is disintegrated it should be replaced to provide effective protection Excessive corrosion of the zinc rod indicates electrolytic action A careful inspection should be made to determine if this action is caused by a short circuit or external grounded electric current These conditions must be eliminated to avoid frequent replacement of the zinc rods If these conditions do not exist it is evident that the corrosion is due to local electrolysis If rods are corroded with foreign material they should be cl
50. ted 6 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 equip ment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated 6 19 SECTION 6 C 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 D Only a Twin Disc Incorporated authorized factory representative shall have authority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated E 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 o
51. the transmission identification plate 2 4 Oil Recommendations A Oil Viscosity See your unit s lubrication data plate for type of oil and viscosity recommendations Transcribe the information from your transmission s lubrication data plate to the sample plate found at the front of this manual for ease of reference MG6000 SERIES ONLY Some MG6000 series units that were manufactured prior to 2003 do not utilize a lubrication data plate The recommended oil for these units is SAE 40W Use only SAE API service class CD engine oil that is certified by the vendor to pass TO 2 or C 3 test specifications A CAUTION Multi viscosity oils i e 15W 40 etc automatic transmission fluid ATF and synthetic oils are not approved for use in Twin Disc marine transmissions without written approval from Twin Disc 2 3 SECTION 2 24 B Oil Pressure and Temperature A CAUTION All units have provisions to install oil pressure and oil tempera ture gauges Oil pressure gauges are recommended for all installations By monitoring main oil pressure and tempera ture you detect problems before major damage to the unit occurs Your unit s identification plate specifies minimum oil pressure when cruising This specification is the main oil pressure measured with the oil temperature in the normal operating range and engine speed at approximately 2 3 throttle setting It is suggested that an alarm system be installed to
52. then repeat the above procedure with the oppo site solenoid Store the removed solenoid where the override plug was stored until repairs are performed Operation 3 Type 2 Selector Manual Override Lever Type 2 electric selector valves Fig 2 have a lever that can be put into the manual override position If electrical power is interrupted the manual override feature can be used to engage the clutches The control cable must always place the selector lever on the valve into the detented positions Operation in an improper lever position can cause clutch failure a Rotate the lever to the neutral position counterclock wise and pull outward view 1 in Fig 2 b Rotate the selector lever to select forward or reverse view 2 Fig 2 NOTE Some vessels may have a cable at the operat ing station that lets the operator manually control clutch selection when in the manual override position c Once electrical power is restored to the selector valve switch the lever back to electric control e Put lever in neutral e Push the lever into the valve body It will be more difficult to push the lever in if the engine is running e Lock it in place by rotating clockwise 3 19 SECTION 3 4 Type 3 Selector Manual Direction Control Valve Remove the locking pin from the Manual Direction Control Valve and push the valve in to engage Clutch A or pull it out to engage Clutch B Note that the center position is Neutr
53. transmission bearings and replace as necessary l Overhaul Interval Overhaul the transmission at the same time the engine is overhauled 4 2 Storage Maintenance Procedures It is sometimes necessary to store Twin Disc transmissions or boats equipped with Twin Disc components In order to pre vent corrosion damage the following procedures are recom mended A Short Term Storage Less than One Year Transmission installed in a boat on an engine that can be run Boat in the water 1 To the extent possible store boat in a location that minimizes exposure to the elements 2 Prior to storage drain oil and refill to full level on the dipstick with recommended new oil Install new filter if applicable After changing oil and filter run engine B Maintenance long enough to bring oil to operating temperature and operate transmission in all ranges Shut down Use only recommended oils to maintain proper levels Do not use preservative type oils Every three months check oil level and availability of coolant Start engine and run at approximately 1000 rpm to bring oil temperature up to normal operating range Run engine at least five minutes shifting into each range and shut down Drain and refill with recommended oil and change filters if applicable prior to returning unit to regular service Check the condition of the zinc rods in the heat ex changer according to Section 4 1 E Long Term Storage More than
54. ts or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer as to which Twin Disc Incorporated makes no warranty and assumes no liability against defective materials or workmanship for a period of twenty four 24 months from the date of shipment by Twin Disc Incorporated to original customer but not to exceed twelve 12 months of service whichever occurs first This is the only warranty made by Twin Disc Incorporated and is in lieu of any and all other Warranties express or implied including the warranties of merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc Incorporated The original customer does notrely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering B The exclusive remedy provided by Twin Disc Incorporated whether arising out of warranty within the applicable warranty period as specified or other wise including tort liability shall at the sole option of Twin Disc Incorpo rated be either the repair or replacement of any Twin Disc Incorporated part or product found by Twin Disc Incorporated to be defective and the labor to perform that work and to remove and reinstall or equivalent credit In this context labor is defined as the flat rate labor hours established by Twin Disc Incorporated in the published Twin Disc Flat
55. ts will be furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit January 16 2002 6 22
56. ual and otherwise identical with components of the original equip ment Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc Incorporated C As consideration for this warranty the original customer and subsequent pur chaser 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 D Only a Twin Disc Incorporated authorized factory representative shall have au thority to assume any cost or expense in the service repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by Twin Disc Incorporated E Twin Disc Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorpo rate 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 F If failure occurs within the warranty period and constitutes a breach of warranty repair or replacement par
57. w apply to all except the MG509 transmission listed in the preceding Applicability section For the MG509 transmissions proceed directly to step k below Use procedure in step d above and bar engine over to align remaining two come home screws in the clutch housing with the come home access plug holes in the manifold Lock transmission output shaft to prevent shaft rotation Failure to lock the output shaft may result in shaft rotation due to current or wave action against the propeller With two come home screws mechani cally locking the clutch such shaft rotation will cause the clutch housing and the engine crank shaft to turn and could result in injury to person nel and or damage to equipment Use screwdriver or internal hex wrench and tighten remaining two come home screws as far as they can go 3 13 SECTION 3 3 14 D k m Unlock transmission output shaft Reinstall plugs in come home screw access holes in manifold In the case of a pump failure where pressure lubrica tion of the transmission is not possible an auxiliary lube oil pump should be run if available Otherwise plug the dipstick tube and completely fill the transmis sion with oil Prior to starting engine drain the oil down to full oil level Repeat this process every eight hours Do not start engine after mechanically locking a transmission clutch before assuring that the transmission will be adequately lubricated Operat
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