MULTIFLO PUMPS

By MULTIFLO AUSTRALIA Pty. Ltd.

Twin Disc Incorporated

General Information & Safety
This manual provides general operating information for Twin Disc Transmissions. Specific
product details and performance characteristics can be obtained by contacting the nearest
Twin Disc authorised Distributor or Service Dealer.

All personnel servicing this equipment should employ safe operating practices. Twin Disc,
Incorporated will not be responsible for personal injury resulting from careless use of hand
tools, lifting equipment, power tools, or unaccepted maintenance/working practices.

Because of the possible danger to person(s) or property from accidents that may result
from the use of machinery, proper installation, maintenance and operation procedures
must be followed. Twin Disc, Incorporated will not be responsible for personal injury
resulting from careless maintenance/working practices.

Inspect as necessary to assure safe operations under prevailing conditions. Proper guards
and other safety devices that may be specified in safety codes should be provided. These
devices are neither provided by nor are they the responsibility of Twin Disc, Incorporated.

Warning!! Selecting Neutral disengages transmission clutches but does not prevent
propeller shaft rotation. If you require positive neutral (prop 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 battery cables and remove ignition key from the switch.

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
and charts are provided in the manual for recommended maintenance of the equipment.

Ordering of Parts and Obtaining Service

Warning!! All replacement parts or products (including hoses and fittings) must be of
Twin Disc origin or equal, and otherwise identical with components of the original
equipment. Use of any other parts or products will void the warranty and may result in
malfunction or accident, causing injury to personnel and/or serious damage to the
equipment.

Renewal parts, service parts kits, optional equipment and product service assistance may
be obtained from any authorised Twin Disc distributor or service dealer. Contact Twin
Disc for the distributor or service dealer near you.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

Twin Disc, having stipulated the bill of material number on the unit’s nameplate, absolves
itself of any responsibility resulting from any external, internal, or installation changes
made in the field without the express written approval of Twin Disc. All returned parts,
new or old, emanating from any of the above stated changes will not be accepted for
credit. Furthermore, any equipment that has been subjected to such changes will not be
covered by a Twin Disc warranty.

Description and Specifications

While most Twin Disc transmissions are forward/reverse reduction units, some units
provide speed increasing capability. All may be used with standard (right hand) rotation
engines and certain models may be modified to accommodate non-standard (left hand)
rotation engines. Contact your Twin Disc distributor if you anticipate using non-standard
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 transmissions can be operated through either primary or secondary
clutch at full-rated horsepower for forward (ahead) propulsion using standard engines.
Contact Twin Disc for the rated horsepower if you anticipate using non standard engines.

Transmission clutches are hydraulically applied using regulated oil pressure. All bearings,
clutches and gears are lubricated and cooled with oil.

Construction Features
Oil Pump Drive
For most transmissions, the secondary clutch shaft drives the oil pump. The only
exception is the MG540. It has two pumps - one driven by the primary shaft and one
driven by the secondary shaft.

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 the shafts. Output shaft bearings are gravity and/or splash
lubricated. Some transmissions use pressurized oil spray to lubricate gears and bearings.

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.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

All Twin Disc transmission are equipped

with an Identification Plate. In addition to
information identifying the unit (i.e. model
number, bill of material number, ratio, serial
number etc) the identification plate provides
information on oil capacity, and oil check/oil
change intervals for your particular
transmission. All operators of this
equipment are responsible to read and
apply the information provided on the
transmission identification plate.

See your I.D. plate on the unit regarding oil

viscosity and type.
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.

Operation
Selector Valve
A selector valve controls application of clutches in Twin Disc transmissions. In most
transmissions a lever-actuated mechanical valve with detented positions for
engage/disengage is used.

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 engagement and minimizes shift shock.

Warning!! Control systems that fail to place a mechanical selector valve in detented
positions will damage or cause failure to the clutch packs. Manually holding the shift
selector out of the detented position will also damage or cause failure of the clutch packs.

Whenever maintenance is performed on the 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.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

Pre Start 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 lines for leaky connections, kinks, cracks and other
damage. Replace damaged lines.

5. Check pressure and temperature gauges where applicable.

6. Inspect drive line and input and output shaft oil seals for signs of leakage. Replace
parts as required.

7. Inspect unit identification plate and lube plate for looseness and corrosion. Tighten
mounting screws that are loose and replace corroded plates.

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
1. Assure that the transmission control is in neutral.

2. As soon as engine starts check transmission oil level as follows.

a) 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).
c) Add or remove oil as necessary to bring level to full mark on gauge.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

Normal Operation

1. For maximum service life, make all shifts from neutral into engage with engine
running at low idle.

2. When a shift range is selected, assure that the control level is in the fully detented
position for the range selected.

3. The recommended engine rpm for shift changes is 800rpm.

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.

Maintenance
General Maintenance
Oil Level Check
Check oil level daily or very 10 hours. Check with engine running at low idle and with
transmission in neutral. Transmission oil temperature should be in normal operating range
prior to checking oil level.

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 lube fitting. Apply
grease every 100 hours. No other lubrication is required.

NOTE: Preferred grease is one with lithium soap, NGLI consistency #2 for
component temperatures above 20°C (68°F).

Filter and Oil Change Interval

With a new transmission, change the oil and filter element within the first 50 hours of
operation. Change oil and filter element after each 1000 hours thereafter or more often if
conditions warrant.
For a rebuilt transmission, check the 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.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

NOTE: Situations involving debris in the hydraulic system will require that
heat exchangers and all connecting lines and hoses be thoroughly cleaned. If the
ehat 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.

NOTE: Dispose of used oil and oil filters in accordance with federal, state of
local laws. Exercise precautions to prevent environmental contamination during
any transmission 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 precautions to prevent entry of dirt and debris.

Oil Capacity
See lubrication plate on transmission. 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 as per Part 3 “Start Up”.

Heat Exchanger
Check for leaks. Heat Exchanger works in conjunction with engine cooling system, and
does not use pit water for cooling.

Suction Strainer
Remove and clean the suction strainer at every oil change or sooner if necessary.

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 temperatures 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, whichever occurs first. Torsional vibration,
misalignment, degradation by contaminants (oil), heat, ultraviolet radiation, and excessive
system torque can cause cracks or other signs of distress to appear on the surface of the
rubber. The above-described items affect the life of the coupling element.

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.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

Overhaul Interval
Overhaul the transmission at the same time the engine is overhauled.
Storage Maintenance Procedures
It is sometimes necessary to store Twin Disc transmissions. In order to prevent corrosion
damage, the following procedures are recommended:-

Short Term Storage (Less Than One Year)

Transmission installed on an engine that can be run.
1. To the extent possible, store 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 long enough to bring oil to operation temperature and
operate transmission in all ranges. Shut down.

3. Use only recommended oils to maintain proper levels. Do not use

preservative-type oils.

4. Every three months, check oil level and availability of coolant. Start engine
and run 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.

5. Drain and refill with recommended oil and change filters, if applicable, prior
to returning unit to regular service.

Long Term Storage (More Than One Year)

Transmission installed where the engine cannot be run.
1. Use standard recommended oil for the following procedures:
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.

2. Seal breather, dipstick tube and all other openings with waterproof tape.

3. Grease exposed members that are subject to corrosion.

4. Every three months rotate output shaft four or five revolutions.

5. Tag transmission to show date it was placed in storage and current

status relating to storage procedure.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

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 the dipstick.

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
The following chart is intended as a guide for determining the cause of problems that
could be encountered and the corrective actions for those difficulties.

The transmission is one part of a complete drive train system. Problems before the
transmission (in the engine) or after the transmission (in the output shaft) can cause
problems to develop in the transmission. It is important that the entire system be
considered when transmission problems are encountered.

SYMPTOM CAUSE REMEDY

1. Low main oil pressure Partially clogged oil strainer Remove and clean oil strainer

Stuck pressure regulation piston Disassemble the selector valve

in selector valve. and clean the piston.

Worn or broken piston rings on Remove the collector and

clutch shaft(s). inspect piston rings. Replace
damaged piston rings.

Damaged or worn oil pump Replace damaged or worn oil

assembly. pump assembly. (Pump is not
serviceable).

Incorrect linkage adjustment to Adjust linkage so that control

control valve assembly. valve stem is indexed properly
by detent.

Clogged or plugged orifice in Remove orifice plate cover.

orifice plate. Clean parts.

Shimming required between Shim as required.

inner and outer springs and
rate-of-rise piston.

Engine idle speed too low. Raise engine speed.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

SYMPTOM CAUSE REMEDY

2. No main oil pressure, or Oil pump suction strainer Remove and clean strainer
erratic low pressure at plugged.
control valve tap.
Oil level low. Check oil level and correct.

Air leak on suction side of pump. Correct cause of air leak.

Pump drive broken. Disassemble and repair as

required.

Regulating valve stuck in open Remove, disassemble, clean and

position. repair the regulating valve.

Oil pump defective. Replace oil pump.

Leaking heat exchanger has Replace heat exchanger.

caused oil to be lost

3. High main oil pressure. Regulating valve stuck. Remove and clean regulating
valve.

Wrong oil type. Use recommended oil.

4. High temperature. Improper oil level (high or low). Check and fill or drain with
proper oil to the correct level.

Faulty heat exchanger. Inspect, repair or replace heat

exchanger.

Blockage in heat exchanger line Replace defective line.

preventing free flow of oil or
water through heat exchanger.

Clutches slipping. Check clutch. Apply oil

pressure. If pressure is normal,
remove, disassemble and repair
slipping clutch.

Bearing failure. Overhaul transmission.

Air leak on suction side of pump. Inspect and correct cause of

suction leak.

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Hydrau-Flo Valves
MULTIFLO PUMPS
By MULTIFLO AUSTRALIA Pty. Ltd.

SYMPTOM CAUSE REMEDY

5. Excessive Noise. Bearing failure. Overhaul transmission.

Worn or damaged input Remove transmission. Replace

coupling. worn or damaged coupling.

Gear rattle from torsional Raise low idle setting.

vibrations.

Worn or damaged gears. Overhaul transmission.

Improper alignment. Check alignment of engine and

transmission and transmission
output flange to propeller shaft.
Correct as necessary.

Misfiring engine. Repair engine.

6.. No neutral (Neutral Clutch plates warped. Remove clutch plate. Overhaul
selected but pump unit unit.
remains engaged.)
Control valve incorrectly Check and adjust control
indexed. linkage.

Worn seal rings. Check clutch, apply pressure.

Replace seal rings as necessary.

Repair control linkage.

Broken or faulty clutch linkage.
7. Harsh engagement. Regulating piston or rate-of-rise Disassemble control valve,
piston stuck. Clean parts. Replace parts if
necessary.

Orifice plate ball in control valve Remove orifice plate cover.

not seating properly. Clean parts. Replace parts if
necessary.

Engine speed too high. Reduce engine speed.

8. Low lube oil pressure. Pump GPM output too low. Replace pump.

Pump suction strainer plugged. Remove, clean, inspect and

install the suction screen.

Air leak on suction side of pump. Inspect and correct cause of

suction leak.

Lube regulator valve stuck. Remove and clean or replace

parts as necessary.

Broken piston rings. Replace damaged piston rings.

9. Oil spilling out of breather. Oil level too high. Adjust oil level.

Wring type of oil. Drain and refill with

recommended oil.

Troubleshooting assistance, as well as maintenance, repair and parts service is available

from your Twin Disc distributor or service dealer.

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